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PLC And HMI Programming

Lv Switchgear Panels

Current control systems use a PLC (Programmable Logic Controller) to manage motors, valves, and various other equipment within a process. Computer-based Human Machine Interface (HMI) products provide the means for process personnel to interact with the PLC control system. A well-designed integration of PLCs and HMIs can form a robust foundation for meeting your process automation needs.
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CoreSystems integrates the right components with customized designs to deliver high-quality automation solutions. Our goal is to provide efficient, well-documented programs that integrate seamlessly with existing system logic and maintenance personnel expertise. With extensive knowledge of current development platforms and a proven track record, we offer technologies that enhance process efficiency.

What is Done During PLC and HMI Programming?

PLCs control entire machines or equipment based on I/O signals. The programming of a PLC must meet production requirements and be structured for easy fault diagnosis. Typically, a PLC program is written on a computer and then downloaded to the controller. Most PLC programming software uses Ladder Logic, a traditional programming language known for its visual simplicity.
When direct access to a laptop or PC is not possible, you can upload/download the PLC program via a USB through the HMI. This process allows the PLC and HMI to interface effectively.
HMI programming provides a user interface with the machine, enabling functions such as fault diagnosis, production reports, equipment status, and manual controls. An HMI application should be intuitive and tailored to customer needs.

Why Choose PLC and HMI Programming?

Programmable Logic Controllers (PLCs) offer businesses the ability to customize their mechanical processes. Acting as the “brain” of the control system, PLCs provide automated solutions by managing operations based on a network of inputs and outputs. Common programming languages used include:
  • Structured Text
  • Sequential Flow Chart (SFC), similar to traditional flowcharts

  • Instruction List

  • Function Block Diagram

PLC programming is highly beneficial for several reasons:

  • Reduces the monotony of simple work tasks
  • Simplifies wiring and lowers material costs
  • Enables the creation of complex routines that traditional mechanical relay-based controls cannot handle
  • Provides cost-effective solutions for both minor and major manufacturing needs, including process control, complex assembly, and testing
Human Machine Interfaces (HMIs) are chosen for their user-friendly graphical interfaces, which feature color coding for easy identification. Benefits of HMIs include:
  • Alarms and warnings
  • Reliable messaging
  • Easier overall plant management
  • Accurate testing with simulation
  • Cost reduction
  • Improved communication

Choosing an HMI

An HMI is a significant investment, so understanding its roles is crucial. An HMI can serve three primary functions:
  • Pushbutton Replacer: Replaces physical controls like LEDs, switches, and buttons with visual representations on the LCD screen while maintaining all control functions.
  • Data Handler: Monitors and provides stable feedback, often equipped with large memory capacities.
  • Overseer: Centralized systems that monitor and control extensive sites or complexes.

How is HMI PLC Programming Done?

PLC programming typically uses Ladder Logic. The procedure includes:
  • Analyze and Design: Understand the control application and design using a flowchart.
  • Open and Configure Software: Launch the PLC programming software, select the hardware model, and configure it with appropriate I/O modules. Choose Ladder Logic and name the program.
  • Add Rungs and Address: Insert the necessary rungs based on control logic and assign addresses to inputs and outputs.
  • Verify and Simulate: Use the online mode to check for errors. Make corrections in offline mode if needed.
  • Download to PLC: After successful simulation, download the program to the PLC CPU via network or communication cable.

HMI-PLC Programming

To interface a PLC and HMI, follow these steps:
  • Copy the PLC program to a USB memory stick.
  • Insert the USB into the HMI’s USB port.
  • Access the HMI system menu.
  • Navigate to the “Up/Download” submenu.
  • Select the “HMI <-> PLC” transfer mode using the navigation buttons.
  • Choose the PLC program file from the USB.
  • Select the port connected to the PLC on the HMI.
  • The HMI will automatically detect the PLC.
  • Click the Download button to transfer the program.

Data Exchange Requirements

For data exchange between a PLC and HMI, the requirements are:
  • Components:1.A physical link, such as Ethernet or RS-485, with compatible ports on both PLC and HMI. 2. A common protocol supported by the physical connection. 3. Protocol drivers to interface the communication interface with the protocol.
  • Data:What information is exchanged between the HMI and PLC.

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PLC And HMI Programming

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Auto Transfer Switch

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| July 22, 2024
Auto Transfer Switch In emergency power systems, automatic transfer switches (ATS) are used to provide a continuous power source for lights and other critical loads by switching from the normal power supply to an emergency power source…

Capacitor Bank

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Capacitor Bank

Capacitor Bank

Comprehensive Electrical Maintenance: Tailored for the UAE's Dynamic Needs

At Core Systems, we specialize in Electrical Maintenance Contract in Dubai and across the UAE. Our team of certified professionals is dedicated to ensuring the longevity and efficiency of your electrical systems. With our Electrical Maintenance Service, we provide comprehensive checks and repairs to prevent downtimes and ensure compliance with UAE’s stringent electrical standards.
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The proportionality rate between real power and apparent power is defined as the power factor, which is measured in kilowatts (kW). Apparent power, measured in kilovolt-amperes (kVA), is a fundamental measure that reflects the electric efficiency of distributing voltage and current, regardless of whether it is actually performing work. Power factor correction is achieved by adding capacitors to the power distribution system. An automatic controller, which switches capacitors and reactors at intervals, is the most effective method. The most basic application involves employing a fixed capacitor bank. When the power factor drops below specified values, power factor correction capacitors can reduce energy charges by bypassing the standard electric utility charges. These capacitors are installed to address power factor issues caused by inductive loads affecting the electric utility.
Premature failures in power factor correction capacitors and related circuitry can be caused by several factors, including:
  • Harmonic currents
  • Poor ventilation
It is crucial to routinely inspect power factor correction capacitors to ensure they are functioning properly. 

Safety First

Although most capacitors are equipped with a discharge circuit, there is still a risk of electric shock if the circuit is damaged. Extreme caution is necessary when testing capacitors with voltage applied. Maintenance of capacitor banks requires careful attention to individual equipment and its application. Additional hazards are associated with working with current transformer (CT) circuits, including wiring and shorting blocks. Even if the capacitor bank is de-energized, there is still a risk of electrical shock from the CT wiring due to the potential for lethal voltages across the CT terminals.

Visual Inspection and Cleaning

Conduct a thorough visual inspection of the system, including:
  • Checking for damaged components and leaking capacitors
  • Looking for signs of heat or moisture damage
  • Replacing filters in cooling fans
  • Avoiding the use of compressed air for cleaning; instead, use a vacuum to clean the units
Before re-energizing the capacitors, perform an insulation integrity test between the bus phase-to-phase and phase-to-ground points.

Capacitor Bank Infrared Inspection

A thermal imager is an invaluable tool for evaluating electrical capacitor banks. Before testing, ensure the system has been energized for at least one hour. Begin by checking the controller display to confirm that all stages are connected and verify that the cooling fans are operating correctly.

Perform an infrared examination of the enclosure before opening the doors. Based on your arc flash assessment, wear the appropriate PPE when working near energized equipment. Use the thermal imager to inspect power and control wiring, looking for loose connections. A thermal analysis can identify poor connections by showing increased temperatures due to extra resistance at connection points. Ideally, a good connection should show no more than a 20°F increase above the ambient temperature. There should be minimal temperature variation phase-to-phase or bank-to-bank at connection points.

An infrared inspection can also detect a blown fuse by highlighting temperature differences between blown and intact fuses. A blown fuse in a capacitor bank stage reduces the available correction. Some units have blown fuse indicators, while others do not. If a blown fuse is detected, shut down the entire bank and investigate the cause. Common causes include faulty capacitors, reactor issues, and poor connections at line-fuse, load-fuse, or fuse clip points.

Additionally, check for temperature variations among individual capacitors. A capacitor not involved or connected during the inspection should be cooler. Keep in mind that temperature may be higher in the upper sections due to convection. However, if the controller indicates that all stages are connected, significant temperature variations typically point to an issue. For example, high temperatures could cause the capacitor’s internal pressure device to activate before the external fuse, causing the capacitor to be removed from the circuit unexpectedly.

Capacitor Bank Current Measurements

Use a multimeter to measure the current input to the controller from the capacitor bank by employing a current clamp around the CT secondary conductor. Measure the current through the breaker feeding the capacitor bank for phase imbalance with all stages connected. Log all readings to establish a future benchmark.

Capacitor Bank Power Factor Measurements

Use a meter that measures voltage, current, power, and demand simultaneously for power factor measurement. A DMM isn’t sufficient, but a power quality analyzer with a current clamp can provide accurate data. A power logger can also perform a 30-day load study for a comprehensive analysis.

Capacitor Bank Capacitance Measurements

Before measuring capacitance, de-energize the capacitor bank and wait for the duration specified in the manufacturer’s service bulletin. While wearing the appropriate PPE, verify with a properly rated meter that no AC voltage is present. Follow your facility’s lockout/tag-out procedures. Use a DC meter rated for the voltage being tested, and measure capacitance for each stage—phase-to-phase and phase-to-ground. There should be no voltage present. The presence of voltage indicates the capacitor may not be fully discharged. If no voltage is detected, measure the capacitance with the meter and compare the reading to the manufacturer’s specifications for each stage.

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PLC And HMI Programming

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Auto Transfer Switch

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Auto Transfer Switch

Auto Transfer Switch

In emergency power systems, automatic transfer switches (ATS) are used to provide a continuous power source for lights and other critical loads by switching from the normal power supply to an emergency power source if the normal supply voltage falls below preset limits. This guide provides information on the general inspection, operation, and maintenance procedures for both manual and automatic transfer switches.

Manual Contents for Automatic Transfer Switch Testing and Maintenance:
  • Visual and Mechanical Analysis of the Transfer Switch
  • Inspection of Main Contacts and Bolted Connections
  • Standard Transfer Operation Procedures
  • Insulation Resistance Inspection
  • Evaluation of Operational Timing and Automatic Transfer
  • Functional Testing Procedures for Automatic Transfer Switch
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Auto Transfer Switch

To determine the appropriate system ratings and connections, initially compare the equipment data with the project design and specifications. Verify the phase rotation and integrated operation according to the application requirements. Inspect the environmental condition of the transfer switch for approval. Ensure the proper installation of the switch covers.
Ensure that the cabled network and phase rotation power for both sources are identical. Perform a mechanical stability analysis to check for any damaged or worn parts.
Sustain a clear and free of blockage transfer switch. To avoid any accumulation of dust, dirt, or moisture in the switch inspection must be done cleaned by vacuuming or wiping with a dry cloth or soft brush. Moving current-carrying element and the sliding surfaces are to be examined for the appropriate lubrication. Standard transfer caution should be attached apparently. Invest engine start connections of all control wires to avert wreck.

Major Bolted Connections

The condition of the auto transfer switch barriers, arc chutes, and contacts is analyzed and any issues are addressed. Contacts that are worn are replaced, and any material deposits are removed with a clean cloth. Verification of contact/pole resistance is executed. If the manufacturer’s information is not available, consider standards that differ from the adjacent switches or poles by no more than 50 percent of the lowest value. Inspect bolted electrical connections for high resistance using one of the following methods:
  • Low-resistance ohmmeter
  • Calibrated torque-wrench method
  • Thermographic survey

ATS Standard Transfer Performance

For maintenance purposes, a manual operator handle is provided in the transfer switch. Ensure the switch is de-energized before operating it electrically. Operate the transfer switch smoothly without binding between the Normal and Emergency positions.

ATS Analysis of Insulation Resistance

Investigation of insulation resistance is performed on all control wiring with respect to ground. Insulation resistance values of control wiring should not be less than two mega ohms. Compare the results with previously obtained values for maintenance, ensuring they are not less than two mega ohms.

ATS Automatic Transfer Tests

Execute the following automatic transfer tests:
  • Simulate the loss of normal power.
  • Mimic power wastage.
  • Fabricate single-phase conditions.

ATS Operational Timing Evaluation

Verify the correct operational timing of the following functions:
  • Source voltage & frequency relays.
  • Engine start progression.
  • Automatic transfer operation.
  • Switch function limitations.
  • Simultaneous time delay & power restoration.
  • Engine shutdown and cool-down components.

ATS Peripheral Visual Review

Repair the unit if there are any signs of wreckage or damage in the line.

ATS Moisture Sign Examination

Never attempt to operate a wet or damp transfer switch, as accumulated moisture from high humidity or contact with a foreign source can pose a serious hazard. During operation, excessive heat generated by the automatic transfer switch can cause discoloration, abnormality, and damage to contacts.

ATS Dust Evacuation

Use a vacuum to remove dust and debris, as it can impede connections and reduce the effectiveness of the ATS. Clean the transfer switch using an approved industrial solvent, ensuring that all foreign materials and dirt are completely removed.

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PLC And HMI Programming

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Auto Transfer Switch

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Capacitor Bank

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Categories
Services

Lv Switchgear Panels

Lv Switchgear Panels

The purpose of commissioning is to satisfy pre-determined standards, that all the equipment erection is correct and that all the equipment connections and cables have been installed in accordance with the approved erection drawings and diagrams. Furthermore to demonstrate to the satisfaction of the client that the foregoing work has been done and that the equipment functions as designed.
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  • The commissioning procedures outlined in this document will be executed by the commissioning teams under the guidance of the Principal Commissioning Engineer (PCE). The PCE will assume overall responsibility for the documentation, drawings, client liaison, commissioning lists and methods, and the supervision and direction of the commissioning teams. Additionally, the PCE will oversee the client’s approval and acceptance process.
  • The composition of the commissioning teams will naturally vary from contract to contract based on the specific work content and requirements. Typically, the Principal Commissioning Engineer (PCE) will be supported by one or more Senior Commissioning Engineers (SCEs), who are authorized to act on behalf of the PCE in their absence. Additionally, the team will include the relevant Factory Test Engineers (FTEs) and any Subcontractor Commissioning Engineers (CEs), who are essential members of the team.
The ‘Commissioning Procedures’ document addresses the standard operational and electrical pre-commissioning and commissioning tests and checks. It does not include the post-erection ‘mechanical’ checks, which are the responsibility of the Factory Test Engineers (FTEs) as part of their installation duties.
  • To avoid any confusion, this document encompasses all tests and checks that are genuinely considered part of the commissioning procedures to be conducted by the commissioning team, and therefore fall under the direction of the Principal Commissioning Engineer (PCE).
  • To ensure that the commissioning procedures are conducted as effectively and efficiently as possible, it is essential to maintain a high level of cooperation and flexibility among all involved personnel, including erection engineers (both factory and subcontractor), factory test engineers, commissioning engineers, and client representatives.

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Lv Switchgear Panels

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Lv Switchgear Panels The purpose of commissioning is to satisfy pre-determined standards, that all the equipment erection is correct and that all the equipment connections and cables have been installed in accordance with the approved erection drawings…

PLC And HMI Programming

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Auto Transfer Switch

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