Post on 05-Apr-2018
7/31/2019 Lokesh Report2
1/44
PREFACE
As a part of the curriculum prescribed for Bachelors Degree of Engineering by
UNIVERSITY INSTITUTE OF ENGG. & TECHNOLGY, CHANDIGARH a total
of 24 days practical training has to be taken after third year completion. Thus being
a student of engineering I have completed my training at VIDEOCONINDUSTRIES LIMITED SHAHJAHANPUR.
Practical training is one of the major tasks for any professional course.
The real place where a professional person faces and tackles the problems was ableto get familiar to various processes in the industry.
I was given a project on UTILITY in the duration of 24 days.
7/31/2019 Lokesh Report2
2/44
ACKNOWLEDGEMENTS
I am highly thankful to Mr. Gaurav , Mr. Raj kumar Gupta for providing me the
opportunity to work on the current project i.e."PLC" with their prestigiousorganization and Mr. Bhram Prakash, Mr. Sher Singh and Mr. Yogesh Gupta who
allowed me to take my training as per the curriculum of the Bachelors Degree of
Engineering, as prescribed by UNIVERSITY INSTITUTE OF ENGG. &TECHNOLOGY, CHANDIGARH.
I am deeply indebted to Mr. Gaurav for assigning the project, and also
grateful to Mr. Raj kumar Gutpa for sharing his views and giving total insight into
the minor details of the project as well as that of the organization and grateful to
him for helping me in preparing my Training Report. The help rendered by Mr.
Surendra Jingar from time to time is also thankfully acknowledged. The keen
Interest shown by Mr. Yogesh Gupta during the course of the final project and these
investigations is creditable.
7/31/2019 Lokesh Report2
3/44
Contents:-
1. Introduction to company
2. Company profile
2.1 Background of AB Videocon
2.1.1 Details of shahjahanpur plant
3. Name of plant shops
3.1 Process flow chart
4. Function of different departments
4.1 Production Department
4.2 Plant Engg. Department
4.3 Quality Assurance Department
4.4 Material Department
4.5 Design & Development Department
4.6 Manufacturing Engg. Department
4.7 HR Department
4.8 Commercial Department
4.9 Maintenance Department4.9.1 Purpose
4.9.2 Scope
4.9.3 Defination
4.9.4 Responsibility
4.9.5 Decision
5. Scope of Study
6. Brief description of PLC7. Project on S5 series of PLC
8. Introduction to S7 (Micro series) PLC
9. Introduction to S7 (Modular series) PLC
10.Inverter (Frequency drive)
10.1 Parameters
7/31/2019 Lokesh Report2
4/44
Introduction of the Company
Videocon Leasing & Industrial Finance Limited, was incorporated on 4th
September,1986 as Adhigam Trading Private Limited. In terms of the necessary
resolutions passed under Sec. 21 of the Companies Act, 1956, the name of the
Company was changed to Videocon Leasing & Industrial Finance Limited on 14th
February, 1991.The Company received a fresh certificate of incorporation from theRegistrar of Companies, Gujarat at Ahmedabad on 14th
February, 1991.Adhigam Trading Pvt.Ltd. (ATPL) was promoted by Mr. Indrakant T. Parikh and
Naishad I. Parikh in September, 1986 as a private limited company and was initiallyengaged in the business of trading in paper tubes. In September, 1988 the Company
decided to diversify in the business of lease financing, hire purchase and investment
activities.
The Management of the Company underwent a change in the year 1990-91 by way
of transfer of equity shares to the Videocon Group.1,00,000 Equity Shares of Rs.
10/- each of Adhigam Trading Private Limited were purchased by the Videocon
Group at a premium of Rs. 3/- per share in April, 1991.The total consideration ofRs. 13 Lakhs was paid by cheques.
2005
-Videocon acquires entire stake of Videocon India on July 07, 2005.
-Videocon takes over Hyundai Electronics.
7/31/2019 Lokesh Report2
5/44
COMPANY PROFILE
Videocon is an Indian multinational with interests in Consumer Electronics, HomeAppliances, Colour Picture Tube Glass, and Oil & Gas. Videocon was founded in 1987byNandlal Madhavlal Dhoot. At that time it used to manufacture TV and Washing Machine.In 1989-90, Videocon started manufacturing Home Entertainment Systems, ElectricMotors & AC. Videocon entered Refrigerators and coolers segment in 1991. In1995,Videocon started manufacturing Glass shells for CRT and in 1996 it ventured intoKitchen appliances and crude oil segment. In 1998, Videocon started manufacturingCompressors & Compressor Motors. In the year 2000, Videocon took over Philips ColourTV Plant. In 2005, Videocon took over 3 plants of Videocon India and acquired Thomson
CPT. Today, it has evolved into a giant conglomerate with annual revenues of overU$4.1 billion.The Videocon group emerges as a USD 2.5 Billion global conglomerate continuing to settrends in every sphere of its activities from a conference room sized assembly linein 1979.Today the group operates through 4 key sectors:Consumer DurablesThomson CPTCRT GlassOil & Gas
Background of VIDEOCON
Videocon was formed in 1986, Videocon is a Multinational company registered in
Stockholm, Sweden. It is one of the worlds leading manufacturers of Household
Appliances operating in 60 countries and Employing 111,000 people worldwide. Its
product range include Refrigerators, Washing machine, Vacuum cleaners,
Microwave ovens, Airconditioners, Dishwashers, Lawn movers Garden Tractors,
And Aluminum product for industrial Application etc. It owns several global brand
names which Include VIDEOCON, WHITE WESTINGHOUSE, FRIGDAIRE,
KELVINATOR, EUREKA ZANUSSI, AMERICOLD AND AEG.
7/31/2019 Lokesh Report2
6/44
Videocon is providing Videocon Kelvinator Ltd. (EKL) the latest technology,
developed and presently used in the Videocon Groups European facilities. This
technology is environment friendly and energy efficient.
Maharaja International Ltd. was renamed to VIDEOCON KELVINATOR Ltd.
with effect from 8th
Feb 1999. The company is at present engaged in the
manufacturing of Domestic Refrigerators under famous brand name of
KELVINATOR.
Details of Shahjahanpur Plant
The existing plant has a land covering an area of 81085 sq. meters and is free from
Encumbrances and has a clear title. The companys existing Factory, Building
includes total Refrigerator production facility, Utility Block, Stores, D&D with
Auto-Cad Design Facility, Canteen and Administrative block and has a covered area
of 27000 sq. meters.
It employs approx.1000 persons. It manufactures 3 different models of domestic
refrigerators (i.e.165, 175L single door, 195/210/220L single door and 315L double
door.
At present the company is producing approx. 4 lacks refrigerators per year. The
Company is catering the needs of domestic and neighboring countries. The plant
received ISO 9001 certificate in February 2000, by D.N.V, B.V. Netherlands formanufacturing and design of refrigerators.
7/31/2019 Lokesh Report2
7/44
History
Geographical Location
Shahjahanpur, Rajasthan
Kelvinator Refrigerators
Plant Profile Home Slid
7/31/2019 Lokesh Report2
8/44
Today
Videocon - European market leader in white goods
Worlds largest producer of floor-care products,
absorption refrigerators, and compressors.
Videocon
7/31/2019 Lokesh Report2
9/44
7/31/2019 Lokesh Report2
10/44
Food service equipment Market leader in Europe
World s second largest producer
Laundry equipment World leader in equipment for
laundry rooms, hotels
& institutions
Leisure appliances
World leader in absorbtion
refrigerators for caravans
& hotel rooms
Components World s largest producers
of compressors
Professional Products
Worlds
Leadingsuppliers of
Professional
Kitchens
Forestry equipment Leadin g brands for
professional chainsaws
Videocon
7/31/2019 Lokesh Report2
11/44
Controlling, Accounting
Taxes, Auditing, ITTreasury Organisational Development
& Management Resources
White Goods &
Outdoor ProductsNorth America
Robert E Cook
White Goods
Europe & New
Markets
MatsOla Palm
Outdoor
Products
outside North
America
Bengt Andersson
Floor careProducts &
Small Appliance
Hans Straberg
Indoor Products
Detlef Munchow
Outdoor Products
Bengt Andersson
CONSUMER DURABLES PROFESSIONAL PRODUCTS
Communication
& Public Affairs
Legal
President & CEO
Videocon Organisation Structure
7/31/2019 Lokesh Report2
12/44
Name of Plant Shops
Press shop
Paint shop
Vacuum forming shop
Foaming area
Pre-Assembly shop
Final Assembly shop
Process Flow Chart
7/31/2019 Lokesh Report2
13/44
Function Of different departments
PRODUCTION DEPARTMENT
1. To plan for the monthly & yearly targets of quality production for the year.
2. To co-ordinate with Q.A, Purchase. Maintenance for achieving the targets.
3. To achieve the average demerit value as prescribed for the year
4. To reduce the scrap cost per refrigerator.
5. To reduce the material consumable cost as per the value prescribed for the year.
6. To increase the productivity.
7. To solve day to day problems in production in various shops.
8. To study the process for further improvement & modification for quality &
productivity.
9. To educate the Engineers, Staffs & Workers about quality
10.To carry out preventive actions for the non-conformities.
PLANT ENGG. DEPARTMENT
1. Plan for optimum utilization of plant machinery to achieve production targets.
2. Preparation of maintenance budget.
3. Plan & execution of preventive maintenance schedule.
4. To study & improve the working environment & conditions for critical
machines.
7/31/2019 Lokesh Report2
14/44
5. Spare parts planning procuring &in degeneration of critical imported spares.
6. Installation & erection of new machines.
7. Plan & execution of block shut down on annual basis.
8. Maintenance of utilities.
9. Average break down % of plant to be 4.5% for the year.
10.Plan & execute energy conservation in plant.
11.To liaison & co-ordinate with the functionaries of government i.e. Rajasthan
State Electricity Board, RIICO, Pollution Control Board & other deptt.
12.To develop the concept of TPM (Total Preventive Maintenance).
QUALITY ASSURANCE DEPARTMENT
1. Process Monitoring through instruction with QA executives.
2. Documenting trends in quality.3. Control of the nonconforming products authorized for taking deviations.
4. Developing & implementation of plans for customer complaint resolution.
5. To reduce call rate.
6. Assessment of preliminary & on going process capability.
7. To reduce de merit value.
8. Monitoring inspection & testing at incoming, in-process & final stage.
9. Co-ordination calibration of equipment.
10.Co-ordination validation of inspection jigs & test status on product.
11.Providing inspection & test status on product.
12.To identity & implement statistical technical for process & product.
7/31/2019 Lokesh Report2
15/44
13.To verify the effectiveness of corrective & preventing actions.
MATERIALS DEPARTMENT
1. To identify the suitable vendors/suppliers for the procurement of BOM items,
production consumables and indented items.
2. Preparation of procurement schedule against P O to different vendors based on
monthly material plan.
3. To look after complete stores for the inventory and its proper storage accounting
to take preventive measure in case of any shortage/excess.
4. To prepare dispatch schedule plan as per monthly corporate logistic indent to
send finished goods at different branches /locations in India.
5. Liaison with private/union transport for in time dispatches
6. To ensure correct physical availability of material finish goods as per bookbalance.
7. To impart training to subordinate for the development purpose.
DESIGN & DEVELOPMENT DEPARTMENT
1. Design & Development of new products /models.
2. Modification /Upgradation for existing product design.
3. System design /Performance testing of refrigerator.
4. Control of drawing specifications document & release of ECN.
5. Prototype & model making for development /testing.
6. Process support to shop floor.
7/31/2019 Lokesh Report2
16/44
7. Up gradation of product quality.
MANUFACTURING ENGG.DEPARTMENT
1. To formulate capital budget & investment plan.
2. To identify machine capacity & man power planning.
3. Selection of equipment & identification of suppliers for capital equipment.
4. Procurement of Equipment & machines.5. Installation & commissioning of new machines.
6. To design & provide material handling equipment for better productivity.
7. To design moulds & tools for optimum production at vendors end.
HR DEPARTMENT
1. To maintain smooth & cordial industrial relation.
2. Man power planning for & present requirement.
3. To co-ordinate performance Appraisal/Review exercise.
4. To organize for identification of training needs of both blue &White collar
employees & preparation of Annual Training Calendar & implementation of the
same.
5. Organize recruitment as per approved standard force both for staff as well as
workmen.
6. To ensure all statutory obligations under the various provisions of the labor laws.
7/31/2019 Lokesh Report2
17/44
7. To ensure smooth functioning of all welfare activities.
8. Responsible for the implementation of quality systems with regard to training.
COMMERCIAL DEPARTMENT
1. Responsible for Finance, Accounts, Costing, Excise & Administrative control of
IT operation.
2. Responsible for finalization of monthly reporting to corporate & Videocon
Corporate Office.
3. Responsible for finalization of annual accounts & tax audit.
4. Responsible for annual budget preparation, monitoring of budget & profit
improvement plan.
5. Monthly variance analysis of budget & actual.
6. Handling excise & sales tax.
MAINTENANCE DEPARTMENT
1.0 PURPOSE
To establish and maintain a system for keeping all the machinery andequipment of plant in good working condition to ensure continuing process
capability.
2.0 SCOPE
Applicable to all plant machinery and equipment including utilities, electrical
installations used in the plant.
7/31/2019 Lokesh Report2
18/44
3.0 DEFINITION
FH (PE) : Functional Head (Plant Engineering)
Mnt. : Maintenance
4.0 RESPONSIBILITY:
4.1 Functional Head (Plant Engg) is overall responsible for proper functioning of
all the machines and equipment of the plant. Respective Incharge
(Maintenance) for the activities assists him.
4.2 Incharge (Mechanical Maintenance), Incharge (Electrical Maintenance) and
Incharge (Utilities) are responsible for maintenance related to their area ofactivities.
4.3 Shift Incharge (maintenance) are responsible for maintenance during any
particular shift.
4.4 Individual responsibilities for specific activities are given below in
description.
5.0 DIFFERENT TYPE OF MAINTENANCE:
5.1. Individual maintenance
7/31/2019 Lokesh Report2
19/44
5.1.1Identify the key machines / equipments, which affect quality and to be covered
under maintenance Maintain a List of the identified machines / equipments
5.1.2
Decide the jobs / activities to be carried out and the frequency for themaintenance based on information given in machine manuals and/or previous
history of Breakdowns. Discuss the same with respective Incharge(s) of
Maintenance.
5.1.3
Decide the jobs / activities to be carried out and the frequency for the
maintenance based on information given in machine manuals and/or previoushistory of Breakdowns. Discuss the same with respective Incharge(s) of
Maintenance.
5.1.4
Based on the above, prepare Annual Maintenance Schedule for electrical,
mechanical and utilities.
5.1.5
Ensure recording of various checks parameters of DG set, air compressors,thermopac, and RO plant in respective logbooks. The control parameters for
each operation are as per specification sheets.
5.1.6Maintain list checksheets for each category of machines and equipment.
5.1.7
Periodically examine Maintenance Schedule and inform the concerned
Maintenance Crew for carrying out Preventive Maintenance activities as per
relevant checklists.
5.1.8
Get Checklist from respective Incharge (Maint.) and carry out all activities as
given in checklist.
5.1.9
Inform the activities carried out including earlier slippage if any, to respective
Incharge (Maint.) who updates the Maintenance Schedule.
-do-Nil
7/31/2019 Lokesh Report2
20/44
5.1.10
If any of the maintenance activities are not carried out as per schedule /checklist, enter the details in maintenance log book/ utilities logbook for
inclusion next time.
5.1.10.1
Review the maintenance log book and make necessary arrangement for re-
scheduling the maintenance activities at next available opportunity. Monitor
them for accomplishment.
5.1.11In case any major replacement / repairs are carried out, enter the details inMachine History Card
5.1.11.1
Review the machine history card once in every six months. If required, change
the preventive maintenance frequency and inform respective Incharge (Mnt.)
accordingly.
5.2
Predictive Maintenance
5.2.1
Take a round of the plant daily in the General Shift and examine the condition of
machines / Equipments.
5.2.2Inform the abnormality observed if any to concerned Section Incharge and
request for sparing the machine for needful
5.2.3
In case the machine can not be spared due to urgency of production but the same
can work, record the observations in maintenance log book/utilities log book.
-do-
L01-0910
L02-0910
5.2.4
Periodically examine the maintenance/utilities log book and get it corrected on
7/31/2019 Lokesh Report2
21/44
7/31/2019 Lokesh Report2
22/44
5.3
Breakdown Maintenance
In order to attend the breakdowns in most effective manner & in the shortestpossible time the following procedure is adopted.
5.3.1
On receipt of complaint (by verbal / written) from user deptt. Depute technician
for carrying out necessary repairs
5.3.2
Identify the nature of defects & arrange repair.
5.3.3
In case of problems beyond control consult shift incharge / Engineer & arrange
repair / rectification as directed.
5.3.4
When ever required, procure materials from stores by raising demand & issue
slip after getting authorization from shift incharge.
5.3.5
In case of low / no stock raise Purchase Requisition whenever required.
5.3.6
In case the machinery / equipment is to be sent outside the factory for repairs put
up the requisition for out going material after authorization from FH (PE).
5.3.7
After completion of repairs and satisfactory operation enter details in
maintenance / utilities log book.
7/31/2019 Lokesh Report2
23/44
5.3.8
Maintain a list of essential spare parts with minimum stock level required forsmooth operation.
List Authorized by FH (PE)
5.3.9
Interact with maintenance purchase Incharge & maintenance store Incharge to
ensure the availability of minimum stock as required.
5.4
5.4.1
Compile machine Breakdown time for the month of all area of activities
including Breakdown Analysis (i.e. causes).
5.4.2
Discuss the Machine Breakdown Trend Chart in Management Review Meetings
and take suitable corrective measures to meet as well as improve upon the laid
down objectives.
5.4.3Submit Monthly Utility Report to management about generation and
consumption of energy and fuels.
5.4.5
Submit maintenance overtime report to the management about manpower
utilization.
7/31/2019 Lokesh Report2
24/44
Scope of Study
Study of PLC System at Videocon, Various Frequency Drives use and their
programming, Power Supply, SCADA Package for MIMIC programs used for datatransfer to PLC, Communication and Networking of PLC.
Following PLC Systems study in respect to their Operating Software, Hardware,
and Programming of Small PLC Logic and necessary modification in existing
Programs along with trouble shooting in PLC System
Siemens PLC with S5 Series
Seimens S7 (Micro Series) PLC Series
Siemens S7 (Modular Series) PLC series
Along with PLC system study of Various Frequency Drive i.e. Micro Master
Inverters with following scope of Study
Introduction of Frequency Drives Hardware
Programming of Frequency drives as per requirementFunction and Operation of Frequency drivesApplication
Type of Frequency of Frequency Drives
Siemens Micro Master from 0.5 HP to 3.0 HP
Siemens Micro Master Vector Drive 3.0 HP
Omron Inverter 0.5 HP
Power Supply
7/31/2019 Lokesh Report2
25/44
7/31/2019 Lokesh Report2
26/44
PLC are manufactured by the SEIMENS in 2 version they are -:
S5S7
Further S7 has 2 versions -:200 (Micro Series)
300 (Modular Series)
Depending on the number of the input modules connected to the PLC
The languages been used
LAD-ladderCascade Statement Function CSF
STLstatement line
We have interfacing of the plc to the pc or vice versa through different modes
TTY-text to text interface (interface between single pc to single plc)
PPI- point to point interface (connections of different pc to a number of plc)
MPI-multiple point interface (connection of number of plc to more than one plc)
7/31/2019 Lokesh Report2
27/44
Project on S5 Series PLC
At Videocon one of machine named as MARISTED-1 Used to Cabinet Foaming forRefrigerators having S5 Series PLC used for the Automatic control of the machine.
This machine program required to be modified to avoid accident in machine
because of malfunctioning of Input devices (Limit Switches) and to ensure smooth
trouble free operation of Machine
Machine PLC Details
MRSDT1Power Supply-AC 230V/115V
DC 24V 2A
SIEMENS S5-100U
CPU 103
DI 8X24V DC- 10 in no.DO 8X115/230V AC /0.5 A10 in no.
Problem
During the transfer of Foamed cabinet fixture from foaming station to insidecarriage Insider carriage should be in backward position. But sometimes when this
carriage is at forward position and because of Foam or otherwise Limit Switch
might got stuck-up in backward position, It will give false input to PLC and both
Inputs of Carriage forward & Backward will be available to PLC. This causes
fixture transfer without carriage and causes damage to cylinders and major Accident
occurs
Introduction of S7 (Micro Series) PLC
7/31/2019 Lokesh Report2
28/44
The S7-series is a line of micro-programmable logic controllers (micro PLCs) thatcan control a variety of automation applications. Its a compact design,
expandability, low cost and powerful instruction set make the S7-200 controllers aperfect solution for controlling many applications In addition, the wide variety of
CPU sizes and voltages provide you with the flexibility you need to solve yourautomation problems. The S7-212/213/214/215/216 CPUs combine a central
processing unit (CPU), power supply, and discrete I/O points into a compact, standalone device. The CPU executes the program and stores the data for controlling
the automation task or process. The power supply provides electrical power for the
base unit and for any expansion module that is connected.
The inputs and the outputs are the system control points: the input monitors
the signals from the field devices (such as sensors and switches), and the outputs
control pumps, motors, or other devices in your process.
The communication port allows you to connect the CPU to a
programming device or to other devices. Status lights are been provided to provide
visual information about the CPU mode (RUN or STOP), the current state of the
local I/O, and whether a system fault has been detected.
The S7 Micro Series programming software offers powerful programming and
debugging tools which make you more effective and this means cost savings.
We use the programming in the same manner as the Windows applications User
programs are written using simply mouse clicks, tool bars, or simply drag & drop
operations .It have the following properties: -
4 or 6 independent hardware counters at the rate of 30 kHz each for interfacingto incremental encoders or high-speed pulse trains.
7/31/2019 Lokesh Report2
29/44
4 independent interrupt input with 0.2ms input filter times to adjust reactiontimes for maximum process response.
2 high speed pulse outputs at the rate of 20khz each either pulse widthmodulation or pulse train output , e.g. for control of stepper motor , drives or
temperature .
High-speed analog inputs signal conversion with 25micro seconds, 12 bitresolution.
Real time clock.
2 timed interrupts (adjustable from 1ms in intervals of 1 ms) for precise controlof processes that change over time.
EEPROM CARTRIDGE
A small optional EEPROM cartridge saves significant time and money.
We can use it easily copy, update or replace your applications program on your S7-200 CPU.
And if required, one can mail a program rapidly and at a low cost, using the
cartridge. Simply turn off the power and the user program is updated in a flash.
BATTERY CARTRIDGE
To guarantee that applications data are never lost , the optional battery module
permits long term backup for typically 200 days beyond the internal backup of 5
days .
7/31/2019 Lokesh Report2
30/44
REAL TIME CLOCK
Whether we require it to count operating hours, preheat rooms or provide timestamps for messages; the real time clock of the S7-200 is software controlled to
provide exact seconds and dates even taking leap years into account.
ANALOG POTENTIOMETERS
With the S7200 s analog potentiometers we can optimize our process by means
of a screwdriver. We can set memory values, timer values, counter presets or other
variables without
Introduction of Siemens S7 (Modular Series) PLC
Siemens has introduced a mini PLC in the PLC family. It is an ideal choice
when the job calls for something fast and powerful. It has a program memory for up
to 16k statements, 1024 digital inputs and outputs and an MPI interface forprogramming devices and operator panels. The speed of the PLC of CPU, the most
powerful one is 0.3ms to process 1024 binary statements It holds an incredible 256
digital i/os in addition to the CPU. Every module has 16/32 isolated channels.
The S7-300 needs a 24v DC power supply. This is provided by load
current supply modules, which convert the 120/230v AC line voltage to the 24v DC
operating voltage.
The S7-300 series is the is an advance version of the S5 series .The additions havebeen made to the programming languages Statement List, Ladder Diagram and
7/31/2019 Lokesh Report2
31/44
Functional block Diagram. The instruction set can be used in all blocks and in all
programming languages.
S7-300 has central data storage and a perfectly matched suite of individual
functions. This means that we need to enter only the data once, at a single userinterface. And we can use the same functions for every task. From configuring and
programming to startup and documentation. We can write the program in any
language and switch from one to another as we want.
S7-300 consists of the following components-:
1. Power Supply (PS)2. Central Processing Unit(CPU)3. Signal Modules(SM)
4. Function Modules(FM)
5. Communication Processor (CP)
Power Supply (PS):
It converts line voltage (230 V ac/115V ac) into 24v dc which provide
power to S7-300 it is switching mode power supply
Central processing unit (CPU):It has a central processing unit CPU which takes merely .3ms to process
1024 binary statements and it is equally good at word oriented processing .The
system include a number of CPUs FOR different performance requirements.
CPU executes the user program provides the 5V supply for the 5v supply for the S7-300 back plane bus. It communicates with other modes by MPI (multi point
interface).
Communication Processor (CP):
It means how to interface PLC to PC or PC to PLC. We also interface other
devices to PLC.
7/31/2019 Lokesh Report2
32/44
We can interface it by three ways
1. MPI2. PPI
3. TTY
In S7-300 we use MPI for interfacing. In communication process we use twotypes of connector:
1. RS485 PLC)
2. RS232 (PC)
Every module has 16/32 channels; it can be increased till 250 digital I/O
INVERTER (Frequency drive)
Inverter is a frequency drive used to invert the A.C. to D.C. and control the rpm of
AC motors by variable frequency. The drive converts the phase from single phase to
three phase if the power supplied is in single phase .These inverters are microprocessor controlled A special pulse width modulation
with selectable pulse frequency permits extremely quiet motor operation.
Microprocessor is available for reliable and flexible control. Remote control
capability is also used to control inverters. It has a builtin non-volatile memory forstoring parameter settings. Output frequency can be controlled by one of the five
methods -:
Digital frequency setpoint
Analogue setpoint
Potentiometer
Fixed frequencyRemote data transmission
The inverter has a built in dc injection brake which stops the motor by
applying a DC current, this causes heat to be generated in the motor rather than the
inverter and holds the shaft stationary until the end of the braking period. Braking is
effective for the period of time set.
But the frequent use of long periods of DC injection braking can cause the motor to
overheat. Automatic load compensation is done by flux current control.
7/31/2019 Lokesh Report2
33/44
The Power supply is supplied in single phase or in three phases and has an output
always in three phases, so a 4 core wire is used for connection..
Following are the specifications of the inverter -:
Input frequency47 Hz to 63 HzPower factor - >=0.7
Output frequency0 Hz to 650 Hz
Resolution0.1
Overload capacity150% for 60 s, related to nominal current
Protection againstinverter overtemperature
Motor overtemperature
Overvoltage and undervoltage
Additional protection Against short circuit and earth/ ground faults pullout
protection
Protection against running with no load.
Regulation and controlFCC (flux current control) voltage /frequency curve
Ramp times-0-650s
Invert efficiency97%
Operating temperature0 c to +40c
Parameters can be changed and set using the membrane-type buttons to adjust the
desired properties -:
Parameter-
P000
Its function is to operate the display. This displays the output selected in P001 .In
the event of a faliure the relevant error message is displayed .In the event of a
warning the display flashes .If output frequency has ben selected (P001=0) the
display alters between the selected frequency and the actual frequency.
P001
Its function is to display selection .0-7 Numbers are used for display selection
0-output frequency
1-speed at which inverter is set
2-motor current
3- DC-link voltage
4- motor torque
7/31/2019 Lokesh Report2
34/44
5-Motor rpm
6-uss status7-closed loop display mode
P002
Ramp up time is the function done by this parameter, which is the time taken by the
motor to reach the maximum frequency from the standstill condition, Its range is
from 0-650 sec.
P003
Ramp down time, it is the time taken to decelerate from maximum speed to
minimum standstill position.
P004
Its function is to smooth the acceleration /deceleration of the motor.
P005
Digital frequency set point0-650.00
P006
Frequency set point type selection0-2
0- digital1- 1-analogue2- fixed frequency or motor potentiometer
P007Enable /disable front panel buttons
0-1
0-run, jog and reverse are disabled
1-front panel buttons can be selected
P009
Parameter protection setting
0-3
7/31/2019 Lokesh Report2
35/44
0- only parameters from P001P009 can be read / set
1- all the parameters can be read and P001-P009 can be set2- all the parameters can be read /set but P009 is automatically set to zero when
power is removed3- all can be read/set
P010
Display scaling
P011
Frequency setpoint memory
0-1
0-disable
1-enable after switch off
P012
Minimum motor frequency
0-650
P013
Maximum motor frequency
0-650
P015
Automatic restart0-1
0-disable
1- automatic restart
P016
Start on the fly
0-4
Allows the inverter to start on to a spinning motor, to avoid overcurrent trip.
7/31/2019 Lokesh Report2
36/44
P017Smoothing type
1-21- continuous smoothing2- discontinuous smoothing
P018
Automatic restart after fault
P021Minimum analogue frequency
0-650
P022
Maximum analogue frequency
0-650
P023
Analogue input type
P024
Analogue setpoint addition
P025
Analogue output
P031
Jog frequency right (Hz)
P032
Jog frequency left (Hz)
P033
Jog ramp up time
P034
Jog ramp down time
7/31/2019 Lokesh Report2
37/44
P0411
stfixed frequency
P042
2nd
fixed frequency
P043
3rd
fixed frequency
P044
4rth fixed frequency
P045
Inversion fixed setpoints for fixed frequencies
P046
5th
fixed frquency
P047
6th
fixed frequency
P0487
thfixed frequency
P049
8th
fixed frequency
P050Inversion fixed setpoints for fixed frequencies
P051
Selection control function , DIN1
P052
Selection control function , DIN2
7/31/2019 Lokesh Report2
38/44
P053Selection control frequency,DIN3
P054
Selection control function , DIN4
P055
Selection control function , DIN5
P061
Selection relay output RL1
P062
Selection relay output RL2
P063
External brake release delay
P064
External brake stopping time
P065
Current threshold for relay
P070
Braking resistor duty cycle
P071
Slip compensation
P072
Slip limit
P073
DC injection braking
7/31/2019 Lokesh Report2
39/44
P074Motor derating curve as temperature protection
P075
Braking resistance
P076
Pulse frequency
P077Control mode
P078
Continuous boost
P079
Starting boost
P081Nominal frequency for motor
P082
Nominal speed for motor
P083
Nominal current for motor (A)
P084
Nominal voltage for motor (V)
P085
Nominal power for motor (kW)
P086
Motor current limit
7/31/2019 Lokesh Report2
40/44
P087Motor PTC enable
P088
Automatic calibration
P089
Stator resistance
P091
Slave address
P092
Baud rate
P093
Time out
P094
Serial link nominal system setpoint
P095
USS compatibility
P101Operation for Europe or USA
P111
Inverter power rating (kW/hp)
P121Enable /disable RUN button
P122
Enable/disable FORWARD/REVERSE button
P123
7/31/2019 Lokesh Report2
41/44
Enable /disable JOG button
P124
Enable /disable
P131Frequency setpoint
P132
Motor current
P133
Motor torque
P134
DC link voltage
P135
Motor RPM
P201
Closed loop mode
P201
Proportional gain
P203
Integral gain
P204
Derivative gain
P205
Sample interval (x25ms)
P206
Sensor filtering
7/31/2019 Lokesh Report2
42/44
P207
Sensor reading
P2110% setpoint
P212
100% setpoint
Minimum frequency mode
P720
Special input /output functions
P721
Analogue input voltage
P722
Analogue output current
P723
State of digital inputs
P724
Relay output control
P910Local/Remote mode
P922
Software version
P923Equipment system number
P930
Most recent fault code
P931
Most recent warning type
7/31/2019 Lokesh Report2
43/44
P944Reset to factory default settings
P971
EEPROM storage control
7/31/2019 Lokesh Report2
44/44