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Contents

1. Identify the major parts in the VFD 2. Understand the setup of the VFD 3. PLC controls VFD to activate three phase induction motor 4. PLC controls VFD to activate three phase induction motor with encoder feedback

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1. To identify the major parts in the VFD

1.1 Outside Views and Functions

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1.2 Circuit Diagram

This diagram shows a standard wiring of the main circuit.

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1.3 Terminal functions

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2. To understand the setup in the VFD

2.1 Wiring Diagram

Power CircuitNoise Filter

Braking Circuit

PLC

3 phase Motor

FR

RESS1S2S3

VFD

L N

MCB

KM

KM

RL1

SL2

E Stop FuseStart

KM

Stop

UV

W

2.2 VFD exercises by manual operation

2.2.1 Setting the operation frequency by using the built-in potentiometer to run and stop the induction motor

Procedures:

a. Parameter settings i. Press the MODE key to display RUN ii. Press either the key or key to select “Cn0d” iii. Press ENTER key to display the default parameter setting iv. Change the setting to 1 v. Press the ENTER key to save the changed parameter vi. Repeat the procedure i to v for the parameter “Fn0d” vii. Pressing the MODE key twice to return the display to standard monitor

mode

Title Function Programmed Value Cn0d Command mode selection 1 Fn0d Frequency setting mode selection 0

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b. Operation Frequency setting on the VFD: Set adjusting position of notches on the potentiometer Run/stop the induction motor: Press the Run and Stop keys on the panel

2.2.2 Setting the operation frequency by using the built-up potentiometer a. Parameter settings

Title Function Programmed Value Sr1 Speed Operation frequency1 0 Sr2 Speed Operation frequency2 5 Sr3 Speed Operation frequency3 10 Sr4 Speed Operation frequency4 15 Sr5 Speed Operation frequency5 20 Sr6 Speed Operation frequency6 25 Sr7 Speed Operation frequency7 30

2.2.3 Selection of speed operation frequency and direction of motor by using the

Control Box a. Wiring Diagram

Power CircuitNoise Filter

Braking Circuit

CC

3 phase Motor

FR

RESS1S2S3

VFD

L N

MCB

KM

KM

RL1

SL2

E Stop FuseStart

KM

Stop

UV

W

ForwardReverseResetPreset Speed 1Preset Speed 2Preset Speed 3Common

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VFD Training Kit

AC cable

Input cable Output cable VFD cable

Control Box

MCB

VFD PLC

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Front view of the Control Box

Back View of the Control Box

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b. Installation

i. Connect the Plug cable to the P1 at the back of the Control Box ii. Connect the VFD cable to the CN1 at the back of the Control Box iii. Connect the AC cable to the AC source

c. Parameter Setting d. Operation

i. Switch on the MCB ii. Turn the Switch at the back of the Control Box to On position iii. Turn the selector at the front of the Control Box to the CC position iv. Turn the selector F to the right position v. Set the selected frequency by switching on the preset speed contact

input signals S1, S2 and S3

vi. Observe the speeds on the VFD panel and direction of the motor vii. Turn the selector F to the left position and then turn the selector R

to the right position viii. Set the selected frequency as in ii ix. Observe the speeds on the VFD panel and direction of the motor

Title Function Programmed Value Cn0d Command mode selection 1 F113 Input terminal selection 3 (RES) 10

Preset Speed Terminal 1 2 3 4 5 6 7 S1 • • • • S2 • • • • S3 • • • •

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3 PLC controls VFD to activate inductor motor

3.3.1 Wiring Diagram

1M 1L+ 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 1.0 1.1 M L+2M 2L+

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 1.0 1.1 1.2 1.3 1.4 1.5 M L+2M1MPLC

24V

Power CircuitNoise Filter

Braking Circuit

PLC

3 phase Motor

FR

RESS1S2S3

VFD

Switching Power Supply

L N

MCB

KM

KM

L N

RL1

SL2

E Stop FuseStart

KM

Stop

24V 0V GND

UVW

3.3.2 PLC Ladder Diagram

Description: Use the Control Box as input to control the start and stop of the 3 phase induction motor.

Input Address Description Output Address Description I0.0 Start Button Q0.0 Forward Direction I0.1 Stop Button Q0.5 Speed set to 10 Hz

I/O Table

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Ladder Diagram 3.3.3 Procedures:

a. Connect the Input cable to the CN1 at the back of the Control Box b. Plug the Output cable to the VFD cable on the training kit c. Set Slide Switch SW1 to PLC mode in the VFD. d. Key-in the provided PLC program. e. Download the PLC program to the controller. f. Run and test the program.

3.3.4 Exercises

Write a PLC program to use the Control Box as input to control the direction and speed of the 3 phase induction motor. Input Address Description Output Address Description I0.0 Start Button Q0.0 Forward Direction I0.1 Stop Button Q0.1 Reverse Direction Q0.3 Speed set to 0 Hz Q0.4 Speed set to 5 Hz Q0.5 Speed set to 10 Hz

I/O Table

a. Press the start button to run the motor in anti-clockwise direction.

Press the stop button to stop the motor at once. b. Press the start button to run the motor in clockwise direction at 10 Hz.

Press the stop button to stop the motor at once. c. Press the start button to run the motor in anti-clockwise direction at 20

Hz. d. Press the stop button to stop the motor at once.

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3.3.5 Configure the VFD with Trapezoidal profile exercises

Description: The student puts the dummy parcel at the start position. The sensor 1 detects the parcel and conveyor will start to move at 30 Hz. After the sensor 2 detects the parcel. The conveyor will stop

Input Address Description Output Address Description I1.1 Sensor 1 Q0.0 Forward Direction I1.0 Sensor 2 Q0.1 Reverse Direction Q0.4 Speed set to 5 Hz Q0.5 Speed set to 10 Hz

I/O Table Procedures:

a. Parameter settings on VFD b. Key-in the PLC program in the computer and download to the PLC

controller. Then run the program.

Title Function Programmed Value AU1 Automatic acceleration/deceleration 0 ACC Acceleration time 1 2 dEC Deceleration time 1 2

Sensor 1Sensor 2

Conveyor

Gear BoxAnd

Motor

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c. Observe the phenomenon of the parcel at the start and stop position.

d. Comment the accuracy and repeatability of the parcel.

e. Change the parameter settings on VFD

Title Function Programmed Value ACC Acceleration time 1 5 10 15 20 dEC Deceleration time 1 5 10 15 20

f. Repeat the procedures d to e. g. Comment on the accuracy and repeatability of the parcel for different

programmed value. h. Change the parameter settings on VFD to Automatic tune for acceleration

and deceleration time

Title Function Programmed Value AU1 Automatic

acceleration/deceleration 1

i. Observe the phenomenon of the parcel at the start and stop position. j. Edit the AU1 parameter from 1 to 2. k. Observe the phenomenon of the parcel at the start and stop position. l. Comment on the accuracy and repeatability of the parcel for different

programmed value when AU1 is changed from 1 to 2.

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3.3.6 Write PLC program to implement the acceleration and deceleration profile

3.3.6.1 Rectangular Profile

Description: After 0.5 second for the student to put the parcel which is detected by the Sensor 1 on the conveyor, the conveyor will start to move for 0.5 second. After that, the conveyor will stop.

Input Address Description Output Address Description I1.1 Sensor 1 Q0.0 Forward Direction I1.0 Sensor 2 Q0.1 Reverse Direction Q0.4 Speed set to 5 Hz Q0.5 Speed set to 10 Hz

I/O Table

Sensor 1Sensor 2

Conveyor

Gear BoxAnd

Motor

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PLC Program

Procedures:

1. Key-in the PLC program. 2. Download the program to the PLC controller. 3. Run and test the program.

3.3.6.2 Trapezoidal Profile Exercise

Procedures:

a. Write the PLC program. b. Download the program to the controller. c. Run the program. d. Test the program.

Discussion: i. Compared with rectangular profiles,

what are the advantages and disadvantages of using trapezoidal profile in speed control ?

ii. Where you could find the application of Trapezoidal profile in speed control ?

Time(s)

Speed(Hz)

3

25

5

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4 PLC control VFD with encoder feedback

4.1 PLC reads encoder signals

4.1.1 Wiring Diagram

1M 1L+ 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 1.0 1.1 M L+2M 2L+

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 1.0 1.1 1.2 1.3 1.4 1.5 M L+2M1MPLC

24V

Power CircuitNoise Filter

Braking Circuit

PLC

3 phase Motor

FR

RESS1S2S3

VFD

Switching Power Supply

L N

MCB

KM

KM

L N

RL1

SL2

E Stop FuseStart

KM

Stop

24V 0V GND

UVW

Encoder

Red

BlackGreenWhite

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4.1.2 PLC Program

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Procedures: a. Wiring the encoder signals into the PLC controller.

Input Address Encoder Signal Encoder Wire I1.2 Phase A Green Color I1.3 Phase B White Color L+ 24V+ Red Color COM(Output) GND Black Color

b. Key-in the PLC program. Download and run the program to observe the

reading of the encoder when the conveyor moves.

4.2 PLC reads encoder signals to control 3 phase induction motor

Input Address Description Output Address Description I1.1 Sensor 1 Q0.0 Forward Direction I1.0 Sensor 2 Q0.1 Reverse Direction Q0.4 Speed set to 5 Hz Q0.5 Speed set to 10 Hz

I/O Table

Sensor 1Sensor 2

Conveyor

Gear BoxAnd

Motor

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PLC program

Main Program

Subroutine 0

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Key-in the program and download to the PLC controller. Observe the followings: a. accuracy b. repeatability Why the defects happen? Could it possible to improve the accuracy and repeatability? How?

Exercise There are two sensors at each floor in the lift system. When the lift will move to the destination floor, it will pass the first sensor to decelerate the speed of the lift. After detection of the second sensor, the lift will stop immediately. Student is required to prepare a program and tune the VFD to demonstrate this situation from Ground Floor to the Sixth Floor. ------ End ------