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Power Quality Analysis of Household Appliances and Speed Control of Three Phase Induction Motor using PLC and

HMI
PROJECT REPORT Submitted in Partial Fulfillment of the Requirements for the Award of Degree of

Bachelor of Technology in Electrical Engineering


Submitted By: Faraz Ahmad, Mohammad Saud, Mohammad Zaid Under the Supervision of Dr. Asfar Ali Khan
DEPARTMENT OF ELECTRICAL ENGINEERING ZAKIR HUSAIN COLLEGE OF ENGINEERING AND TECHNOLOGY ALIGARH MUSLIM UNIVERSITY 2013

Power Quality Analysis of Household Appliances and Speed Control of Three Phase Induction Motor using PLC and HMI

Faraz Ahmad, Mohammad Saud, Mohammad Zaid

DEPARTMENT OF ELECTRICAL ENGINEERING ZAKIR HUSAIN COLLEGE OF ENGINEERING AND TECHNOLOGY ALIGARH MUSLIM UNIVERSITY MAY 2013
Authors: Faraz Ahmad, Mohammad Saud, Mohammad Zaid

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DEPARTMENT OF ELECTRICAL ENGINEERING ZAKIR HUSAIN COLLEGE OF ENGINEERING AND TECHNOLOGY ALIGARH MUSLIM UNIVERSITY

Certificate
This is to certify that the work contained in the thesis titled

Power Quality Analysis of Household Appliances and Speed Control of Three Phase Induction Motor using PLC and HMI
by Mr. Faraz Ahmad, Mr. Mohammad Saud and Mr. Mohammad Zaid, has been carried out under my supervision and that this work has not been submitted elsewhere for a degree.

Dr. Asfar Ali Khan (Assistant Professor) Department of Electrical Engineering Zakir Husain College of Engineering and Technology Aligarh Muslim University
Authors: Faraz Ahmad, Mohammad Saud, Mohammad Zaid

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ACKNOWLEDGEMENT
We wish to express sincere gratitude to Dr. Asfar Ali Khan (Assistant Professor, Department of Electrical Engineering) for his encouragement and guidance throughout the work on this project. The invaluable suggestions given by him have helped me to improve the performance of my project and deliver the project in time. We express our heartfelt thanks to Mr. Sharique Khan and Mr. Majid Khan (ZMS Technologies) for their training and invaluable encouragement and support. Mr. Shahid Karim (Siemens India Ltd) was a great mentor and helped us in obtaining the various technical support. Finally yet importantly, I would like to express my heartfelt thanks to my beloved parents for their blessings, my friends and classmates for their help and wishes for the successful completion of this project.

Faraz Ahmad Mohammad Saud Mohammad Zaid

Authors: Faraz Ahmad, Mohammad Saud, Mohammad Zaid

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PREFACE TO THE PROJECT


With the rapid change in industries and information technology in recent years, some traditional bulk electronic appliances have to be monitored for a long time. All of their control devices such as communication interfaces gradually enter the internet information era. The control of all equipment has been performed through the use of computers. Most equipment use PLCs to connect with computers to monitor each load and electricity consuming devices. Programmable Logic Controllers are widely used in industrial control because they are inexpensive, easy to install and very flexible in applications. A PLC interacts with external world through its inputs and outputs. Since technology for control of electric drives became available, the use of programmable logic controllers (PLC) with power electronics in electric machines applications has been introduced in the manufacturing automation. This use offers advantages such as lower voltage drop when turned on and the ability to control motors and other equipment with a virtually unity power factor. Many factories use PLC in automation processes to diminish production cost and to increase quality and reliability. To obtain accurate industrial electric drive systems, it is necessary to use PLC interfaced with power converters, personal computers and other electric equipment. The project presents a PLC-based monitoring and control system for a three phase induction motor and power monitoring of electrical devices. It describes the design and implementation of the configured hardware and software hardware and software. The test results obtained on induction motor performance show improved efficiency and increased accuracy in variable-load constant-speed controlled operation, thus, PLC correlates and controls the operational parameters to the speed set point requested by the user and monitors during normal operation and under trip conditions.

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INDEX
Objective of the Project 1. Introduction I. Power Quality Analysis II. Programmable Logic Controllers III. Architecture of PLC 2 IV. Siemens PLC S7 300 V. S7 300 Datasheet VI. Automation Pyramid VII. Networking in Industrial Automation VIII. Human Machine Interface 3 2. Analysis of Household Loads 3. Programming of PLC I. Introduction to Totally Integrated Automation (TIA) Portal 4 II. Steps involved in Programming PLC S7 300 using TIA III. Programming in ladder Logic 4. Speed Control of Induction Motor I. Rotor Resistance Speed Control II. Variable Voltage Speed Control 5 III. Pole Changing IV. Variable Frequency Speed Control V. Variable Voltage Variable Frequency Speed Control 5. Experimental Setup I. Power Quality Analysis of Household Loads 6 II. Control of Three Phase Induction Motor III. Circuit Diagram for Rotor Resistance Speed Control IV. Network Connection of Siemens PLC S7 300 and HMI 6. Results and Program I. Power Quality Analysis of Household Loads II. Speed Control of Three Phase Slip Ring Induction Motor 7 using PLC and HMI 7. Project Report Generated from TIA I. Screenshots of HMI 8 8. Conclusion 9 Future Work 10 References *Page numbers altered post-formatting. Serial No. 1 Content Page No* 4 5 to 13 5 6 7 8 9 10 11 13 14 15 to 21 15 16 19 22 to 28 23 24 25 26 27 29 to 33 29 31 32 33 34 to 51 34 47 47 48 52 54 55 to 56

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List of Abbreviations

a. b. c. d. e. f. g.

PLC SCADA S7 HMI PQA TIA THD

: : : : : : :

Programmable Logic Controller Supervisory Control and Data Acquisition Step Seven (7) Human Machine Interface Power Quality Analyzer Totally Integrated Automation Total Harmonic Distortion

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OBJECTIVE OF THE PROJECT

Power Quality Analysis of Household Appliances and Speed Control of Three Phase Induction Motor using PLC and HMI

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Chapter 1 Introduction
Power Quality Analysis Programmable Logic Controllers Architecture of PLC Siemens PLC S7 300 S7 300 Datasheet Automation Pyramid Networking in Industrial Automation

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INTRODUCTION
I. Power Quality Analysis
Power quality is an issue that is becoming increasingly important to electricity consumers at all levels of usage. Sensitive power electronic equipment and non-linear loads are widely used in industrial, commercial and domestic applications leading to distortion in voltage and current waveforms. With ongoing regulatory, policy and structural changes in the Indian electricity industry, following the Electricity Act 2003, the issue of Power Quality is poised to become a figure-of-merit amongst the competing distribution utilities. Improvement of Power Quality has a positive impact on sustained profitability of the distribution utility on the one hand and customer satisfaction on the other. The analysis helps to monitor losses and also tells when to replace such appliances that are faulty and are source of loss. As an example, analysis of an office can help a company to monitor its consumptions and take necessary steps for energy saving. The analyzer used in our project for the PQ analysis is Janitza Smart Meter UMG 511. This analyzer has the following features: Features Over 2000 parameters. Flicker Measurement. Short term interruptions with fault recorder function. Transient Measurement. Measurement of Harmonics up to the 63rd. Inrush current Measurement. Continuous monitoring of the power quality e.g. EN 50160. Ethernet gateway for subordinate measurement points. Analysis of electrical faults for network problems. Monitoring of the internal distribution network according to EN 61000-4-7, 4-15, 4-30 Report generator for EN 50160 analysis. Remote control operation

The UMG 511 supports connectivity with the Ethernet backbone and integration with the other smart devices and control modules.

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II.

Programmable Logic Controller

A Programmable Logic Controller (PLC) is a microprocessor-based controller with multiple inputs and outputs. It uses a programmable memory to store instructions and carry out functions to control machines and processes. The PLC performs the logic functions of relays, timers, counters and sequencers. It is a digital computer used for automation of electromechanical processes. Before the PLC, control sequencing, and safety interlock logic for manufacturing automobiles was accomplished using hundreds or thousands of relays, cam timers and drum sequencers and dedicated closed-loop controllers. Richard E Morley is considered to be the inventor of First PLC. PLC development began in 1968 in response to a request from an US car manufacturer (General Electric Hydramatic) The first PLC was designated the 084 because it was Bedford Associates' eightyfourth project. Later it was called as MODICON. PLCs were installed in industry in 1969.
Figure 1: Richard Morley

Early PLCs were designed to replace relay logic systems. These PLCs were programmed in ladder logic, which strongly resembles a schematic diagram of relay logic. The computer is connected to the PLC through Ethernet, RS-232, RS-485 or RS-422cabling. A small PLC will have a fixed number of connections built in for inputs and outputs. Typically, expansions are available if the base model has insufficient I/O. PLC programs are typically written in a special application on a personal computer, and then downloaded by a direct-connection cable or over a network to the PLC. The program is stored in the PLC either in battery-backed-up RAM or some other non-volatile flash memory. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. The PLCs have many applications in the day to day life. They are easily programmable and they can be operated using the cables, modems etc. All the automation processes are been done but using the PLCs, as they are more reliable.

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III. Architecture of Programmable Logic Controller (PLC)


A PLC is a microprocessor based system. Various parts in a PLC are shown below as a block diagram:

Analog Input & Output

Networking Block

Memory

Processor
Clock ADC & DAC

Digital Input & Output

Figure 2: Architecture of a Programmable Logic Controller

Analog and Digital inputs and outputs are ports for interfacing external equipment with the PLC. Networking Block is used for communication between PLC-Computer, PLC-PLC, PLCSmart Transducers (IP Based) and PLC-Smart Meters. Memory is used to store the program and data for computation. It also stores events when it is a part of SCADA in memory cards such as MMC, SD and Micro-SD. Processor is the heart of PLC. All the computation is done is by the processor. Other important part of a PLC is a clock that synchronizes all the actions.

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IV. Siemens PLC S7 300

External Memory Slot

Central Processing Unit

Interface/ Communication Ports

Input and Output Ports

Figure 3: Representation of S7 300 in TIA

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V. Siemens S7 300 Data Sheet


DATA SHEET WORK MEMORY 192KB 0.6MS/1000 INSTRUCTIONS DI-24/DO-16 AI-5/AO-2 INTEGRATED 4 PULSE OUTPUTS (2.5KHZ) 4 CHANNELS COUNTING AND MEASURING WITH 24 V (60KHZ) INCREMENTAL ENCODERS INTEGRATED POSITIONING FUNCTION PROFINET INTERFACE AND 2 PORTS PROFINET CBA PROXY TCP/IP TRANSPORT PROTOCOL COMBINED MPI/DP INTERFACE (MPI OR DP MASTER OR DP SLAVE) MULTI-TIER CONFIGURATION UP TO 31 MODULES CAPABLE OF SENDING AND RECEIVING IN DIRECT DATA EXCHANGE CONSTANT BUS CYCLE TIME

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VI. Automation Pyramid


All the devices in a modern automation system are arranged in a pyramid structure as shown below. This is usually referred to as Automation Pyramid. This pyramid shows a hierarchy of the communication of network elements.

Figure 4: Automation Pyramid

The various layers according to the automation pyramid are: 1. The Process/ Field layer consists of sensors, valves, actuators and servo motors. It is the basic layer where the process is implemented. All the elements in this layer either act or provide feedback for a given command. The command is provided by the Control Layer. 2. The Control Layer consists of PLCs. These PLCs are programmed to command the Field Layer to perform the specified task. They are further monitored and controlled by the SCADA layer. 3. The SCADA layer is the management layer and it does all the supervisory functions. This layer keeps a track of all the activities in real time and controls all the processes connected to it. 4. Strategic Data Exchange layer is the enterprise layer and ERPs are executed at this level. This is the highest level in the automation pyramid where all the SCADA layers merge to give a central control.
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VII. Networking in Industrial Automation


The various layers in the automation pyramid interact with each other by the communication interfaces such as Ethernet, Fast Ethernet. The industrial communication network is based on Profinet, Profibus, Optical Fibers, etc. a. Ethernet: Ethernet is a family of computer networking technologies for local area networks (LANs). Ethernet was commercially introduced in 1980 and standardized in 1985 as IEEE 802.3. Ethernet has largely replaced competing wired LAN technologies. The Ethernet standards comprise several wiring and signaling variants of the OSI physical layer in use with Ethernet. The original 10BASE5 Ethernet used coaxial cable as a shared medium. Later the coaxial cables were replaced by twisted pair and fiber optic links in conjunction with hubs or switches. Data rates were periodically increased from the original 10 megabits per second to 100 gigabits per second. Systems communicating over Ethernet divide a stream of data into shorter pieces called frames. Each frame contains source and destination addresses and error-checking data so that damaged data can be detected and re-transmitted. As per the OSI model Ethernet provides services up to and including the data link layer. Since its commercial release, Ethernet has retained a good degree of compatibility. b. Fast Ethernet: In computer networking, Fast Ethernet is a collective term for a number of Ethernet standards that carry traffic at the nominal rate of 100 Mbit/s, against the original Ethernet speed
Figure 5: Ethernet connector RJ45

of 10 Mbit/s. Of the Fast Ethernet standards 100BASE-TX is by far the most common and is supported by the vast majority of Ethernet hardware currently produced. Fast Ethernet was introduced in 1995 and remained the fastest version of Ethernet for three years before being superseded by gigabit Ethernet. Fast Ethernet is an extension of the existing Ethernet standard. c. Profibus: PROFIBUS (Process Field Bus) is a standard for field bus communication in automation technology and was first promoted in 1989 by BMBF (German department of education and research) and then used by Siemens. It should not be confused with the PROFINET
Figure 6: Profibus Adapter

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standard for industrial Ethernet. The figure alongside shows a Profibus Adapter. PROFIBUS is not an openly published and royalty-free protocol as MODBUS. PROFIBUS was defined in 1991/1993 in DIN 19245, was then included in EN 50170 in 1996 and, since 1999, established in IEC 61158/IEC 61784. There are two variations of PROFIBUS in use today; the most commonly used PROFIBUS DP, and the lesser used, application specific, PROFIBUS PA: 1. PROFIBUS DP (Decentralized Peripherals) is used to operate sensors and actuators via a centralized controller in production (factory) automation applications. The many standard diagnostic options, in particular, are focused on here. 2. PROFIBUS PA (Process Automation) is used to monitor measuring equipment via a process control system in process automation applications. This variant is designed for use in explosion/hazardous areas (Ex-zone 0 and 1). The Physical Layer (i.e. the cable) conforms to IEC 61158-2, which allows power to be delivered over the bus to field instruments, while limiting current flows so that explosive conditions are not created, even if a malfunction occurs. PA has a data transmission rate of 31.25 Kbit/s. However, PA uses the same protocol as DP, and can be linked to a DP network using a coupler device. d. Profinet: PROFINET is the open industrial Ethernet standard of PROFIBUS & PROFINET International (PI) for automation. PROFINET uses TCP/IP and IT standards, and is, in effect, real-time Ethernet. The PROFINET concept features a modular structure so that users can select the cascading functions themselves. They differ essentially because of the type of data exchange to fulfil the partly very high requirements of speed. In conjunction with PROFINET, the two perspectives PROFINET CBA and PROFINET IO exist. PROFINET CBA is suitable for the component-based communication via TCP/IP and PROFINET IO used for the real-time communication with real-time requirements in modular systems engineering. Both communication options can be used in parallel. PROFINET IO was developed for real time (RT) and isochronous real time (IRT) communication with the decentralized periphery. The designations RT and IRT merely describe the real-time properties for the communication within PROFINET IO. PROFINET CBA and PROFINET IO can communicate at the same time on the same bus system. They can be operated separately or combined so that a PROFINET IO subsystem appears as a PROFINET CBA system from a system perspective.

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VIII. Human Machine Interface

Figure 7: Siemens HMI TP 117B

Human-machine interface is the part of the machine that handles the Human-machine interaction. Membrane Switches, Rubber Keypads and Touchscreens are examples of that part of the Human Machine Interface which we can see and touch. The HMI used is a Touch Panel TP 117 B. It is a 6 touch screen. The HMI is used to monitor and control the inputs of PLC and other devices connected to the HMI. The HMI has an operating system installed on it. TP 117B uses Windows as the operating system. Program is built and burned through TIA or WinCC Flexible software. The Tags are kept same so that both PLC and HMI can use same inputs, outputs and memories.

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Chapter 2 Analysis of Household Loads

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ANALYSIS OF HOUSEHOLD LOADS


The analysis of common household Loads have been carried out. A three phase motor has also been analyzed. The list of the analyzed loads is as follows: a. Tube Light b. Compact Florescent Lamps (CFL) c. Fan d. Three Phase Induction Motor The following parameters have been analyzed:

TubeLight

Power Current

Power Quality Analysis

CFL

CFL Vs. CFL CFL Vs. Incandascent Lamp

Fan

THD by Fan With Resistive Regulator With Triac Regulator VI analysis for Triac Regulator

Induction Motor

Power THD Voltage-Current

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Chapter 3 Programming of PLC


Introduction to Totally Integrated Automation (TIA) Portal Steps involved in Programming PLC S7 300 using TIA Programming in Ladder Logic

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PROGRAMMING OF PLC
I. Introduction to Totally Integrated Automation (TIA)
PLC is programmed in a similar way as we program a microprocessor. It is more like a microcomputer with an operating system running on it. The coding is done in a standard or a customized programming language. The customized programming languages are developed by the manufacturers of PLC to counter piracy and enhance product security. The programming environments comes in a software package for an easy and interactive use. Languages are Function Block Diagram (FBD), Ladder Logic, and STL. Siemens uses Simatic Manager and Totally Integrated Automation as the programming software. Totally Integrated Automation is the recent version and an upgrade to Simatic Manager. It features a simulation environment and an online monitoring tool too. The supported programming languages are: a. Ladder Logic b. Function Block Diagram (FBD) c. Statement List (STL) The TIA Portal is characterized by a software architecture designed for high efficiency and user-friendliness, and is suitable both for first-time users and experienced users. All functions required for parameterization are stored in a task-oriented manner and can be called and executed by the user-friendly, intuitive user interface. Powerful and task-oriented editors make program creation and configuration of visualization a lot easier. A program editor is available to create sequence controllers, for example, which graphically visualizes the steps. A powerful editor with the SCL (Structured Text) high-level language is available for programming of functions.

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II.

Steps Involved in Programming Siemens PLC S7300 using TIA

Step 1: Open TIA Software.

Figure 8: Totally Integrated Automation (TIA V11) startup window.

Step 2: Create a new Project.

Figure 9: Create a NEW Project

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Figure 10: Project Options

Step 3: Add device(s) from Devices and Network Tab

Figure 11: Add device(s)

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Step 4: Select PLC Simatic S7 300 CPU CPU 314 C-2 PN/DP 6ES7 314-6EH04-0AB0

Figure 12: Select Appropriate CPU (CPU 314 C-2 PN/DP in our case)

Step 5: Program in TIA using FBD or STL or Ladder Logic.

Figure 13: Main Console (GUI) for programming PLC (S7 300)

The console has numerous options to configure and program PLC as the user desires.

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III. Programming in Ladder Logic


Ladder logic is the simplest relay logic programing language. Ladder logic is a programming language that represents a program by a graphical diagram based on the circuit diagrams of relay logic hardware. It is primarily used to develop software for programmable logic controllers (PLCs) used in industrial control applications. The name is based on the observation that programs in this language resemble ladders, with two vertical rails and a series of horizontal rungs between them. Ladder logic uses simple logic of opening or closing of switches (or relays). Some of the functions are: a. Normally Open: Represented as --| |-b. Normally Close: Represented as --|/|-c. Load: Represented as ( ) d. Timer ON e. Timer OFF f. Count UP g. Count DOWN h. Compare [* Explain Ladder Logic] A program in ladder logic looks like this:

Figure 14: AND Gate Simulated in Ladder Logic using TIA

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Tag_1 and Tag_2 are Inputs and Tag_3 is the output. The above program is a representation of an AND gate. The NO (Normally Open) contacts are closed when switched on and remain normally opened when switched off. During closed condition, it allows the flow of current and during off condition it provides infinite resistance to the current flow (ideally). The NC (Normally Closed) contacts are opened when turned on and remains closed when turned off. At the ON state it provides infinite resistance to current flow (ideally) and acts as short circuit otherwise. Another program for a simple coffee dispensing machine simulated in LD Micro is shown below:

Figure 15: Ladder Logic Program of a Coffee Dispensing Machine

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This coffee dispensing machine has three options: Tea Coffee Lemon Tea

The machine has three dispensers to mix the pre-mix coffee ingredient with hot water and pour the mixture in a glass. This process is carried out as follows: The power of the machine is switched ON The required drink (Tea/ Coffee/ Lemon Tea) The response is stored in a memory (internal relay RT/ RC/ RLT ) The memory is recalled and the corresponding motor is switched ON after checking that all fuses are intact and there is no fault The mixture is poured by the Dispenser (YDispenser). The fuses (FuseT/ FuseC/ FuseLT) are for protection and blow in case of a fault.

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Chapter 4 Speed Control of Induction Motor


Rotor Resistance Speed Control Variable Voltage Speed Control Pole Changing Variable Frequency Speed Control Variable Voltage Variable Frequency Speed Control

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SPEED CONTROL OF INDUCTION MOTOR


An induction motor is an asynchronous motor. This is a type of alternating current motor where power is supplied to the rotor by means of electromagnetic induction. Such electric motors operate because of a magnetic force (rotational torque) that is produced between the stationary electromagnet called the stator and a rotating part called as a rotor. The three induction motor rotates because of magnetic force exerted between a motionless electromagnet called the stator and a rotating electromagnet called the rotor. The motor is either a slip ring type or a squirrel cage type. The squirrel cage type of motor runs at a constant speed. Wound rotor or slip ring induction motor is of particular interest as we can have an easy control over its speed.

Figure 16: Three Phase Induction Motor

Following methods are often used for the speed control of a Three Phase Induction Motor: a. Rotor Resistance Speed Control b. Variable Voltage Speed Control c. Pole Changing d. Variable Frequency Speed Control e. Variable Voltage Variable Frequency (VVVF or V/F Control)

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I.

Rotor Resistance Speed Control

This is a conventional method of speed control of a three phase slip ring Induction Motor. This involves stepping of resistance to change the effective rotor resistance and hence, change the speed of motor. The advantage of using this control is that it is easy to implement. There are few demerits of this control as well. Primarily, there is a constant power loss in the resistors. Secondly, this is only possible for slip ring induction motors and not for squirrel cage type induction motors.

Figure 17: Rotor Resistance Speed Control

Note that while the maximum torque and synchronous speed remain constant, the slip at which maximum torque occurs increases with increase in rotor resistance, and so does the starting torque. Whether the load is of constant torque type or fan-type, it is evident that the speed control range is more with this method. Further, rotor resistance control could also be used as a means of generating high starting torque. For all its advantages, the scheme has two serious drawbacks. Firstly, in order to vary the rotor resistance, it is necessary to connect external variable resistors (winding resistance itself cannot be changed). This, therefore necessitates a slip-ring machine, since only in that case rotor terminals are available outside. For cage rotor machines, there are no rotor terminals. Secondly, the method is not very efficient since the additional resistance and operation at high slips entails dissipation.
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II.

Variable Voltage Speed Control

If the stator supply frequency is held at the rated value, the stator voltage cannot be increased above the rated value Vs. but it can only be reduced. The torque equation tells that the magnitude of torque is proportional to voltage squared. The shape of the torque-speed curve will be independent of voltage. Torque speed curves for an induction motor with a variable voltage supply are sketched in the figure below:

Figure 18: Characteristics for Variable Voltage Speed Control

The torque speed curves for a drive with a variable voltage supply do not obviously indicate how a variable voltage supply system may provide speed control. In order to use this approach for speed control, it is important to realize that the speed of an induction motor is dependent of the mechanical load: steady state operation is reached when motor torque equals load torque. Variable voltage control can be easily achieved in practice by chopping the input sine wave, using anti-parallel Thyristor, or triacs in low power applications. As a result, the control is cheap, but introduces significant harmonic content into the supply and motor circuit, reducing efficiency and power factor.

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III. Pole Changing


In pole-changing motors, the stator winding is designed so that, by simple changes in coil connections, the number of poles can be changed in the ratio 2 to 1. Either of two synchronous speeds can then be selected. The rotor is almost always of the squirrel-cage type, which reacts by producing a rotor field having the same number of poles as the inducing stator field. With two independent sets of stator windings, each arranged for pole changing, as many as four synchronous speeds can be obtained in a squirrel-cage motor, for example, 600, 750, 1000, and 1500 r/min for 50-Hz operation.

Figure 19: Pole changing from initial (a) to final (b)

The above figure shows pole changing of an induction motor.


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IV. Variable Frequency Speed Control


The synchronous speed of an induction motor can be controlled by varying the frequency of the applied armature voltage. This varies the flux density and as frequency increases the flux decreases. Since, the machine is operated at knee point, further rise in flux causes saturation and hence iron losses increase. Therefore, it is recommended to use this speed control scheme for frequency above rated and hence speed below rated can be obtained. The characteristic is shown on the following page:

Figure 20: Characteristic for Variable Frequency Speed Control

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V. Variable Voltage Variable Frequency Speed Control


The expression for the synchronous speed indicates that by changing the stator frequency also it can be changed. This can be achieved by using power electronic circuits called inverters which convert dc to ac of desired frequency. Depending on the type of control scheme of the inverter, the ac generated may be variable-frequency-fixed-amplitude or variable-frequencyvariable-amplitude type. Power electronic control achieves smooth variation of voltage and frequency of the ac output. This when fed to the machine is capable of running at a controlled speed. However, consider the equation for the induced E.M.F. in the induction machine. V = 4.44Nmf Where N is the number of the turns per phase, m is the peak flux in the air gap and f is the frequency. Note that in order to reduce the speed, frequency has to be reduced. If the frequency is reduced while the voltage is kept constant, thereby requiring the amplitude of induced E.M.F. to remain the same, flux has to increase. This is not advisable since the machine likely to enter deep saturation. If this is to be avoided, then flux level must be maintained constant which implies that voltage must be reduced along with frequency. The ratio is held constant in order to maintain the flux level for maximum torque capability. Actually, it is the voltage across the magnetizing branch of the exact equivalent circuit that must be maintained constant, for it is that which determines the induced E.M.F. Under conditions where the stator voltage drop is negligible compared the applied voltage the above equation is valid. In this mode of operation, the voltage across the magnetizing inductance in the exact equivalent circuit reduces in amplitude with reduction in frequency and so does the inductive reactance. This implies that the current through the inductance and the flux in the machine remains constant. The speed torque characteristics at any frequency may be estimated as before. There is one curve for every excitation frequency considered corresponding to every value of synchronous speed. From the following curve, it may be seen that the maximum torque remains constant.

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Figure 21: Characteristics of Variable Voltage Variable Frequency

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Chapter 5 Experimental Setup


Power Quality Analysis of Household Loads Control of Three Phase Induction Motor Circuit Diagram for Rotor Resistance Speed Control Network Connection of Siemens PLC S7 300 and HMI

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EXPERIMENTAL SETUP
I. Power Quality Analysis of Household Appliances/Loads
The following block diagram shows the experimental setup for analyzing the quality of power consumed by various household loads.

Figure 22: Experimental Setup for Power Quality Analyzer

L1, L2, L3 and L4 are outputs of the analyzer. I.0-I.8 are digital inputs. O.1-O.4 are digital outputs. The load is being switched on and off manually by the input switch I.1 on the panel. The analyzer shows the power consumed and its quality. The load is supplied through the analyzer via L1, L2, L3, L4 outputs. The analyzer output can be programmed. Following code was written to switch on L1, L2 and L3 simultaneously when input I.1 is switched on:
rem N rem P id0000|null|programmingbase.Repeater|60:75:600:350*MeassuringValue rem P id0001|id0000|programmingbase.DigitalIn|42:23:104:46*1*<Jasic Digital-Input 1> rem P id0002|id0000|programmingbase.DigitalOut|400:17:111:46*1*<Jasic Digital-Output 1> rem P id0003|id0000|programmingbase.DigitalOut|398:66:111:46*2*<Jasic Digital-Output 2>

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rem P id0004|id0000|programmingbase.DigitalOut|375:119:111:46*3*<Jasic Digital-Output 3> rem C id0001:result|id0002:in rem C id0001:result|id0003:in rem C id0001:result|id0004:in jsv_001f = _REALTIME / 500000 AUTOSAVE(jsv_001c, 0) <Jasic Digital-Output 1>=jsv_001c AUTOSAVE(jsv_001e, 0) <Jasic Digital-Output 3>=jsv_001e AUTOSAVE(jsv_001d, 0) <Jasic Digital-Output 2>=jsv_001d sub lbl_0005 lbl_0004: wait(MSYNC) jsv_0020 = _REALTIME / 500000 - jsv_001f jsv_001f = _REALTIME / 500000 jsv_001b = <Jasic Digital-Input 1> <Jasic Digital-Output 1> = jsv_001b jsv_001c = jsv_001b <Jasic Digital-Output 3> = jsv_001b jsv_001e = jsv_001b <Jasic Digital-Output 2> = jsv_001b jsv_001d = jsv_001b goto lbl_0004 endsub gosub lbl_0005

The image below is the program written in graphic mode which is simpler but not all parameters can be toggled here.

Figure 23: Program for Power Quality Analyzer

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II.

Control of Three Phase Induction Motor

The experiment is conducted in the SCADA and Industrial Automation Lab, Department of Electrical Engineering, Aligarh Muslim University. The setup includes the following devices and equipment: a. Siemens PLC S7 300 Kit including: a. Digital Input-Output Interface Board b. Analog Input-Output Interface Board c. Power Supply (230 V, 50 Hz AC Supply) d. Communication Interface (RS 232) e. Human Machine Interface (HMI) b. Three Phase Slip Ring Induction Motor c. Three Phase Rated Supply d. Relays e. Contactors

Figure 24: Siemens PLC S7 300 Kit with HMI

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III. Circuit Diagram for Rotor Resistance Speed Control


Contactor 1 Normally Closed 3 Slip Ring Induction Motor

R Y B

Relay 3

R3

Relay 2

R2 Contactor 2 Normally Open

Relay 1

R1

Figure 25: Experimental Setup for Rotor Resistance Speed Control Scheme

The figure above shows the circuit diagram that is being implemented to control the speed of 3 Slip Ring Induction Motor. The Contactors are used to reverse the direction of the motor. For this purpose, the phase sequence of supply fed to the motor is reversed. Speed control is achieved by rotor resistance variation. This variation takes place in steps as the relays RELAY 1, RELAY 2 and RELAY 3 switch the external resistances connected in series with the rotor windings. The above circuit is simulated in HMI and interfaced with the PLC. The digital outputs of the PLC can later be interfaced with the Relays and Contactors to control the Motor. The Digital Input used are: I 0.4 I 0.5 I 0.1, I0.2, I 0.3 : : : Forward Direction Motor ON Reverse Direction Motor OFF Speed Control in Step 1, 2, 3.

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IV. Network Connection of PLC S7 300 and HMI

Computer System (192.168.0.xxx)

PLC S7 300 (192.168.0.1) HMI Touch TP 117B (192.168.0.2) Janitza UMG 511 (192.168.0.111)

Figure 26: Network Connection for PLC, PQA and HMI over Ethernet

The above connection diagram is the communication network diagram for the devices to communicate among each other. The HMI and PLC have same tags for same output and input functions. This creates a synchronism in the operation, and only required inputs and outputs are connected. All the devices are based on IP Addressing and are configured on Class 3 with IPs starting from 192.168.0.xxx where xxx is the address of the Computers such that all the devices come under same subnet.

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Chapter 6 Results and Program


Power Quality Analysis of Household Loads Speed Control of Three Phase Slip Ring Induction Motor using PLC and HMI Project Report Generated from TIA

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RESULTS AND PROGRAM


I. Power Quality Analysis of Household Loads
Appliances under study: a) Tube Light i. Bajaj 230V, 40W Tube Light.

b) Compact Florescent Lamps (CFL) i. ii. c) Fan i. ii. With Triac controlled Speed Regulator With Resistive Speed Regulator Crompton & Greaves 110V-230V, 18W. Oreva 110V-230V, 8W.

d) Three Phase Induction Motor i. 230V, 1.6A, 0.75 kW

Analysis a) Tube light: The analysis of the waveforms for florescent tube light was done to obtain the following parameters: i. ii. iii. Current Consumption Active power consumption Triac Controlled Glowing waveforms for maximum and minimum firing angles.

Following waveforms have been obtained for the tube light (Bajaj 40W 230 V):

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Discussion:

The current in a florescent tube light is more at the beginning, nearly twice the rated current draws rated current.

spike in the above graph. This is due to the presence of a series inductor known as Choke. As

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Discussion:

The active Power in a florescent tube light is less at the beginning and then as the tube starts g rated power.

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Triac Controlled (Maximum Firing Angle Minimum Voltage)

Figure 27: Maximum Firing Angle

X Axis: Time in Seconds Y Axis: Voltage in Blue. Current in Red Triac Controlled (Minimum Firing Angle Maximum Voltage)

Figure 28: Minimum Firing Angle

X Axis: Time in Seconds Y Axis: Voltage in Blue. Current in Red

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b) Compact Florescent Lamp: These days the use of CFL is increasing on account to its higher efficiency, compact design and low maintenance. But they have a severe drawback, they are major source of harmonics in supply. This creates grave problems as heating up of insulation of cables, noise in transformers, etc. Thus, it is necessary to know how much distortion a power electronic circuit is causing in the supply. Total Harmonic Distortion (THD) is a measure of how much a wave is distorted from a pure sinusoidal wave. The presence of high THD can be known if occasionally some unexplained occurrences such as flickering of lights, alarms going off, or MCBs, MCCBs and Earth Leakage devices tripping for no apparent reasons are experienced. Other signs are cables running hot, hot switchboards or overheating motors. Further, the wear and tear of bearings and insulation in motors is a strong indication of the presence of harmonics. Some of the common and unpredictable effects of excessive harmonic include: Overheating and sustained damage to bearings, laminations and winding insulation on generators, transformers and induction motors causing early life failure, which could potentially result in fire. Overheating of the stator and rotor of fixed speed electric motors; risk of bearing collapse due to hot rotors. Overheating of cables and additional risk of failure due to resonance. Harmonics also decrease the ability to carry rated current due to 'skin effect', which reduces a cables effective cross sectional area. Disruption in the operation of Uninterruptible Power Supplies (UPS). Spurious tripping or failure of sensitive electronic and computer equipment, measurement and protection relays. Voltage resonances leading to transient overvoltage and overcurrent failures in the electrical network. Electromagnetic interference (EMI) resulting in disruption to communication equipment. Malfunction of circuit breakers and fuses.

There are various companies that manufacture CFLs. Here an analysis is done between Crompton and Greaves and Oreva CFLs. Further, a comparison between an incandescent lamps and a CFL is done.

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Figure 29: THD in CFL (C&G vs. Oreva) plotted vs. time

The red plot is for Crompton and Greaves CFL. It distorts the waveform less than an Oreva CFL. It is therefore advised to choose a Crompton and Greaves CFL as it distorts the waveform only half done by Oreva CFL. These days the CFLs are coming with a filter to lower harmonics. The Crompton and Greaves CFL used has filter. Next, the CFL is compared to an incandescent lamps. The plots obtained are as follows:

Figure 30: THD in Incandescent Lamp vs. CFL plotted vs. time

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The red plot is of CFL. The above graph shows that incandescent lamps has THD less than CFL but as its efficacy is less than that of CFL for same power consumption, CFL is preferred over Incandescent lamps. But in some industries the generated THD is a source of serious problems like heating and deterioration of insulation which reduce the life of equipment. Following is a graph for active power consumption. This graph tells primarily that the actual power consumed is more than rated (Incandescent lamp: 100W, CFL: 18W)

Figure 31: Active Power Consumption by Incandescent Lamp and CFL

Further, it is to be noted that the power consumed by the incandescent lamps varies exponentially (nearly quadratic curve) as the voltage is increased. Also, initially there is a spike for the incandescent lamps. This is because at the time of start, the resistance of filament is high therefore more current flows and hence more power is consumed. But as it gets hotter and resistance increases, the power loss decreases for the same magnitude of voltage.

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Following is the graph of the reactive power consumed by CFL and Incandescent lamps.

Figure 32: Reactive Power Consumption by Incandescent Lamp and CFL

The incandescent lamps filament acts as an inductor and consumes inductive power at the time of start. The red plot shows the same. On the other hand, the CFL consumes capacitive power due to the capacitor present in its circuit. As the firing angle is decreased i.e. the voltage is increased, there is an appreciable drop in the reactive power consumption but rise in active power. But the reactive power, like wise active power, remains nearly constant for the CFL.

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c) Fan: Fan used in houses is a single phase squirrel cage induction motor. It runs at rated supply voltage of 230V and usually consumes 40W to 150W power. The speed regulation of fan is a very important aspect. Resistive speed regulators consume more power as a considerable amount of heat is lost in resistance. Further, it is also bulky and needs a bigger space on the switch board. On the other hand, triac controlled speed regulator have higher efficiency and are small in size. Although, they have a problem of higher THD as compared to the resistive speed controllers. This problem is cleared by the use of filters in the triac circuits. The graph below shows the Voltage (Blue) and Current (Red) waveforms for maximum firing angle () i.e. minimum voltage.

Figure 33: V-I Waveform for Maximum Firing angle

Here the waveform is highly distorted and will have maximum THD. The graph below shows the Voltage (Blue) and Current (Red) waveforms for minimum firing angle () i.e. maximum voltage.

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Figure 34: V-I Waveform for Minimum Firing angle

Here the waveform is least distorted and will have lesser THD. The filter present in the regulator suppresses the effect of harmonics. The following graph represents the THD from a resistive speed controller. It is to be noted that the THD is nearly zero at steady state (after switching).

Figure 35: THD generated by a Resistive Speed Regulator plotted against time

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The following graph shows the THD for a triac controlled speed regulator. As the firing angle () is decreased, the THD decreases and finally reduces to zero at minimum firing angle ().

Figure 36: THD generated by a Triac Controlled Speed Regulator plotted against time

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d) Three Phase Induction Motor: The induction motor used here is a 3 phase, 4 pole induction motor. The waveform as obtained by the PQ analyzer for Voltage and Current is shown below.

Figure 37: V-I Waveform of Three Phase Induction Motor

The above graph clearly shows that the motor is inductive as the current waveform (Red) lags the voltage waveform (Blue) by approximately 90o. The graph below shows the reactive and active power consumption:

Figure 38: Active Power Consumption (1: Red, 2: Black, 3: Blue)

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Figure 39: Reactive Power Consumption (1: Red, 2: Green, 3: Blue)

The above graphs indicates that there is an unbalance in the phases. Phase 2 consumes maximum power (both active and reactive power). The graph below shows the THD by each phase of the induction motor. Here the phase 2 generates least THD as compared to other phases.

Figure 40: THD generated by Induction Motor (1: Red, 2: Green, 3: Blue)

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II.

Speed Control of Three Phase Slip Ring Induction Motor using PLC and HMI

The setup is a rotor resistance speed control scheme for slip ring induction motor. The process flow is given below: a. Motor will run as the Forward Mode button is pushed. b. This will switch on the Forward contactor with phase sequence: RYB. c. Speed 1 to 3 is achieved by closing of relays 1, 2 and 3. d. Motor will run in opposite direction as the Reverse Mode button is closed. e. This will switch on the Reverse contractor. f. Speed 1 to 3 is achieved by closing of relays 1, 2 and 3. g. The motor will not run if the above mentioned flow is disturbed or both Forward and Reverse Mode buttons are pressed together. The PLC and HMI both are programmed using TIA but the HMI can also be programmed using WinCC Flexible. The tags used in PLC and HMI are same so that each corresponds to the same function. The input from PLC and HMI are stored in memory tags which can be frequently changed by toggling the switch from HMI as well as the PLC Digital Inputs.

Figure 41: Control Panel on HMI

The program in ladder logic is attached as a project report generated by TIA along with the tag table.

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Chapter 7 Project Report Generated by TIA

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Attached Separetly.

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Screenshots of HMI
The HMI is created on the Model Siemens TOUCH TP 117B. Screen shots are shown below:

Figure 42: Root Screen

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Figure 43: Introduction and Objective

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Figure 44: About Us

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Figure 45: Control Panel to Control the Induction Motor

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Chapter 8 Conclusion

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CONCLUSION
The following conclusions were derived from the work carried in the project titled, Power Quality Analysis of House Hold Appliances and Speed Control of Three Phase Induction Motor using PLC and HMI. a. Power Quality Analysis of Household Loads: i. The Power Quality Analysis of common household loads such as Incandescent Lamps, CFLs and Fan were carried out. The analysis showed that the power consumed by these loads were more than the rated and as specified by the manufacturers. ii. The CFLs produced more THD as compared to the incandescent lamps (which produced nearly zero THD). iii. Two CFLs were compared for THDs. One of them that had filter installed (Crompton and Greaves CFL) produced less THD and the other (Oreva CFL) produced more THD. iv. Analysis of active and reactive power consumption revealed that the CFLs can operate at voltages as low as 100V and consume rated power. The incandescent lamps, on the other hand, consume power depending upon the supply voltage (as P=V2/R). v. It was also observed that at cold/ switch ON time the incandescent lamp allowed a very high current to flow for a very short duration. The reason was found to be the resistance at cold condition is very low as compared to the resistance when it is glowing. (P=V2/R, at start condition R is less therefore, P is high) vi. A fan was connected initially to a resistive speed regulator and then to a traic controlled speed regulator. The waveform were analyzed for the current at maximum firing angle and minimum firing angle. It was observed that at maximum firing angle the THD was least and at minimum firing angle, THD was maximum.

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vii.

Analysis of a three phase induction motor was also carried out where the phases 1 and 3 were found healthier than phase 2. Phase 2 consumed maximum power but generated least THD.

b. Speed Control of Three Phase Induction Motor: i. The PLC (S7 300) was programmed for the speed control of motor using rotor resistance control scheme. ii. The HMI was programmed and interfaced with PLC. The inputs were so programmed that they can be toggled from the digital input panel on PLC and the HMI touch screen as well.

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FUTURE WORK
The project titled, Power Quality Analysis of House Hold Appliances and Speed Control of Three Phase Induction Motor using PLC and HMI, can be further worked upon in the following directions: a. The Power Quality Analyzer can be interfaced with PLC S7 300 and HMI to obtain a complete solution for control of Household Appliance by implementing SCADA and ERP. The measured parameters from PQAs will act as a controlling parameters for the PLCs to run/ stop a process. As an example, an occupancy sensor based healthy power control module can be built over PLC and PQA where only good Quality Power (power quality parameters will be measured by PQA) will be switched ON only when there is occupancy (Detected by sensors connected to PLC) inside the room. b. The PLCs and PQAs can be interconnected via Industrial Ethernet Backbone and a complete Automation Pyramid can be modelled. The setup will include ERP and SCADA layer as well. The backbone will consist of Ethernet, Profinet, Profibus and Optical Fiber communication protocols. c. The HMI can be used to run SCADA using WinCC Flexible. The touch screen module will be used to display and control the various processes in real time. It will also keep a track on the generated alarms and events.

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REFERENCES
[1] [2] [3] [4] [5] Electrical Machinery Fundamentals, Stephen J. Chapman, 4th Edition, 2005. Electrical Machinery, A. E. Fitzgerald, 6th Edition, 2003. Fundamentals of Electric Drives, G. K. Dubey, 2nd Edition, 2001. PLC Programming for Industrial Automation, Kevin Collins, Chapter 1, page 5. Application Layer protocol for decentralized periphery and distributed automation, Specification for PROFINET, Version 2.3, October 2010, Order No.: 2.722, PROFIBUS Nutzerorganisation e.V. (PNO) [6] Industrial communication with PROFINET, Manfred Popp, Order no.: 4.182, PROFIBUS Nutzerorganisation e.V. (PNO) [7] Ethernet: the Definitive Guide, Charles E. Spurgeon, O'Reilly Media. p. 156. ISBN 978-1-56592-660-8(2000). [8] Switched, Fast, and Gigabit Ethernet, Robert Breyer and Sean Riley, Macmillan Technical Publishing. p. 107(1999). [9] "The Ethernet: A Local Area Network", Digital Equipment Corporation, Intel Corporation, Xerox Corporation ACM SIGCOMM Computer Communication Review (1980) Version 1.0 of the DIX specification. [10] "Ethernet", Internetworking Technology Handbook. Cisco Systems. Retrieved April 11, 2011. [11] The Second Information Revolution, Gerald W. Brock, Harvard University Press. p. 151. ISBN 0-674-01178-3. (2003). [12] SIMATIC S7-300 CPU 31xC and CPU 31x: Installation and Operating Instructions, Manual on S7 300, Siemens. [13] SIMATIC PCS 7 Evolution, Presentation by Tobias Koziol, Siemens AG, Germany. [14] PLC Programming for Industrial Automation, Instruction Set, Kevin Collins. [15] SIMATIC Programming with STEP 7 Lite V3.0, Siemens. [16] Speed Control of Induction Motor, Prof. Krishna Vasudevan, Prof. G. Sridhara Rao, Prof. P. Sasidhara Rao, Chapter 8, NPTEL, IIT Madras, India. [17] SIMOVERT MASTER DRIVES Operating Instructions Part II, Siemens.
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[18] Technical Support: a. Siemens India, India b. ZMS Technology, Germany [19] Software Used: a. Grid Vis, Janitza b. LD Micro, Open Source, Jonathan Westhues. c. Totally Integrated Automation, Siemens. d. WinCC Flexible 2008, Siemens.

List of Figures:
Figure 1: Richard Morley.......................................................................................................... 10 Figure 2: Architecture of a Programmable Logic Controller .................................................... 11 Figure 3: Representation of S7 300 in TIA ............................................................................... 12 Figure 4: Automation Pyramid ................................................................................................. 14 Figure 5: Ethernet connector RJ45 .......................................................................................... 15 Figure 6: Profibus Adapter ....................................................................................................... 15 Figure 7: Siemens HMI TP 117B ............................................................................................... 17 Figure 8: Totally Integrated Automation (TIA V11) startup window. ................................... 22 Figure 9: Create a NEW Project ............................................................................................... 22 Figure 10: Project Options ....................................................................................................... 23 Figure 11: Add device(s)........................................................................................................... 23 Figure 12: Select Appropriate CPU (CPU 314 C-2 PN/DP in our case) ..................................... 24 Figure 13: Main Console (GUI) for programming PLC (S7 300) ............................................... 24 Figure 14: AND Gate Simulated in Ladder Logic using TIA .................................................... 25 Figure 15: Ladder Logic Program of a Coffee Dispensing Machine ......................................... 26 Figure 16: Three Phase Induction Motor ................................................................................. 29 Figure 17: Rotor Resistance Speed Control ............................................................................. 30 Figure 18: Characteristics for Variable Voltage Speed Control ............................................... 31 Figure 19: Pole changing from initial (a) to final (b) ................................................................ 32 Figure 20: Characteristic for Variable Frequency Speed Control ............................................ 33 Figure 21: Characteristics of Variable Voltage Variable Frequency ........................................ 35 Figure 22: Experimental Setup for Power Quality Analyzer .................................................... 37 Figure 23: Program for Power Quality Analyzer ...................................................................... 38 Figure 24: Siemens PLC S7 300 Kit with HMI ........................................................................... 39 Figure 25: Experimental Setup for Rotor Resistance Speed Control Scheme ......................... 40
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Figure 26: Network Connection for PLC, PQA and HMI over Ethernet ................................... 41 Figure 27: Maximum Firing Angle ............................................................................................ 46 Figure 28: Minimum Firing Angle............................................................................................. 46 Figure 29: THD in CFL (C&G vs. Oreva) plotted vs. time .......................................................... 48 Figure 30: THD in Incandescent Lamp vs. CFL plotted vs. time ............................................... 48 Figure 31: Active Power Consumption by Incandescent Lamp and CFL .................................. 49 Figure 32: Reactive Power Consumption by Incandescent Lamp and CFL .............................. 50 Figure 33: V-I Waveform for Maximum Firing angle ............................................................... 51 Figure 34: V-I Waveform for Minimum Firing angle ................................................................ 52 Figure 35: THD generated by a Resistive Speed Regulator plotted against time .................... 52 Figure 36: THD generated by a Triac Controlled Speed Regulator plotted against time ........ 53 Figure 37: V-I Waveform of Three Phase Induction Motor ..................................................... 54 Figure 38: Active Power Consumption (1: Red, 2: Black, 3: Blue) ..................................... 54 Figure 39: Reactive Power Consumption (1: Red, 2: Green, 3: Blue) ................................ 55 Figure 40: THD generated by Induction Motor (1: Red, 2: Green, 3: Blue) ....................... 55 Figure 41: Control Panel on HMI.............................................................................................. 56 Figure 42: Root Screen ............................................................................................................. 59 Figure 43: Introduction and Objective ..................................................................................... 60 Figure 44: About Us ................................................................................................................. 61 Figure 45: Control Panel to Control the Induction Motor ....................................................... 62

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