Monitoring and Control of A Variable Frequency Drive Using PLC and SCADA
Monitoring and Control of A Variable Frequency Drive Using PLC and SCADA
Volume: 2 Issue: 10
ISSN: 2321-8169
3092 3098
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Monitoring and Control of a Variable Frequency Drive Using PLC and SCADA
Rinchen Geongmit Dorjee
Advanced Technical Training Centre
Bardang, Singtam, East Sikkim
[email protected]
Abstract Programmable Logic Controller (PLC) and Supervisory Control And Data Acquisition (SCADA) are two new approaches to control
a Variable Frequency Drive (VFD) whose output is fed to a three-phase induction motor and driving a conveyor belt. The conveyor belt has
three sensors are inputs which senses a passing object and carries out the necessary instructions programmed in ladder logic programming of the
PLC through the medium of a personal computer (PC). The SCADA software installed in the PC in turn enables the human operator to control
the entire operation away from the plant and just by using the virtual inputs designated on his computer screen. The results have been verified
with a validating experiment.
Keywords- Variable Frequency Drive, Programmable Logic Controller, Supervisory Control And Data Acquisition, RS-Logix, Intouch Software
9.5
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I.
INTRODUCTION
II.
RELATED WORKS
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temperature and speed for protection purposes. It was found
that PLC was able to achieve optimum accuracy with a
virtually power factor along with easy error detection and
correction, along with being more reliable than traditional
methods. The monitoring of three-phase induction motor
driven by VFD, with PLC as a controller provided high
accuracy in the regulation of its speed. Maria G. Ioannides et
al. [3] has developed a PLC based continuously monitoring
and control of a three-phase induction motor. Various types of
sensors were used for monitoring the parameters such as speed
and current. With the help of PLC ladder logic programming,
it was proven that speed control of motor was achieved with
high accuracy as well as efficiency. It was found that at high
speeds and loads, the efficiency of the system was increased up
to 10 to 12%. In brief this paper proved that PLC was a
versatile and efficient control tool in industrial electric drives
applications. N D Ramesh [5] presented a study on PLC
which uses a programmable memory for implementing
specific functions such as logic sequencing, timing, counting,
and arithmetic control through digital or analog input/output
modules. The functions of PLC include on-off control,
sequential control, feedback control and motion control, to
name a few. Industrial PLCs normally operate at an inputoutput voltage supply of 24V DC. Physical connections from
the real world to the PLC are designated inputs such as limit
switches, push button switches, sensors or basically anything
that works on the principle of switching a signal on or off.
Outputs of a PLC are usually solenoids, lamps, contactors,
relays, etc. The number of digital input/outputs can be
increased by adding additional digital input/output modules.
One of the most common methods of PLC programming is
also known as Ladder Logic programming which is a language
using relay symbols as a base in an image similar to a hardwired relay sequence. It looks like a ladder, whose sides are
the power rail on the left and ground rail on the right. The
rungs of the ladder consist of virtual relay components which
perform certain tasks based on the instructions given in the
program. S. Da'na [4] has discussed the design and
implementation of a platform to remotely monitor and control
PLC-based processes over TCP/IP or by using the GSM
network. The platform is built using industry-standard off-theshelf PLCs. Integrated with each PLC are communication
processors that can be used for connectivity to the network and
to a GSM modem. The communication processor module
(Ethernet module) used in this work, provides an industrial
compatible protocol over TCP/IP that achieves the same
functionality as Profinet but at a much higher bandwidth
(10/100 Mbps). Additionally, a mobile-based communication
protocol that facilitates remote monitoring and control of PLCs
using SMS messages has also been developed. The intent here
is to provide system users with a back-up communication
mechanism in case of a network failure. M Zajmovic et al. [6]
presented a paper on the management of induction motors
using PLC which executes instructions according to the
programmed logic and sends signals to the Variable Speed
Drives, from which it receives feedback of the motor speed so
as to control its speed by modulation of voltage and frequency.
A Zelio PLC was used with the help of a frequency
transformer which controlled a 5.5 kW asynchronous induction
motor at a speed of 1500 rpm. A windows XP operating
system with SCADA software from DAQFactory was used for
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power systems, preprocessing of data at the RTU level using
Fuzzy Logic and Fuzzy-Genetic algorithm, substation
automation etc. are already being supported by this laboratory.
A. Objectives
A PLC-SCADA based monitoring and control system for
a Variable Frequency Drive system was developed which
controls a three-phase induction motor attached to a conveyor
belt, having three proximity sensors serving as inputs to the
PLC's ladder logic programming. . PLC was introduced in the
1970's for the automotive manufacturing industry to provide a
replacement for large relay based control panels. With the
advent of the microprocessor, PLCs have been enhanced to
accomplish more complex industrial applications over the
years. SCADA is a type of industrial control system which
are computer-controlled systems for monitoring and control of
industrial processes. A distinct advantage of SCADA lies in
the control ability of large scale processes which includes
multiple sites and large distances.
The integration of PLC and SCADA for industrial
automation comprises of: a human-machine interface which is
the device presenting processed data to a human operator,
who monitors and controls the process; a Remote Terminal
Unit collects the information by connecting to sensors in the
process, converting sensor signals to digital data and sending
digital data to the supervisory system after which that
information is displayed on a number of operator screens;
PLC used as field devices for their economical, versatile,
flexible and configurable attributes.
This integrated system provides a platform for developing
the concepts for thorough understanding of how an industrial
automated system works comprising of all the above
components.
B. V/f method of speed control
The motor speed can be controlled by varying supply
frequency. Voltage induced in stator is directly proportional to
product of supply frequency and air-gap flux. If stator drop is
neglected, terminal voltage can be considered proportional to
product of frequency and flux. V1 f. Effect of supply
frequency change without terminal voltage change:
1. Reduction of supply frequency without change in
terminal voltage will cause an increase in the air gap
flux thereby saturating the motor. This will cause the
increase in magnetizing current, core loss and stator
copper loss and cause distortion in line current and
voltage and produce high-pitch noise.
2. Increase of supply frequency without change in
terminal voltage will cause decrease in flux therefore
leading to reduction of torque capability of the
motor.
Figure 2 shows the Torque-Speed characteristics of an
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AC motor, main drive controller assembly, and drive operator
interface. The AC electric motor used in a VFD system is a
three-phase induction motor which is generally the most
economical motor choice. The VFD controller is a solid state
power electronics conversion system consisting of three
distinct sub-systems: a rectifier bridge converter, a direct
current link, and an inverter. In a VSI drive, the DC link
consists of a capacitor which smoothens out the converter's
DC output ripple and provides a stiff input to the inverter.
This filtered DC voltage is converted to quasi-sinusoidal AC
voltage output using the inverter's active switching elements.
VSI drives provide higher power factor and lower harmonic
distortion than phase-controlled Current Source Inverter.
VFD control has been chosen specifically because they
provide the advantages of energy savings, low motor starting
current, reduction of thermal and mechanical stresses on
motors and belts during starts, simple installation, high power
factor and lower KVA.
A PLC-SCADA based control system has been set up
comprising of an Allen-Bradley PLC, an Allen-Bradley
PowerFlex 4M Variable Frequency Drive, a three-phase
induction motor and the workstation has been developed,
configured and integrated together for the monitoring and
control of the motor driving a conveyor belt load.
Various control schemes have been used to operate the
induction motor in Speed and Position control modes of
operation using PLC programming and through animated
SCADA screens developed on the workstation.
Variable Frequency Drives are generally required because
many applications are not run at the same speed all of the time
due to surrounding circumstances. The revolutions per minute
of the driven shaft need to be increased or decreased
depending on load changes, application requirement or other
circumstances.
The PLC has been connected to control and monitor a VFD
which is the acts as a go-between the three-phase induction
motor and the PLC. A conveyor load is connected to the
induction motor and three proximity sensor inputs are
connected uniformly across the conveyor. The forward
direction of the motor is controlled by the first sensor, the
second sensor directs the motor to pause for a given period of
time and the reverse direction of the motor is controlled by the
third sensor.
The sensor inputs are fed to the PLC which processes the
inputs according to the ladder logic programming and initiates
corresponding output to the VFD. The VFD in turn once again
processes the PLC input to it and accordingly controls the
speed and position of the three-phase induction motor. Ladder
logic programming is carried out in RS-Logix in the personal
computer.
SCADA elements are written into the ladder logic program
itself by assigning a tag or point which represents a single
input or output value monitored or controlled by the system.
With the help of SCADA system, labour costs are reduced by
minimizing site visits for inspection, data collection and
making rectifications. User defined controls such as start, stop
are developed on the software window in order to control the
system remotely.
Figure 4 shows the system layout diagram.
0.75 kW (1 Hp)
Rated Voltage
Rated Current
4.2 A
Rated Torque
3.5 kg
Description
Details
Dimensions HxWxD
90 x 180 x 87 mm
Weight
0.9 kg
Number of I/O
24V DC
24V DC:
15 A for 20 ms
Power consumption
50W
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3. Input Variables taken:
Three proximity sensors to detect motion of
object on conveyor belt
Frequency parameter of VFD to control output
4.
this input within the drive and finally controls the speed
and position of the motor. The ladder logic programming
is shown in Figure 5
B. Conduction of Experiments
Allen-Bradley PLC, Allen-Bradley PowerFlex 4M
Variable Frequency Drive, a three-phase induction motor
driving a conveyor belt load controlled by ladder logic
software and Intouch 9.5 software was connected for the
conduction of the experiment in which for various values of
input supply frequencies, the corresponding values of motor
speed in rpm were obtained as shown in Table 3.
Table 3 Frequency input vs. speed output
Input supply
frequency in Hz
Motor speed in
rpm
250
10
620
15
940
20
1240
25
1495
30
1809
35
2100
40
2350
45
2590
50
2800
55
3200
60
3450
V.
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Figure 6 shows the graph for the experiment conducted
VI.
4000
CONCLUSION
3500
3000
Input
supply
frequenc
y in Hz
2500
2000
1500
1000
500
0
1
7 10 13
VI.
Figure 6 Frequency input vs. speed output
TAG TYPE
ACCESS
NAME
TAG LINK
BOTT
MEMORY REAL
MEMORY
MEMORY
L1
I/O DISCRETE
DRIVE
B3:0/10
L2
I/O DISCRETE
DRIVE
B3:0/6
L3
I/O DISCRETE
DRIVE
B3:0/5
L4
I/O DISCRETE
DRIVE
T4:0/TT
SEN1
I/O DISCRETE
DRIVE
B3:0/5
SEN2
I/O DISCRETE
DRIVE
T4:0/TT
SEN3
I/O DISCRETE
DRIVE
B3:0/6
SW1
I/O INTEGER
DRIVE
B3:1/0
SW2
I/O INTEGER
DRIVE
B3:1/1
SW3
I/O INTEGER
DRIVE
B3:1/2
TIMER
I/O INTEGER
DRIVE
T4:0.ACC
WH
MEMORY REAL
MEMORY
MEMORY
CONCLUSION
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