PCS System

请求决策 For Decision

信息通报 Information Distribution
需要支持 Need support

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 Diagram block system control PCS

Paint circulation
system is mainly to
ensure that the paint in
the pipeline in circulation
and provide a certain
pressure and temperature
of the paint to the spray
gun to meet the spraying
process requirements.
The system is
powered by an electric
pump. The operation
status of each module,
including liquid level,
temperature, stirrer start
and stop, solenoid valve
open and close, electric
pump start and stop and
work mode, outlet
pressure, work pressure
flow can be displayed on
the system monitor
screen.
上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA
 Network Communication

❑ Networking
Between the PLC master station
and the slave station uses between the
ethernet, the PLC and the agitator
frequency changer uses between the
ethernet, PLC and the GRACO
network management uses between the
ethernet, the gateway module and the
ACS module uses the double line 485
communication way, uses MODBUS
agreement. The whole network is a
ring network structure. PLC and clean
room between which the use of fiber-
optic remote communication station.

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 Network Communication

The IP address of each equipment of this system is as follows:

Device Ip address Device Ip address
EN2TR 192.168.1.1 CHASSIS6 192.168.1.6
CHASSIS2 192.168.1.2 CHASSIS7 192.168.1.7
CHASSIS3 192.168.1.3 CHASSIS8 192.168.1.8
CHASSIS4 192.168.1.4 CHASSIS9 192.168.1.9
CHASSIS5 192.168.1.5 CHASSIS10 192.168.1.10
上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA
 Network Communication

Device Ip address Device Ip address

CKP1 circulation agitator VFD 192.168.1.12 GRACO network gateway module 192.168.1.151
CKP1 mix tank VFD 192.168.1.13 HMI 192.168.1.11
BC1 circulation agitator VFD 192.168.1.14 ACS IP Address 192.168.1.5
BC1 mix tank VFD 192.168.1.15
ACS Module ID
BC2 circulation agitator VFD 192.168.1.16
Primer coat : 1 BC 4 :5
BC2 mix tank VFD 192.168.1.17 BC 1 :2 BC 5 :6
BC3 circulation agitator VFD 192.168.1.18 BC 2 :3 Clear :7
BC 3 :4 Solvent :8
BC3 mix tank VFD 192.168.1.19
BC4 circulation agitator VFD 192.168.1.20
BC4 mix tank VFD 192.168.1.21
BC5 circulation agitator VFD 192.168.1.22
BC5 mix tank VFD 192.168.1.23
CC1 circulation agitator VFD 192.168.1.24
CC1 mix tank VFD 192.168.1.25
WST agitator 192.168.1.26

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 ELECTRIC PUMP Control

The electric pump control system in PCS is designed to Hazardous Area Non-Hazardous Area
meet explosion proof safety standards, so that all devices
used have the required safety standards. Functionally, the Inverter
E-Flo pump functions to circulate paint and ensure FREQUENCY SIGNAL IN

pressure and flow are in accordance with the parameters Pressure FREQUENCY SIGNAL OUT
set, as follows is an electric pump control system. tranducer
Safety barrier ACS Module
a. Electric pump Electric
TDC Sesor

3HP (2.2KW)/ 5HP (3.7KW) ATEX certified motor with pump

RS485
POS Sensor
explosion proof design which is used to circulate paint Thermistor
Rellay
PTC Sensor
from the mix room to the robot.
b. Sensor Gateway
• Top dead center (TDC) sensor is used to measure
motor speed,
• position sensor (POS) is used to determine the position 1763 - ETAP
of the motor
• pressure transducer (PT) is used to measure paint
pressure at the pump outlet Ehernet IP

• PTC sensor is used as a safety which detects when the

DIGITAL OUTPUT
PLC

DIGITAL INPUT
motor is overheating,
• These three sensors will send feedback to the ACS 1756-L72
Control
module through the safety barrier and the PTC sensor logix5572
for safety from the motor will be connected to the PLC controller
via the thermistor relay.

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

ELECTRIC PUMP Control

c. Safety barrier (digital: KFD2-SOT2-Ex2 analog: KFD2-STC4-Ex2)

used as part of an intrinsically-safe protection system, sending a
signal from the sensor located in the Hazardous area to the ACS
module in the non-hazardous area where the signal from the
sensor is a signal of about 2.5 V DC max. at 10 mA the signal cannot
be directly read by the ACS module so it requires a safety barrier to
convert the signal into an electric current that can be read by the
ACS module

d. ACS Module (24H372)

basically, the ACS module is a device that regulates the rotation
speed of the electric pump to keep the fluid pressure stable according
to the parameters that have been set in the ACS software.
The ACS module will receive a feedback signal from the sensor on
the electric pump which will then be calculated to determine the
frequency output that will be given to the VFD,

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 ELECTRIC PUMP Control

e. Inverter/ VFD (Schnieder ATV32HU22N4)

Is a device that functions to regulate the speed of a 3 Phase AC motor by changing its frequency, on the
Electric pump PCS system, the VFD receives a signal on pin (A13) from the ACS module to determine how
much frequency must be supplied to the electric pump.

f. Gateway (Model CSMSTRSX)

Allows communication between ProMix 2KS and a PLC over an ethernet. Enables process equipment to
read variables while operating, as well as control the ProMix 2KS and change setup. It does not provide
access to job and alarm logs.

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 Mix Circulation pump Control

Circulation
Circulation tank agitator and mix circulation pump agitator
function to keep the paint in the tank circulating or not
settling to avoid paint clumping, as well as the agitator Mix
Inverter Inverter
control device. circulation
pump
Ethernet Cable
❑ Motor Agitator
Limit switch
0,37 KW 3 phase motor tersertifikasi ATEX explosion proof level sensor 1783-US08T
Ethernet Switch
❑ Inverter/ VFD (Schnieder ATV32HU22N4)
Is a device that functions to regulate the speed of a 3 Phase AC
motor by changing the frequency, in the agitator system, the VFD is 1763 - ETAP

connected to the PLC via an ethernet cable, which functions for real
time monitoring of VFD parameters and also regulates the output Ehernet IP
frequency of the VFD via PLC.
❑ Limit switch level sensor PLC

DIGITAL OUTPUT
DIGITAL INPUT
The limit switch level sensor on the agitator pump system is to 1756-L72
provide feedback to the PLC level on the tank, which will later Control
logix5572
become a reference for the agitator rotation speed. When the level in controller
the tank is low, the agitator speed will decrease and when the tank
level is high, the agitator rotation speed will increase.
上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA
 Robot Interlock

The interlock system between the robot and the PCS is in the form of a digital signal via a DC
rellay, and also PLC module

❑ List Interlock ❑ Diagram interlock robot

PCS interlock to robot Robot interlock to PCS Rellay

Interlock
interlock SPRAYBOOTH
ROBOT From PCS
To PCS
CKP ready (F4702CR) To PCS production (CR0EB)
BC1 ready (F5102CR) To PCS Idle (CR0EC)
BC2 ready (F5104CR) (1756-OB32)
BC3 ready (F5106CR) - CKP Work and sleep signal
PLC
BC4 ready (F5108CR) - BC1 Work and sleep signal

DIGITAL OUTPUT
DIGITAL INPUT
1756-L72

BC5 ready (F5110CR) - BC2 Work and sleep signal Control

logix5572 Rellay
CC ready (F5402CR) - BC3 Work and sleep signal controller interlock
to Robot
- BC4 Work and sleep signal
- BC5 Work and sleep signal
- CC Work and sleep signal PCS Panel

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 Cooling system

The temperature control system on the PCS functions to maintain the paint
temperature in accordance with predetermined parameters. PLC
❑ Cooling water system Rellay

DIGITAL OUTPUT
Selenoid valve
Basically, the CW system is in charge of providing cooling water supply that

DIGITAL INPUT
1756-L72
will be used to control the paint temperature. Control
Contactor
logix5572
The cooling water temperature is set to 20°C, the electrical devices in the
Temp controller
CW system are: Valve
RTD sensor : The RTD sensor provides feedback to the PLC temperature Circulation
Pump
from the cooling water. Circulation
Tank
Automatic valve : automatic valve regulates the supply of chiller water that

ANALOG OUTPUT
ANALOG INPUT
enters the heat exchanger, the automatic valve opening itself is regulated RTD RTD Automatic
AO
input Valve
by the PLC using PID by calculating the feedback temperature data from module
MODULE
1734-
the RTD sensor. 1734-IR2 OE2C
Pump Circulation: serves to circulate cooling water to the mixing room RTD
tank.
❑ Circulation Mix tank cooling system CW system
To maintain the paint temperature, the circulation tank has a heat
exchanger that uses a cooling water supply, the device that regulates the
temperature parameters of the paint in the circulation tank are:
RTD sensor : The RTD sensor provides feedback on the PLC temperature of
the paint in the circulation tank.
Selenoid Valve : a valve controlled by PLC to move the temperature valve.
Temperature Valve : is a valve that uses air to open and close the valve, this
valve serves to regulate the cooling water that enters the heat exchanger in
the circulation tank.

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 VFD

❑ Schnieder ATV32H037N4 is VFD that use in all electric pump

Drawing

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 VFD

❑ VFD Parameter for all electric pump

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 VFD

❑ Schnieder ATV32H037N4 and ATV320U04N4B is use for mix agitator and circulation agitator.
Drawing

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 VFD

❑ VFD Parameter for Mixing Agitator

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 VFD

❑ VFD Parameter for Circulation Agitator

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 Software VFD configuration

SoMove Software
SoMove software incorporates various functions for the device setup phases, such as:
• configuration preparation
• testing and start-up
• Maintenance
• Backup Parameter
To facilitate setup and maintenance, SoMove software
can use a direct USB/RJ45 cable (Modbus serial) link.

SoMove operates in the following PC environments and configurations:

Compatibility:
• Microsoft Windows® 7 Professional, 32 and 64 bit
• Microsoft Windows® XP Professional SP3, 32 and 64 bit
• Microsoft Windows® 8, 32 and 64 bit
• Microsoft Windows® 8.1, 32 and 64 bit
Minimum configuration:
• 1 GHz Pentium® IV processor (or equivalent)
• 1 GB available disk space
• 1 GB of RAM

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 ACS Module

24H372 ACS Module

The ACS module provides an analog drive signal to the VFD. Use one ACS module for each E-Flo pump. The ACS
module can be controlled by a local control box mounted in the hazardous area, or via communication protocol (such as modbus).
Important Use the following VFD configuration settings:
• analog input scaling
• 4 mA = 0 (zero) Hz
• 20mA = 80 Hz
• Acceleration rate = 1.0 second (for full range 0-80 Hz)
• Deceleration rate = 0.5 second (for full range)-80 Hz)

How to configure ACS module

1. Connect ACS module with PC (IP Address 192.168.1.5)
2. Open Chrome ( 192.168.1.5:9080)
3. Set Node based on backup
ACS Module ID
Primer coat : 1 BC 4 :5
BC 1 :2 BC 5 :6
BC 2 :3 Clear :7
BC 3 :4 Solvent :8

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 ACS Module

4. Open Software Graco and set parameter Open active pump

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 ACS Module

5. Set Configuration

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 PLC Input

❑ Digital Input ❑ ACS pressure and Flow

❑ VFD / Interter ❑ Temperature

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 PLC Output

❑ Digital Output ❑ Output to VFD

❑ Output to ACS

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 PLC Program

❑ How to see function block instruction logic:

1 2

Right click Click

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 PLC Program

❑ Pump condition function block ❑ Pump Ready instruction logic

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 PLC Program

❑ Temperature control function block ❑ Instruction logic

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 PLC Program

❑ Level condition function block ❑ Instruction logic

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 PLC Program

❑ Alarm function block ❑ Alarm instruction logic

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA

 Thank you

上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA