Plc

CONTENTS

1. PLC GENERAL 3

2. ALLEN BRADLEY PLC 19

3. WONDERWARE INTOUCH SCADA 29

4. SIEMENS S7 200 PLC 43

5. SIEMENS S7 300 PLC 53

6. MODICON PLC 65

7. AC DRIVES 77

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2

PLC GENERAL

3

4

Automation

Industrial automation is the use of control systems such as computers to

control industrial machinery and processes, replacing human operators. In the scope

of industrialization, it is a step beyond mechanization. Automation greatly reduces the

need for human sensory and mental requirements.

PLC (Programmable Logic Controller)

NEMA (National Electrical Manufactures Association) defines PLC’s as

“Programmable logic Controller is a digital electronic device which uses a

programmable memory to store instructions and data and implements specific

functions such as timing, counting, logics etc to control various machines or process”.

A PLC is a device that was invented to replace the necessary sequential relay

circuits for machine control. The PLC works by looking at its input and depending

upon their state, turning ON / OFF its inputs. The user enters a program, usually

through software, that gives the desired result. A PLC can be defined as a solid state

device. It is capable of storing instructions to implement control functions such as

sequencing, timing, counting, arithmetic, data manipulation and communication to

control industrial machines and processes.

Architecture of PLC

Inputs Outputs Input

Interface

Output

Interface CPU

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CPU

A PLC is composed of two basic sections namely CPU (Central Processing

Unit) and I/O (Input / Output) section. The CPU section is formed by three

components namely Processor, Memory and Power supply. The CPU controls all

arithmetic and logical operations, control signals to various outputs etc. During

operation the CPU reads or accepts the input data or status of the field devices

through the input interfaces; executes the control program stored in memory and

writes or updates the output devices through output interfaces.

The I/O system forms the interface by which field devices are connected to the

controller. The main purpose of interface is to condition the various signals received

from or sent to external field devices. Incoming signals from sensors such as push

buttons, limit switches analog sensors etc are wired to the terminals on the input

interfaces. Devices that will be controlled like motors, starters, solenoid valves etc are

connected to the terminals on the output devices. The system power supply provides

all necessary voltages required for the proper operation of the various CPU sections.

Memory

Processor

Power supply

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Advantages of PLC

1. Reduced Space

PLC’s are fully solid state devices and hence extremely compact compared to

hard-wired controller which uses electromechanical devices.

2. Energy Saving

The power consumption is very less compared to other controllers. The

average power consumption is just 1/10th of power consumed by an equivalent Relay

Logic Control.

3. Ease of Maintenance

We can easily replace the different modules of PLC’s. Trouble

shooting and error diagnostics with programmer are also very easy in PLC’s.

4. Economical

Considering one time investment PLC is most economical system.

Cost of PLC’s recovers with in a short period.

5. Greater Life and Reliability

PLC is a solid state device and they have greater life than any other

devices. It is also a static device; hence lesser number of moving parts reduces wear

and tear. In case of hard wired logic control , hardwire is either electromechanical or

pneumatic and therefore it is more prone to faults due to wear and tear and tear of

moving parts results in lesser ON time of system.

6. Tremendous Flexibility

To implement changes in control logic no wiring is required so

considerable time is saved.

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7. Advanced Computation Supported

PLC can carry out complex functions such as generation of time

delays, counting, comparing, arithmetic operations etc.

8. Speed and Flexibility

It gives high processing speed and great flexibility in the processing of

both analog and digital signals.

9. Closed Loop Control Supported

PLC’s are suitable for closed loop control and also it can handle

several closed loop tasks.

10. Shorter Project Time

The hard-wired control system can be constructed only after the task is

fully defined. In the PLC, however, the construction of controller and wiring are

independent of control program definition. This means that the total hardwire is

standard and desired control is achieved through program.

Programming Languages in PLC

Different programming languages are there in PLC. Some of the main

programming languages are

1. Ladder Logic (LAD)

2. Structured Text (ST)

3. Instruction List (IL)

4. Sequential Function Chart (SFC)

5. Functional Block Diagram (FBD)

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Main Symbols Used in Ladder Logic

Basic

Electrical

Symbols Normally open Normally Closed Output

(NO) (NC)

PLC Normally open Normally Closed Output

Symbols (NO) (NC)

Structure of Ladder Logic

Rung 0

S1 O1

Positive Negative

Rail S2 O2 Rail

Rung 1

Figure shows an example for a ladder diagram. Positive and negative

logic rails are there in the ladder diagram. Current flow is from positive to negative

and from top to bottom. Each positive to negative section are known as rungs. The

outputs connected becomes ON when the positive to negative path completes.

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Scan Time

A PLC works by continually scanning a program. The scan cycle

consists of three important steps.

1. Check Input Status

PLC first checks all input status that are connected in it. That means it

checks whether the input is ON / OFF. PLC records all data that into its memory.

2. Execute Program

After checking all input status PLC executes the program according to

the various input data that are collected. It will store the execution result for use in the

later step.

3. Update Output Status

Finally PLC updates the status of outputs. It updates the outputs based

on which were on during the first step and the results of executing the program during

the second step.

After the whole process the PLC goes back to the step 1 and repeats

the steps continuously. These three steps are known as Scan Cycle. The time taken to

complete one scan cycle is known as Scan Time.

Check Input Status

Execute Program

Update Output Status

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Sinking and Sourcing

Normally two types of sensors are used in industries. They are

1. Sourcing Type

2. Sinking Type

The difference between two types is whether the load is switched to

ground or positive voltage. An NPN type sensor has the load switched to ground

whereas a PNP device has the load switched to positive voltage.

NPN Sinking Sensor

To PLC Input

Ground (0 V)

On the NPN sensor we connect one output to the PLC’s input and the other

output to the power supply ground.

PNP Sourcing Sensor

To Positive (V+)

To PLC Input

On the PNP sensor we connect one output to the Positive voltage and the other

output to the PLC’s input.

SensorOutputCircuit

SensorOutputCircuit

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Basic Gates

1. AND Gate

Symbol Truth Table

A

Y

B

Ladder Diagram

A B Y

2. OR Gate

Symbol Truth Table

A

Y

B

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Input

A

Input

B

Output

Y

0 0 0

0 1 0

1 0 0

1 1 1

Input

A

Input

B

Output

Y

0 0 0

0 1 1

1 0 1

1 1 1

Ladder Diagram

A Y

B

3. NAND Gate

Symbol Truth Table

A

Y

B

Ladder Diagram

A Y

B

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Input

A

Input

B

Output

Y

0 0 1

0 1 1

1 0 1

1 1 0

4. NOR Gate

Symbol Truth Table

A

Y

B

Ladder Diagram

A B Y

5. NOT Gate

Symbol Truth Table

A Y

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Input

A

Input

B

Output

Y

0 0 1

0 1 0

1 0 0

1 1 0

Input

A

Output

Y

0 1 1 0

Ladder Diagram

A Y

5. Ex-OR Gate

Symbol Truth Table

A

Y

B

Ladder Diagram

A B Y

A B

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Input

A

Input

B

Output

Y

0 0 0

0 1 1

1 0 1

1 1 0

Example

Draw a PLC program to latch an output when START switch is pressed. The output

should remain in latch condition until STOP switch is being pressed?

Ladder Diagram

START STOP OUTPUT

OUTPUT

General Classification of PLC

PLC’s are generally classified into two types

1. Modular Type PLC

2. Integrated type PLC

1. Modular Type PLC

In modular type PLC each modules means Digital Input module, Digital

Output module, Analog Input Module and Analog Output Module are placed in each

separate racks or modules. The addressing of these PLC’s comes with the slot

number. We can place the different modules according to our needs. We can also

increase the number of inputs according to our needs in these types of PLC’s. So it is

called as Modular Type PLC.

0 1 2 3 4Power Digital Digital Analog Analog Supply CPU Input Output Input Output

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2. Integrated Type PLC

Field Inputs

Field Outputs

In Integrated Type PLC the inputs and outputs are fixed. All the inputs are

comes in single module. We cannot increase the number of inputs and outputs in these

types of PLC’s.

PLC

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18

ALLEN

BRADLEY PLC

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ALLEN BRADLEY PLC

Allen-Bradley is the brand-name of a line of Factory Automation

Equipment manufactured by Rockwell Automation. The company manufactures

programmable logic controllers (PLC), human-machine interfaces, sensors, safety

components and systems, software, drives and drive systems, contactors, motor

control centers, and systems made of these and similar products. Rockwell

Automation also provides asset management services including repair and consulting.

Allen Bradley PLC’s are mainly classified into three types according to

the number of inputs and outputs. They are

Plc Types No: of Digital

I/O

No: of Analog

I/O

Memory

Low end

Pico

Micrologix

24

256

2

2

8 K

8 K

Medium end SLC-500 4096 8 8 K

High end

PLC

Flexlogix

Controllogix

10000

> 20000

16

256

16 K

256 K

Here we use Micrologix and SLC-500 PLC’s. Micrologix PLC is an

integrated type PLC. Micrologix PLC’s are mainly classified into three types. They

are

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Micrologix PLC

1000 1200 1500

Series A Series A Series A

Series B Series B Series B

Series C Series C Series C

SLC-500 is a modular type PLC. It is mainly classified into five

different CPU versions. They are

SLC-500 PLC

5/01

5/02

CPU Types 5/03

5/04

5/05

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Memory

Program Files Data Files

SYS-0 Reserved Files

SYS-1

LAD-2 Main Program

LAD-3

Sub Routines

LAD-255

Memory is mainly classified into two types.

1. Program Files

Program file consists of SYS-0, SYS-1, Ladder-2, Ladder-3 etc up to Ladder-

255. SYS-0 and SYS-1 are reserved files. They are used for the initial start up of the

Plc. Ladder-2 is the main program. Ladder-3, Ladder-4 ------ Ladder-255 are

subroutines.

2. Data Files

Data Files consists of inputs, outputs, status, timer, counter etc. Inputs and

outputs are used for input and output addressing. Status register is used for monitor

any error status, also setting of real time clock etc. Timers are used for setting time

delay functions. Counters are used for counting number of pulses given to it. Control

register is used for controlling and taking some outputs which are used in some

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File No: File Name File Type

0 Output O

1 Input I

2 Status S

3 Binary B

4 Timer T

5 Counter C

6 Control Register R

7 Integer N

8 Floating F

instructions. Integer register is used for storing integer values used in arithmetic or

logical operations. Floating register is used for storing floating point values.

Addressing syntax

Addressing syntax for SLC-500

SLC-500 is a Modular Type PLC.

Syntax is File Type : Slot Number . Word / Bit

Digital Input Digital Output

I:1.0/0 O:2.0/0

I:1.0/1 O:2.0/1

I:1.0/2 O:2.0/2

I:1.0/15 O:2.0/15

I:1.1/0 O:2.1/0

I:1.1/1 O:2.1/1

Addressing syntax for Micrologix

Micrologix is an Integrated Type PLC.

0 1 2 3Power Digital Digital AnalogSupply CPU Input Output Input & Output

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Syntax is File Type : Slot Number . Word / Bit

Digital Input Digital Output

I:0.0/0 O:0.0/0

I:0.0/1 O:0.0/1

I:0.0/2 O:0.0/2

I:0.0/15 O:0.0/15

I:0.1/0 O:0.1/0

I:0.1/1 O:0.1/1

Analog Addressing

If we are using digital signal we can store it in a single bit. But if we are using

analog signals we cannot store the values in a bit so it should be stored in a word. The

analog signals used in industries are normally 0-10 V and 4-20 mA.

0 4 0000 0000 0000 0000 0

10V 20mA 0111 1111 1111 1111 32767

Combinations

Parity Bit

Parity bit can be zero or one. Parity bit becomes zero when the analog value is

positive and it becomes one when the analog value is negative. If we give one analog

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signal the PLC converts it into 0 to 32767 combinations. We get the corresponding

digital signal and it should be stored in memory locations. We can use this value for

controlling analog signals.

Analog Addressing Syntax is File Type : Slot Number . Word

Analog Input Analog Output

I:3.0 O:3.0

I:3.1 O:3.1

I:3.2 O:3.2

Addressing Syntax For Others Except Binary

Syntax is File Type File Number : Element

Status S2:0, S2:1, S2:2, --------- S2:255

Timer T4:0, T4:1, T4:2, --------- T4:255

Counter C5:0, C5:1, C5:2, --------- C5:255

Control Register R6:0, R6:1, R6:2, --------- R6:255

Integer N7:0, N7:1, N7:2, -------- N7:255

Floating Point F8:0, F8:1, F8:2, --------- F8:255

Addressing Syntax For Binary

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Syntax is File Type File Number : Word / Bit

B3:0/0

B3:0/1

B3:0/2

B3:0/15

B3:1/0

B3:1/1

Binary bits are used in programs for certain applications. In some programs

we have to take some intermediate outputs which are not used as field outputs. In such

outputs if we use normal output address then these outputs are wasted. So in those

cases we use Binary outputs and thus we can save the outputs.

Driver Software

Driver Software is used for interfacing personal computer with PLC. The

driver software used for Allen Bradley PLC is RS Linx.

Direct Connection

19.2 Kb/Sec

RS-232 RS-232

Personal Computer

Allen Bradley PLC

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Personal computer supports only RS-232 Protocol. Allen Bradley PLC also

supports RS-232 Protocol. So we can directly connect Allen Bradley PLC to personal

computer. If the PLC didn’t support RS-232 protocol then a converter is also used.

The Baud rate for Allen Bradley PLC is 19200 Bits/second.

Programming Software

The programming software’s used in Allen Bradley PLC’s are

For Medium end PLC’s and Low end PLC’s RS Logix 500 English

For High end PLC’s RS Logix 5000 English

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WONDERWARE INTOUCHSCADA

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WONDERWARE

Wonderware is a supplier of industrial automation and information software

solutions, having sold more than 500,000 software licenses in over 100,000 plants

worldwide. Wonderware has customers in virtually every industry including utilities,

mining, oil & gas, food & beverage, pharmaceuticals, transportation, pulp & paper,

semiconductors and metals. Wonderware is a business unit of Invensys.

Wonderware has been an industrial software leader since 1987, when the

company introduced InTouch® software, the first human-machine interface (HMI)

based on the Microsoft Windows® operating system.

Wonderware is a market leader in real-time operations management industrial

software which includes: Supervisory HMI, GeoSCADA, Production Management,

Performance Management etc. Wonderware delivers significant cost reductions

associated with designing, building, deploying and maintaining secure and

standardized applications for manufacturing and industrial operations. Wonderware

software solutions enable companies to synchronize their production operations with

business objectives, obtaining the speed and flexibility to attain sustained profitability.

SCADA

SCADA means Supervisory Control and Data Acquisition Software. SCADA

software is used for controlling the process in industries. SCADA software is also

used for monitoring the process parameters. Through SCADA software we can

control the whole process or whole plants in industries.

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Block Diagram of SCADA

I/P O/P I/P O/P I/P O/P

The above figure shows the block diagram of SCADA. In industries normally

number of PLC’s are there for controlling various plants. Each plant is controlled by

one or more than one PLC’s. The input and outputs of each PLC’s are connected to

SCADA through RTU’s. RTU means Remote Terminal Unit. The RTU act as an

interlink between PLC’s and SCADA. The RTU’s can be a Junction Box or a Master

PLC for controlling auxiliary PLC’s. SCADA software is being used in the control

room. Through SCADA software we can control the entire plants.

Types Of Communications

The different types of communications are

1. Landline Communication

2. Optical Communication

3. Satellite Communication

SCADA Software

RTU

PLC PLC PLC

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Landline Communication

In landline communication the communication is achieved through

normal wires or cables. Different protocols are used in these types of

communication. The different communication protocols are RS-232, RS-485,

DH-485, DH+.

RS-232

Maximum communication length = 15 Meters

Baud rate = 19200 bits/second

Maximum number of nodes supported = 1

RS-485

Maximum communication length = 1.3 KMs

Baud rate = 9600 – 18700 bits/second

Maximum number of nodes supported = 32

DH-485

Maximum communication length = 1.2 KMs

Baud rate = 9600, 19200 bits/second

Maximum number of nodes supported = 31

DH +

Maximum communication length = 18 - 25 KMs

Baud rate = 19200 bits/second

Maximum number of nodes supported = 255

Optical Communication

In optical communication optical fibers are used. In optical

communication we can communicate to a longer distance than normal cables. The

main advantages are low noise, greater life, high data transfer speed, etc.

Satellite Communication

Normally satellite communication is used in remote places. In satellite

communication transmitter, receiver, encoders, decoders etc are used.

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Different SCADA Software

Sl.No. Company Name SCADA Software

1. Wonderware Intouch 2. Rockwell Automation RSview 3. Siemens Win CC 4. Intellution iFix 5. GE Fanuc Cimplicity 6. Merz Aspic 7. Kpit Astra

SCADA To PLC Communication Software

For communicating with PLC to SCADA we need communication software.

The different communication software’s used are

Allen Bradley PLC ABKF2

S7200 PPI (For Low End PLC)

SCADA Siemens PLC

ATS DDE (For Medium End PLC)

Modicon PLC Modbus Communication

Different Packages in InTouch

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The InTouch software package consists of Tags (Memory + I/O). The package

is available in 64, 256, 1000 and 64,000 Tags with the two options

1. Development + Runtime + Network (DRN)

2. Runtime + network (RN).

With DRN package you can develop as well as run the application but in case

of RN you cannot develop or modify the application. The application can be

developed by using DRN package and can be installed on RN package.

Features of SCADA

1. Real Time Trend

We can monitor the real time values by using Real time trend. Real-time

trends are dynamic. They are updated continuously during runtime. The real time

trend is plotted graphically. We can give many parameters in this Real time trend.

Different parameter variations are plotted by different colours. They plot the changes

of up to four local Tag Names or expressions as they occur.

2. Historical Trend

By using historical trend we can store the previous values. By giving correct

date, time etc we can easily get the parameter variations at that time. They plot the

changes of up to eight local Tag Names or expressions.

3. Alarms

Any hazardous conditions are monitored in industries by using these alarms.

Human safety is the most important factor in all industries. Usually the alarms give

the variations in any parameters as sound information or any light indication. The

alarms becomes off when the change in variation goes into normal conditions. In

SCADA, 1-999 alarms are there and they are mainly classified into four groups. They

are

Alarm Number Alarm Type

1- 249 Hazardous Alarms

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250-499 Major Alarms

500- 749 Minor Alarms

750-999 Advisory Alarms

4. Security

Security on an application is an optional feature. If implemented, it provides

the ability to control specific operators to perform specific functions or changing

specific parameters. Normally passwords are used for locking SCADA. By giving

passwords only the user can enter into the SCADA programs. 1 – 9999 access levels

are there in SCADA. One access level is given to each person. The access level of

administrator is always greater than 9000. The person who has access level greater

than 9000 can change any thing in SCADA. The administrators also have their own

user name and password. He can also enter into the programs by giving their user

name and passwords.

5. Report Generation

By using Report generation we can generate the parameter variations

as report in excel sheet automatically. We can create the parameter variations for each

scan cycle.

6. Recipe Management

Recipe management is an important feature in SCADA. By using

recipe management we can set the values for different ingredients. For example in

medicine manufacturing industries the ingredients are same for different medicines

but their ratio will vary. So in those cases we can set the ratio of different ingredients

by using SCADA. When we select the medicine the values are automatically loaded

and we get the correct medicine. The recipe functions are done by using Recipe

Manager in SCADA.

7. Scripts for Program Development

Normally the Programs are called as scripts.

Tag Name

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Tag name is the user defined address for a particular variable. For

example if we are using some objects in SCADA we have to give some names for

indicating that objects and also for using it in programs. These names are known as

Tag Names. Tag Names are mainly classified into four types. They are

1. Discrete

2. Integer

3. Real

4. Message

If we give any Tag Name we have to define or save it according to its

conditions. Discrete conditions mean 0/1 or ON/OFF. That means if we are using Tag

Names for switches, lamps etc then we have to define it into Discrete. If the Tag

Name is varying values like tanks, temperatures etc, then we have to define it into

Integer. If there are some floating values then Tag Name should be defined as Real.

The string values are stored as Message.

Each Tag Name is again classified into two types. They are

1. Memory

2. I/O

If we are using only SCADA programming then the Tag Names are

saved in Memory. If PLC to SCADA or PLC to excel communication is there, then

the Tag Names are saved in I/O.

Script

Script is the Programming language used to link two or more Tag

Names. Generally the programs are called as Scripts.

Types of Scripts

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Scripts are mainly classified into six. They are

1. Application scripts

2. Window scripts

3. Key scripts

4. Conditional scripts

5. Data change scripts

6. Quick function scripts

1. Application scripts

The script which is applicable for the entire project is known as

Application scripts. We can use application scripts to start other applications, create

process simulations, calculate variables etc. Three options are there in Application

Scripts.

On Startup Executes one time when the application is initially started up

While running Executes continuously at the specified frequency while the application is running.

On shutdown Executes one time when the application is exited

2. Window scripts

The script which is applicable for a particular project is known as

Window scripts. Three options are there in Window Scripts.

On Show Executes one time when the window is initially shown

While showing Executes continuously at the specified frequency while the window is showing.

On Hide Executes one time when the window is hidden.

The initial conditions of Tag names are given in On Show. The On show

conditions are applicable during starting of run time. For example if we want one

switch becomes OFF during starting run time then we have to give it as zero in On

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Show. The main program is known as While show. On hide means the conditions of

objects that we have to give when return back from run time. Normally in SCADA we

avoid On Hide because we don’t need the conditions during return back from run

time.

3. Key scripts

The programs which are assigned to a particular key is known as Key

Script. They are executed when the operator presses the correct key. Three options are

there in Key Scripts.

On Key Down Executes one time when the key is initially pushed

While Down Executes continuously at the specified frequency while the key is held down

On Key Up Executes one time when the key is released.

4. Conditional scripts

The program which is executed when satisfying a particular condition

given to it is called as Conditional scripts. Four options are there in Conditional

Scripts.

On True Executes one time when the condition transitions to true.

On False Executes one time when the condition transitions to false.

While True Executes continuously while the condition is true.

While False Executes continuously while the condition is false.

5. Data change scripts

The program which is used for data transfer purpose is called as Data

change scripts.

6. Quick function scripts

Sub routines or sub programs are called as Quick function scripts.

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Window Properties

Replace

Automatically closes any window(s) it intersects when it appears on the screen

including popup other replace type windows. You can change a window's type

whenever it is open in Window Maker by using the Window Properties command.

Overlay

Appears on top of currently displayed window(s) and can be larger than the

window(s) it is overlaying. When an overlay window is closed, any window(s) that

were hidden behind it will reappear. Clicking on any visible portion of a window

behind an overlay window will bring that window to the foreground as the active

window.

Popup

Similar to an overlay window except, it always stays on top of all other open

windows (even if another window is clicked). Popup windows usually require a

response from the user in order to be removed.

Programming Syntax

The programming syntax is

IF ‘CONDITION’ THEN ‘ASSIGNMENT’; ENDIF;

In conditions the symbols used are ‘= =, > =, < =, >, <, ><’. In

assignment only symbol used is ‘=’.

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Sample program

Write a program to ON/OFF a lamp when we press the switch?

For doing the program first select one switch and lamp from SCADA. After

selecting the objects first give the tag names for each object. After that the tag names

must be defined according to their properties.

Tag name=S1 Tag name=L1

Save as both tag name as Memory discrete. Then write the program in window

scripts.

Window Scripts

On Show

S1=0; L1=0;

While Show

IF S1= =1 THEN L1=1;ENDIF;

IF S1= =0 THEN L1=0;ENDIF;

We can write the above program in single line by using ELSE.

IF S1= =1 THEN L1=1;ELSE L1=0;ENDIF;

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SIEMENS S7 200PLC

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SIEMENS PLC

Siemens is the Europe's largest engineering conglomerate and the

largest electronics company in the world. Siemens international headquarters are

located in Berlin and Munich, Germany. The company is a conglomerate of three

main business sectors namely Industry, Energy and Healthcare. Siemens six

operational business areas were Automation & Control (Automation & Drives,

Industrial Solutions & Services, Siemens Building Technologies), Power (Power

Generation, Power Transmission & Distribution), Transportation (Transportation

Systems, Siemens VDO), Medical (Siemens Medical Solutions), Information &

Communication (Siemens Communications, Siemens IT Solutions and Services), and

Lighting (OSRAM GmbH, OSRAM Sylvania).

Siemens PLC’s are generally classified into two types.

Siemens PLC

S5 Series S7 Series

S5 series is DOS based version and S7 series is windows based

version. The different S5 series versions PLC’s are 100u, 110u, 115u etc. S5 series is

the old version PLC. Almost all of the S5 series PLC’s are replaced in all industries.

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Handheld programming can also do in this type of PLC’s. S7 Series PLC’s are again

classified into three types according to the number of inputs and outputs.

Plc Types No: of Digital I/O No: of Analog I/O

Low End S7 200 256 32

Medium End S7 300 1024 256

High End

S7 400

C7

M7

16384

> 20000

≈ 1500

256

Here we use S7 200 low end PLC. The different CPU versions of S7

200 PLC’s are

S7 200 Plc

21 X Series 22 X Series

210 221

211 222

212 223

213 224

214 225

215 226

216

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Here we use S7 200 PLC with CPU version 216. It has 24 digital inputs and

16 digital outputs.

Programming Software

The programming software used for S7 200 PLC is STEP 7 MICROWIN 32

RS-232 RS-485

Siemens PLC supports only RS-485 protocol. So a converter is used

for connecting with personal computer. The converter is called as PPI (Point to Point

Interface). The baud rate for Siemens PLC is 9600 bits/sec.

Addressing syntax

Siemens PLC addressing is basically Byte oriented. One byte means

eight bits.

Addressing syntax for Digital Input And Output

Syntax is File Type Byte . Bit

Digital Input Digital Output

I0.0 Q0.0

I0.1 Q0.1

I0.2 Q0.2

I0.7 Q0.7

I1.0 Q1.0

I1.1 Q1.1

PersonalComputer

PPI SiemensPLC

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I2.7 Q1.7

Addressing syntax for Analog Input And Output

Syntax is A File Type W Word

Analog Input Analog Output

AIW0 AQW0

AIW2 AQW2

AIW4 AQW4

Memory

Memory is mainly classified into four types. They are

1. Special Memory (SM)

2. Memory (M)

3. Variable Memory (V)

4. Local Memory (L)

1. Special Memory (SM)

In special memory each bit is having its own predefined function.

These bits can be used in programs. For example

SM0.0- Always ON

SM0.1- ON for the first scan cycle only.

SM0.2- ON for one scan cycle if retentive data is lost.

SM0.3- ON for 1 scan cycle when RUN mode is entered from a power-up condition.

SM0.4- Clock pulse that is ON for 30 s, OFF for 30 s, for a duty cycle time of 1 min.

SM0.5- Clock pulse that is ON for 0.5 s, OFF for 0.5 s, for a duty cycle time of 1 s.

48

Pot0 Value SMB28- This byte stores the value entered with analog adjustment 0.

Pot1 Value SMB29- This byte stores the value entered with analog adjustment 1.

2. Memory (M)

Memory is used for storing integer or floating values. Mathematical

and logical operations are done in these Memory locations.

3. Variable Memory (V)

Variable memory is used in FIFO and LIFO applications.

4. Local Memory (L)

Local Memory is used as addressing memory.

Memory Addressing

1. Special Memory Addressing

Bit Byte Word Double word

SM0.0 SMB0 SMW0 SMD0

SM0.1 SMB1 SMW2 SMD4

SM0.2 SMB2 SMW4 SMD8

SM0.3 SMB3 SMW6 SMD12

49

2. Memory Addressing

Bit Byte Word Double word

M0.0 MB0 MW0 MD0

M0.1 MB1 MW2 MD4

M0.2 MB2 MW4 MD8

M0.3 MB3 MW6 MD12

3. Variable Memory Addressing

Bit Byte Word Double word

V0.0 VB0 VW0 VD0

V0.1 VB1 VW2 VD4

V0.2 VB2 VW4 VD8

V0.3 VB3 VW6 VD12

50

4. Local Memory Addressing

Bit Byte Word Double word

L0.0 LB0 LW0 LD0

L0.1 LB1 LW2 LD4

L0.2 LB2 LW4 LD8

L0.3 LB3 LW6 LD12

In all these memory addressing, in the word wise classification next

memory location of MW0 is MW2 and also in double word wise classification the

next memory location of MD0 is MD4 . The reason is that Siemens PLC addressing is

byte oriented. The memory locations MW0 and MD0 consists of

MW0 = MB0 + MB1

MW1 = MB1 + MB2

MW2 = MB2 + MB3

So in MW0 and MW1, the MB1 location is common. So if we use

MW0 and MW1 then memory clash will occurs. So to avoid this MW2 is used after

MW0. Like that in double word also next three locations are not used.

51

Timers

Timer Type Resolution Maximum Value Timer Number

TONR 1 ms 32.767 s T0, T64

10 ms 327.67 s T1-T4, T65-T68

100 ms 3276.7 s T5-T31, T69-T95

TON, TOF 1 ms 32.767 s T32, T96

10 ms 327.67 s T33-T36, T97-T100

100 ms 3276.7 s T37-T63, T101-T255

In Siemens PLC normally 255 numbers of timers are there. The types

of timers are TON, TOF and TONR. In siemens PLC we cannot use any timer number

for different types of timers. The timer number is predefined. We have to give the

correct timer number for different types that means TON, TOF and TONR. Also in

Siemens PLC the highest time base is 100ms. So we have to calculate correct preset

value for giving a time. For calculating time delay one formula is there.

Time delay = Preset value * Time Base

For example if we are using T37 timer and we need 10s time delay. So

T37 is a 100ms timer. Formula is

So for giving 10s time delay by using T37 timer we have to give preset

value as 100. Like that we can calculate the time delay according to our need.

The On-Delay Timer (TON) instruction counts time when the enabling

input is ON. When the current value (Txxx) is greater than or equal to the preset time

(PT), the timer bit is ON. The On-Delay timer current value is cleared when the

enabling input is OFF. This timer continues counting after the Preset is reached, and it

stops counting at the maximum value of 32767.

Time delay = Preset value * Time Base

10s = Preset value *100

10 *1000ms = Preset value *100

Preset value = 100

52

SIEMENS S7 300PLC

53

54

SIEMENS PLC

Siemens is the Europe's largest engineering conglomerate and the

largest electronics company in the world. Siemens international headquarters are

located in Berlin and Munich, Germany. The company is a conglomerate of three

main business sectors namely Industry, Energy and Healthcare. Siemens six

operational business areas were Automation & Control (Automation & Drives,

Industrial Solutions & Services, Siemens Building Technologies), Power (Power

Generation, Power Transmission & Distribution), Transportation (Transportation

Systems, Siemens VDO), Medical (Siemens Medical Solutions), Information &

Communication (Siemens Communications, Siemens IT Solutions and Services), and

Lighting (OSRAM GmbH, OSRAM Sylvania).

Siemens PLC’s are generally classified into two types.

Siemens PLC

S5 Series S7 Series

S5 series is DOS based version and S7 series is Windows based

version. The different S5 series versions PLC’s are 100u, 110u, 115u etc. S5 series is

55

the old version PLC. Almost all of the S5 series PLC’s are replaced in all industries.

Handheld programming can also do in this type of PLC’s. S7 Series PLC’s are again

classified into three types according to the number of inputs and outputs.

Plc Types No: of Digital I/O No: of Analog I/O

Low End S7 200 256 32

Medium End S7 300 1024 256

High End

S7 400

C7

M7

16384

> 20000

≈ 1500

256

56

Architecture of S7 300 PLC

Rails/ Slots

Rack 0

1 2 3 4 11

Rack 1

1 2 3 4 11

Rack 2

1 2 3 4 11

PowerSupply

CPU IM DI / DO

IM

IM

57

The above figure shows the architecture of Siemens S7 300 PLC. Siemens S 7

300 PLC is Modular type PLC. The architecture is based on Rack and Rail

configuration. The above figure each full block is known as Rack. Eleven slotted

Rails are there in each Rack. In Rack 0 the first Rail (Rail 1) is allotted for Power

Supply, Rail 2 is allotted for CPU, Rail 3 for Interfacing Module (IM) and in other

Rails we can add Digital Input Module, Digital Output Module, Analog Input

Module, Analog Output Module etc according to our needs.

In Siemens S7 300 PLC one CPU can supports four Racks. So for

communicating with other Racks, each Rack contains one Interfacing Module (IM).

So in Rack 1, Rack 2 and Rack 3 the first Rail is allotted for Interfacing Module (IM).

The connection from CPU of Rack 0 is given to the Interfacing Modules of others.

The CPU and Power Supply are common for all four Racks.

Here we use S7 300 Medium end PLC. The different CPU versions of S7 300

PLC’s are CPU 312 ---------318. Here we use S7 300 CPU 312 C. In CPU 312 C, ‘C’

indicates Compact. SIMATIC S7-300 is optimized for high performance machines

and factory automation. The SIMATIC S7-300 saves space, and it is compact and

modular.

Features of S7 300

Built-in functions (eg: high-speed counting, closed-loop control, motion

control, etc.).

Extensive selection of CPUs and modules for almost every application.

Compact design reduces control cabinet size.

Integrated system diagnostics assure high degrees of controller availability.

Innovative Micro Memory Card provides maintenance- free (no battery

required) program backup plus the ability to store production and project

information.

58

Fail-safe version provides machine safety and standard automation in a single

controller.

Programming Software

The programming software used for S7 300 PLC is

SIMATIC MANAGER 5.1 – 5.5

RS-232 RS-485

Siemens PLC supports only RS-485 protocol. So a PPI (Point to Point

Interface) converter is used for connecting with personal computer. The baud rate

used is 9600 bits/sec.

CPU Memory Concept

CPU Memory

Load Memory System Memory Work Memory

1. Load Memory

The Load memory is located on the SIMATIC Micro Memory Card (MMC).

The size of the load memory corresponds exactly to the size of the SIMATIC Micro

Memory Card. It is used to store code blocks, data blocks and system data

(configuration, connections, module parameters, etc). Blocks that are identified as non

PersonalComputer

PPI Siemens PLC

59

runtime related are stored exclusively in load memory. You can also store all the

configuration data for your project on the SIMATIC Micro Memory Card.

2. System memory

The System memory is integrated in the CPU and cannot be expanded. It

contains the address areas for address area memory bits, timers and counters, the

process image of the I/Os, local data.

3. Work Memory

The Work Memory is integrated in the CPU and cannot be extended. It is used

to run the code and process user program data. Programs only run in RAM and system

memory.

Retentivity of Load Memory, System Memory and

Work Memory

CPU is equipped with a service-free retentive memory, i.e. its operation does

not require a buffer battery. Data is kept in retentive memory across Power OFF and

Restart.

1. Retentive data in load memory:

Program in load memory is always retentive. It is stored on the SIMATIC

Micro Memory Card, where it is protected against Power Failure or CPU memory

Restart.

2. Retentive data in system memory:

The diagnostic buffer, MPI address and operating hour counter data and

generally written to Retentive Memory area on the CPU. Retentivity of the MPI

address and baud rate ensures that the CPU can continue to communicate, even after a

power loss, memory reset or loss of communication parameters (e.g. due to removal

of the SIMATIC Micro Memory Card or deletion of communication parameters).

3. Retentive data in Work Memory:

60

The contents of retentive DBs are always retentive at Restart and Power

ON/OFF. CPUs V2.1.0 or higher also support volatile DBs (the volatile DBs are

initialized at restart of Power OFF-ON with the in initial values from load memory).

Figure: Compact PLC S7-300 (CPU xxx C)

(1) Status and Error Displays

(2) Micro Memory Card (MMC)

(3) Connection of Integrated I/O

(4) Power Supply Connection

(5) 2 connected X2(PtP nebo DP)

(6) 1 connected X1( MPI)

(7) Mode Selector Switch

61

Status and Error Indicators: CPU 31xC

LED designation Colour Meaning

SF Red Hardware or Software error

BF ( for CPUs withinterface only s DP)

Red Bus error

DC5V Green 5-V power for CPU and S7-300 which indicates bus is Ok

FRCE Yellow Force is active

RUN Green CPU in RUN

STOP Yellow CPU in STOP and HOLD or STARTUP

Features of S7 300 312-C

Work Memory: 32 Kb

Number of timers/counters: 128/128

Digital Channels: 256

Analog Channels: 64

Networking: MPI (Multi Point Interface)

62

Addressing syntax

Siemens PLC addressing is basically Byte oriented. One byte means

eight bits. In Siemens PLC for Digital I/O they allocate 4 Bytes for each slot and for

Analog they allocate 16 Bytes for each slot.

Addressing syntax for Digital Input And Output

Syntax is File Type Byte . Bit

Digital Input Digital Output

I0.0 Q0.0

I0.1 Q0.1

I0.2 Q0.2

I0.7 Q0.7

I1.0 Q1.0

I1.1 Q1.1

I3.7 Q3.7

Addressing syntax for Analog Input And Output

Syntax is A File Type W Word

Analog Input Analog Output

AIW0 or PIW0 AQW0 or PQW0

AIW2 or PIW2 AQW2 or PQW2

AIW4 or PIW4 AQW4 or PQW4

63

Memory Addressing

Bit Byte Word Double word

M0.0 MB0 MW0 MD0

M0.1 MB1 MW2 MD4

M0.2 MB2 MW4 MD8

M255.7 MB255 MW254 MD252

In all these memory addressing, in the word wise classification next

memory location of MW0 is MW2 and also in double word wise classification the

next memory location of MD0 is MD4 . The reason is that Siemens PLC addressing is

byte oriented. The memory locations MW0 and MD0 consists of

MW0 = MB0 + MB1

MW1 = MB1 + MB2

MW2 = MB2 + MB3

So in MW0 and MW1, the MB1 location is common. So if we use

MW0 and MW1 then memory clash will occurs. So to avoid this MW2 is used after

MW0. Like that in Double word also next three locations are not used.

64

MODICON PLC

65

66

MODICON PLC

Schneider Electric is a French global company. It was founded in 1836 by two

brothers, Eugene I and Adolphe Schneider. Different brand names are there for

Schneider electric such as Merlin Gerin, Telemecanique and Square D. Today, the

company has grown into a world leader in Power and Control solutions. Schneider

electric also has a number of R&D centers like

Global Technology Center India in Bangalore

Global Technology Center Mexico at Monterrey City.

CRDC in Shanghai, China

which mainly focus on Electromechanical, Electronic and software developments to

meet the global product requirements.

Modicon PLC’s are mainly classified into three types they are

Plc Types No: of Digital

I/O

No: of Analog

I/O

Software

Low End

Zelio

Nano

24

48

0

2

Zelio Soft

PL7 Junior

Medium End

Twido

Micro

144

248

2

8

Twido Soft

PL7 Pro ver:3.1-3.4

High End

Premium

Quantum

5000

20000

16

256

PL7 Pro ver:4.1-4.4

Modsoft

Display 16 4 CPU TER Digital Analog UP Input Input

1 3 5

67

Analog

Port

H

S

C

HSC – High speed counter. It is used for counting high speed pulses from

Tachometers.

PCMCIA – Personal Computer Memory Card International Association. It is used as

extra memory cards for Modicon PLC’s.

Driver Software

Driver Software is used for interfacing personal computer with PLC.

The driver software used for Modicon PLC is X Way Driver Manager.

Programming Software

The programming software’s used in Modicon PLC’s are.

For Micro PLC’s PL7 Pro Ver 3.4

For Premium PLC’s PL7 Pro Ver 4.3

Display 16 4 CPU TER Digital Analog UP Input Input

2 4 6

68

Processor Types

For Micro PLC’s TSX 3722 V 3.3 and TSX 3721 V1.0

For Premium PLC’s TSX 57203 V 5.1

Addressing syntax

Addressing syntax for Digital Signals

Syntax is % Type Slot Number . Element

Digital Input Digital Output

%I1.0 %Q2.0

%I1.1 %Q2.1

%I1.2 %Q2.2

%I1.15 %Q2.11

Addressing syntax for Analog Signals

Syntax is % Type W Slot Number . Word

Analog Input Analog Output

%IW3.0 %QW4.0

%IW3.1 %QW4.1

%IW3.2

%IW3.3

69

Memory

Memory is used for storing integer and floating point values. It is also

used in arithmetic and logical operations.

Memory Addressing

Bit Byte Word Double word

%M0 %MB0 %MW0 %MD0

%M1 %MB1 %MW1 %MD2

%M2 %MB2 %MW2 %MD4

%M3 %MB3 %MW3 %MD6

%MW0 = %MB0 + %MB1

%MW1 = %MB2 + %MB3

%MW2 = %MB4 + %MB5

In word wise classification the values are stored in two bytes. But the

memory locations are different. So in Modicon PLC we can take all the Word

Memory locations. That means we can take %MW0, %MW1, %MW2 etc. The

storing byte location can be calculated using the formula

For example if we want to calculate the storing locations for the word

%MW10. Then first calculate the value of j.

ie j = 2i

%MWi = %MBj + %MB(j+1) ,

Where j = 2i

70

j = 2 * 10

j = 20

Then %MWi = %MBj + %MB(j+1)

%MW10 = %MB(20) + %MB(20 + 1)

%MW10 = %MB20 + %MB21

Thus we can calculate the memory locations in word wise

classification. But in double word wise classification the values are stored in two

Words. So if we use one double word location then the next location is not used. In

%MD0 and %MD1, the %MW1 location is common. So if we use %MD0 and %MD1

then memory clash will occurs. So to avoid this %MD2 is used after %MD0.

%MD0 = %MW0 + %MW1

%MD1 = %MW1 + %MW2

%MD2 = %MW2 + %MW3

Timers

Timers are mainly classified into three categories. They are

1. Timer (TON / TOF /TP)

TON AND TOF is like that of normal ON Delay and OFF Delay

timers. Another timer is there TP (Pulse Timer). In TP we get constant output for a

single input pulse. We get constant output for a predetermined preset value. For

example consider the preset value as five and time base as one second then we get

constant output for five seconds for an input pulse. The input and output waveforms

are shown below. The addressing of these three timers is

%TM0, %TM1, %TM2 ---------- %TM63

Input

Output

5 Sec 5 Sec

71

2. Series 7 Timer

Series 7 Timers are Retentive timer’s, means the accumulator values

are retained in these timers even if the input is OFF. In Modicon PLC’s initially the

number of timers is zero. So if we want Series 7 Timer we have to decrease the

number of normal timers and increase the Series 7 Timer as required numbers. After

that we have to save it and thus we can use Series 7 Timer. Addressing of Series 7

Timer is

%T0, %T1 ……….

3. Monostable Timer

Monostable Timer is almost same as that of Pulse Timer. In

Monostable Timers when an input pulse is given we get constant output as that of

Pulse Timer. But if we give a second input pulse at the time of working then the timer

starts from that time and the ON time duration is thus increased. For example consider

the preset value as five and Time Base as one second, then the input and output

waveforms are shown below. Addressing of Monostable Timers is

%MN0, %MN1 ----------- %MN7

Input

2 Sec

Output

5 Sec 2 Sec 5 Sec

7 Sec

4. Counters

72

In Modicon PLC Up and Down Counter block is used. The addressing

of Counters is

%C0, %C1, %C2 ----------- %C31

5. Registers

Registers are used in FIFO and LIFO operations. The addressing of

Registers is

%R0 ----------- %R3

6. Drums

Drums are used as sequencer output function. Addressing is

%DR0, %DR1 ----------- %DR7

Operator Block

Operator Block is used for performing Move, Shift and Mathematical

operations.

Move Function

Example:

%MW0 := 100

%MW0 := %MW1

In first example the value 100 is moved to the location %MW0. The

destination is %MW0. In second example the value stored in memory location

%MW1 is moved to %MW0.

Math function

Example:

%MW0 := %MW1 + %MW2

%MW0 := %MW1 - %MW2

%MW0 := %MW1 * %MW2

%MW0 := %MW1 / %MW2

%MW0 := SQRT(%MW1)

73

Shift function

%MW0 := SHL(%MW1,4)

%MW0 := SHR(%MW1,4)

%MW0 := ROL(%MW1,4)

%MW0 := ROR(%MW1,4)

Comparison Block

Two types of comparison blocks are there in Modicon PLC. They are

1. Horizontal Comparison Block

2. Vertical Comparison Block

1. Horizontal Comparison Block

We can compare timer values using Horizontal comparison block. For

example consider one Timer %TM0. For comparing accumulator value of Timer give

%TM0.V then comparison symbol and value.

For calling Accumulator value of Timer %TM0.V

For changing Preset value of Timer %TM0.P

%TM0.V > 10

74

2. Vertical Comparison Block

C

In Vertical comparison block we get four outputs corresponding to one

compare value.

CompareEN

%TM0.V

5

75

76

AC DRIVES

77

78

AC Drives

AC motor

An AC motor is an electric motor that is driven by an alternating current. It

consists of two basic parts, an outside stationary stator having coils supplied with AC

current to produce a rotating magnetic field, and an inside rotor attached to the output

shaft that is given a torque by the rotating field.

STATOR

AC 1Ø SHAFT

ROTOR

There are two types of AC motors, depending on the type of rotor used. The

first is the synchronous motor, which rotates exactly at the supply frequency or a

submultiple of the supply frequency. The magnetic field on the rotor is either

generated by current delivered through slip rings or by a permanent magnet.

The second type is the induction motor, which turns slightly slower than the

supply frequency. The magnetic field on the rotor of this motor is created by an

induced current.

79

Specifications of Motor

1. Voltage rating (V)

2. Current rating (A)

3. Phase (1Ø or 3Ø)

4. AC or DC

5. RPM

6. Power Rating (HP)

7. Casing

Block Diagram of Drives

Ac supply is given to the input of Drives. Then the AC supply is

converted into DC supply. In low power applications diodes are used. But in high

power applications Thyristors (SCR’s) are used. Then the DC supply is again

converted into AC. In this also in high power applications IGBT’s are used. Then the

output signal is then given to AC Motor.

AC to DC Converter (Rectifier)

DC to AC Converter (Inverter)

AC Motor

Pulse Generator PWM

80

Drives Connection Diagram in Industries

In industries the main power supply is given through MCB (Miniature Circuit

Breaker). Then one Choke coil is used to avoid voltage fluctuations. Then AC Drives

is connected and last section is the Load or Motor.

Classification of Drives

Drives

AC Drives DC Drives

VVD VFD

VVD Variable Voltage Drive

VFD Variable Frequency Drive

Drives are mainly classified into two types, AC Drives and DC Drives. AC

Drives are again classified into two types VVD and VFD. VFD’s are commonly used

in industries because we can easily change the frequency. But in VVD some voltage

drop occurs and we don’t get the desired output.

MCB Choke Coil

Drives

Motor

81

Speed (Ns) = 120 f

P

Where f = Frequency

P = Number of Poles

Here we use Altivar 28 AC Drive. The company name of Altivar 28 is

Schneider Electric. Altivar 28 has four Digital inputs namely LI1, LI2, LI3 and LI4. It

also has three analog inputs namely AI1, AI2 and AIC. AI1 and AI2 are voltage

inputs and AIC is current input. We can assign either AI2 or AIC at one time but not

both. One Analog output is also there named as AO. One Common (GND) terminal is

also there for both analog and digital inputs.

Digital Inputs LI1, LI2, LI3 and LI4

Analog Inputs AI1, AI2 and AIC

Analog Output AO

Common (Ground) Both for Analog and Digital

General formula for calculating Motor speed is

In our Motor Number of Poles (P) = 2. Then the formula becomes

Speed (Ns) = 120 f

P

= 120 f

2

= 60 f

82

Modes of Operation

Altivar 28 AC Drive can be mainly operated in two modes

Modes of Operation

2C (2 Wire Configuration) 3C (3WireConfiguration)

2C 4 Speed 2C 8 Speed

In 2C configuration the main control inputs are Forward and Reverse and

hence it is known as 2C configuration. In 3C configuration the main control inputs are

Forward, Reverse and Stop.

2C Configuration

2C 4 Speed Configuration

In 2C 4 Speed Configuration the four digital inputs are used for

controlling different speeds.

LI1 Forward Direction

LI2 Reverse Direction

LI3 and LI4 inputs are used for adjusting different speeds.

83

LI4 LI3 Speed

0 0 LSP

0 1 SP2

1 0 SP3

1 1 HSP

2C 4 Speed Configuration Settings

Up Down Enter Esc

For setting 2C 4 Speed Configuration first press Enter.

IO Mode setting

Press Enter

SET DRC IO SUP

Select IO by using Up and Down Switch.

IO Tcc = 2C

LI2 = Rrs

LI3 = PS2 (2 Preset Speeds)

LI4 = PS4 (4 Preset Speeds)

Set Mode setting

After setting IO mode then go to SET Mode and set different frequency for

LSP, HSP, SP2 and SP3.

84

2C 8 Speed Configuration

In 2C 8 Speed configuration LI2, LI3 and LI4 inputs are used for

controlling different speeds. Remaining is one input; LI1 is used for forward

direction. So only forward direction option is there in 2C 8 Speed Configuration. For

setting 2C 8 Speed configuration change LI2 as PS8.

LI2 LI4 LI3 Speed

0 0 0 LSP

0 0 1 SP2

0 1 0 SP3

0 1 1 SP4

1 0 0 SP5

1 0 1 SP6

1 1 0 SP7

1 1 1 HSP

IO Mode setting

Press Enter

Select IO by using Up and Down Switch.

IO Tcc = 2C

LI2 = PS8

LI3 = PS2

LI4 = PS4

85

Set Mode setting

After setting IO mode then go to SET Mode and set different frequency for

LSP, HSP, SP2, SP3, SP7.

Analog Control of Motor Using Drives

For controlling the motor using analog voltage, connect the voltage inputs

(AI1 or AI2) to 0-10 V. Also for controlling with Analog current connect the Current

input (AIC) to 4-20 mA. By varying the current or voltage we can vary the motor

speed. Using Analog Output AO we get Analog Output Voltage corresponding to

motor speed. This Analog Output can be used for controlling other devices.

3C Configuration

In 3C configuration the main control inputs are Forward, Reverse and Stop. In

3C Configuration one normal speed and jog speed occurs. The normal speed can be

set only in LSP.

LI1 Stop

LI2 Forward Direction

LI3 Reverse Direction

LI4 Jog Speed

IO Mode setting

Press Enter

Select IO by using Up and Down Switch.

IO Tcc = 3C

LI2 = For

LI3 = Rrs

LI4 = Jog

86

Set Mode setting

After setting IO mode then go to SET Mode and set different frequency for

LSP and JOG.

DC Injection Breaking

An important feature in this AC Drive is DC Injection Breaking. Normally if

we press the stop button of a high speed motor then it stops only slowly. By applying

DC Injection Breaking we can suddenly stops the motor. The general principle is that

if we give DC Injection Breaking then the drives cuts the AC input applied to the

motor and continuous DC is injected to it. Thus the motor cannot able to rotate and it

suddenly stops. Thus we can suddenly stop a high speed running motor. For setting

DC Injection Breaking in 3C Configuration change the value of LI3 as DCI. So if we

use DC Injection Breaking feature in 3C Configuration then the reverse option is not

there because we change the reverse input to DCI function.

For DC Injection Breaking LI3 = DCI

Advantages of Drives

1. Energy Saving.

2. We can run the motor at Constant Speed.

3. We can run the motor at Variable Speed.

4. We can run the motor in both directions (Forward and Reverse).

5. We can run the motor at Jog Speed.

6. We can suddenly stop the motor by using DC Injection Breaking.

87