Long time lurker, first time poster, please be gentle – and thanks to all for the shared experience and knowledge.
I have a particular interest in this thread and am curious to learn of any updates JasonV may have regarding your outcome and final implementation.
I have a similar project, six motors all operate independently, tied to no other equipment, no interlocks, no PID loops, all operated locally and manually with pushbuttons at the controller panels; four soft starters and two VFD all ABB. No remote control or indication, my assignment is to provide both. How to put this delicately, my operation and maintenance community are not tremendously sophisticated. That may sound like a put down, but it is not intended to be, as a practical matter it places an additional constraint that the system be easy to configure and maintain - field replaceable units must have simple configuration instructions.
The basic guidance, to call them requirements would be gilding the lily, is to provide remote control and indication. When I presented a basic design, the response came back we want all controllers replaced with VFD, you cannot use HOA switches, we must have a way to override remote operation locally (I know, that’s what and HOA switch is for), and we want commands to operate in the manner of a three-way light switch without a formal control location transfer. Sometime later they added that they want all Allen Bradley equipment and a Wonderware user interface. I may be able to get around Wonderware with a Panel View solution.
Additionally, I am a consultant and once the design is completed, I ride off into the sunset; perhaps I’ll be around for installation and commissioning, but not necessarily. I certainly will not be here years from now if/when a component fails. What this means is nothing fancy or subtle. I cannot in good faith require much more than entering nameplate motor data and an IP address on VFD network interfaces.
The network consists of three self-healing fiber rings with Ethernet drops at each controller location. What I would like to do is what JasonV did, deploy AB PowerFlex VFD with Ethernet interface for configuration, control, and indication. In all of the AB illustrations there seems to always be a controller between the HMI and the VFD. In my case that adds a single point vulnerability, some additional configuration, and ladder logic. Nothing outrageous, but not skills the O&M crew have. I realize these controllers are highly reliable components and not likely to fail, but they could and Murphey’s Law etc.
In reviewing the AB VFD Offerings, it seems the PowerFlex 400 Packaged units meet my requirements. I think the line reactor and bypass options are appropriate given the context. For example, if all else fails and the VFD cannot be reconfigured after some unforeseen event, operations can account for the inrush current and shut the bypass contactor to get the motor running. To be specific, here is what I come up with using the AB configuration tool: 23C-D142E10ENNNANN-LR - PowerFlex 400, Fan & Pump Drive. 480 VAC, 3 PH. 124 Amps. 100 HP. Type 4. Fixed Keypad. Ethernet. 3 Contactor Full Feature Bypass with Circuit Breaker.
So a central and secondary control station each with UPS, Wonderware, or possibly Panel View, and six network dropped connections to PowerFlex 400 VFD. This seems like as simple a solution as possible. One problem that I have is there is nobody here with the expertise and experience to review or discuss the design and tradeoffs, so I encourage your opinions and suggestions.
Thanks in advance for any feedback.
