CHAPTER 1

INTRODUCTION
Programmable logic controller is defined as a digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog input/output models, various types of machines or processes. CPU is the heart of PLC wherein the processing takes place. A processor appears in a PLC and it can be either 1 bit or word processor. The processor memory module is a major part of CPU housing. Memory is the where the control plan or program is held or stored in the controller. The information stored in the memory related to the way the input and output data should be processed. Here we are using Step- 7 Micro win which is a windows-based software application used for programming the S7-200 Micro PLC (programmable logic controller).The STEP 7-Micro/Win programming software package provides a set of tools required to program the S7-210 in either Statement list (STL) or ladder logic (LAD) programming language. By using PLC S7-200 (CPU 226), EM 235 and Micromaster Vector Drive we are going to control the speed of the motor by setting the different control word in PLC.

NEED AND SIGNIFICANCE OF THE PROJECT:

The speed of the induction motor is determined by the frequency of the power supply and the number of magnetic poles in the design of the stator. An induction motor can run only at its rated speed when it is connected directly to the main supply. But many applications need variable speed operation. So we are going to control the speed of the motor by setting the different control word in PLC.

OBJECTIVE OF THE PROJECT:

The objective of the project is to control the speed of three phase induction motor by varying the supply frequency which is achieved through PLC.Based on the speed requirement, we have to set the control word in PLC.The output analog voltage proportional to the word is given to the micromaster vector drive which will vary the supply frequency based on the speed requirement. .

CHAPTER 2
SYSTEM IMPLEMENTATION
2.1 BLOCK DIAGRAM DESCRIPTION

Based on the speed requirement, the control word is set in PLC. The extension module EM235 will convert the control word into the analog voltage and this analog voltage is fed back to the inverter drive which will vary the frequency. For control word 32000(16 bit), the analog voltage of 10v is applied to the inverter drive and drive will provide 50HZ supply to IM, the motor will run at rated speed and for control word 16000, the analog voltage of 5V is applied to the drive and it will provide 25 HZ supply to IM and the motor will run at half of the rated speed.

2.2 Connecting Power to the S7-200 CPU

The first step is to connect the S7-200 to a power source. Figure shows the wiring connections for either a DC or an AC model of the S7-200 CPU.

CHAPTER 3
PROGRAMMABLE LOGIC CONTROLLER.
3.1 Connecting the S7-200 CPU

Connecting your S7-200 is easy. For this example, you only need to connect power to your S7-200 CPU and then connect the communications cable between your programming device and the S7-200 CPU.

Defining the requirements for the application Example Designing the control logic Putting the control logic into a program Creating a project with STEP-7 Micro/Win, Creating a symbol table Creating the program and Down load and monitoring the sample program

3.2

Connecting the RS-232/PPI Multi-Master Cable

Above Figure shows an RS-232/PPI Multi-Master cable connecting theS7-200 to the programming device. To connect the cable: 1. Connect the RS-232 connector (marked PC) of the RS-232/PPI MultiMaster cable to the communications port of the programming device. (For this example, connect to COM 1.) 2. Connect the RS-485 connector (marked PPI) of the RS-232/PPI MultiMaster cable to Port 0 or Port 1 of the S7-200. 3. Ensure that the DIP switches of the RS-232/PPI Multi-Master cable are set Figure shows the S7-200 RS-232/PPI Multi-Master Cable dimensions, label and LEDs.

Tip
Examples in this manual use the RS-232/PPI Multi-Master cable. The RS 232/PPI Multi-Master Cable replaces the previous PC/PPI cable. A USB/PPI Multi-Master cable is also available.

3.3

Starting STEP 7--Micro/WIN

Click on the STEP 7--Micro/WIN icon open a new project. Figure shows a New project. Notice the navigation bar. You can use the icons on the navigation bar to open elements of the STEP 7--Micro/WIN project. Click on the Communications icon in the navigation bar to display the Communications dialog box. You use this dialog box to set up the communications for STEP 7-Micro/WIN.

3.4 Verifying the Communications Parameters for STEP 7-Micro/WIN

The example project uses the default settings for STEP 7--Micro/WIN and the RS-232/PPI Multi-Master cable. To verify these settings: 1. Verify that the address of the PC/PPI cable in the Communications dialog box is set to 0. 2. Verify that the interface for the network parameter is set for PC/PPI cable (COM1). 3. Verify that the transmission rate is set to 9.6 kbps.

3.5

Establishing Communications with the S7-200

Use the Communications dialog box to connect with your S7-200 CPU: 1. Double-click the refresh icon in the Communications dialog box. STEP 7Micro/WIN searches for the S7-200 station and displays a CPU icon for the connected S7-200 station. 2. Select the S7-200 and click OK. If STEP 7--Micro/WIN does not find your S7-200 CPU, check the settings for the communications parameters and repeat these steps. After you have established communications with the S7-200, you are ready to create and download the example program.

3.6

Creating a Sample Program

Entering this example of a control program will help you understand how easy it is to use STEP 7--Micro/WIN. This program uses ten instructions in four networks to create a very simple, Speed control of 3 phase induction motor. For this example, you use the Ladder (LAD) editor to enter the instructions for the program.
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By giving 32,000 scaling value to the IN (input) MOV_W instruction, we get output from Analog output AQW0. 32000 digital Value= 10 Volt 10Volts = 50 Hz 50 Hz = 1500 r.p.m

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By giving 16,000 scaling value to the IN (input) MOV_W instruction, we get output from Analog output AQW0 16000 digital Value= 5 Volt 5Volts = 25 Hz 25 Hz = 750 r.p.m

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By giving 8,000 scaling value to the IN (input) MOV_W instruction, we get output from Analog output AQW0 8000 digital Value= 2.5 Volt 2.5Volts = 12.5 Hz 12.5 Hz = 375 r.p.m

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Address areas of the S7-200

The diagram below shows the memory addresses of the S7-200 PLC where inputs and outputs are mapped. For example, if a voltage is applied to a physical input, this 1 signal is mapped at an address in the memory that is assigned to this input. The memory areas which form the interface with the screw terminals (inputs and outputs) of the PLC are called the process image of the inputs (PII) and the processes image of the outputs (PIO). These memory areas contain an image of the signals from your control process.

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3.7

Saving the Sample Project

After entering the three networks of instructions, you have finished entering the program. When you save the program, you create a project that includes the S7-200 CPU type and other parameters. To save the project: 1. Select the File > Save As menu command from the menu bar. 2. Enter a name for the project in the Save As dialog box. 3. Click OK to save the project. After saving the project, you can download the program to the S7-200.

3.8

Downloading the Sample Program

1. Click the Download icon on the toolbar or select the File > Download menu command to download the program. See Figure. 2. Click OK to download the elements of the program to the S7-200.

If your S7-200 is in RUN mode, a dialog box prompts you to place the S7-200 in STOP mode. Click yes to place the S7-200 into STOP mode.

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3.9 Placing the S7-200 in RUN Mode

For STEP 7--Micro/WIN to place the S7-200 CPU in RUN mode, the mode switch of the S7-200 must be set to TERM or RUN. When you place the S7200 in RUN mode, the S7-200 executes the program:

1. Click the RUN icon on the toolbar or select the PLC > RUN menu command. 2. Click OK to change the operating mode of the S7-200. When the S7-200 goes to RUN mode, the output LED for Q0.0 turns on and off as the S7-200 executes the program.

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CHAPTER 4
SIMATIC S7-200 EM235
INPUT BLOCK DIAGRAM EM235

The 12 bits of the digital-to-analog converter (DAC) readings are left-justified in the output data word format. The MSB is the sign bit: zero indicates a positive data word value.

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Output Block Diagram for EM 235

Output Data Word Format for EM 235

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CHAPTER 5
MICROMASTER Vector Drive
5.1 MM Vector Drive

The MICROMASTER Vector (MMV) is a standard range of inverters with sensor less vector capability suitable for controlling the speed of 3 phase motors. Various models are available, ranging from the compact 120 W MICROMASTER Vector up to the 75 kW MIDIMASTER Vector. Sensorless vector control allows the inverter to calculate the changes required in output current and frequency in order to maintain the desired motor speed across a wide range of load conditions.

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5.2

Block Diagram - MICROMASTER Vector

Using a Digital Input.

The digital inputs on the inverter are programmable and many different functions can be selected. The digital inputs have default settings which are used below, but can be easily changed. With the potentiometer still connected, set parameter P007 to 0 to disable the front panel controls, and connect a switch between terminals 5 (digital input 1, default function ON right) and 9 (15V supply for this purpose). Closing the switch should start the inverter, which will run at a frequency set by the potentiometer as before.

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Using a Potentiometer with the Analog Input.

Set Parameter P006 = 001 and connect a potentiometer (between 5kohm and 100kohm) to the analog input . The Potentiometer is wired as shown:

The inverter can be started using the front panel controls, and the output Frequency adjusted using the potentiometer. The default maximum and minimum settings for the analog input are 50 (P022) and 0Hz (P021) respectively, so the inverter will run at a frequency 22

somewhere between this frequencies, depending on the potentiometer position. Changing P021 and P022 will change the range of the potentiometer Accordingly, but remember the absolute maximum and minimum settings are set by parameters P012 and P013. Note that many parameters cannot be changed while the inverter is running. The display will flash if this is attempted. Note that the Run and Stop control is still via the front panel buttons.

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CHAPTER 6
CONCLUSION

The Proposed system based on program logic controller is found to be less complex, which can be readily used in monitoring and controlling the speed of the Three Phase induction motor by the control word is set in PLC. The extension module EM235 will convert the control word into the analog voltage and this analog voltage is fed back to the inverter drive which will vary the frequency. By varying the Frequency, the motor will run at proportional speed

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BIBLIOGRAPHY

Werner Leonhard, Control of Electrical Drives, Springer, 2001. 1. S7-200 Programmable Controller System Manual 2. Information and Training for Automation and Drive Engineering 3. SINUMERIK & SIMODRIVE Systems for Machine-tool Automation 4. http://support.automation.siemens.com 5. http://www.siemens.de/micromaster

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APPENDIX I

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Shows how to configure the EM 235 module using the configuration DIP Switches

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