Training Documentation

Electrical Design Automation

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INDEX S. No. 1.0 1.1 2.0 2.1 2.2 2.3 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 Figures: 1.0 Fig ----------- Design flow electronic system level --------------------------------------- 3 1.1 Fig ------------Power saving opportunities on design flow------------------------------- 3 1.2 Fig ------------PLC panel --------------------------------------------------------------------- 9 1.3 Fig ------------VFD panel--------------------------------------------------------------------- 12 Questions?---------------------------------------------------------------------------------------------CONTENTS Page No.

Definition ---------------------------------------------------------------------------------- 2 Advantages of designing ------------------------------------------------------------------ 4 Selection of automation products for designing--------------------------------------- 4 PLC selection ------------------------------------------------------------------------------ 4 HMI selection ------------------------------------------------------------------------------- 5 Scada selection------------------------------------------------------------------------------ 5 Drive selection ------------------------------------------------------------------------------ 6 AC Drives ---------------------------------------------------------------------------------- 6 DC Drives ----------------------------------------------------------------------------------- 6 Servo system -------------------------------------------------------------------------------- 7 Control panel designing ------------------------------------------------------------------- 8 PLC control panel -------------------------------------------------------------------------- 8 VFD control panel ------------------------------------------------------------------------- 11 DC drives control panel ------------------------------------------------------------------- 14

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ELECTRICAL DESIGN AUTOMATION

1.0 Definition: Designing is considers an industrial control panel an assembly in cooperating two or more pieces of industrial control equipment or related control circuit devices, provided with interconnecting wiring and terminals for connections in the field. Installation can be completed in two ways: in an enclosure as "enclosed type" equipment, or arranged onto a mounting panel as "open type" equipment. For open type equipment, the assembly is installed in an enclosure or at the installation site. Why have Panel & Machine Design Best Practices? Capture lessons learned for a more consistent design. Improve safety and lowering life cycle cost. Standardized designs are reusable and transportable. Common template for drawings and specifications. Pay back in lower design and life cycle costs. Simplify maintenance training spare parts etc Simplifymaintenance, training, spare parts, etc

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Fig 1.0 Design flow electronic system level

Power saving opportunities on design flow

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1.1 Advantages of Designing: Maximum system flexibility for easy reuse of system software and hardware components; Rapid scalability to quickly turn a single-station, single-unit testing environment into an environment with multiple stations capable of multiproduct, parallel testing; and Minimized total cost of ownership including software, hardware, development, Deployment, training, and maintenance costs.

2.0 Selection of Automation Products for Designing: 2.1 PLC Selection: While selecting a PLC first choose the brand of the PLC. Depends up on the application take the I/O count DI, DO, AI, AO, & PID. Choose analog I/O type as variable or constant. Select the PLC which can be useful for future I/O requirements (Expandability). Select the PLC which is having communication ports / inbuilt, expansion I/Os. While selecting the PLC, budget also very important. Depends up on the application select the memory card size. Main: I/O processing, alarms, timers, closed loop (PID), Analog etc. E.g.: 10 words for discrete (DI/DO)/ Rung network,15 words for analog/rung network safe side. After brand selection select sequence PS/CPU/DI/DO/AI/AO/EXP/COUNT. Select accessories RACK/RAIL/CONNECTORS/STRIPS/WIRES etc. Connectors used for connecting I/O modules. Select the software and communication cables which support the selected PLC type. Need to know any third party automation devices are available or not. Take the cables and connectors between the PLC, HMI, SCADA, DRIVES. Take the consideration that distance between field devices and other devices. While selecting a PLC first check how many onboard ports are available and how many modules we can expand it. Special I/O, Encoder, Stepper motor, counters, closed loop etc. Cross check onboard I/Os remote I/Os and distance. Depends on the application check the PLC CPU scan time and ROM capacity. For future expansion check the programming memory, user memory, MMC need.

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Take ambient temperature also as consideration while select the PLC. IP Protection also important while selecting the PLC.

2.2 HMI Selection: Select the body metal of the HMI either steel or fiber. First select the HMI depends on the application. In application select which type of variants the customer requires. As per the application select the variant type. Choose the communication selection depends upon devices. Select how many timers and counters required for the application. Select the report generation (variant, time to time bases) if required. If the application needs the customized logging data select the data logging. Select the memory high/low while selecting a HMI. Take ambient temperature also as consideration while select the HMI. IP Protection also important while selecting the HMI.

2.3 SCADA Selection: Depends on the application choose the SCADA. SCADA used for control, monitor, acquisition, network, communication. Most of the SCADA applications are industrial applications like food and beverages. Connect the PLC, RTD (remote units) if the SCADA needs. Select the number of tags (DI/DO/AI/AO) depends on I/Os given in the application. If the application needs the customized logging data select the data logging, trending. Select the network communication for remote monitoring and controlling. Select the tags type either RC or RT. RC tags are configuration type we can configure the application and do monitoring, controlling in RT type we can only do controlling. Without using animation properties if the customer needs the programming by using scripting select the scripting type either VB or C. Take ambient temperature also as consideration while select the SCADA.

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3.0 DRIVES Selection: 3.1 AC DRIVES: While selecting a drives first take the motor name plate details. Depends on the application select the drive normal duty or heavy duty.P0 Consider power ratings (KW/HP). Consider the voltage ratings (input/output). Consider the current ratings full load current and output current. Based on DI/DO/AI/AOs select the drive. If the application requires the PID select the drive which can with stand PID. Communication cards/interfacing is very important while selecting the drive. Select the drive which can with stand onboard/ future expandability. Depends on the customer requirements select the drive which is having additional features like breaking chopper, breaking resistance. IP protection is also very important. Consider the ambient conditions and type of loads. Maintenance accessibility, duty cycle, horse power, power factor and more.

Optional: Select BOP, MOP, IOP, AOP. Select the MMC card if required. Depends on the customer requirement consider the filters at the incomer side. Consider the I/O chokes for secure purpose

3.2 DC DRIVES: Select the drive depends on the Application. Consider the voltage (field & armature) ratings (200-240v, 380-480v, 500-600v, 690v AC). Consider the power rating (KW/HP). Select the drive depends on the ampere current, field current, armature current. Overload current capacity 150% 60sec, 200% 2min Etc. Based on DI/DO/AI/AOs select the drive. If the application requires the PID select the drive which can with stand PID. Depends on the customer requirements select the drive which is having additional features like overload protection, regeneration, PID control, feedback Etc. Page 6

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Select the drive depends on voltage DC armature, DC field. IP protection weather proof, dust proof very important. Consider the type of body, ambient conditions, speed range, load factor, duty cycle. Environment conditions, efficiency, power factor.

Optional: Select BOP, MOP, IOP, AOP. Select the MMC card if required. Depends on the customer requirement consider the filters at the incomer side. Consider the I/O chokes for secure purpose.

3.3 SERVO SYSTEM: Motor: Drive: Depends on the application select the drive. Consider power ratings (KW/HP). Consider the voltage ratings (input/output). Based on DI/DO/AI/AOs select the drive. Communication cards/interfacing is very important while selecting the drive. Feedback is more important in servo drives. Consider the axis selection also while selecting the drive. Select the drive which can with stand onboard/ future expandability. Page 7 In servo system motor and drives both are important. Accuracy is more in servo systems. It is a closed loop system. First select the motor details. Torque and speed capability. Consider power ratings (KW/HP) priority. Select the breakings depends on the application. Type of encoder required for the application (incremental, absolute). Consider Cooling and type of body,gear box. Type of shaft required for the application (half key, full key, without key). IP protection weather proof, dust proof very important. Mounting of motor either foot mounted or flange mounted.

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Depends on the customer requirements select the drive which is having additional features like breaking chopper, breaking resistance. IP protection is also very important. Consider the ambient conditions and type of loads. Maintenance accessibility, environment, duty cycle, horse power, power factor and more.

4.0 Control Panel Designing 4.1 PLC Control Panel: Check the bill of materials and freeze. Consider the application while taking the dimensions of the control panel. Dimensions of all PLC modules, SMPS. Consider Power devices with dimensions. Consider Control devices with dimensions. Other devices and dimensions. Rough dimensions of all devices. Rough estimation on mounting plate. Place all devices in a sequence. Consider 20% spare size in all sides. Select the panel type Rittal/Normal/other etc. Size the panel accordingly. Check the control panel room dimensions/limitations. Size the panel dimensions select IP, select access of panel. Check the cutouts, sizes exactly as required. Select panel accessories lock, handle, mounting plate, gland plates, documentation folder etc. Select wiring items mounting related like PVC channels, MCB channels, screws, litting hocks. In wiring accessories select the type of wiring according to customer needs. In ferrules check lugs, terminals, end clamps, ties, sticks etc. Panel drawings, wiring according to dimensions. Check Mounting, wiring of PLC, wiring of terminals and others. Test the panel as per drawings. Pack the panel within wooden boxes as per standard. Check weather proof, packing and indicate the dimension of the panel and dispatch.

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Fig:1.2 PLC panel

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PLC panel front view

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4.2VFD Control Panel (AC DRIVES): Consider the application while taking the dimensions of the control panel. Check the bill of materials and freeze. Consider the drive ratings KW/HP. Take Dimensions of the drive. Depends on the type two charts we need to take the drive incomer MCB/MCCB ratings. In drives control panel we have 3 types standalone, star/delta (DOL). Rough dimensions of all devices. Rough estimation on mounting plate. Place all devices in a sequence. Consider 20% spare size in all sides. Select the panel type Rittal/Normal/other etc. Size the panel accordingly. Check the control panel room dimensions/limitations. Size the panel dimensions select IP, select access of panel. Check the cutouts, sizes exactly as required. Select panel accessories lock, handle, mounting plate, gland plates, documentation folder etc. Select wiring items mounting related like PVC channels, MCB channels, screws, litting hocks. Select input chokes and output chokes at before and after the drive to reduce fluctuations. Consider the dimensions of chokes also while designing a control panel. In wiring accessories select the type of wiring according to customer requirement. In ferrules check lugs, terminals, end clamps, ties, stick etc. Panel drawings, wiring according to dimensions. Check Mounting, wiring of drive, wiring of terminals and others. Test the panel as per drawings. Pack the panel within wooden boxes as per standard. Check weather proof, packing and indicate the dimension of the panel and dispatch.

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Fig: 1.4 VFD drive panel

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VFD drive panel front view

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4.3 DC Drives Control Panel: Consider the application while taking the dimensions of the control panel. Check the bill of materials and freeze. Consider the drive ratings KW/HP. Take Dimensions of the drive. Height of the control panel same but depth may change. Mountings on door are ASS/VSS/energy meters/pivot/push button/indications. Depends on the type two charts we need to take the drive incomer MCB/MCCB ratings. In drives control panel we have 3 types standalone, star/delta (DOL). Rough dimensions of all devices. Rough estimation on mounting plate. Place all devices in a sequence. Consider 20% spare size in all sides. Select the panel type Rittal/Normal/other etc. Size the panel accordingly. Check the control panel room dimensions/limitations. Size the panel dimensions select IP, select access of panel. Check the cutouts, sizes exactly as required. Select panel accessories lock, handle, mounting plate, gland plates, documentation folder etc. Select wiring items mounting related like PVC channels, MCB channels, screws, letting hocks. Select input chokes and output chokes at before and after the drive to reduce fluctuations. Consider the dimensions of chokes also while designing a control panel. In wiring accessories select the type of wiring according to customer requirement. In ferrules check lugs, terminals, end clamps, ties, stick etc. Panel drawings, wiring according to dimensions. Check Mounting, wiring of drive, wiring of terminals and others. Test the panel as per drawings. Pack the panel within wooden boxes as per standard. Check weather proof, packing and indicate the dimension of the panel and dispatch.

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Conclusion: Electronic design automation or computer-aided design as an engineering field has been evolving through the past several decades since its birth shortly after the invention of integrated circuits. On the one hand, it has become a mature engineering area to provide design tools for the industries. On the other hand, many challenges and unsolved problems still remain in this exciting field as on-chip device density continues to scale. As long as electronic circuits are impacting our daily lives, design automation will continue to diversify and evolve to further facilitate the growth of semiconductor industry and revolutionize our future.

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1) What is designing and advantages of designing? Ans: . 2) What are the points must be consider while selecting a PLC? Ans: .. 3) What are the points must be consider while selecting a drive? Ans: .. 4) What are the necessary points to take while designing control panel? Ans: . 5) Advantages of designing? Ans: .. ...

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