Rockwell Automation 1413-ME-PEA User Manual

Capacitor Bank Controller

1413-CAP

User Manual

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com

) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

IMPORTANT

ATTENTION

Identifies information that is critical for successful application and understanding of the product.

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence

SHOCK HAZARD

Labels may be located on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD

Labels may be located on or inside the equipment, for example, a drive or motor, to alert people that surfaces may be dangerous temperatures.

Allen-Bradley, Rockwell Automation, ControlLogix, Powermonitor 3000, MicroLogix, PanelView 550, PanelBuilder32, and RSLinx are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Preface

General Information

Installation

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . 3

Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Description of the Capacitor Bank Controller . . . . . . . . . . . . . 5

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 2

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Optional Additional Powermonitor Meters . . . . . . . . . . . . 8

System Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Base System with Serial Options. . . . . . . . . . . . . . . . . . . . 9

Base System with Ethernet Options. . . . . . . . . . . . . . . . . 10

Assemble, Mount, and Connect Your Controller . . . . . . . . . . 11

MicroLogix 1500 Controller (All Configurations) . . . . . . . 11

AIC + Interface Converter (All Configurations) . . . . . . . . 14

Powermonitor Meter (All Configurations) . . . . . . . . . . . . 14

PanelView 550 Serial Terminal (Serial HMI options) . . . . 16

PanelView 550 Ethernet Terminal (Ethernet HMI Option) 18

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Communications Configuration . . . . . . . . . . . . . . . . . . . . . . 20

Base Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Serial HMI Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Ethernet HMI Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Additional Powermonitor Meters Option . . . . . . . . . . . . . 22

Powermonitor Meter Configuration . . . . . . . . . . . . . . . . . . . 23

Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 24

Set Parameters with the Powermonitor Display Module . . 24

Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Use the DAT for Configuration . . . . . . . . . . . . . . . . . . . . 31

Configuration with the PanelView 550 Terminal

(Optional HMI Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Chapter 3

Operation

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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

CTPT Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Operator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Data Access Terminal (DAT) . . . . . . . . . . . . . . . . . . . . . 40

Optional PanelView 550 HMI . . . . . . . . . . . . . . . . . . . . . 42

2 Table of Contents

SCADA Interface

Add Special Functionality

Catalog Number Explanation

Chapter 4

Power-circuit Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Chapter 5

PFMGR4 Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Power Factor Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Step Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Step Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

User Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Appendix A

Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

With Serial Powermonitor 1413-CAP-MS A . . . . . . . . . . . 61

With Ethernet Powermonitor 1413-CAP-ME A . . . . . . . . . 62

Additional HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Serial Base Unit with Serial HMI 1413-CAP-MS-PS A . . . . 62

Serial Base Unit with Ethernet HMI 1413-CAP-MS-PE A . . 62

Ethernet Base Unit with Ethernet HMI 1413-CAP-ME-PE A 62

Glossary

Index

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Preface

Read this to familiarize yourself with the rest of the manual. It provides information concerning:

• who should use this manual.

• where to go for more information.

Who Should Use This Manual

Additional Resources

Use this manual if you are responsible for designing, installing, programming, or troubleshooting the Capacitor Bank Controller system.

You should have a basic understanding of electrical circuitry and familiarity with relay logic. If you do not, obtain the proper training before using this product.

Please refer to the following publications for additional information on how to assemble, install, connect, operate and maintain your capacitor bank controller.

Additional Resources

For This Information Refer to Publication

MicroLogix 1500 Technical Data 1764-TD001

MicroLogix 1500 User Manual 1764-UM001

Powermonitor 3000 Installation Manual 1404-IN007

Powermonitor 3000 User Manual 1404-UM001

Powermonitor 3000 Display Module Installation Manual

PanelView 550 Installation Guide 2711-IN009

PanelView Standard Operator Terminals User Manual

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1404-IN005

2711-UM014

4 Preface

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General Information

Chapter

Introduction

Description of the Capacitor Bank Controller

The capacitor bank controller is a replacement for standard, fixed-function capacitor controllers currently on the market. The controller consists of standard, off-the-shelf, Allen-Bradley hardware with the application ladder code necessary to perform power factor correction. The controller is designed to provide the same base functionality as a fixed-function capacitor bank controller. Also, you may add additional code to the controller to fit its functionality to special circumstances.

The capacitor bank controller is a pre-engineered control system containing a MicroLogix 1500 controller, a standard data access terminal (DAT), one or more Powermonitor 3000 modules, and an optional additional human-machine interface (HMI). Pre-engineered ladder logic code in the controller gathers real and reactive power data from up to four power feeds (utility feeds and/or generators). The logic operates on the data in standard engineering units of kVAR and kW and acts to minimize imported and exported reactive power by switching up to 10 steps of capacitance. This strategy controls power factor while reducing the likelihood of voltage surge caused by excessive kVAR export.

Functions

• Auto configure

• Manual configure

• Discharge timer on each step

• Selectable operating modes

– Manual operation – Linear, last-in, first-out – Balanced, level-out usage of capacitor steps – Optimal, finds best match of capacitor step to system kVAR

needs

– Special, customer-defined – %THD, Linear mode with a voltage %THD setpoint

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6 General Information

• Alarms

– Bad step, indicates blown fuse, capacitor failure – Target power factor not achieved – High / Low voltage – %THD High – Current unbalance – Metering

• Powermonitor data concentrated into the MicroLogix 1500 controller

• Phase current, line voltage, frequency, real and reactive power, power factor and THD

Options

• Up to three additional Powermonitor meters to aggregate up to four total feeds

• PanelView 550 keypad HMI terminal with serial or Ethernet communications

• Ethernet Powermonitor meters to produce power and energy data via your local area network

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Chapter

Installation

The capacitor bank controller system is supplied as a number of components that you assemble, install, and connect in a suitable enclosure.

System Components

All Configurations

Key Quantity Part Number Description

1 1 1764-24BWA MicroLogix 1500 base unit with: 120/240V ac control power,

2 1 1764-LRP MicroLogix 1500 enhanced processor

3 1 1764-DAT MicroLogix 1500 data access tool

4 1 1761-NET-AIC Advanced interface converter (used for PM comms)

5 1 1761-CBL-AC00 MicroLogix controller to AIC+ cable, 9-pin D-shell to 9-pin D-shell,

6 1 1404-DM Powermonitor 3000 display unit with 3 m (9.84 ft) cable

Base Unit with Serial Meter 1413-CAP-MSA

Key Quantity Part Number Description

7 1 1413-M5000 A Powermonitor 3000-M5 meter with RS-485 communications port

The key number in the component lists are referenced in the illustrations that follow.

(12) 24V dc inputs, and (12) relay outputs

cm (17.1 in.) long

including programmed MicroLogix 1500 8 k memory module with real-time clock (1764-MM1RTC)

Base Unit with Ethernet Meter 1413-CAP-MEA

Key Quantity Part Number Description

7 1 1413-M5ENT A Powermonitor 3000-M5 meter with Ethernet communications port

including programmed MicroLogix 1500 8 k memory module with real-time clock (1764-MM1RTC)

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8 Installation

Optional Serial HMI, Serial Meter 1413-CAP-MS-PSA

Key Quantity Part Number Description

7 1 1413-M5000NM A Powermonitor 3000-M5 meter with RS-485 communications port

including programmed memory module with real-time clock (1764-MM1RTC) and programmed 2 MB flash memory card (2711-NM13)

8 1 2711-NC21 PanelView terminal to MicroLogix communication cable

9 1 2711-K5A16 PanelView 550 operator terminal with RS-232 DF1 serial

communications

Optional Serial HMI, Ethernet Meter 1413-CAP-ME-PSA

Key Quantity Part Number Description

7 1 1413-M5ENTNM A Powermonitor 3000-M5 meter with RS-485 and Ethernet

communications ports including programmed memory module with real-time clock (1764-MM1RTC) and programmed 2 MB flash memory card (2711-NM13)

8 1 2711-NC21 PanelView terminal to MicroLogix controller communication cable

9 1 2711-K5A16 PanelView 550 operator terminal with RS-232 DF1 serial

communications

Optional Ethernet HMI 1413-CAP-ME-PEA

Key Quantity Part Number Description

7 1 1413-M5ENTNM A Powermonitor 3000-M5 meter with RS-485 and Ethernet

communications ports including programmed memory module with real-time clock (1764-MM1RTC) and programmed 2 MB flash memory card (2711-NM13)

10 1 1761-NET-ENIW MicroLogix Ethernet interface module with Web interface

11 1 1761-CBL-AM00 MicroLogix controller to AIC+ cable, 8-pin DIN to 8-Pin DIN, 45 cm

(17.1 in.) long

12 1 3.05 m (10 ft) CAT5 Ethernet crossover cable

13 1 2711-K5A20 PanelView 550 operator terminal with Ethernet/IP communications

Optional Additional Powermonitor Meters

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The controller is designed to operate with up to three additional Powermonitor meters. Additional Powermonitor meters must be ordered separately. Please contact your local Allen-Bradley distributor for information.

Installation 9

System Architecture

This section illustrates the base system with the serial and Ethernet options.

Base System with Serial Options

F10

7 8 9

4 5 6

1 2 3

. 0 -

<--

< >

PanelView 550

<-------'

Allen-Bra dle y

F1F6F2F7F3F8F4F9F5

Optional Serial HMI

25.04M WATT

Powermonitor 3000Allen-Bradley

25.04M WATT

Powermonitor 3000Allen-Bradley

25.04M WATT

Powermonitor 3000Allen-Bradley

25.04M WATT

Powermonitor 3000Allen-Bradley

Allen-Bradley Powermonitor 3000Allen-Bradley P owermonitor 3000Allen-Bradley Powermonitor 3000Allen-Bradley Powermonitor 3000

Optional Additional Powermonitor Meters

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10 Installation

Base System with Ethernet Options

F10

7 8 9

4 5 6

1 2 3

. 0 -

<--

< >

PanelView 550

<-------'

Allen-Bradley

F1F6F2F7F3F8F4F9F5

Optional Ethernet HMI

Ethernet Local Area Network by Customer

25.04M WATT

Powermonitor 3000Allen-Bradley

25.04M WATT

Powermonitor 3000Allen-Bradley

25.04M WATT

Powermonitor 3000Allen-Bradley

25.04M WATT

Powermonitor 3000Alle n-Bradley

Allen-Bradley Po wermonit or 3000Allen-Bradley Powermonitor 3000Allen-Bradley Powermonitor 3000Allen-Bradley Powermonitor 3000

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Optional Additional Powermonitor Meters

TIP

Ethernet crossover cable (12) is used if there is no connection to a local area network.

Installation 11

Assemble, Mount, and Connect Your Controller

This section describes how to mount the MicroLogix 1500 controller and connect it to an AIC+ interface and PanelView module for use with the capacitor bank controller.

MicroLogix 1500 Controller (All Configurations)

TIP

1. Mount the MicroLogix 1500 base unit (1).

Please refer to Publication 1746-UM001, Chapter 2, for information on performing these tasks.

Mounting Template

2. Install the MicroLogix 1500 processor module (2).

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12 Installation

3. Install the MicroLogix memory module (7a).

This module may be found packaged with the Powermonitor meter (7).

4. Install the data access terminal (3).

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5. Connect the MicroLogix 1500 controller to 120V ac control

power, earth ground, capacitor step contactors (or interposing relays as required), and an alarm circuit as shown in the wiring diagram.

Wire the Controller

Fault-protection relays can be used to immediately discharge all or specific capacitor steps during a fault occurrence. Input 0 is wired to a normally closed fault-protection relay and discharges all capacitor steps during a fault occurrence (low-state condition). Inputs 1… 10 are wired to normally closed fault-protection relays, and discharges its respective capacitor step during a fault occurrence (low-state condition). If fault protection is not being used for a specific capacitor step, then that respective input is wired closed using the controller supplied 24V dc power.

A normally-open momentary pushbutton is wired to Input 11. This pushbutton is used to reset the controller after a fault occurrence.

Fault Relay Power

Installation 13

Output 0 is used as an alarm relay and is wired normally open to an external alarm indicator. Output 1…10 is wired to normally-open contactors for each respective capacitor step.

Controller Wiring Diagram

Capacitor Step Contractors or Interposing Relays

Inputs

1764-24BWA

Outputs

24V dc to AIC+

85-265

VAC

120V ac Control Power

Isolated Alarm Output

POWER

OUT

VDC 0

Ground

Capacitor Step Control Power

VAC

COM

VDC 1

VAC

Master Fault Relay

Group 0

COM 0

I / 0

VAC

VDC 2

O / 1O / 0 O / 2

Group 1

Fault Relay 2

Fault Relay 1

I / 1

I / 2

VAC

VDC 3

Group 2

Fault Relay 3

I / 3

COM 1

VAC

VDC 4

O / 3

Group 3

Fault Relay 4

I / 4

I / 5

O / 5

O / 4

Group 4

Fault Relay 6

Fault Relay 5

Fault Relay 7

Group 1

I / 6

O / 6 O / 9

Group 2

COM 2

I / 7

O / 7 O / 8

VAC

VDC 5

Group 5

Fault Relay 8

I / 9

I / 8

Fault Relay 9

Fault Relay 10

I / 11

I / 10

O / 10

O / 11

Reset

24BWA

Spare Output

Capacitor Step Contractors or Interposing Relays

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14 Installation

AIC + Interface Converter (All Configurations)

1. Mount the AIC+ communications converter (4) within 45 cm

(18 in.) of the left edge of the MicroLogix 1500 controller.

2. Connect the DB9 to DB9 cable (5) between Port 1 of the AIC+

(4) and Channel 1 of the MicroLogix 1500 controller (1).

3. Connect a source of 24V dc to the control power terminals on

the bottom of the AIC+.

The 24V dc power may be obtained from the DC Power Out terminals on the MicroLogix 1500 controller.

4. Verify that the DC Source switch is in the External position and

that the Baud Rate selector is set to ‘Auto’.

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Powermonitor Meter (All Configurations)

1. Mount the Powermonitor meter (7) within 1200 m (4000 ft) of

the AIC+ communications converter (4).

2. Use a 2-conductor shielded cable, that you provide, to connect

the AIC+ RS-485 port to the Powermonitor RS-485 port.

Installation 15

AIC+

24 V Power Supply

Blue

CLR

SHLD

Powermonitor 3000 Device

SHLD

RS-485

Red

Black

AIC+ Powermonitor 3000 Meter

A -

B +

SHLD SHLD

Blue

CLR

SHLD

3. Connect any additional, optional Powermonitor meters RS-485

ports in a daisy-chain fashion, + to +, - to -, Shld to Shld.

In certain cases, terminating resistors may improve communications robustness.

Refer to publication 1404-IN007 for more information.

4. Connect the Powermonitor meter to the power circuit, control

power, and earth ground.

See the instructions found in publication 1404-IN007.

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16 Installation

PanelView 550 Serial Terminal (Serial HMI options)

1. Mount the PanelView 550 HMI terminal in a suitable cutout

within 5 m (16 ft) of the MicroLogix controller.

Refer to publication 2711-IN009 for detailed installation instructions.

Mounting Studs

(3 Top / 3 Bottom)

Protective Installation Label

Self-locking Nuts

(6 used, 8 provided)

2. Install the memory card and retainer.

Memory Card

Retainer

Retainer Base

Base Mounting Screws

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3. Connect 120V ac control power and earth ground.

Installation 17

Power Terminal Block (fixed)

120/240V ac, 3 Wire,

U.S. Color Code

GND GND

Green

Black (Line)

White

(Neutral)

Green

(Earth Ground)

(Earth Ground )

To P ower Sou rc e

120/240V ac,

3 Wire, European

Harmonized Color Code

Brown (Line)

Blue

(Neutral)

Green/Yellow

(Protective Earth)

To Power Source

4. Connect the communications cable between the MicroLogix

1500 controller Channel 0 and the PanelView 550 terminal serial port.

Printer Port

Comm Port

2711-NC21

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18 Installation

PanelView 550 Ethernet Terminal (Ethernet HMI Option)

1. Mount the PanelView 550 HMI terminal in a suitable cutout

within 100 m (328 ft) of the MicroLogix controller.

Refer to publication 2711-IN009 for detailed installation instructions.

Mounting Studs

(3 Top / 3 Bottom)

Protective Installation Label

Self-locking Nuts

(6 used, 8 provided)

2. Install the memory card (7b, packed with the Powermonitor

meter) and retainer.

Memory Card

Retainer

Retainer Base

Base Mounting Screws

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3. Connect 120V ac control power and earth ground.

Installation 19

Power Terminal Block (fixed)

120/240V ac, 3 Wire,

U.S. Color Code

GND GND

Green

Black (Line)

White

(Neutral)

Green

(Earth Ground)

(Earth Ground )

To P owe r S our ce

120/240V ac,

3 Wire, European

Harmonized Color Code

Brown (Line)

Blue

(Neutral)

Green/Yellow

(Protective Earth)

To Power Source

4. Install the Ethernet interface module (9) within 45 cm (18 in.) of

the Channel 0 connector on the MicroLogix 1500 controller (1).

To Ethernet LAN

ETHERNET

RS232

FAULT

NET

TX/RX

PWR

CABLE

EXTERNAL

5. Verify that the DC Source switch on the Ethernet interface

module is in the Cable position.

6. Connect the cable (11) between Channel 0 of the MicroLogix

1500 controller and the Ethernet interface module.

7. Connect the PanelView 550 terminal to the Ethernet interface

module using the Ethernet crossover cable (12) if the system will not be connected to a local area network.

8. Connect both the PanelView 550 terminal and the Ethernet

interface module to the Ethernet local area network via a suitable hub or switch using user-provided CAT5 Ethernet cables if the system will be connected to a local area network.

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20 Installation

Configuration

The capacitor bank controller base unit has been set up to require minimal out-of-box configuration.

The base system has default communications settings. Certain circumstances and options require additional configuration of communications, which may include the use of programming software not included with the controller.

You are required to configure the Powermonitor meters to coordinate them to the power circuit in the base unit and all options. Configuration of the Powermonitor meter is performed using the display module.

The controller requires configuration to coordinate it to the number and size of steps that exist in the capacitor bank being controlled, as well as the desired operating mode and other selections. Use the data access terminal (DAT) or the optional PanelView 550 operator terminal to configure the controller.

ATTENTION

Do not operate the capacitor bank controller without first configuring it to suit the controlled capacitor bank and system options. Unpredictable operation, including undesirable power system effects, may result.

Communications Configuration

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The following sections provide information on configuring communications for the components.

Base Unit

Communications settings are factory configured. The MicroLogix 1500 controller settings are contained in the EEPROM memory module. Powermonitor meter settings are stored in onboard non-volatile memory (NVRAM). Configuration settings are listed below.

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