380ft Carriage Controls - Line Diagram.pdf

380’ Tank Carriage Controls Setup

April, 2019

A. King

Restoring functionality to the 380’ Tank carriage after the HVAC renovations to Rickover Hall was a challenging task. The primary problems were a faulty motor contactor and a tripped GFCI outlet. This document lays out the controls & equipment required to power and run the carriages on the 380’ tank for future use.

A) 380 Carriage Control Console in Control Room

The main interface for controlling the carriage is a Maple touchscreen (model HMI 550H-005E).

Upon first powering up the Carriage controls, a “PLC No Response” error occurred. After researching, we determined this error meant the touchscreen was unable to communicate with the

Programmable Logic Controllers (PLCs) further down the wire. This was due to the Linksys VPN router not having power, breaking the Ethernet connection to the Motor Room equipment. The wiring diagram of the control console is shown below:

B) Linksys RV016 VPN Router (Inside E-Stop enclosure, mid-tank)

The Ethernet connections from the Control Room are connected to the 16 port VPN router mid-tank. This boosts & routes the signal going to the Motor Room behind the wave maker end of the tank. There is a WRC-CANX-DIN-C7 card within the enclosure as well with an input & output cable, which acts as a CANBUS extender. I believe the output runs to the Motor Room F841-1 encoder splitter, but I’m not sure where the input connects. To resolve a “PLC no response” error at the

Control Room touchscreen, verify the VPN router is getting power, and that the Ethernet cables are securely connected.

C) Motor Room Control Cabinet

The Ethernet connections from the VPN Router enter the cabinet via a conduit in the top left corner. One cable runs to the AnywhereUSB box, where it feeds two USB cables running to Baldor

NextMove ESB1 and ESB2. Another Ethernet cable runs to the VLinx Ethernet Serial Server, where it feeds two Serial cables: one connecting to the Maple touchscreen on the door (VINEX_1), and the other connects to the Trimble location system. A third Ethernet cable connects directly to the

Maple touchscreen. A spare Ethernet cable is coiled in the base of the cabinet.

Another cable runs from the conduit to the input serial connection (X1) of the F841-1 Encoder

Splitter. I believe this connects to the WRC-CANX-DIN-C7 card within the mid-tank E-Stop enclosure, but have not been able to verify this. Output Serial cables are connected to ports X2, X3, and X4. X2 connects to the ABB Drive through cable X5-1; X3 connects to ESB1 through the ESB 1_4 on X5; and

X4 connects to ESB2 through ESB 2_4 on X5.

There are 2 CAT5 cables from the CAN ports on ESB1 and ESB2, which are split into individual wires and connect to the ABB CAN adaptor. The CAN Adaptor then uses TXD and RXD wires to connect to the ABB Drive.

Finally, the BARCODE/TRIMBLE selector switch takes a 24V power connection and connects to

ESB2 at the X8 DIN Input.

Tripped GFCI

Outlet = “PLC no response” error.

CANBUS

Extender

Board

A picture of the Control Cabinet interior is shown below:

AnywhereUSB

VLinx Serial Server

ABB CAN Adaptor

Barcode/Trimble

Switch

NextMove ESB1

NextMove ESB2

F841-1 Encoder

Splitter

D) Wireless Routers

There are two wireless routers contained within the smaller E-Stop enclosures. Their purpose right now is unknown; it’s suspected they may be part of the wireless transmission of the Leuze Barcode reader.

E) Motor Room Power

There are a number of switches and protective devices involved in providing power to the carriage controls and motors. A one line diagram of this system is shown below:

A large knife switch is located on the right side of the Tow Tank DP Panel.

Next, a large breaker switch (1000 Amps) in the Tow Tank DP Panel provides power to the Tow

Tank EM-HV-S panel.

Main Power

Knife Switch

The 2 panels, EM-HV-S (high voltage) and EM-LV-S (low voltage) are seen below. Inside the HV panel is a breaker for the Tow Tank Controls.

Large Breaker

Switch

(1000 Amps)

Activating the tow tank controls breaker, seen in the figure below, sends power to a motor contactor, and then to the control cabinet.

The motor contactor is located on the far wall, outside of the motor room. Currently, the contactor is blowing fuses and will not pull in to complete the electrical connection. IAP is looking into replacements. A 2013 quote from EAGLE engineering mentioned a replacement contactor; it looks like it is finally required. The current contactor is shown below:

Tow Tank Controls

Breaker

Under normal operation, the Tow Tank controls breaker is turned on, then the Knife Switch and

1000 Amp breaker are turned on. This provides power to pull in the Motor Contactor, and powers up the rest of the equipment in the Control Cabinet.

Motor Contactor

Fuse

Unused Old Fuses

Input Power Wires

Output Power to

Control Cabinet