{"id":1834,"date":"2018-03-12T05:12:57","date_gmt":"2018-03-12T05:12:57","guid":{"rendered":"https:\/\/wireless-telemetry.com\/blog\/?p=1834"},"modified":"2018-03-12T05:12:57","modified_gmt":"2018-03-12T05:12:57","slug":"navionics-research-introduces-allen-bradley-architecture-class-variable-frequency-drive-to-critical-pumping-station","status":"publish","type":"post","link":"https:\/\/wireless-telemetry.com\/blog\/?p=1834","title":{"rendered":"Introducing Architecture-Class Variable Frequency Drives from Allen Bradley for Critical Pumping Stations"},"content":{"rendered":"
\"admin\"

Jim Mimlitz, NRI<\/p><\/div>\n

Navionics Research Inc. is pleased to introduce the PowerFlex 753-Series VFD<\/strong><\/a>\u00a0to our Water and Wastewater Utility Clients.\u00a0 This Architecture-Class, Made in the USA<\/strong>\u00a0drive from Allen Bradley<\/strong> offers a modular design and can be flexibly configured for most any potable water or wastewater pumping application.<\/p>\n

We recently had the privilege of commissioning a 150 HP PowerFlex 753<\/strong> at Gateway Regional Water District as part of an emergency repair project at their critical raw water intake.\u00a0 During the course of this project, NRI’s VFD & Energy Analytics Firmware Module<\/strong> was expanded to accommodate the nuances of the PowerFlex 753’s 32-bit Modbus control and monitoring data structures.<\/p>\n

Additionally, in order to enhance electrical protection for both the VFD and the Pump Motor, a\u00a0Line Reactor<\/strong><\/a>\u00a0and dV\/dT Load Filter<\/strong><\/a>\u00a0(MTE Corporation<\/strong><\/a>) were provided to condition the incoming and outgoing power, respectively.<\/p>\n

The project was a successful joint-venture between Navionics Research Inc.<\/strong> and JF Electric (Edwardsville, IL)<\/a>, <\/strong>with excellent support by NRI’s vendors French Gerleman (St. Louis, MO | Quincy, IL | Columbia, MO)<\/strong><\/a>,\u00a0Rockwell Automation\/Allen Bradley (Milwaukee, WI)<\/strong><\/a> and Fabrication Specialists (Alton IL)<\/strong><\/a>.<\/p>\n

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Pump Station Electrical and Chemical Feed Building.<\/p><\/div>\n

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Pump Station Motor and Pump Building.\u00a0 Note the Dual 150HP\/480VAC\/3-\u03c6\u00a0Submersible Pumps and Above-Grade-Mounted Motors.<\/p><\/div>\n

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Damaged Legacy VFD, Before Replacement.<\/p><\/div>\n

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Installation of New VFD, Reactors, and dV\/dT Filter by Trevor Kurlbaum, J. F. Electric.<\/p><\/div>\n

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Legacy Back Panel. Note that Shallow Depth and Proprietary Cutout for One Particular Make\/Model VFD \u2014 Which Was No Longer Available.\u00a0 A Replacement Full-Depth Back Panel Design Was Submitted to Our Local Machine Shop, Fabrication Specialists (Alton, IL), for Construction.<\/p><\/div>\n

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Replacement Back Panel: Painted and Installed.<\/p><\/div>\n

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New Allen Bradley PowerFlex 753 VFD. Note That the New Back Panel Allowed for the Full-Depth of the Bay to be Utilized.<\/p><\/div>\n

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Line Reactor Installed to Condition Incoming Utility Power, Providing a Measure of Protection to the New VFD.<\/p><\/div>\n

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DV\/DT Filter Installed on the Outgoing Power Cables to the Motor, Providing a Measure of Protection to the Motor Windings and Bearings. This Was Especially Important, Due to the Long Length (~200 Ft.) of these Cables.<\/p><\/div>\n

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New #1 Pump VFD to the Left. Legacy #2 Pump VFD to the Right.<\/p><\/div>\n

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Repair\/Replacement Completed.<\/p><\/div>\n

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Allen Bradley 20-COMM-H Modbus\/RTU RS-485 Network Communication Module.<\/p><\/div>\n

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Allen Bradley PowerFlex 20HIM-C6 VFD User Interface. Panel-Mounted over Hole for Legacy Display. The 20HIM-C6 Is Used Extensively During Initial Setup. After Commissioning, the Customer Can Monitor and\/or Manually Control the VFD Using This User-Friendly Interface.<\/p><\/div>\n

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Allen Bradley PowerFlex 753 Factory: Mequon, Wisconsin.<\/p><\/div>\n

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PowerFlex 753 Nameplate. Made in the USA in Mequon, Wisconsin.<\/p><\/div>\n

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NRI VFD & Energy Analytics: Enhanced Monitoring and Control of Variable Frequency Drives<\/strong><\/h3>\n

In order to fully take advantage of the new PowerFlex 753 VFD, NRI installed its new VFD & Energy Analytics Firmware<\/strong> module. This new module allowed for enhanced monitoring and control of the drive using the industry-standard Modbus\/RTU Protocol<\/strong>. The following historical trending charts illustrate a sampling of the new capability:<\/p>\n

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24-Hr History Chart: VFD Running.<\/p><\/div>\n

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24-Hr History Chart: VFD Speed (0-100%).<\/p><\/div>\n

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24-Hr History Chart: Pump Flow (Gallons per Minute).<\/p><\/div>\n

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24-Hr History Chart: VFD Output Power (KW).<\/p><\/div>\n

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24-Hr History Chart: Pump GPK Efficiency (Gallons per Kilowatt-Hr). The average GPK depicted in this chart is 1250. \u00a0If, for example, the cost of a Kilowatt-Hr is $0.10, then the Water District is able to pump 12,500 gallons of water per $1.00 of electricity. Alternatively, the ratio can be inverted to show that the Water District pays $0.08 (electricity) per 1000 gallons to pump from the Lake Intake to the Plant.<\/p><\/div>\n

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24-Hr History Chart: VFD Bus Voltage, Normalized to 480V Reference. Note that the Bus Voltage dips by approximately 5% while the Pump Running, which is Normal.<\/p><\/div>\n

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24-Hr History Chart: VFD Internal Temperature (degF). Note that the VFD Temperature Rises by Approximately 40 degF while the Pump is Running. A Cooling Fan Failure can be easily detected as an Abnormally-High increase in VFD Temperature.<\/p><\/div>\n

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24-Hr History Chart: Detected VFD Fault Codes. No Fault Codes Were Detected During this 24-Hr Period. Fault Codes are Represented as an Integer, whose Meaning can be Interpreted from a Lookup Table.<\/p><\/div>\n

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New Setpoints Were Programmed to Provide the Operators with the Ability to Reset VFD Faults Remotely using the SCADA System GUI.<\/p><\/div>\n

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NRI’s VFD & Energy Analytics Firmware<\/strong> provides a groundbreaking, unique ability to monitor overall pumping system efficiency in the form of Gallons-per-KilowattHr (GPK)<\/strong>, which is analogous to MPG for a vehicle.\u00a0 GPK<\/strong> was formulated by NRI as the ratio of Pump Flow-Rate<\/strong> (Gallons per Hour) divided by VFD Output Power<\/strong> (KW). This unique efficiency measurement represents an advance in the state-of-the-art of rural water SCADA monitoring.<\/p>\n

Bus Voltage<\/strong>\u00a0\u2014 an important VFD and Electric Utility health measurement \u2014 is monitored, trended, and alarmed in the system.\u00a0 VFD Temperature<\/strong> is another valuable data tag, which helps the Water Utility to avert temperature-related failures that can occur due to fan failures. Note that there are cooling fans in the VFD, as well as in the overall Motor Control Center.<\/p>\n

About Modbus:\u00a0<\/strong>One of the key industrial protocols utilized within Navionics Research SCADA Systems to communicate with VFD’s and other smart devices, MODBUS has become a de facto standard of industrial\u00a0communication protocols. It is an especially important protocol when connecting control equipment from an in-homogeneous set of manufacturers. Gathering momentum and support since 1979 when it was first introduced by Modicon (now a division of Schneider Electric), it is the most common means of connecting industrial electronic devices. It is openly published, royalty-free, and forms a relatively easy-to-deploy industrial network.<\/p>\n

Conclusion:<\/strong><\/h3>\n

NRI’s first pump application using Allen Bradley’s Architecture-Class PowerFlex 753<\/strong> was interesting, exciting, and\u00a0\u2014 most importantly \u2014 successful!<\/strong><\/em>\u00a0 Furthermore, the expertise that was gained during this project is ready to be applied to Water Plants and Pumping Stations throughout the Region.\u00a0 Are you interested in upgrading to a PowerFlex 753 VFD?\u00a0 If yes, then let me know, and we’ll get started.<\/p>\n

And as always, if you have any questions, please don’t hesitate to reach out by phone or email.<\/p>\n

Telemetry, SCADA, & Controls Newsletter<\/strong><\/p>\n

Was this article helpful?\u00a0 Would you be interested in receiving updates such as these in our occasional email-delivered newsletter?\u00a0 If so, here’s our sign-up page:<\/p>\n

Subscribe to\u00a0Navionics Research’s\u00a0“Telemetry, SCADA, & Controls Newsletter”<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"

Navionics Research Inc. is pleased to introduce the PowerFlex 753-Series VFD\u00a0to our Water and Wastewater Utility Clients.\u00a0 This Architecture-Class, Made in the USA\u00a0drive from Allen Bradley offers a modular design and can be flexibly configured for most any potable water or wastewater pumping application. We recently had the privilege of commissioning a 150 HP PowerFlex …<\/span> Read More →<\/span><\/a><\/span><\/p>\n","protected":false},"author":1,"featured_media":1866,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[3,4,9,12,15,20],"tags":[25,32,47,89,90,103,105,125],"class_list":["post-1834","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-applications","category-communications","category-industrial-pc","category-pc-based-controls","category-rtu","category-vfd","tag-allen-bradley","tag-architecture-class-vfd","tag-custom-back-panel","tag-modbus","tag-modbus-rtu","tag-powerflex","tag-powerflex-753","tag-rs-485"],"_links":{"self":[{"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=\/wp\/v2\/posts\/1834","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=1834"}],"version-history":[{"count":1,"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=\/wp\/v2\/posts\/1834\/revisions"}],"predecessor-version":[{"id":1844,"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=\/wp\/v2\/posts\/1834\/revisions\/1844"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=\/"}],"wp:attachment":[{"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=1834"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=1834"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/wireless-telemetry.com\/blog\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=1834"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}