Control equipment reference

Control equipment reference

Switchboard, PLC, DMX controller, RDM management, inverter, sensors, relays and protection equipment

The control equipment transforms the movement of water and light into a coordinated program. Starting the show, changing the height of the fountains, combining colors, compensating for water level drops and reacting to wind or equipment failure are all dependent on this section.

In addition to performing the show, the appropriate control system should determine the condition of the equipment, provide the possibility of maintenance, and have a defined reaction in abnormal conditions. A large number of channels or software features, without coordination with pumps, lights, sensors and protection circuits, does not guarantee optimal performance.

According to the initial list of the book, this chapter introduces the eight main groups of control equipment and provides criteria for selecting and recording their specifications.

Product information note: The specifications of the samples are extracted from the official pages of the manufacturers. Incomplete or inconsistent information has been identified. In the final order, the model, hardware and software version, accompanying equipment and connection plan must be determined.

61–1. The structure of the fountain control system

Fountain control tasks can be divided into three groups:

These tasks may be implemented in several independent devices or in an integrated system; But the responsibility of each task must be clear.

For example, the display software can issue the command to increase the height of the fountain, but allowing the pump to start must be adapted to the state of the water level, the readiness of the drive, and other necessary conditions.

The usual direction of command

The display program sends the command to the controller; The controller communicates with the light driver, inverter or valve starter through the appropriate interface. At the same time, sensors and power equipment provide status information back to the operating system.

The presence of the "on" command in the software alone does not prove that the pump is actually working or that the water flow is established.

Figure note from the source manuscript

Instead of Figure 61–1

Connection schematic of display controller, PLC, light driver, inverter, valves and sensors. Power, command and feedback paths are displayed with three different colors.

61–2. electrical panel; Complete set specifications

The switchboard is the place of energy distribution, installation of power equipment and organization of command and protection circuits. Its quality depends on the choice of parts, internal arrangement, wiring, heat dissipation and quality of construction.

At least the following items should be recorded in the specifications of the board:

The IEC 61439 family deals with the requirements for low pressure switchgear assemblies. The first part states the general rules and should be used together with the part related to the type of board; Compliance of individual parts alone does not prove compliance of the complete board. Source: IEC 61439-1:2020 ^[411]

heat dissipation

To estimate the thermal load of the panel, the actual losses of inverters, power supplies and other equipment are added:

$P_{loss,total}=\sum P_{loss,i}$

This value is different from the total nominal power of the motors connected to the panel. Ambient temperature, sunlight, chamber dimensions and installation conditions also have an effect on the choice of cooling method.

The degree of protection declared for the enclosure must be maintained in the assembly design after installing the fan, filter, gland and other components.

61–3. PLC; Operation controller

A PLC receives inputs, executes the program logic and gives the appropriate output. In the fountain, its common uses are:

• Reviewing the permitted conditions for launching;

• Tank filling control;

• Coordinating display and purification pumps;

• Obtain wind, pressure and flow conditions;

• Manual and automatic mode management;

• Recording warnings and working hours.

PLC selection criteria

4-20mA input, 0-10V input and dry contact are not directly interchangeable. Relay and transistor output also have different behavior and capacity.

Normal PLC and safety PLC

For tasks that require safety performance, appropriate architecture and equipment should be selected. Simply having a normal PLC or writing a stop condition in the program does not make the circuit a certified safety system. Industrial manufacturers such as Siemens offer family-specific controllers and safety I/Os. Source: SIMATIC Safety Integrated ^[412]

61–4. Preparation of input and output list

Before choosing the controller model, the input and output list or I/O List should be prepared.

The signal type in the table is a design example and should be adapted to the actual output of the equipment. Speed ​​command may be transmitted via network instead of analog output.

For each signal, the normal state, the error state, the behavior when the cable is disconnected and the location of the terminal should also be recorded. Capacity reservation should be determined based on the likely development of the project.

61–5. DMX controller; Capacity and how to use

DMX is used to transmit display commands to compatible equipment. Each DMX universe has a maximum of 512 data channels with 8-bit resolution. Each device consumes one or more channels depending on its working mode. Source: DMX glossary in ETC ^[413]

Therefore, the term "512 channel controller" does not mean independent control of 512 devices.

Example of capacity calculation

Suppose the project includes the following equipment:

In terms of the number of addresses, this arrangement fits in one universe; But the number of branches, electrical capacity of the network, distances and controller facilities should be checked separately.

Also, the number of sockets or output lines is not necessarily equal to the number of independent universes. They may have multiple outputs, same data or common capacity.

Addressing table

For each device, the universe, starting address, number of channels and the function of the channels must be specified. Two devices with a common address receive the same commands if the working mode is compatible; For independent control, they must have independent address allocation.

61–6. DMX network cabling and division

In the conventional wired DMX network, the equipment of each branch is connected in a chain. Inactive branching of Y can reduce communication reliability. The end of the line should also be terminated according to the instructions with proper termination, usually 120 ohms between the two data lines. Source: DMX512 manual in ETC ^[414]

A suitable splitter is used to divide the path. The following should be checked in its specifications:

• number of inputs and outputs;

• electrical isolation of branches;

• RDM support, if needed;

• Cable condition and route length;

• environmental protection;

• Behavior when there is a power outage or a branch failure.

Light power amplifier and DMX data splitter are two different devices. The first one is related to the load current and the second one is related to the control signal distribution.

61–7. RDM; Management of equipment on the network

RDM provides two-way communication over the DMX network. Its uses can include device identification, setting the start address, and receiving status or errors. The ANSI E1.20-2025 standard describes this communication method. Source: Introduction of RDM standard in ESTA ^[415]

The title "RDM Controller" should be interpreted strictly. RDM is usually the management capability of a DMX system and not necessarily a standalone device to run the show.

The presence of RDM does not mean that all quantities can be read. For example, receiving the temperature of the device is possible only when its hardware and software support this data.

61–8. Inverter or variable speed drive

The inverter controls the speed of the motor and thus the pump performance is changed. Its selection should be done according to the engine specifications and display requirements.

The power listed on the inverter alone is not a sufficient criterion. Rated motor current, type of load and thermal conditions must be adapted to the usable capacity of the drive.

Two executive points

Connecting and disconnecting the contactor between the inverter and the motor while feeding the motor can damage the equipment. If there is such a contactor in the design, the sequence of operation should be according to the instructions of the same drive. Source: Schneider Electric manual ^[416]

Also, the STO or "Safe Torque Off" function is not equivalent to electrical isolation. The ABB manual specifies that STO does not interrupt the voltage of the main and auxiliary circuits of the drive. Source: ACS580-01 manual ^[417]

For a pump with an internal controller or DC motor, the approved control method of the same product must be used.

61–9. sensors; Information needed to make a decision

The sensor must measure a quantity that is meaningful for project control.

Level control

At least these situations should be distinguished from each other:

1. Normal level; 2. Dewatering start level; 3. Dewatering end surface; 4. Too low level to prevent the pump from working; 5. Abnormally high level, if needed.

The levels must be in harmony with the necessary depth of the pump, the volume of the tank and the oscillation of the fountain. The distance between the start and end of water extraction and the appropriate delay prevent frequent interruptions caused by waves.

Wind control

The height reduction threshold and the stop threshold should be determined from the actual spraying conditions, the shape of the nozzle and the scope of the project. A fixed number is not suitable for all fountains. Delay and threshold difference should also be taken into account to return to the display.

61–10. Relays, contactors and power outputs

The output of the controller does not provide the necessary power for any type of consumer directly. Depending on the load, an interface relay, contactor or electronic starter may be required.

The stated capacity for a resistive load should not be extrapolated to a coil or motor without checking.

For induction coils, the transient voltage suppression method should be selected according to the circuit. In fast valves, the type of braking circuit can change the spool release time; Therefore, its coordination with the timing of the show is important.

A regular relay is no substitute for an LED driver for fast and continuous light changes.

61–11. Protective equipment

Protective equipment must be selected in accordance with:

In the circuit with inverter, the type of residual current protection should be compatible with the fault current shape and the manufacturer's instructions. Schneider Electric explains the suitability of type B for three-phase drives; This issue should not become the same choice of sensitivity and type of protection for all projects. Source: RCD and three-phase drives ^[418]

For the electrical installation of the fountain basin and its surrounding area, IEC 60364-7-702 is one of the relevant references. Implementation requirements should be adapted to the applicable regulations of the project location and the type of people's access to water. Source: IEC 60364-7-702 ^[419]

61–12. Control equipment introduced in GSO

A) DMX data readers

The following two products are introduced in the GSO list:

The family page introduces receiving DMX commands and controlling outputs. However, in the explanation of the four-channel model, the term three channels is also seen; Therefore, the number of output and current of each channel must be confirmed with the technical sheet of the same model. Source: GSO data readers ^[420]

In the order, the voltage, type of output, current of each channel, total allowed current, addressing method, RDM support and behavior during data interruption should be specified.

b) SW.DW level sensor

SW.DW product with code 449 has been introduced for level control and coordination of drainage and overflow. In the table of the site, one inch fresh water connection, two inch overflow and 304/316 material are mentioned. The type of electrical output and the final grade must be specified in the order; Mechanical adjustment numbers should also not be considered equivalent to measurement accuracy. Source: SW.DW in GSO ^[421]

c) 4000 level control package

Level adjustment values are not the same in text and page table. Adjustment range, accuracy, signal type and immersion conditions should be verified before operational use. Source: Level 4000 control package ^[422]

61–13. OASE reference sample

The WECS III 1024/DMX/02 controller is an example of a dedicated water and light display controller.

Source: official specifications of OASE WECS III 1024 ^[423]

This example shows that four physical lines do not necessarily mean four independent universes with full capacity; The declared total capacity of this model is 1024 channels. How to allocate lines and limits of digital outputs should be extracted from the instructions of the same version.

61–14. Crystal Fountains reference sample

The LEDPS300 family is introduced to control the display and some peripheral functions of the fountain.

Source: Crystal LEDPS300 ^[424]

A dry contact is not a motor power source and must be matched to the appropriate power circuit. Also, NEMA 4 should not become a definitive equivalent IP code without examining the scope of the tests. Power configuration and contacts capacity must be specified for order model.

61–15. Error reaction logic

Prepare a "cause and action table" for each project. The following table is an example for developing the logic and should be adapted to the final design.

The appropriate state for disconnection is not necessarily to send zero to all channels; The meaning of zero in the channel map of each device must be known.

Nor should the operator's manual mode render essential safeguards ineffective. Each mode of service must have certain limits and responsibilities.

61–16. Settings, access and backup

The system delivery file must include the following:

• PLC program and usable project file;

• display files and necessary software version;

• Map of DMX and network addresses;

• Settings of inverters;

• List of thresholds and delays of sensors;

• Backup and recovery method;

• Operator and administrator access levels;

• Error list and action guide.

Settings affecting safety and equipment limitations should be separate from the operator's daily editing. If remote access is anticipated, the method of connection, authentication and change logging should also be part of the delivery specification.

61–17. Testing and acceptance of control equipment

Factory test checks board and logic function before installation. Project site testing verifies their relevance to actual equipment and conditions.

Error tests should be performed in a controlled manner; The pump does not need to be intentionally run without water to demonstrate dry-run protection functionality. The input and related logic can be simulated according to the approved test method.

Record each result with test ID, initial state, action, expected result, and actual result.

61–18. Pictures and suggested documents of the chapter

Board and equipment images should be selected from real archives. An instructional schematic can be prepared to explain the connections; The wiring diagram, number of terminals and protection settings should be extracted from the approved engineering documents of the project.

Note to complete the printed version: In the GSO products section, complete the final specifications of the data readers, the signal type of the level sensors, the IP68 conditions and the items included in each package. A project-oriented selection sheet should also be included for the panel, PLC, and inverter, so that the capacities and settings of a project are not taken as fixed specifications of all fountains.