PUMP - Lib V23 Examples - Description V110 3ADR023042M9901

Example Description V110
PS563-WATER Library Package

PUMP_AC500_V23 Pumping Library
Application Examples
Content
1.
INTRODUCTION TO DOCUMENT ............................................................................. 3

1.1 Scope of the document .................................................................................................... 3
1.2 Overview of the Content ................................................................................................... 3
1.3 Compatibility ..................................................................................................................... 3
1.4 Safety Instructions ............................................................................................................ 3
2.
Overview of Water Pumping Library ........................................................................ 4

2.1 Introduction ....................................................................................................................... 4
2.1.1 Application Blocks........................................................................................................... 5
2.1.2 Auxiliary Blocks............................................................................................................... 6
2.1.3 Optimization Blocks ........................................................................................................ 6
2.2 Preconditions for the Use of the PUMP_AC500_V23 Library ....................................... 7
2.3 Overview of the PUMP_Library Components according to their Call Names ............. 7
3.
Configuration ............................................................................................................. 9
3.1 Automation Builder configuration ................................................................................... 9
3.2 ACQ810 drive configuration........................................................................................... 10
4.
Example programs .................................................................................................. 11

4.1 Example Simple Level Control in PM 564 .................................................................. 12
4.1.1.1 Station configuration ............................................................................................................ 12
4.1.1.2 Pump interface ..................................................................................................................... 13
4.1.2 Pumping programs ....................................................................................................... 14

4.1.2.1 Level control ......................................................................................................................... 14
4.1.2.2 Auto-change function ........................................................................................................... 15
4.1.2.3 Retain data function ............................................................................................................. 16
4.1.3 Simulation Pump Station .............................................................................................. 16

4.1.3.1 Tank Simulation ................................................................................................................... 16
4.1.4 Visualization.................................................................................................................. 17
4.2 Example Simple Boost Control in PM 564 ................................................................. 18
4.2.1 Configuration Programs ................................................................................................ 19
4.2.1.2 Pump Interface ..................................................................................................................... 19
4.2.2.1 Boost control ........................................................................................................................ 19

4.2.4 Visualization.................................................................................................................. 21
4.3 Example Multi Pump Boost Control w. auxiliary functions in PM 573 .................... 22
Simple Pumping - Water Library

Introduction and Examples Description
AC500 / Issue: 09.2015
4.3.1.2 Pump Interface ..................................................................................................................... 23

4.3.2.1 Boost control ........................................................................................................................ 23

4.3.3.1 Tank Simulation ................................................................................................................... 23
4.3.4 Visualization.................................................................................................................. 24
4.3.5 Additional Functionalities .............................................................................................. 24
4.3.5.1 Pump Antijam ....................................................................................................................... 24
4.3.5.2 Pump Flow Calc ................................................................................................................... 26
4.3.5.3 Pump Protection ................................................................................................................... 26
4.3.5.4 Pump Sleep .......................................................................................................................... 27
4.3.5.5 Pump Energy Calculation..................................................................................................... 28
4.4 Example Traditional Pump Boost Control w. auxiliary functions in PM 573 .......... 29
4.4.1.2 Pump Interface ..................................................................................................................... 30

4.4.2.1 Boost control ........................................................................................................................ 31

4.4.3.1 Tank Simulation ................................................................................................................... 31
4.3.4 Visualization.................................................................................................................. 31
4.5 Example Multi Pump Boost Control w. Drive Simulation in PM 573 ....................... 33
4.5.1.2 Pump Interface ..................................................................................................................... 34

4.5.2.1 Boost control ........................................................................................................................ 35

4.5.3.1 Tank Simulation ................................................................................................................... 35
4.5.4 Visualization.................................................................................................................. 35
4.5.5 Additional Functionalities .............................................................................................. 36
4.5.5.1 Pump Antijam ....................................................................................................................... 36
4.5.5.2 Pump Flow calc .................................................................................................................... 36
4.5.5.3 Pump Protection ................................................................................................................... 36
4.5.5.4 Pump Sleep .......................................................................................................................... 36
4.5.6 Simple Drive Simulation................................................................................................ 37

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4.6 Quick Start Guide for Example Programs ........................................................................ 38
5.
REVISION HISTORY ................................................................................................ 42

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1.
INTRODUCTION TO DOCUMENT
1.1 Scope of the document

The manual is intended as introduction for configuring and using the water library in the example program.
This document gives a short introduction to water pressure boost and level application and describes the
software architecture of the water library by using it in an example program. Further functional description of
the water library and details of the blocks are available in on-line help of IEC-61131-3 Editor.
1.2 Overview of the Content

Chapter 2 gives an Introduction to the water pumping and the Pump library.
The example programs described in chapter 4 are designed for controlling and monitoring of water pressure
boost control and level control. In this chapter five example programs are explained in Detail:
Example Name
Complexity
Example_PM564_PUMP_Level_simple.project
Example_PM564_PUMP_Boost_simple.project
Example_PM573_PUMP_Boost_complete.project
Simple pumping
Example_PM573_PUMP_Boost_traditional.project
Example_PM573_PUMP_Boost_complete_sim.proj
ect
Complete multi
pump
Complete traditional
pump setup
Complete multi
pump; with drive
simulation:
Application
block
Level control
Boost
Chapter
4.1
4.2
4.3
4.4
4.5
All projects do have a simple simulation of pumps and a tank to enable a simple test and familiarization.
1.3 Compatibility
In the application programs the serial communication (MODBUS RTU) is used to transfer and receive data
between AC500 PLC and ACQ810 drives and is described in more detail
PUMP_AC500_V23.lib can be also used with any other communication protocol (or drive) supported by
PS553 ACS drives library.. User needs to configure PS553 ACS drives library accordingly to establish the
communication between the drives and the AC500 PLC.
The example program explained in this document is compatible with the
o Simple pumping function water library, for theAC500 PLC
o ACS drives family.
1.4 Safety Instructions

The user must follow all applicable safety instructions and the guidelines mentioned in the user documents of
the ABB products used in the example program
o Read the complete safety instructions for the ACQ810drive before installation and commissioning
the drive. The complete safety instructions are given at the beginning of the ACQ810 users manual.
o Read all safety instructions of the AC500 PLC.
See System description AC500 (2CDC125015M0201 [English]) or
the online help in IEC-61131-3 Editor
(Help > Contents >Target System > AC500 / S500 > Introduction > Overview > Regulations).

AC500 / Issue: 09.2015
2.
Overview of Water Pumping Library
2.1 Introduction
The PUMP Library is intended for smaller pump stations (or pump skids) and medium sized stations. It
contains the block for the basic functionalities as well as advanced functions for very different applications.
This version is usable for 1-3 pumps as can be seen in the below picture, and assumes the use of drives for
each pump or at least one in the traditional setup.
The minimal sensor equipment for boost control applications is a pressure (or flow) sensor, for level control a
level sensor. Often additionally also at the input a sensor is placed e.g. for advanced protection.
The two main pumping applications in water and waste water are:
o Boost (typically pressure boost) control: Used in Network feeding or lift applications
o
Level control: Used for tank or reservoir filling or emptying applications
For both applications a special application block is available, which has all the needed basic functionality, so
that with minimal programming and mainly configuration an application can be setup.
Further auxiliary and optimization blocks are part of the library, which help in putting additional advanced
functionality with again minimal programming effort.
This block type concept helps in always having the necessary functionality without using too much PLC
resources (Memory) and keeping the applications as simple as possible. Therefore the Pumping library can
be used throughout the AC500 Platform, starting from the small AC500eco.
The next picture shows the blocks and their use for an application for small pump stations or sets. The main
application block is in the middle of the picture, dotted blocks are optional. The number in brackets shows
how often such a block is used in a setup with 3 pumps.

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This picture shows a simple but typical application for small pump station or pump-skid (suitable e.g. als for
AC500eco also with 3 pumps). It uses the BOOST_CTRL and the PID. The Station as such is configured by
the STATION_CONFIGRURATION block with an ID, Name and Nr. of used pumps.
Dotted blocks are optional depending on the application. The PUMP_INTERFACE block is used for detailed
configuration of each pump and for interfacing to the drives/actuators. The interface blocks allow a variety of
Actuators (one drive with direct-on-line hard- or soft-switched DOL pumps, Drive controlled pumps and
discrete- or bus- connection to the drive(s)).
Note
The parameter and status exchange between the different blocks is done by a structured
variable (symbolized by the light blue layer in the above picture) which is connected to all
blocks with control functionality. It contains substructures depending on the function and
use.
This concept minimizes memory usage, the connection work and still allows advanced
diagnosis if necessary.
2.1.1 Application Blocks

o
Boost control works with a closed loop control signal, typically coming from a PID controller with
a pressure (or flow) sensor. The PID gives a speed set point for the boost pumping station. The
boost control block then distributes start/stop and speed commands, depending on its chosen
operating mode and parameters, to e.g. a multi-pump setup. The boost application is typically
used for
o
network feeding to control a pressure in the network over a wide range of flow, which is
given by the varying demand in the network.
Irrigation, where either pressure or the flow is controlled to achieve a uniform and
controlled irrigation.
The Level control block works with discrete definable Levels to switch the pumps and set
appropriate fixed speeds. Level control is used e.g.
o
for pumping water between reservoirs or to fill a reservoir to a defined level in order
provide water reserves or direct network feeding.
for lift stations (emptying mode) where e.g. in waste water applications a waste water
reservoir needs to be prevented from overflowing and the water is emptied into further
reservoirs.

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In addition to these main application and control blocks a set of auxiliary and optimization function blocks
exist in the library.
2.1.2 Auxiliary Blocks

The auxiliary blocks provide necessary additional functionality in a modular way, to further minimize
programming needs and mainly do configuration instead.
o PID control with extended functions for pumping applications with this library
o
Auto-change functionality (ensures distribution of operation hours on the pumps)
Station Configuration, Pump Interface Blocks simplify configuration and interfacing to the drives.
The retain block stores selected values which have to sustain through power failures.
2.1.3 Optimization Blocks

The optimization blocks help in further optimizing the pumping station operation by providing additional
information or functionality to save energy and protect the equipment (pumps, pipes, tanks).
o The Flow Calculation block estimates with the help of the drives measured power output and few
pump curve data points of the PQ curve the actual flow, which can save a separate instrument
and its integration work.
o
The Energy Calculation block totalizes the flows and energy consumptions and provides
Efficiency values. If no flow-meter is there, the Flow calculation block can be used.
The Sleep function helps to save energy in PID operation if demand is low (e.g. at night in a
network) and works closely together with PID and boost block.
The Protection block provides advanced protections features for pump, pipe and tank based on
the available information in the station.
The Anti-Jam block provides a configurable cleaning function per used pump with a drive.
The below picture shows a complete overview of the concept and options with the pump library, including
auxiliary and optimization blocks.
For further details please check the application examples and their documentation, which are provided with
the PS563-WATER library product package and are also available for download from www.abb.com/plc
Application Examples (choose English as language for the page first). Please check also if a more up to
date version exists as a download.
AC500 / Issue: 09.2015
2.2 Preconditions for the Use of the PUMP_AC500_V23

Library
Note
Note
The application version of the library PUMP_AC500_V23.lib is tested with the equipment
and configuration used in the attached example programs "Example_
PM573_Boost_Ctrl.pro".
This example uses a PM573. A reduced Program for the Ac500 eco is available as well.
ABB ACQ810 drive is used with AC500 PLC via Modbus RTU communication.
Any other combination with AC500, other busses or drives equipment should work as well,
but is not separately tested
The Function Blocks of the PUMP_AC500_V23 library are only working in the RUN mode of
the PLC. Usage of these libraries in the simulation mode will not provide any valid or usable
diagnostic information
The Function Blocks of the library PUMP_AC500_V23.lib are available in AC500 control systems with a
runtime system of version V 1.3 and above.
2.3 Overview of the PUMP_Library Components according to

their Call Names
Block Name
Application Function blocks
PUMP_LEVEL_CTRL
PUMP_BOOST_CTRL
Function
Level control application block for filling or emptying of the

tank/container.
This block runs the single pump/ multi pump/ traditional pumping
stations up to three pumps
Auxiliary- and Configuration- Function blocks

PUMP_PID
This function block uses PID for closed loop control of pressure
PUMP_FLOW_CALC
Provides a flow estimation from drive power and pump curve values
PUMP_STATION_CFG
Configures pump station parameters
PUMP_RETAIN_DATA
Stores important values in retain memory for power loss situations
PUMP_INTERFACE
Configures and Interfaces to the pump, or the Drive of the pump
Optimization Blocks
PUMP_SLEEP
PUMP_ANTIJAM
PUMP_AUTOCHANGE
PUMP_PROTECTION
PUMP_ENERGY_CALC
Simulation Blocks
PUMP_TANK_SIMU
PUMP_DRIVE_SIMU
PUMP_DOL_SIMU
This block uses sleep mode of the pump to maximize energy saving
at the time low demand.
Pump cleaning functions
Changes Sequence of the pumps in the application control blocks
This block used for protection of the system against low or high
pressure and flow.
Calculates and Totalizes Energy and Flow Values and derived values
like efficiency and savings
This function block is Simple simulation of the water tank for
emptying and filling mode
This function block is Simple simulation of the drives and PLC
communication
This function block is Simple simulation of the Direct OnLine (DOL)
pumps.

AC500 / Issue: 09.2015
For all blocks except retain a visualization is available in the library.

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3.
Configuration
This chapter describes how to configure the ACQ810 drive and AC500 PLC for use with the example
programs. The examples are all using Modbus RTU (except the one with the drive simulation). Other Busses
or discrete connection via IO can be used as well.
The instructions in this chapter are intended to be used after the mechanical and electrical installation has
been completed, as explained in AC500 and ACQ810-quick installation guide. The document does not cover
the instructions related to mechanical and electrical installations to commission the AC500 and the ACQ 810
drives
FSCA is the field bus adapter which needs to be mounted for Modbus communication on the ACQ810
drives. The communication cable must connect the ACS500 COM1 port and the FSCA module on the
ACQ810 drive. For the detailed information related to the communication the FSCA user manual must be
referred.
3.1 Automation Builder configuration

The user must install the Automation Builder.Once the AB is installed the example program can be opened.
The same MODBUS setting must be given both in the automation builder project and in the drive parameters
1. In CBP, in the left pane, select the Interfaces.
2. Right Click COM1 and select Plug Device. A new window will open and then select COM1
Modbus.
3. In the right pane (Module parameters), configure the following parameters:
Name
Value
RTS control
Telegram
Baud Rate
19.2kbit/s (Same as in the Drive)
Parity
None (Same as in the Drive)
Data Bits
8 (Same as in the Drive)
Stop Bits
1 (Same as in the Drive)
Operation Mode
Master
Address
Since the mode of communication selected in MODBUS RTU, the COM1 port is configured to establish the
communication between the PLC and the drive. The configuration is given in the following picture.

AC500 / Issue: 09.2015
3.2 ACQ810 drive configuration

The ACQ810 parameterization can be done either using the keypad mounted on the drive or the drives
studio tool. The drives studio tool can be downloaded from www.abb.com/drives.
In the following table the parameter list is given. This parameterization is required to establish the MODBUS
communication between the AC500 and ACQ810.
All motor related parameters must be configured as per actual configuration.
User can set drive parameters for the Modbus communication using drive studio or keypad. ACQ810 drive
parameter list and values are as follows
Parameter
Name
Value
1001
EXT1 COMMANDS
FBA, Selects the source of start and stop

commands for external
control location 1 (EXT1).
2101
REF1 SEL
EFB ref1, Speed reference selection
5004
FBA REF1
Speed
5005
FBA REF2
Raw
5006
FBA ACT1
P.01.01 Motor Speed
5007
FBA ACT2
P.01.23 Motor Power
5801
PROTOCOL ENABLE
MODBUS RTU
5803
STATION ID
1 This parameter indicates slave ID. No two

drives on the same network can have the
same ID
5804
BAUD RATE
19.2kbit/s (192)
5805
PARITY
8 None 1
5806
CONTROL PROFILE
0, ABB Classic

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4.
Example programs
The example programs described in this chapter are designed for controlling and monitoring of water
pressure boost control and level control. In this chapter five example programs are explained in Detail:
Example Name
Complexity
Example_PM564_PUMP_Level_simple.project
Example_PM564_PUMP_Boost_simple.project
Example_PM573_PUMP_Boost_complete.project
Simple pumping
Example_PM573_PUMP_Boost_traditional.project
Example_PM573_PUMP_Boost_complete_sim.proj
ect
Application
block
Level control
Boost
Complete multi
pump
Complete traditional
pump setup
Complete multi
pump; with drive
simulation:
Chapter
4.1
4.2
4.3
4.4
4.5
All projects do have a simple simulation of pumps and a tank to enable a simple test and familiarization.
Once the library package is installed, the help files of the water library can also be found in the IEC-61131-3
Editor help.
In the Help Contents tab, expand
Target System > AC500 / S500 >Water Library
o
Getting help on a specific function block

In IEC-61131-3 Editor, select the title of the function block and press F1.
The library view also contains information on the function blocks and their inputs and outputs. Press Alt +
Enter to enter the library view.

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AC500 / Issue: 09.2015
4.1 Example Simple Level Control in PM 564

This program Example_PM564_PUMP_Level_simple.project supports following major functionalities
1.
Configuration of pump station with three pumps, each driven by motor and ACQ810 drive
2.
Level control application block
3.
Auto change function to optimize the duty cycle of the pump
Since the project is meant for a simple pumping station which controls level and uses few special functions,
PM 564 is an ideal CPU selection.
The right side picture shows the screenshot of the POUs in the example project
The application example Example_PM564_PUMP_Level_simple.project, has folders in which the

programs are put as per their functions. There are two main folders in the project, Simple Pumping and
Simulation Pump Station.
1) Simple Pumping It has two folders, Configuration programs and Pumping programs. The folder
Configuration Programs has programs related to configuration of station, settings of pumps and the
drive communication. The Pumping Programs folder contains the application related programs,
level control, auto-change and retain data.
2) Simulation Pump Station in this folder additional function blocks are provided, which allows a
simple simulation of a water process called PUMP_TANK_SIMU4.1.1 Configuration Programs
4.1.1.1 Station configuration

To configure the pumping station the function block PUMP_STATION _CFG is used.

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This function block creates the station Station1, with three pumps in the network. As discussed, each pump
is driven by the drive-motor combination.
The variable tsStationData is created as a global variable in the application program with the data type
PUMP_STATION_TYPE.
This tsStationData is an IN/OUT variable which links all the function blocks of the water library.
4.1.1.2 Pump interface

The PUMP_INTERFACE block needs to be inserted for each pump. In the project Pump1_Interface,
Pump2_Interface and the Pump3_Interface programs call the PUMP_INTERFACE function bock. This
block serves to configure the pump library parameters and interface to its drive as the actuator
As in this case each pump is driven by the motor-drive combination the function block takes the actual ready,
operating and the tripped status from the drive status word. Similarly it transfers the drive start command and
speed reference to the drive.
The PUMP_INTERFACE function block needs a unique pump identification number ranging
from 1-3 in this version of the library.
Note
Note
Note
If the priority of all the pumps is entered same then the starting sequence of the pump is in
the order of its Pump Id i.e. 1, 2 and 3.
If the user enters different priority values for each pump then the starting sequence of
pumps is based on the ascending order of the priority. Ex: Pump with the priority value 1
starts first and the priority value 2 starts later.
If the PUMP_INTERFACE is used to configure the pumps with the boost application then all
the pumps must have the same value of the FOLLOWER_MODE, which is setting the
follower mode of this pump in the boost operation.

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As it can be seen in the above screen shot the pump interface takes inputs from the drive status and then
sends the outputs to control the drive.
The following picture explains the interface between this function block and the ACS drive communication
blocks.
This function block also calculates the actual runtime of each pump. If the user wants to reset the actual
runtime of any pump = 0seconds, he/she needs to toggle the input PUMP_RUNTIME_RESET to TRUE
value.
4.1.2 Pumping programs

4.1.2.1 Level control
Prg1_PumpLevelCtrl program calls the PUMP_LEVEL_CTRL function block, which is designed for
controlling a station of 1 to 3 pumps that is used for either emptying or filling a container.
The level control functionality is activated by setting parameter level mode to Emptying or Filling. The
start levels for the pumps (as well as the alarm levels) are set by parameters.

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Note
The FB needs to define the various levels. These levels are accepted in a particular order,
which depends on the emptying or the filling mode.
Emptying mode :
LOW_LEVEL < STOP_LEVEL < START_LEVEL_1 < START_LEVEL_2 <
START_LEVEL_3 < HIGH_LEVEL
Filling mode :
LOW_LEVEL < START_LEVEL_3 < START_LEVEL_2 < START_LEVEL_1 <
STOP_LEVEL < HIGH_LEVEL
The level control function block is not designed to operate for the traditional pumping
station. It is only used for the pumping station where all the pumps are run by the drives.
Note
4.1.2.2 Auto-change function

This function is a special feature of the water library. Prg2_Autochange program calls the
PUMP_AUTOCHANGE function block which is used to optimize the duty time between multiple pumps by
varying the sequence in which pumps are started as the required pumping capacity increases.
There are three auto-change modes selectable by parameter auto-change style
1) Fixed intervals: The starting sequence is shifted periodically at pre-defined intervals auto-change
interval.
Example: in this case since there are three pumps with IDs 1, 2, 3 so the original sequence to run a
pump station becomes Pump1, Pump2 and Pump3. For the auto-change style = 1 and auto-change
interval 1hour. After every 1 hour if the situation is such that there are one or two pumps operating
such that there is at least one pumps spare, then the sequence changes from 1-2-3 to 2-3-1. Due to
which the pump with the highest runtime goes to stop.
2) Runtime equalization (Hour count): The starting sequence is rearranged when the difference
between the runtimes of two pumps exceed a limit. In the new sequence, the pump with the lowest
runtime will be started first; the pump with the highest runtime will be started last.
Example: in this case since there are three pumps with IDs 1, 2, 3 so the original sequence to run a
pump station becomes Pump1, Pump2 and Pump3. For the auto-change style = 2 and auto-change
runtime difference equal to 1hour. So if actual runtime difference between any two pumps exceeds
this limit, and the situation is such that there are one or two pumps operating and minimum one
pumps spare, then the sequence changes from 1-2-3 to 2-3-1. Due to which the pump with the
highest runtime goes to stop.
3) Auto-change when stopped (All stop): The starting sequence is shifted every time the pump stops.

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4.1.2.3 Retain data function

PUMP_RETAIN_DATA function block is designed to retain the data such as last operating sequence and
the pump runtime. This function block record the last data before the PLC power is switched off.
Especially when the auto change function is used, then PUMP_RETAIN_DATA helps to retain the last
sequence in which the pumps need to operate.
4.1.3 Simulation Pump Station

Simple simulation blocks on the process side are part of this example. The PUMP_TANK_SIMU function
block is used for a simple tank simulation.
4.1.3.1 Tank Simulation

Function block PUMP_TANK_SIMU basically simulates a tank with inlet, pumps and outlet flows. The
tank volume is calculated using height, depth, and width. The operation of the tank is selected (filling or
emptying) using the MODE input. Inlet flow, outlet flow and individual pump flow are used to calculate
cumulative water level in the tank. This water level is also converted to pressure (at the bottom = outlet of
the tank).
The actual flows of the pumps are connected to this function block as inputs. The output then can be
further used as a feedback to level control or boost control (or more exactly PID e.g. pressure).
The water volume can be set to an INITIAL_LEVEL using SET_LEVEL input in order to start a meaningful
simulation with a start level.
Note
Pump Flow Calc function block is not used in this program. User needs to connect flow
signal to PUMP1_ACT_FLOW, PUMP2_ACT_FLOW, and PUMP3_ACT_FLOW inputs of
the Tank Simulation Function Block.

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Note
This kind of simple simulation is intended only for simple off-site tests when hardware and
the water process are not available.
It can be used for lab type simulation only. It cannot be used to fully and accurately simulate
a real installation.
4.1.4 Visualization
The visualization screenshot shown below is used to control the example programs and the simulation of
the pump station and also to diagnose the actual status of the pump functions.
On the right hand upper part of the visualization the Simulation controls section enables the user to start
the simulation, enable level control function block and to start/ stop the level control function block.
Start Simu is used to start the simulation and water level will change depending upon inflow and outflow
of the tank.
Initial Volume can be set using set volume.

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4.2 Example Simple Boost Control in PM 564

This program Example_PM564_PUMP_Boost_simple.project supports following major functionalities
1.
2.
Boost control application block
3.
Since the project is meant for a simple pumping station which controls boost and uses few special functions,
PM 564 is an ideal CPU selection.
The application example Example_PM564_PUMP_Boost_simple.project, has folders in which the programs

are put as per their functions. There are two main folders in the project, Simple Pumping and Simulation
Pump Station.
Boost control, auto-change and retain data.
2) Simulation Pump Station in this folder the function block PUMP_TANK_SIMU is provided to
simulate the filling/ emptying process.

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4.2.1 Configuration Programs

This is already explained in earlier chapter. Please refer 4.1.1.1 for details.
4.2.1.2 Pump Interface

4.2.2.1 Boost control

Prg1_PumpBoostCtrl program calls the PUMP_BOOST_CTRL and PUMP_PID function block which is
designed for controlling a station of 1 to 3 pumps that is used for either emptying or filling a container.
Boost functionality is activated by setting parameter operation mode to single, multi pump and traditional
pump. Traditional mode takes care of conventional (only one pump with drive and remaining pumps with
DOL) pumping configuration , while multi pump takes care of unconventional (all pumps with separate
drives) pumping configuration.
Note
For this Function Block start and stop speed of the slaves needs to be defined in particular
order.
START_SPEED_SLV_1 < START_SPEED_SLV_2 ,
STOP_SPEED_SLV_1 < STOP_SPEED_SLV_2 ,
STOP_SPEED_SLV_1 < START_SPEED_SLV_1 and
STOP_SPEED_SLV_2 < START_SPEED_SLV_2
Function Block inputs OP_MODE and MASTER_LOC should not be changed while pump is
running.
Note
PUMP_PID is used for closed loop control of the process parameter such as pressure. The set point and
actual values are compared and error value is feed in as an input to the PID. PID output is calculated
based on proportional gain KP, Integral Time TN and Derivative time TD. The PID output is then scaled
and converted into required speed reference to the drive. PID_SPEED_REF is internally connected to the
PUMP_BOOSTPCTRL.
The PUMP_PID sends the speed reference based on the process demands to the PUMP_BOOST_CTRL
and then PUMP_BOOST_CTRL controls the start/stop sequence for the pumps based on the process
requirements.

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PUMP_PID Function Block works in the range of 0 100 % of set and actual value.
KP,TN, TD needs to calibrated as per process requirement.
Note


Note
1. All the pumping function programs which are using the data structure - STATION_DATA
must be called in the same task (it can be freewheeling or cyclic)
2. The retain data MUST be first in the list. This is to make sure that the data structure gets
updated with the last retained value before any pumping function uses it..

PUMP_TANK_SIMU function block is used for tank simulation 4.2.3.1
Tank Simulation
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AC500 / Issue: 09.2015
Note
Pump Flow Calc function block is not used in this program. User needs to connect flow
signal to PUMP1_ACT_FLOW, PUMP2_ACT_FLOW, and PUMP3_ACT_FLOW inputs of
the Tank Simulation Function Block.
4.2.4 Visualization
The visualization screenshot shown below is used to control the simulation of the pump station and also
to diagnose the actual status of the pump functions.
On the right hand top Simulation control section enables the user to start the simulation, enable PID, and
enable Pump Boost function block and to start/ stop the pump boost function.
of the tank.

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4.3 Example Multi Pump Boost Control w. auxiliary

functions in PM 573
This program Example_PM573_PUMP_Boost_complete.project supports following major functionalities
1.
2.
3.
4.
Additional pumping functionalities

Pump_Antijam, Pump_Flow_Calc, Pump_Protection, Pump_Sleep, Pump_Energy_Calc
Since the project is meant for a pumping station which controls Boost and uses all additional special
functions, PM 573 is an ideal CPU selection.

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AC500 / Issue: 09.2015
The application example Example_PM573_PUMP_Boost_complete.project, has folders in which the

simulate the filling/ emptying process
3) Additional Functionalities It has three folders, Pump1, Pump2 and Pump3. Each folder contains
special functions like Pump_Antijam, Pump_Flow_Calc, Pump_Protection and Pump_Sleep. These
function blocks provide additional features to the pump and they are used only if they are required
for process.






PUMP_TANK_SIMU function block is used for tank simulation


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AC500 / Issue: 09.2015
4.3.4 Visualization
of the tank.
4.3.5 Additional Functionalities

Additional Function blocks like Pump_Antijam, Pump_Flow_Calc, Pump_Protection and Pump_Sleep are
available for each pump.These Function Blocks can be used by pumps as per process requirement.
4.3.5.1 Pump Antijam

Pump cleaning function can be used to prevent solids from building up on pump impellers or piping. The
function consists of a programmable sequence of forward and reverse runs of the pump to shake off any
residue on the impeller or piping. This is specifically useful with booster and wastewater pumps.
The cleaning sequence can be programmed to occur at suitable intervals, or whenever certain triggering
conditions are met.

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AC500 / Issue: 09.2015
Not all pumps can be rotated in the reverse direction.

Note
There are various modes in which the anti-jam works,, which is decided by the input TRIGGER.
A) In auto mode, i.e., when the anti-jam needs to be called in the pump boost operations:
Note
In this version of the library the anti-jam auto modes i.e. TRIGGER = 1, 2, 3 are only
possible with the PUMP_BOOST_CTRL and not the PUMP_LEVEL_CTRL. However the
anti-jam manual mode i.e. TRIGGER = 4, is possible in both boost control and the level
control functionalities.
The anti-jam works for the following trigger:

1.
TRIGGER = 1, master enabled: the pump which is designated as master performs the anti-jam
operation when ever started.
2.
TRIGGER = 2, follower enabled: the pump which is the designated slave performs the anti-jam
operation whenever started.
3.
TRIGGER = 3, at start: whenever the pump starts is performs the specified anti-jam operation.
B) Manual mode of anti-jam operation

4.
TRIGGER = 4, manual mode:
To perform the anti-jam operation in the manual mode it is important to perform following step:
a) Assign PUMP_ON = FALSE, from the PUMP_INTERFACE block, for the pump which requires
manual anti-jam operation. This would not allow this pump to go in the pump boost or the level control
functionality, until PUMP_ON = TRUE again.
b) Enable the PUMP_ANTI_JAM function block by turning EN = TRUE.
c) Assign the input TRIGGER = 4
d) Enter all the anti-jam settings, i.e. time delays, speeds and no. of steps.
e) Give the rising edge input FALSE->TRUE, to the START_MANUAL
The above steps would start the anti-jam operation, which would stop at the end of designated time and
steps.

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AC500 / Issue: 09.2015
4.3.5.2 Pump Flow Calc

The flow calculation function provides a reasonably accurate (typically 58%) calculation of the flow
without the installation of a separate flow meter. The flow is calculated on the basis of pump
characteristics.
The user can define a PQ (power/flow) performance curve of the pump for the flow calculation function.
The P (power input) and Q (flow rate) coordinates of five points on the curve are entered. The values are
provided by the pump manufacturer. All points defined should lie within the practical operating range of
the pump.
Note
The flow calculation function is not to be used for invoicing purposes

The flow calculation function cannot be used outside the normal operating range
of the pump.
4.3.5.3 Pump Protection

This Function Block contains protective functions for two-level analog pressure monitoring of both the
inlet and outlet of the pump.
In analog monitoring, whenever the pressure being monitored meets the first limit, the drive indicates a
warning, trips on a fault, or starts to follow a pre-defined reference. When the second limit is met, the
drive either stops or trips on a fault.
Flow monitoring
The control program has a monitoring function for flow that can be configured to generate an alarm or a
fault whenever the flow falls below or rises above predefined limits. The flow can either be calculated or
measured using a flow meter connected to, for example, an analog input.

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AC500 / Issue: 09.2015
4.3.5.4 Pump Sleep

The sleep function is suitable for PID control applications where the consumption varies, such as clean
water pumping systems. When used, it stops the pump completely during low demand, instead of running
the pump slowly below its efficient operating range.
The water consumption falls at night. As a consequence, the process PID controller decreases the motor
speed. However, due to natural losses in the pipes and the low efficiency of the centrifugal pump at low
speeds, the motor would never stop rotating. The sleep function detects the slow rotation and stops the
unnecessary pumping after the sleep delay has passed. The drive shifts into sleep mode, still monitoring
the pressure. The pumping resumes when the pressure falls under the predefined minimum level and the
wake-up delay has passed.

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AC500 / Issue: 09.2015
4.3.5.5 Pump Energy Calculation

This function block calculates energy consumed by direct on line pumps and drive connected pumps.
This is then used to calculate saved energy by using drives. CO2 emission reductions and money saved
is also computed using energy saved.
It also calculates efficiency of flow verses power. Instant, Hourly and 24 hourly (daily) efficiency is
calculated continuously.
Total Volume and total Energy is calculated and connected as in out parameter to the function block. To
retain this data, Global retain variables needs to connected in the user program.

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AC500 / Issue: 09.2015
4.4 Example Traditional Pump Boost Control w. auxiliary

functions in PM 573
This program Example_PM573_PUMP_Boost_traditional.project supports following major functionalities
1.
Configuration of pump station with single pump driven by motor and ACQ810 drive, and up to two
other motors switched e.g. via a relay or soft starter direct on to the grid direct on-line DOL.
2.
3.
4.
Additional pumping functionalities for pump connected to ACQ810 drive

Pump_Antijam, Pump_Flow_Calc, Pump_Protection, Pump_Sleep,
5.
On / Off commands are generated for DOL motors.
The application example Example_PM573_PUMP_Boost_traditional.project, has folders in which the

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AC500 / Issue: 09.2015
simulate the filling/ emptying process.
3) Additional Functionalities It has one folders i.e. Pump1. This folder contains special functions like
Pump_Antijam, Pump_Flow_Calc, Pump_Protection and Pump_Sleep. These function blocks
provide additional features to the pump and they are used only if they are required for process.


The pumping station involves the traditional pumps which mean that the Pump1 is driven by the drive and
motor and the other pumps are running the DOL motors or the motor with the soft starters.
Pump1 needs to be configured the same way as defined in the section 4.1.1.2. The feedback signals from
drive have to be attached to the READY, OPERATING, TRIPPED inputs. Similarly the control signals
have to be sent back to the drive i.e. PUMP_START and PUMP_REF to the drive.
For the pumps which are connected to the DOL motor or the soft starter, it is important to connect the
TRIPPED signal, so that the pumping functions gets the status of an unhealthy motor. Since the DOL
mechanism might not have a good feedback system so it is not mandatory to connect the READY and
OPERATING input feedbacks to the PUMP_INTERFACE block. In the traditional pumps it is common not
to have such feedbacks. However if the system can send the correct READY and the OPERATING
status, then the programmer is advised to connect it as this would help to calculate the pump runtime.
Any speed inputs such as nominal speed and the follower speed values given to the pumps has not
significance since the traditional DOL operated motor runs at its own speed depending on the supply
voltage.
However all other inputs which are mentioned below work in the same way for both, the traditional and
the multi pump with drives.
PUMP_ID, PUMP_PRIORITY, PUMP_ON, FOLLOWER_MODE, STATION_DATA I/O.

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AC500 / Issue: 09.2015

This is already explained in earlier chapter. Please refer 4.2.2.1 for details. The prime difference is the
value of the input OP_MODE. Since the pumping station is the traditional pump, the input OP_MODE = 1.
It is not possible to operate the rotating master location i.e. MASTER_LOC = 0 when the OP_MODE = 1.
The function block throws error code 16#4043 for such combination.

This is already explained in earlier chapter. Please refer 4.1.2.2 for details. In the traditional pumping station
it is not necessary that the user gets the proper feedback mechanism for the actual motor status. In this
version of the library, because of this limitation, the traditional pump has not been provided the fixed auto
change mode and the runtime difference auto change mode. This is because both the auto change mode
needs to understand if the pump is in standby or in the operating condition.
So the auto change style = 3 is suitable for the traditional pumping station. When this style is selected, the
order would change from 1-2-3 to 2-3-1 to 3-1-2 whenever the pump boost control is restarted.

the pump runtime. This FB record the last data before the PLC power is switched off. Especially when the
auto change function is used, then PUMP_RETAIN_DATA helps to retain the last sequence in which the
pumps need to operate.


4.3.4 Visualization

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AC500 / Issue: 09.2015
of the tank.

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AC500 / Issue: 09.2015
4.5 Example Multi Pump Boost Control w. Drive Simulation

in PM 573
This program Example_PM573_PUMP_Boost_complete_sim.project supports following major
functionalities
1.
2.
3.
4.
Additional pumping functionalities

Pump_Antijam, Pump_Flow_Calc, Pump_Protection, Pump_Sleep
5.
Simple Drive Simulation Function block is used to simulate also drive functionality. This function
block simulates drive and generates status word and speed actual using control word and set speed.
The simulation of the drives enables a simple preparation and first testing of a new pumping station
project fully on an office desk, only with the use of a CPU. All other parts as drives, pumps and water
tank is simulated.

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AC500 / Issue: 09.2015
The application example Example_PM573_PUMP_Boost_complete_sim.project, has folders in which the

Additional Functions It has three folders, Pump1, Pump2 and Pump3. Each folder contains
special functions like Pump_Antijam, Pump_Flow_Calc, Pump_Protection and Pump_Sleep.
These function blocks provide additional features to the pump and they are used only if they
are required for process.
2) It has two folders, Tank_Simulation and Simulation_Drive_Comm_Block.

The folder Tank_Simulation contains the function block PUMP_TANK_SIMU used for tank
simulation This is already explained in earlier chapter. Please refer 4.1.3.1
The folder Simulation_Drive_Comm_Block contains thee function blocks PUMP_DRIVE_SIMU to
simulate the drive functionality including the the power consumption of the drive.
The following diagram shows how application and simulation blocks are interconnected:


34
AC500 / Issue: 09.2015




4.5.4 Visualization
of the tank.

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AC500 / Issue: 09.2015
4.5.5 Additional Functionalities

Additional Function blocks like Pump_Antijam, Pump_Flow_Calc, Pump_Protection and Pump_Sleep are
available for each pump.These Function Blocks can be used by pumps as per process requirement.
4.5.5.1 Pump Antijam

4.5.5.2 Pump Flow calc

4.5.5.3 Pump Protection

4.5.5.4 Pump Sleep


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4.5.6 Simple Drive Simulation

This function block simulates the drive functionality. It will simulate the drive status like Ready, Operating
and Tripped based on the Speed_reference and start Commands. This function block eliminates need of
the physical drive. This can be used effectively for demo and training purpose.
This PUMP_DRIVE_SIMU function block functionality is similar to the ACS_DRIVES_CTRL_STANDARD

from the PS553-DRIVES library.
Note
Note
1.
Simple drive simulation is prepared for the simulation purpose of the Drive
communication signals when physical drive is not present.
2.
It is an not an exact simulated replica of ACS_DRIVES_CTRL_STANDARD .
3.
Only drive healthy status and actual speed is simulated using start command and
reference speed.
4.
Actual power of the Drive is simulated based on the DRIVE_MAX_SPEED and

DRIVE_MAX_PWR inputs.

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AC500 / Issue: 09.2015
4.6 Quick Start Guide for Example Programs

All above example programs are tailor made and hence all the necessary interconnection are done for all
the function blocks. These programs can be downloaded to the PLC and once drive communication is
established with PLC, user can run this application.
All necessary function block are called in Task Configuration.
All the function blocks are called in freewheeling task except Pump Energy Calculation and
Simulation. Both these programs need to be in cyclic task of 50 ms.
Step 1.) Open the example xyz in Automation Builder

Check and adapt the example project configuration if necessary (see chapter 3.1)
Step 2.) Configure your drives (see chapter 3.2)
Step 3.) Start the AC500 IEC-61131-3 Editor program
Step 4.) Download the program to your PLC
(Clean and Rebuild all is recommended, go to Run)
Step 5.) Open the visualization xyz
Buttons Enable PI an BOOST are already enabled by default

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AC500 / Issue: 09.2015
Step 6.) press Buttons StartPumpBoost and Start Simu

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AC500 / Issue: 09.2015
Start pump boost starts the pump boost application, which defines which drive needs to be turned on and
the follower / slaves sequence. Drive Set point is generated by the difference of set and actual value of
PUMP_PID. If demand is more then the drives turn on one by one.
Step 7.) Press Set Volume sets the volume of tank using set Volume value given to the simulation
Function Block. Now all the drives are running as actual value of PID is still less than set value

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AC500 / Issue: 09.2015
As demand decreases means Actual value is approaches set value of PID, all the drives starts to switch off
as defined in Pump Boost Ctrl
Pump 2 and 3 has been turned off as demand decreases.
---------------------------------------------------------------------------------------
All the other example programs can be run using similar steps.
Note

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AC500 / Issue: 09.2015
5.
REVISION HISTORY
Rev. ind.
Page (P)
Chapt. (C)
Description
Date
Dept./Init
V01
All
Example water library document first release
V110
All
Simulation function block description and screenshots are

updated based on the new library V110.

42
17/10/2013
DMLP
15/09/2015
IDC/NKS
AC500 / Issue: 09.2015
abb
ABB Automation Products GmbH
Wallstadter Str. 59
68526 Ladenburg, Germany
Phone: +49 62 21 701 1444
Fax : +49 62 21 701 1382
E-Mail: plc.sales@de.abb.com
www.abb.com/plc
Note:
We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed
particulars shall prevail. ABB AG does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.
We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its
contents in whole or in parts is forbidden without prior written consent of ABB AG.
Copyright 2012 ABB , All rights reserved

PUMP - Lib V23 Examples - Description V110 3ADR023042M9901

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Example Description V110

PS563-WATER Library Package

INTRODUCTION TO DOCUMENT ............................................................................. 3

Overview of Water Pumping Library ........................................................................ 4

Example programs .................................................................................................. 11

4.1.2 Pumping programs ....................................................................................................... 14

4.1.3 Simulation Pump Station .............................................................................................. 16

4.2.3 Simulation Pump Station .............................................................................................. 20

Simple Pumping - Water Library

AC500 / Issue: 09.2015

4.3.1.2 Pump Interface ..................................................................................................................... 23

4.3.2 Pumping programs ....................................................................................................... 23

4.3.3 Simulation Pump Station .............................................................................................. 23

4.4.2 Pumping programs ....................................................................................................... 31

4.4.3 Simulation Pump Station .............................................................................................. 31

4.5.2 Pumping programs ....................................................................................................... 35

4.5.3 Simulation Pump Station .............................................................................................. 35

4.5.6 Simple Drive Simulation................................................................................................ 37

Simple Pumping - Water Library

AC500 / Issue: 09.2015

4.6 Quick Start Guide for Example Programs ........................................................................ 38

REVISION HISTORY ................................................................................................ 42

Simple Pumping - Water Library

AC500 / Issue: 09.2015

1.1 Scope of the document

1.2 Overview of the Content

1.4 Safety Instructions

Simple Pumping - Water Library

AC500 / Issue: 09.2015

Overview of Water Pumping Library

Level control: Used for tank or reservoir filling or emptying applications

Simple Pumping - Water Library

AC500 / Issue: 09.2015

2.1.1 Application Blocks

Simple Pumping - Water Library

AC500 / Issue: 09.2015

2.1.2 Auxiliary Blocks

Auto-change functionality (ensures distribution of operation hours on the pumps)

2.1.3 Optimization Blocks

AC500 / Issue: 09.2015

2.2 Preconditions for the Use of the PUMP_AC500_V23

2.3 Overview of the PUMP_Library Components according to

Level control application block for filling or emptying of the

Auxiliary- and Configuration- Function blocks

Simple Pumping - Water Library

AC500 / Issue: 09.2015

For all blocks except retain a visualization is available in the library.

Simple Pumping - Water Library

AC500 / Issue: 09.2015

3.1 Automation Builder configuration

19.2kbit/s (Same as in the Drive)

None (Same as in the Drive)

8 (Same as in the Drive)

1 (Same as in the Drive)

Simple Pumping - Water Library

AC500 / Issue: 09.2015

3.2 ACQ810 drive configuration

FBA, Selects the source of start and stop

EFB ref1, Speed reference selection

P.01.01 Motor Speed

P.01.23 Motor Power

1 This parameter indicates slave ID. No two

Simple Pumping - Water Library