UNDERSTANDING MICRO 850 PLC FOR UV INSTALLATION
Possible Comm Protocol:
Ethernet/IP
CIP Serial (DFI)
CIP Symbolic (Ethernet)
ASCII DNP3
Modbus RTU and TCP
DHCP Client
Socket Client/Server
TCP UDP(printers, barcode and PCs)
Ports Available
RJ 45 Port for Ethernet/IP
RS 232/485 Serial Port (circular)
Type B USB Port
LED Indications
MS: Module status
NS: Network Status
Power:
Run:
Fault:
Force(lock):
Comm:
Mode Selection Switch
RUN:
REM:
PRG:
UNDERSTANDING MICRO 850 PLC FOR UV INSTALLATION
OEM Manufacturer of the UV: Nuvonic
CPU Model: 2080-L50E-48QWB
Module: 2080-SERIALIAOL
2080-OF2 2Pcs
Current Information and Site Data
New UV Pipe dimensions
Length: 140mm
Diameter: DN200
Old UV Pipe dimensions
Length: 100mm
Diameter: DN100
A DN
What is the home and away option of the wiper ?
For dose signal, what is meaning of Red & average ?
2 UV Panel to be installed at DAW and WTP
Is the panel already fitted with Control and Program?
SIX between UV and Montelektro at DAW (Breumax)
SIX between UV and s7 400 at WTP (Siemens)
Questions:
1. Meaning of DAW De
2. Is PLC already configured
3. What data is required for signal exchange
4. Will data be required for
Display
Shutdown action
Sequence of Steps
DAW Tie in Point
Incoming Supply cable from the brewery
Confirm existing cable type and voltage of the old panel at DAW
Incoming supply is single phase, 380 – 400VAC
Decommissioning of OLD UV Panel at DAW point
Installation of New UV Panel
Instrument and Cable Termination
SIX mapping between Micro 850 and S7 400
UNDERSTANDING MICRO 850 PLC FOR UV INSTALLATION
Comm protocol to use
Hardware and Comm Cable
WTP Tie in Point
Installation of New UV Panel
Instrument and Cable Termination
SIX mapping between Micro 850 and S7 400
Comm protocol to use
Hardware and Comm Cable
Terminal Block Numbers
6BK
Descriptio Equipment TB-N0 Descriptio Equipmen TB-N0
n n t
Drive Filter RB1 16 Circuit K1 1
17 Breaker 3
Lamp Circuit 2 Lamp TA1 L1
Driver Breaker driver
4 L2
DI Signals to consider
Chamber safety temp
Wiper at LS1 (home
option)
Wiper at LS2 (away
option)
Water leak (option)
Remote start/stop Need external signal
Lamp cover removed
Remote CIP request Need external signal
Reduce power Need external signal
Remote pulse start Need external signal
Remote pulse stop Need external signal
Remote reset Need external signal
Ballast supply enabled
Cabinet Temp warning
Cabinet temp trip
SPD Status
UPS on battery Link to 24vdc if no UPS
(X2:18(3)) required
DO Signals to consider
UNDERSTANDING MICRO 850 PLC FOR UV INSTALLATION
Drive wiper to LSI
(home)
Drive wiper to LSI (away)
Enable Bleed valve
Set system remote Need external signal
System available Need external signal
System warming up
Flow enable Need external signal
Running Need external signal
Cooling Need external signal
Common alarm warning Need external signal
Common Alarm trip
Low UV dose Need external signal
Water Leak trip Need external signal
OK to CIP Need external signal
Configurable output 1 Need external signal
Configurable output 2 Need external signal
Configurable output 3 Need external signal
AI Signals to consider
Temp Sensor
UV Intensity Sensor
Flow
UV Transmission
SPARE - Wired
SPARE - Wired
SPARE – not Wired
SPARE – not Wired
AO Signals to consider
TB Number
Dose (red) -X3 T1, T2
Dose (average) -X3 U1, U2
UV Intensity -X3 V1, V2
Configurable output -X3 W1, W2
Installation Pre requisite
If the ETA Plus ballasts in the cabinet have been unused for more than 2
years, elevated leakage currents may arise on the internal electrolytic
capacitors which can damage the ballast. As a preventative measure,
apply 115–230 VAC to the ballast main supply for one hour to reform the
UNDERSTANDING MICRO 850 PLC FOR UV INSTALLATION
capacitors BEFORE reconnecting the normal power supply and operating
the ballast.
The standard cable length between system components is 10 m (32.8 ft).
If the cables provided are longer than required, we recommend that they
are shortened by a competent electrician. Do not coil the cables. If longer
cables are required, please contact your supplier representative.
separate the wiper wiring from the high tension and power cables.
Confirm connection of bleed valve. This opens when the bleed valve Temp
setpoint is reached. We recommend that the bleed temperature should be
at least 10°C (18°F) below the alarm temperature of the system.
Before attempting to start the system, ensure that the chamber is full of
water. This procedure is not required if your system is set up to deliver a
known log reduction of a specific pathogen (see section 3.9). Once the
system is installed and running, the initial intensity value measured by the
UV sensor (known as S0) must be entered into the software to allow the
dose to be calculated correctly. The system may generate Low UV alarms
until this is completed.
Electrical Works
Termination of Power cable
Tools required
Termination of Power cable Cable laying with cable
Cable required tray
Multimeter Termination to TB-X1
Cold Loop check
Voltage check
Termination of Field signal to OEM Cable provided UV cover to JB
JB UV Temp sensor to JB
Limit switch to JB (home
& away option)
UV sensor to JB
Termination of Field signals Termination of 12 core to
(UV) to Control cabinet TB-X3
Termination of Signals from
client system to UV Panel
Confirm the following signals required for remote start and stop of UV.
Installation Works
UNDERSTANDING MICRO 850 PLC FOR UV INSTALLATION
Tools Required
Lift and Support of UV Chain Block
Chamber
Pressure Test of UV
chamber to prevent
leakage
Install UV Lamp into UV Inch Pipe (25mm) Removal of Thimble
Chamber Electrical Tool box Loosen Quartze nipple
Rubber Gloves
Cabinet Mounting to Wall
Automation & Commissioning Steps
Completed Installation of
UV
Completed Installation of
UV Panel
Termination Power and
IO Checks on UV Panel
Termination of DO & DI
Signals from Client
Control System
Powerup of UV Panel
UV sensor verification
Signal Exchange Available DO & DI WTP Program
Between UV Panel & Channels
S7400 system
Commissioning Steps:
Isolate Inlet and Outlet of UV
Powering Up of UV Installation
IO Simulation checks for
Modification of program of IO Signals to send and receive from UV
UNDERSTANDING MICRO 850 PLC FOR UV INSTALLATION
Mechanical Installation
a. Site Preparation (1 Day)
Tasks:
o Ensure adequate space as per the UV system layout drawing.
o Confirm environmental factors (e.g., avoid direct sunlight, maintain
5–45°C ambient temperature).
o Prepare wall/floor mounts for the control panel and UV chamber.
Tools: Drill, level, anchors, screws, spanners.
b. UV Chamber Mounting (1 Day)
Tasks:
o Position the UV chamber horizontally.
o Attach inlet/outlet pipes and include bypass lines for maintenance.
o Secure the UV chamber to reduce vibrations.
Tools: Pipe wrenches, sealant, pipe brackets, lifting equipment (if heavy).
c. UV Lamp Installation (2 Hours)
Tasks:
o Handle lamps with gloves to prevent contamination.
o Insert lamps into quartz sleeves and secure with ceramic fittings.
Tools: Cotton gloves, screwdrivers.
2. Electrical Installation
a. Power and Control Panel Wiring (1 Day)
Tasks:
o Connect main power (e.g., 380–480 VAC, 3-phase) as per system
rating.
o Ground all components.
o Establish communication connections (e.g., Ethernet, Modbus, or
Profinet).
Tools: Multimeter, wire strippers, ferrule crimpers.
b. Sensor and Peripheral Wiring (4 Hours)
Tasks:
o Wire flow meters, UV intensity sensors, pressure switches, and
safety interlocks.
UNDERSTANDING MICRO 850 PLC FOR UV INSTALLATION
o Verify connections with the control panel's terminal blocks.
Tools: Screwdrivers, cable ties, electrical testers.
3. Siemens PLC Integration and Programming
a. PLC Configuration (2 Days)
Tasks:
o Set up the PLC hardware in Siemens TIA Portal.
o Configure I/O modules for inputs (e.g., UV intensity, flow rate) and
outputs (e.g., alarm signals).
o Develop logic for automated operations, including fault detection
and interlocks.
Tools: Siemens TIA Portal software, programming laptop.
b. SCADA/HMI Integration (1 Day)
Tasks:
o Map critical parameters (e.g., UV dose, flow rate) to the SCADA or
HMI system.
o Implement alarms and trends for key variables.
Tools: SCADA/HMI software, Ethernet cables.
4. Commissioning and Validation
a. Testing System Functionality (1 Day)
Tasks:
o Run water through the system and verify UV dose calculations.
o Test interlocks (e.g., low flow shutdown, high-pressure alarm).
o Simulate faults and observe system behavior.
Tools: Flow meters, loop calibrators.
b. Documentation and Training (Half Day)
Tasks:
o Provide manuals and system diagrams.
o Train plant operators on UV system operation and maintenance.
Manpower: 1 engineer.
Required Consumables and Safety
UNDERSTANDING MICRO 850 PLC FOR UV INSTALLATION
Consumables:
Sealant, cable ties, wire ferrules, gloves, and cleaning kits for lamps.
Safety Equipment:
UV-protective eyewear, insulated tools, and proper grounding practices.
Expected Total Duration: ~1 Week
