Electrical drives

1. Basic Electrical an Introduction to
Drives & Automation

2. OHM’s Law
• V Voltage
• I Current
• R Resistance
• P Power

3. Voltage
Voltage is the electrical
force, or "pressure", that
causes current to flow in a
circuit. It is measured in
VOLTS (V or E). Take a
look at the diagram.
Voltage would be the force
that is pushing the water
(electrons) forward

4. Current
Current is the movement
of electrical charge - the
flow of electrons through
the electronic circuit.
Current is measured in
AMPERES (AMPS, A or
I). Current would be the
flow of water moving
through the tube (wire).

5. Resistance
Resistance is anything that
causes an opposition to the
flow of electricity in a circuit.
It is used to control the
amount of voltage and/or
amperage in a circuit.
Everything in the circuit
causes a resistance (even
wire). It is measured in
OHMS (W).

6. Power
Power is the product of
Voltage times Current
and is expressed in
Watts (W)
P = V x I
1W = 1V x 1A
Why Squirrels Make Poor Conductors

7. Ohm’s law means;
A steady increase in
voltage, in a circuit
with constant
resistance,
produces a constant
linear rise in current.

8. In simpler terms, Ohm’s law means;
A steady increase
in resistance, in a
circuit with constant
voltage, produces a
progressively (not a
straight-line if
graphed) weaker
current

9. OHM’s Law
Ohm's Law is a
formulation of the
relationship of
voltage, current, and
resistance,
expressed as:

10. Ohm’s Law
To determine a missing
value, cover it with your
finger. The horizontal
line in the middle means
to divide the two
remaining values. The
"X" in the bottom section
of the circle means to
multiply the remaining
values.

11. Types of Drives
AC
Drive
DC - controls DC Motor speed &
torque with a controlled bridge
rectifier
AC - controls AC Motor speed &
torque by converting AC to DC,
then back to AC
SERVO - controls speed, torque,
and motion or position of a
brushless servomotor
Servo
Drive
DC
Drive
AC-DC
AC-DC-AC
AC-DC-AC
Speed Feedback
Speed Feedback
Position Feedback

13. Elements of Induction Motor: The Rotor
Laminations of
high-silicon
content steel
Cast aluminum
rotor bars
Cast aluminum
end rings
Low-eddy current loss
magnetic medium
Electrically joins rotor
bars at both motor
ends
Carry induced current
(skewed bars shown)
No direct electrical connections are made to the rotor. All forces are
magnetically induced by the stator, via the air gap.
Rotor Bar Current

14. Elements of Induction Motor: The Stator
Stator Core
Lamination stack
of notched steel
plates

15. Elements of Induction Motor: Stator
Steel
Laminations
Stator Windings
Slots
wye or delta
connection types

16. The Stator (4-pole)
t
The stator induces magnetic lines of
flux across the air gap, into the rotor
Rotating
magnetic field

17. wstator
wrotor
Induction Motor Slip
SLIP = (ws - wr ) / ws
• Motor slip is proportional to load
torque.
• Stator speed is known by
frequency
• Rotor speed is measured with an
encoder (Vector).
• Rotor speed can be
approximated, knowing motor and
bus current (Sensorless Vector
algorithm)

18. Magnetic Flux
Lines
Rotor Magnetic Field Dynamics
SLIP creates TORQUE
As the rotor slips, rotor bar current slip frequency
increases, resulting in greater rotor field strength
(more torque).
When rotor speed is near stator speed (light load),
few stator flux lines are cut . Rotor bar current and
slip frequency are low.
Magnetic Flux
Lines
Magnetic Flux
Lines
Light Load Heavy Load

19. AC Induction Motors
Common Rotor Bar Shapes & Effects
All have nearly the same performance at full load
• Low resistance
• Low reactance
• High amps
• Average torque
• High resistance
• Average reactance
• Average amps
• Average torque
• High resistance
• High reactance
• Low amps
• Low torque
At locked rotor...
TORQUE
&
AMPS
SPEED
ACROSS-THE-LINE OPERATION
Best for
Inverter

20. Induction Motor Equivalent Circuit
Stator Rotor
Air
Gap
R1 XLR
XM
XR
RLOAD = R2 / Slip*
Although there is no physical connection between rotor and stator, the
induced field causes the motor model to behave as if there is.
Stator
Resistance
Leakage
Reactance
Magnetizing
Reactance
Rotor
Reactance
*(R2 is rotor bar resistance)
V

21. How Slip Compensation improves speed regulation
Full load 30 Hz
operating point (100%
current & torque)
850 RPM
Sync. or “no-load”
30 Hz speed
900 RPM
Slip (50 rpm)
100
175
150
%
T
Speed Slip (50 rpm)
100
175
150
%
T
Speed
Example: Motor under load at 30 Hz
A motor will lose 50 rpm under full
load with 30 Hz applied frequency,
slipping from 900 to 850 RPM.
By sensing current and other
variables, SLIP COMP will apply
31.7 Hz to the motor, restoring the
speed to 900 RPM.
BEFORE AFTER
New 31.7 Hz
curve
900 RPM
950 RPM
30 Hz curve

22. Typical AC Speed / Torque Curve
“Across-the-line” operation @ 60 Hz, NEMA ‘B’ motor
Full load operating point
(100% current & torque)
1750 RPM (nameplate)
Breakdown point:
Maximum torque motor
can produce before
locking rotor
Synchronous “no-load”
speed
1800 RPM
(50 rpm)
100
175
225
Starting Torque
Pull-Up Torque
150
%T
Speed
SLIP

23. Speed
AC Motor Speed / Torque Curve
with Inverter Power
Slip (50 rpm)
100
175
225
150
%T
Slip (50 rpm)
100% load torque
operating line
Motor base speed:
1750 RPM
At any applied Frequency, an induction motor will slip a fixed RPM at
rated load.
Peak Inverter Torque
(150 -200%)

24. AC MOTOR FORMULA
120 x Frequency
# of Poles
SYNC RPM =
Example: 4-pole motor
SYNC RPM = 120 x 60 / 4poles = 1800 RPM
%SLIP =
SYNC RPM - FULL LOAD RPM
SYNC RPM
X 100
Example: 1750 RPM motor
% Slip = (1800 - 1750) / 1800 x 100 = 3% Slip
SYNCHRONOUS SPEED
MOTOR SLIP
VOLTS / HERTZ
V/Hz =
Motor Line Volts
Motor Frequency
Example: 460 V, 60 Hz motor
V/Hz = 460/60 = 7.66 V/Hz
VOLTS FREQUENCY V/Hz
460 60 7.66
345 45 7.66
230 30 7.66
115 15 7.66
7.66 1 7.66

25. AC MOTOR SIZE
Frame size is directly related to base RPM / Horsepower
Example: 15 HP motors of different base speeds
Base RPM
Frame Size
Torque
Amps
3600 (2-pole)
215
22.5 lb-ft
18.5
1800 (4-pole)
254
45 lb-ft
18.7
1200 (6-pole)
284
67.5 lb-ft
19.3

26. DC Drives
& Application Issues

27. DC DRIVE BASICS
DC Drives convert AC line voltage into variable DC voltage with an SCR phase-
controlled bridge rectifier, to power the DC motor ARMATURE. A separate field
supply provides the motor with DC FIELD excitation.
LINE INPUT MOTOR OUTPUT
Armature
Field
A1
A2
F1
F2

28. Inside the DC Motor(Shunt Field Design)
A1
A2
F1
F2
The commutator &
brushes keep
armature flux in a
fixed position relative
to the field, which
guarantees the torque
force is always
perpendicular to field
magnetization.
N
S

29. Typical DC Motor Armature
Current & Torque Curves
Armature current is
directly proportional to
torque throughout the
loading range.
-200
-100
% T
% IDC
200
100
0
NO
LOAD
MOTORING
REGENERATING
RPM

30. DC Motor Torque & HP vs. Speed
Motor nameplate: 250 / 1000 RPM
100
50
25
75
250 500 750 1000
Base Speed Max.Speed
2 : 1 FIELD
WEAKENING
3 : 1 FIELD WEAKENING
4 : 1 FIELD WEAKENING
FIELD WEAKENED RANGE
4 : 1
CONSTANT HORSEPOWER
CONSTANT TORQUE
TORQUE @ 100% ARMATURE AMPS
FULL FIELD
TORQUE
&
HORSEPOWER
SPEED (RPM)
%

31. The SCR: (Silicon Controlled Rectifier)
a.k.a. - “Thyristor”
ANODE CATHODE
GATE
• Extremely robust solid-state switch / 40+ year proven track record
• Key element in DC Drive power circuit
• Simple pulse gating turns on current flow
• Device has self-turn-off when reverse biased
• Stud-mount, hockey-puck and encapsulated 2-, 4- and 6-pack types
available in certain sizes and ratings.
TRIGGER
-
+

32. Application Issues: AC Line Notching
AC
Input
Commutation notches are caused by the
transfer of current from one SCR to
another.
The notches can cause misfiring on drives
common to the same power line.
V ph-ph
Solution: Installation of a small (25-50 uH range), 3-phase reactor on
each DC controller will prevent cross-talk and other related problems.

33. Elements of a DC Drive:
Non-regenerative type
AC
Input
SCR Firing
Signals
Microprocessor
controller
Operator
Interface
S
E
Q
REF
LO
CA
L
AC MOTOR DRIVE
0.75
KW
200 V v 1.3
HEALTH
L
R
PROG
E
M
RUN
F
W
D
RE
V
JOG
RESET
STOP
RESET
Speed or Torque
Reference
Field
Control
Signals
A1
A2
F1
F2
Tachometer
Feedback
(closed-loop)
Motor voltage
feedback
Line current
feedback

34. Elements of a DC Drive:
Regenerative type
AC
Input
SCR Firing Signals
Microprocessor
controller
Operator
Interface
S
E
Q
REF
LO
CA
L
AC MOTOR DRIVE
0.75
KW
200 V v 1.3
HEALTH
L
R
PROG
E
M
RUN
F
W
D
RE
V
JOG
RESET
STOP
RESET
Speed or Torque
Reference
Field
Control
Signals
A1
A2
F1
F2
Tachometer
Feedback
(closed-loop)
Motor voltage
feedback
FWD/MOT REGEN/REV
F
F F F
F F
R
R
R
R
R
R
Line current
feedback

35. Dynamic Braking on DC Drives
A1
A2
F1
F2
M
M
M
DBR
• Dynamic Braking Resistors are shunted across the motor armature in a
STOP or E-STOP mode.
• Motor counter-EMF (back voltage from motor, acting as generator) appears
across resistor grids.
• Voltage diminishes as resistors dissipate energy.
• Braking Power diminishes exponentially with motor slowdown: P = V2/R
Braking
Power
time
Not failsafe: DB will not function if field supply is absent (i.e. - if power is lost)

36. DC Regen Drives vs. DC Dynamic Braking
• DC regen drives provide constant torque deceleration and stopping.
• DC dynamic braking power diminishes with speed reduction.
• Both require full field power / neither will work in power outage.
• DC regen requires drive to be fully operational (no faults)
• DB can be used in conjunction with a regen drive, for certain
stopping conditions
• DC regen added benefits include full 4-quadrant torque control.
• DB may require an additional contactor, if the manufacturer uses an
AC input contactor.

37. AC Drives
& Application Issues

39. AC DRIVE BASICS
All AC Drives convert “fixed” voltage and frequency into “variable”
voltage and frequency, to run 3-phase induction motors.
LINE INPUT
MOTOR
OUTPUT

40. Types of AC Drives
In today’s marketplace, there are 3 basic AC
Drive categories:
• Open loop “Volts / Hz” Drives
• Open loop “Sensorless Vector” Drives
• Closed loop “Flux Vector” Drives
All are Pulse-Width-Modulated (PWM)
Some manufacturers offer 2-in-1 & 3-in-1 Drives,
combining these attributes.
V/Hz
SENSOR-
LESS
VECTOR
FLUX
VECTOR

41. Open loop “Volts / Hz” Drives
V
o
l
t
s
230
460
30 60 Hz
RPM*
900 1800
(Base)
0
• Motor voltage is varied linearly with frequency
• No compensation for motor & load dynamics
• Poor shock load response characteristics
*( 4-pole motor)
Motor Nameplate V/Hz

42. Sensorless & Flux Vector Drives
V
o
l
t
s
230
460
30 60 Hz
RPM*
900 1800
(Base)
0
• Motor voltage is varied linearly with frequency, with dynamic self-
adjustments
• V/Hz compensation for motor & load dynamics
• Excellent shock load response characteristics & high starting torque
*( 4-pole motor)
Motor Nameplate V/Hz

43. AC Motor Torque & HP vs. Speed
50
100
30 60
900 1800
0
Tq / HP
%
Torque
HP
Hz
RPM
• Motor Torque is constant to base speed
• HP varies proportionally to speed

44. AC
Input
DC
Bus
Caps
AC to DC
Rectifier
Pulse-Width-Modulated Basic Power Circuit
DC Filter
DC to AC
Inverter
IGBTs
AC
Output
All PWM inverters (V/Hz, Vector & Sensorless Vector) share similar
power circuit topologies.
AC is converted to DC, filtered, and inverted to variable frequency,
variable voltage AC.
M

45. RECTIFICATION
ZERO V
RMS
PEAK
PEAK DCVOLTAGE =RMSx1.414

46. PWM Power Circuit: AC to DC
Converter Section
AC
Input
DC
Bus
Caps
AC to DC
Rectifier
DC Filter
+
-
Input Reactor
(option)
DC Reactor
The AC input is rectified and filtered into fixed-voltage DC
•Adding an external AC input reactor will yield similar benefits.
• Both reduce harmonics, smooth and lower peak current.

47. FILTRATION
DC VOLTAGE

48. Power Switches
The IGBT: (Insulated Gate Bipolar Transistor)
An IGBT is a hybrid between a MOSFET and a Bi-polar Darlington Transistor.
=
GATE
COLLECTOR
EMITTER
SWITCH
• An IGBT can switch from “OFF” to “ON” in less than a microsecond.
• Amplified logic signals drive the high-impedance GATE.
Application Issues:
• A 1 microsecond state-change will generate a 1 MHz RF pulse.
• Dv/dt (rapid voltage changes) can stress motor insulation systems.

49. 49
Pulse Width Modulation
(PWM)
Simulates normal sinusoid voltage using pulses
Sine Wave PWM

50. PWM Power Circuit: DC to AC
Inverter Section
DC Filter
DC to AC
Inverter
IGBTs
AC
Output
M
An (Insulated Gate Bipolar Transistor) is a high-speed power semiconductor
switch.
IGBTs are pulse-width modulated with a specific firing pattern, chopping the DC
voltage into 3-phase AC voltage of the proper frequency and voltage.
The resulting motor current is near-sinusoidal, due to motor inductance.
Imotor
Vu-v
U
V
W
IGBT Firing
Signals
+
-

51. IGBT Switching Issues
Controller-to-motor
lead length > 125’
Reflected (standing)
wave phenomena
Carrier frequency in
2 to10Khz range
High dV/dT from fast
switching
R.F. &
Electromagnetic
interference
CONDITION SOLUTION
RESULT
Output reactor installed
near controller
RFI/EMI input filter;
shielded motor cable;
separate ground
conductor
Nuisance trips from
capacitive coupling to
ground
Nuisance trips;
Motor insulation damage
from voltage doubling
Output reactor;
Improved motor
insulation
Higher carrier or
“quiet” algorithm
Interference with
other equipment;
telecommunications
Motor acoustic noise
Motor insulation damage
from voltage doubling
Improved motor
insulation

52. IGBT Firing
Signals
PWM
microprocessor
controller
Operator
Interface
S
E
Q
REF
LO
CA
L
AC MOTOR DRIVE
0.75
KW
200 V v 1.3
HEALTH
L
R
PROG
E
M
RUN
F
W
D
RE
V
JOG
RESET
STOP
RESET
V
f
Basic V/HZ Control Circuit:
Input, Feedback and Control Signals
Motor current &
voltage feedback
DC Bus current &
voltage feedback
Speed reference

53. IGBT Gating
Signals
PWM
microprocessor
controller with
Vector algorithm
Man-
machine
Interface
S
E
Q
REF
LO
CA
L
AC MOTOR DRIVE
0.75
KW
200 V v 1.3
HEALTH
L
R
PROG
E
M
RUN
F
W
D
RE
V
JOG
RESET
STOP
RESET
Flux Vector Control Elements
Encoder Feedback
Motor current &
voltage feedback
DC Bus voltage
feedback
Speed and / or
Torque reference

54. AC PWM Vector Control
Theory
Load torque producing current
Flux or magnetizing
current

55. AC VECTOR CONTROL LOOPS
Speed
Regulator
Torque
Regulator
PWM
Firing
Frequency Feedback
Speed Feedback
Speed Loop Torque Loop
Actual Torque
Speed Error Torque Ref.
Encoder
Freq. & Voltage
Reference
AC Vector Drive
Torque
Calculator
Speed Reference
Torque Reference

56. Induction Motor Advantages
• Low cost (compared with DC)
• Wide availability
• Low maintenance - no brushes or commutator
• Rugged design - can be used in harsh environments
• Low inertia rotor designs
• High electrical efficiency
• Wide speed ranges
• No separately-powered field windings
• Good open-loop performance

57. Motor Current Vectors
Stator Rotor
Air
Gap
R1
XLR
XM
XR
RLOAD
Stator
Resistance
Leakage
Reactance
Rotor
Reactance
Total Current
Magnetizing
Current
Torque
Current
Magnetizing
Current
Torque-Producing Current
Total Current is the Vector sum of
Magnetizing and Torque-
producing current, which are at a
right angle to each other.

58. Motor Current Vectors
Torque-Producing Current
Magnetizing
Current
Torque-
Producing
Current
Torque-Producing Current
LIGHT
LOAD
MEDIUM
LOAD
HEAVY
LOAD
• High % of total current is “magnetizing” current
• Magnetizing current is reactive (low p.f.)
• Measured (total) motor current is not a good
indicator of load level.
• Most of total current is
torque-producing
• Motors run at high
power factor
• Total motor current is
proportional to load level.

59. Autotuning on Sensorless Vector Drives
FACT: Most motor electrical parameters are
difficult to obtain from the manufacturer.
ROTOR RESISTANCE
ROTOR REACTANCE
MAGNETIZING CURRENT
STATOR RESISTANCE
LEAKAGE REACTANCE
A Sensorless Vector AUTOTUNE function makes the job easy:
1. Enter nameplate motor parameters (base speed, full load amps,
voltage, frequency, power factor).
2. Run the ‘AUTOTUNE ‘ function. The controller will pulse the motor &
determine approximate motor electrical characteristics for SENSORLESS
VECTOR Operation.
3. The S-V algorithm can now compute torque- and magnetizing current
vectors for more precise motor control.
?
Not typically found on motor nameplate

60. Facts about Induction Motors
Most AC motors are designed to be used in fixed speed
(across-the-line) operation.
• Rotor bar design, cooling impellers, insulation systems have been designed for
60 Hz sine-wave power.
• When operated on an inverter, performance and reliability may be
compromised:
» Insulation systems may break down from stresses of IGBT PWM power.
» Cooling efficiency from shaft-driven fan will limit low speed range
» Motor harmonics will reduce Service Factor rating.
» Peak running torque is less than optimum.

61. Inverter-Duty Induction Motors
Many motor manufacturers have introduced lines of motors they call
“Inverter Duty” or “Vector Duty”. Features and characteristics vary
between manufacturers.
Typical features found on Inverter-Duty Motors
• High Dielectric strength wire insulation - Thermal-ezeTM (one brand) resists pin-
hole punctures caused by IGBT dV/dT switching stresses.
• Better Cooling - Efficient shaft-fan designs, constant-speed fans, and over
framing.
• Optimized rotor design - Bar profile designs suited for inverter, not line-start
duty.
• Tach-mounting provisions - Easy, non-drive end mounting of encoders for
Vector Duty operation.
• Wider speed ranges - Designs for above-base speed operation and custom V /
Hz ratios

62. AC Induction Motors
Effecting Base Speed through Volts / Hz Design
Motors on inverters don’t have to be wound for “60 Hz”
• Optimal power delivery occurs if voltage peaks at base speed
• Lowest amps occur at peak voltage .
• Drive price / component cost is related to amps.
Example of a 4-pole “550 RPM” base speed motor:
Stator is wound for 460V @ 20 Hz
V/Hz = 460/20 = 23
Hz
RPM (sync.)
20 40 60
460
600 1200 1800
VOLTS
0
3:1 CONSTANT HP
NAMEPLATE
BASE SPEED

63. Motor Operation above Base Speed
Motor base speed: 1750 RPM (4-pole)
Peak Inverter Torque
(150 -200% current)
Speed Slip (50 rpm)
100
175
225
150
%
T
100% current
operating line
Slip (50 rpm)
50
1800 3600
60 Hz
curve
120 Hz
curve
• Above base speed, continuous torque declines to 50% at 2 x base.
• Peak Inverter (overload) torque declines even more rapidly.
• Motor slip increases, for a given torque level.
Base

64. 460
100
V
60
Hz
Hz
60 120
120
Constant Horsepower
Constant Voltage
% T
& HP
Constant Torque
50
“Field Weakened Range”
Motor Operation above Base Speed
Torque a V/Hz
Frequency
increases above
base speed, but
voltage levels off.
The result is
increased speed
with weakened
torque, or constant
HP operation.
Above 2:1 , motor
torque drops
sharply &
operation is not
recommended.

65. AC V/Hz Drives Pro’s & Con’s
Advantages
• Simple, “look-up table” control of
voltage and frequency
• Good speed regulation (1-3%)
• No motor speed feedback needed
• Multi-motor capability
Limitations
• Low dynamic performance on
sudden load changes
• Limited starting torque
• Lacks torque reference capability
• Overload limited to 150%
Best for General Purpose & Variable Torque
Applications:
• Centrifugal Pumps & Fans
• Conveyors
• Mixers & Agitators
• Other light-duty non-dynamic loads

66. AC Sensorless Vector Drives Pro’s & Con’s
Advantages
• High starting torque capability (150% @ 1
Hz)
• Improved speed regulation (< 1%)
• No motor speed feedback needed
• Self-tuning to motor
• Separate speed and torque reference
inputs
Limitations
• Speed regulation may fall short in
certain high performance applications
• Lacks zero-speed holding capability
• Multi-motor usage defaults to V/Hz
operation
• Torque control in excess of 2 X base
speed may be difficult
Suitable for all General Purpose, Variable Torque and moderate to high
performance applications
• Extruders
• Winders and unwind stands
• Process lines

67. AC Closed-Loop Vector
Advantages
• Ultra-high torque and speed loop
performance & response
• Excellent speed regulation to .01%
• Full torque to zero speed
• Extra-wide speed range control
Limitations
• Requires encoder feedback
• Single motor operation only
• May require premium vector motor for full
performance benefits
• 4-quadrant (regenerative) operation
requires additional hardware
Best for High Performance Applications:
• Converting applications
• Spindles & Lathes
• Extruders
• Other historically DC-applications

68. Variable Torque Applications:
Centrifugal Pumps & Fans
• Load varies with the
square of the speed
• HP varies with the cube
of the speed
• Ideally suited for Drives
• Energy savings benefits:
only 50% power required at
80% flow
• Drives replace inefficient
dampers, guide vanes and
valves
Speed
Flow,
Torque
&
Horsepower
100%
100%
T = K x (RPM)2
HP = K x (RPM)3
80%
50%
80%

69. Variable Torque Applications: Centrifugal
Fan Energy Savings
Flow
Power
Consumption
100%
100%
50%
Throttling air volume
mechanically with
dampers or inlet
guide vanes is an
inefficient control
method.

70. Variable Torque Applications:
Centrifugal Pumps & Fans
RPM
Hz
Volts
Load
Torque
60
Base
Since load torque diminishes rapidly
below base speed, the Drive always
appears lightly loaded.
Most drive controllers have a special
“variable torque” V/Hz profile selection
that further cuts down on magnetizing
current at light loads. Since
magnetizing current is purely reactive,
motor losses are reduced .
100%
100%

71. Regenerative Operation of AC Motors
Example: 1750 RPM motor on 60 Hz power
LOAD
TORQUE
&
CURRENT
Current
Motoring
Regenerating
Synchronous Speed
1800 RPM
-100%
+100%
SPEED
1750 1850
Regen Breakdown

72. 4-Quadrant Operation of AC Motors on
Inverter Power
FORWARD
MOTORING
REVERSE
MOTORING
REVERSE
REGENERATING
FORWARD
REGENERATING
+ RPM
- RPM
Clockwise
TORQUE
Counter-
Clockwise
TORQUE

73. WEIGHT
PULL
ROTATION
Regenerating an AC Motor
AC Motors regenerate when pulled faster
than their sync speed at the applied
frequency.
At 60 Hz, if a motor is pulled faster than 1800
RPM*, the motor will behave as an induction
generator.
Regeneration conditions:
• Overhauling loads
• Fast deceleration of high inertial loads
• Stopping on a timed-ramp
• Cyclic loads or eccentric shaft loading
* 1750 RPM base
speed at 60 Hz

74. AC Drive Regeneration
AC
Input
DC
Bus
Caps
IGBTs M
ONE - WAY TWO - WAY
Energy Flow:
+
_
• Current flows back into the DC bus, via the IGBT switching & back diodes.
• AC Drive front-end rectifier is unidirectional; energy cannot flow back into the
AC line.
• Some returned energy is dissipated in losses in the capacitors, switches, and
motor windings (10-15%).
• Excessive regeneration can cause problems, such as DC Bus Overvoltage.

75. Dynamic Braking on AC Drives
AC
Input
DC
Bus
Caps
M
+
_
DBR
DYNAMIC
BRAKING
CONTROL
V
DC
Feedback
SIGNAL
A seventh IGBT, integrally mounted, is modulated when DC Bus voltage is
excessive.
Resistor Grids (external on ratings 5 HP & above) dissipate the excess
energy.
DB is duty-cycle limited to a set number of stopping operations
DB is ACTIVE when:
• Motor has an overhauling load
• Fast decel of high-inertial load
• Stopping in ramp-to-rest mode
DB is NOT ACTIVE when:
• Decelerating a frictional load
• Stopping in coast-to-rest mode
• Drive is disabled or if power
is removed

76. Dynamic Braking on AC Drives:
Application Considerations
DB is not failsafe: if the drive faults or power is removed,
DB will not function.
DB only operates when the drive is running: in coast-rest
or stand-by,
DB is inactive.
DB should not be used in EMERGENCY STOPPING:
the drive will continue on a timed ramp, producing torque
the entire time.
DB is suitable for intermittent operation only: other
regenerative solutions exist for long-term overhauling
loads

77. Application of AC Drives
Common DC Bus
M
M
M
+
-

78. AC Drives on a Common DC Bus:
Theory of Operation
NET
POWER
As individual
drives
regenerate, the
returned energy
is re-distributed
to motoring
drives via the
common DC
bus.
AC
DRIVE
AC
DRIVE
AC
DRIVE
AC
DRIVE
+ -
REGEN
REGEN
MOTORING
MOTORING
Net power
usage is
minimal,
due to the
efficient use
of returned
energy.

79. AC
DRIVE
AC
DRIVE
AC
DRIVE
AC Drives on a Common DC Bus:
Typical Connection Diagram
THERMAL- MAG
BREAKER
INPUT LINE
REACTOR
SEMICONDUCTOR
FUSES
INTERLOCKED
DC CONTACTOR

80. Line Regenerative AC Drives
M
IGBT Firing
Signals
PWM
microprocessor
IGBT Firing
Signals
BI-DIRECTIONAL POWER FLOW
LINE LOAD
CONVERTER INVERTER
• Two sets of 6 - IGBT bridges
• Gating control for both sets
• Converter IGBTs modulate on when bus voltage is excessive.
• More complex regulator design
• More conducted noise to power line
V
DC
Feedback

81. Multi-motor Applications
Motor amps must total less than
controller amp capability
• Each motor must have its own overload
• Drive must be in the “V/Hz” control
mode
• Motor speeds will be within slip-speed
range, with respect to each other.
• Interlock output contactors to drive run
logic, when used.
AC DRIVE
(V/Hz mode)
30 HP
38 Amps
2 hp
2.8 amps
2 hp
2.8 amps
3 hp
3.9 amps
3 hp
3.9 amps
5 hp
7.2 amps
10 hp
12 amps
Total HP = 25
Total Amps = 32.6
OVERLOAD CONTACTS

82. Application of Contactor Bypass
AC
DRIVE
Provides back-up, across-the-line
operation of motor
• Single-speed operation on line only
(must have mechanical control in place)
• Motor overloads are mandatory.
• Contactors are interlocked to prevent
inverter back-feed.
• Popular in HVAC / VT applications.
• Not recommended on “inverter duty
only” motors (high inrush current).
MAIN CB
INVERTER
DISCONNECT
BYPASS
CONTACTOR
INVERTER
CONTACTOR
MOTOR
OVERLOAD
INVERTER
OFF
BYPASS
TYPICAL 3-POSITION
SELECTOR SWITCH

83. AC Drives and Power Factor
AC
Input M
Motor P.F. = .70
(Light Load)
AC INPUT P.F. = .96
REACTIVE
FLOW
AC Drives inherently correct motor Power Factor
• Reactive current bi-directionally flows between the inductive motor and bus capacitors
• Input PF has no relationship to motor PF.
• Since input current is in-phase with voltage, input displacement PF is always near uni
Never use power factor correction capacitors with AC Drives!!!

84. ELECTRONIC LINE
SHAFTING FEATURE*
MASTER LINE
REFERENCE
MASTER FOLLOWER
ENCODER
REFERENCE
INPUT
VELOCITY
FEEDBACK
VELOCITY
FEEDBACK
PHASE-
LOCKED
LOOP
ALSO PROVIDES
ELECTRONIC
RATIO GEARING!
• Absolute position
regulation between
motors
• Closed-loop vector
mode operation
* with system
board option

86. DC DRIVE MARKET
• Most widely used drive in heavy industry
• Account for 40% of total variable speed
drive market (much higher percentage in
process industries).
• Estimate 0 - 5 % growth / annually to
2005
• Very established mature product with
continuing development.
MARKETPLACE FOR THE DC
THYRISTOR DRIVE

87.  Accounts for 60% of total variable speed drive
market (much lower percentage in process
industries)
 Estimated 5 - 10% growth / annual to 2005
 Mature product but due to limited performance
used generally only on peripheral rather than
process drives.
AC DRIVE MARKET
MARKETPLACE FOR THE
V/Hz AC PWM DRIVE

88.  Introduced during last ten years
 “Sensorless” introduced during last three years
 Growing use in most process industries (very strong growth
in elevators & hoists etc)
 Only AC drives currently available with similar or equivalent
performance to DC
AC VECTOR DRIVE MARKET
MARKETPLACE FOR THE
AC FLUX VECTOR DRIVE

89. Measuring Bandwidth Response
Speed Ref
Speed Feedback
1.0
.7071
45 degrees
• A sine-wave signal generator is applied to the reference input
• Feedback is monitored as reference frequency is increased.
• When feedback lags reference by 45 degrees, and amplitude is reduced to 7
of the input signal, this is defined as the “BANDWIDTH RESPONSE”.
“TEST”
Speed
Regulator
Torque
Regulator
PWM
Firing
Frequency Feedback
Speed Feedback
Speed Loop Torque Loop
Actual Torque
Speed Error Torque Ref.
Encoder
Freq. & Voltage
Reference
AC Vector Drive
Torque
Calculator

90. Industry “Typical Range”
Drive Performance Comparison
DC open loop
DC closed loop
AC V/Hz mode
AC Sensorless Vector
AC Flux Vector mode
2 - 3 %
.01 - 1%
1 - 5%
.1- .5%
.01 -.05%
Speed Speed Loop Torque Torque
Regulation Response Accuracy Response
.5 - 2 Hz
10 - 20 Hz
1 - 2 Hz
1 - 10 Hz
20 - 100 Hz
2 - 5%
2 - 5%
10 - 20%
2 - 10%
.5 - 1%
10 - 20 Hz
20 - 100 Hz
5 - 10 Hz
75 - 200 Hz
200 - 1000 Hz
Performance varies widely between drive manufacturers
• Speed regulation is dependent upon speed feedback device used.
• Open loop regulation is motor-dependent
• Response rates are rarely published & can be misleading.
DRIVE TYPE

91. Common Drive Formulas for AC & DC
HP =
Torque x RPM
5252
Torque =
HP x 5252
RPM
For a 4-pole (1800 RPM) motor:
Torque (lb-ft) = 3 x HP
For a 6-pole (1200 RPM) motor:
Torque (lb-ft) = 4.5 x HP
For a 2-pole (3600 RPM) motor:
Torque (lb-ft) = 1.5 x HP
Torque =
Wk2 x D RPM
308 x D tsec
D tsec =
Wk2 x D RPM
308 x Torque
Accelerating / Decelerating an inertial load:
TORQUE AND HORSEPOWER
*(Wk2 is inertia in lb-ft2)

92. Common Electrical Formulas
IDC = IAC / .83
HP = KW / .746
KW = HP x .746
KVA =
VL-L x I x 1.732
1000
AC line current and armature current (DC Drives)
Horsepower and Kilowatts
Three phase Power
KVA = KW / P.F.
% Efficiency =
Pout
Pin
X 100
AC line voltage and DC bus voltage (AC Drives)
VDC = VL-L x 1.41

93. Power losses in AC & DC controllers
CONTROL
& FANS
AC to DC
AC to DC
CONTROL & FANS
DC to AC
Fixed losses = 500 -1000W
Fixed losses = 800 -1500W
SCR losses = 1%
IGBT losses = 1.5%
SCR / Diode losses
= 1%
Cap losses = .5%
98%
96%
EFFICIENCY
EFFICIENCY
DC:
AC:

94. Power Factor on AC and DC Drives
.85
.96
.30
100%
SPEED
AC
DC
20%
POWER
FACTOR
On AC Drives, input
displacement power factor
remains nearly constant with
speed & load.
On DC Drives, power factor
varies directly with SCR phase-
firing angle, peaking near .85 .
Since power increases linearly
with speed, the effects of low
power factor at low speed are
negligible.

95. DC Drive Advantages over AC
• Simple Controller Design- only one power conversion stage, no
power storage elements.
• Higher Controller Efficiency- 98%+ electrically efficient
• Simple, 4-quadrant line regeneration - with 6 reverse SCRs
• Efficient, inherent Torque control - Field & Armature flux always
positioned optimally.
• Retrofit to existing DC motors - previously power by M-G set or
older drive types.
• Most cost-effective drive package above 100HP
• High Controller reliability - Low maintenance due to simple
power module design

96. …more DC Drive Advantages over AC
• Lower power line harmonic contribution - less than 50% of AC
• Smaller line reactors- less costly
• More compact controller size per equivalent HP
• More robust power semiconductors - SCRs have better
overload and peak voltage characteristics, vs. IGBTs.
• Low motor acoustical noise: no “carrier” noise.
• Fewer motor lead-length issues: no capacitive coupling, dV/dT
or standing wave problems.
• Easier troubleshooting & serviceability

97. AC Drive Advantages over DC
• Simple, low-maintenance motor - no brushes or commutator.
• High dynamic performance - low rotor inertia, compared with DC
armature.
• Motors are inexpensive & readily available
• Motors suitable for harsh, rugged environments : some
explosion-proof ratings available.
• Better open-loop speed regulation - with Sensorless Vector &
slip compensation.
• Higher torque response bandwidth - on Vector-type; not limited
by AC line frequency.
• More cost-effective drive package below 100HP
• Multi-motor & inherent load sharing on single controller
• Line-bypass option - permits single-speed motor operation
during controller maintenance

98. …more AC Drive Advantages over DC
• No separate motor field - no field loss sensing required
• Wider speed ranges - motors through 6000 RPM & higher.
• Contactor-free dynamic braking - linear braking power to zero.
• Retrofit onto existing single-speed AC applications
• Smaller motor frame sizes than equivalent DC.
• Longer power-dip ride-through capabilities
• Near unity power factor regardless of speed and load

99. Brushless Servo Advantages & Disadvantages
• Very High Performance
• Very low inertia motors
• No commutation limit (high torque
& high speed)
• Maintenance-free motors
• High power density
• Available motion control
• High cost/kw of motor and control
• Complex feedback devices
• Little standardization of motors
• Limited practical power range
ADVANTAGES DISADVANTAGES

100. AC Drive/Motor Application
Issues
• Motor dv/dt
• Standing Wave”
• Thermal concerns

101. AC Drive Application Issues
• Loads that exceed current rating of
drive
• Motors located more than 50 feet from
drive
• Service KVA more than 10X drive KVA
• Control of drive more than 50 feet from
drive
• Regenerative loads

102. When Not to Use Vector
Control
• More than one motor per drive
• Motor cable lengths in excess of 50 m
• Filters or reactors connected between the
motor and inverter

103. Application 1 : Basic Speed Control
1
2
3
4
5
6
7
8
9
10
0V
AIN1
AIN2
+10V REF
AOUT1
+24V
DIN1
DIN2
DIGIO1
DIGIO2
Feedback
Ref.
MIN/MAX SPEED
RAMP
P2 MAX SPEED
P3 MIN SPEED
CURRENT LIMIT
P6 I NOMINAL
REFERENCE SELECT
P8 JOG SPD
P4 ACCEL TIME
P5 DECEL TIME
PWM CONTROL
V/F SHAPING
CT VT
V
F
V
F
I FDBK
V
F
SPEED DEMAND
START
JOG
FWD/REV
STOP
4-20mA
FWD/REV
d1 Frequency Hz
d2 Speed Setpt %
d3 DC Link Volts V
d4 Motor I A
DIAGNOSTICS
P9 STOP MODE
RL1A
RL1B
User
Relay R
0 NONE
1 HEALTH
2 TRIPPED
3 RUNNING
4 AT ZERO
5 AT SPEED
OP31 RELAY
0 NONE
1 DEMAND%
2 CURRENT%
3 PID ERROR%
4 RAISE/LOWER%
OP01 ANOUT
IDEAL FOR GENERAL PURPOSE
APPLICATIONS, CONSTANT TORQUE
AND VARIABLE TORQUE
IP23 AIN2 TYPE
0 0-10V
1 0-5V
2 0-20mA
3 4-20mA
0 0-10V
1 0-5V
IP13 AIN1 TYPE
SEQUENCING
LOGIC
0 NONE
1 HEALTH
2 TRIPPED
3 RUNNING
4 AT ZERO
5 AT SPEED
OP21 DIGIO2
0 = CONSTANT TORQUE
1 = VARIABLE TORQUE
P7 BASE FREQ
P13 V BOOST
P11 V/F SHAPE
60Hz base frequency
*BLUE is DEFAULT
P1 APPLICATION = 1
p1 Application
p2 Max speed
p3 Min Speed
p4 Accel time
p5 Decel time
p6 Motor rated current
p7 Base frequency
p8 Jog setpoint
p9 Stop mode
p11 V/F shape
p12 HVAC ratings
p13 Fixed boost, (VF only)
p99 Password
STANDARD PARAMETERS

104. Application 2 : Auto / Manual Control
1
2
3
4
5
6
7
8
9
10
0V
AIN1
AIN2
+10V REF
AOUT1
+24V
DIN1
DIN2
DIGIO1
DIGIO2
AUTO REF
MAN.
REF
REF SELECT
AUTO RUN
MAN. RUN
MAN./AUTO
FWD / REV
RUN SELECT
RAMP
CURRENT LIMIT
P6 I RATED
P4 ACCEL TIME
P5 DECEL TIME
PWM CONTROL
P9 STOP MODE
P9 STOP MODE
V/F SHAPING
CT VT
V
F
V
F
I FDBK
V
F
SPEED DEMAND
FWD/REV
MIN/MAX SPEED
P2 MAX SPEED
P3 MIN SPEED
RL1A
RL1B
User
Relay R
0 NONE
1 HEALTH
2 TRIPPED
3 RUNNING
4 AT ZERO
5 AT SPEED
OP31 RELAY
IDEAL FOR AUTOMATIC
CONTROL APPLICATIONS
WITH LIMIT SWITCHES OR
PROXIMITY TRANSDUCERS
IP23 AIN2 TYPE
0 0-10V
1 0-5V
2 0-20mA
3 4-20mA
0 0-10V
1 0-5V
IP13 AIN1 TYPE
SEQUENCING
LOGIC
0 NONE
1 HEALTH
2 TRIPPED
3 RUNNING
4 AT ZERO
5 AT SPEED
OP21 DIGIO2
0 = CONSTANT TORQUE
1 = VARIABLE TORQUE
P7 BASE FREQ
P13 V BOOST
P11 V/F SHAPE
60Hz base frequency
*BLUE is DEFAULT
P1 APPLICATION = 2
d1 Frequency Hz
d2 Speed Setpt %
d3 DC Link Volts V
d4 Motor I A
DIAGNOSTICS
p1 Application
p2 Max speed
p3 Min Speed
p4 Accel time
p5 Decel time
p6 Motor rated current
p7 Base frequency
p8 Jog setpoint
p9 Stop mode
p11 V/F shape
p12 HVAC ratings
p13 Fixed boost, (VF only)
p99 Password
STANDARD PARAMETERS

105. Application 3 : Preset Speeds
1
2
3
4
5
6
7
8
9
10
0V
AIN1
AIN2
+10V REF
AOUT1
+24V
DIN1
DIN2
DIGIO1
DIGIO2
AUTO REF
MAN.
REF
PRESET IN
START/STOP
SPEED DEMAND
SEQUENCING
LOGIC
RAMP
CURRENT LIMIT
P6 I NOMINAL
P4 ACCEL TIME
P5 DECEL TIME
PWM CONTROL
V/F SHAPING
CT VT
V
F
V
F
I FDBK
V
F
SPEED DEMAND
FWD/REV
MIN/MAX SPEED
P2 MAX SPEED
P3 MIN SPEED
IP300 PRESET 0
IP301 PRESET 1
IP302 PRESET 2
IP306 PRESET 6
IP305 PRESET 5
IP304 PRESET 4
IP303 PRESET 3
IP307 PRESET 7
PRESET IN
PRESET IN
P9 STOP MODE
P9 STOP MODE
DIGIO2 DIGIO1 DIN2 PRESET
0V 0V 0V 0
0V 0V 24V 1
0V 24V 0V 2
0V 24V 24V 3
24V 0V 0V 4
24V 0V 24V 5
24V 24V 0V 6
24V 24V 24V 7
(SCALABLE)
RL1A
RL1B
User
Relay R
0 NONE
1 HEALTH
2 TRIPPED
3 RUNNING
4 AT ZERO
5 AT SPEED
OP31 RELAY
IDEAL FOR APPLICATIONS
WHERE MULTIPLE
DISCRETE SPEED LEVELS
ARE REQUIRED
0 = CONSTANT TORQUE
1 = VARIABLE TORQUE
P7 BASE FREQ
P13 V BOOST
P11 V/F SHAPE
60Hz base frequency
*BLUE is DEFAULT
P1 APPLICATION = 3
d1 Frequency Hz
d2 Speed Setpt %
d3 DC Link Volts V
d4 Motor I A
DIAGNOSTICS
p1 Application
p2 Max speed
p3 Min Speed
p4 Accel time
p5 Decel time
p6 Motor rated current
p7 Base frequency
p8 Jog setpoint
p9 Stop mode
p11 V/F shape
p12 HVAC ratings
p13 Fixed boost, (VF only)
p99 Password
STANDARD PARAMETERS

106. Application 4 : Raise/Lower
1
2
3
4
5
6
7
8
9
10
0V
AIN1
AIN2
+10V REF
AOUT1
+24V
DIN1
DIN2
DIGIO1
DIGIO2
RAISE
START/STOP
SPEED DEMAND
RAMP
CURRENT LIMIT
P6 I NOMINAL
P4 ACCEL TIME
P5 DECEL TIME
PWM CONTROL
V/F SHAPING
CT VT
V
F
V
F
I FDBK
V
F
SPEED DEMAND
FWD/REV
MIN/MAX SPEED
P2 MAX SPEED
P3 MIN SPEED
LOWER
RESET
P9 STOP MODE
P9 STOP MODE
RAISE / LOWER
SEQUENCING LOGIC
RL1A
RL1B
User
Relay R
0 NONE
1 HEALTH
2 TRIPPED
3 RUNNING
4 AT ZERO
5 AT SPEED
OP31 RELAY
IDEAL FOR APPLICATIONS
WHICH REQUIRE SPEED
CONTROL FROM MULTIPLE
LOCATIONS
0 = CONSTANT TORQUE
1 = VARIABLE TORQUE
P7 BASE FREQ
P13 V BOOST
P11 V/F SHAPE
60Hz base frequency
*BLUE is DEFAULT
P401 RAMP TIME
P402 MAX VALUE
P403 MIN VALUE
P404 RESET VALUE
P1 APPLICATION = 4
d1 Frequency Hz
d2 Speed Setpt %
d3 DC Link Volts V
d4 Motor I A
DIAGNOSTICS
p1 Application
p2 Max speed
p3 Min Speed
p4 Accel time
p5 Decel time
p6 Motor rated current
p7 Base frequency
p8 Jog setpoint
p9 Stop mode
p11 V/F shape
p12 HVAC ratings
p13 Fixed boost, (VF only)
p99 Password
STANDARD PARAMETERS

107. Application 5 : PID Control
1
2
3
4
5
6
7
8
9
10
0V
AIN1
AIN2
+10V REF
AOUT1
+24V
DIN1
DIN2
DIGIO1
DIGIO2
Feedback
Ref.
MIN/MAX SPEED
SEQUENCING
LOGIC
RAMP
P2 MAX SPEED
P3 MIN SPEED
CURRENT LIMIT
P6 I NOMINAL
REFERENCE SELECT
P8 JOG SPD
P4 ACCEL TIME
P5 DECEL TIME
P9 STOP MODE
PWM CONTROL
V/F SHAPING
CT VT
V
F
V
F
I FDBK
V
F
SPEED DEMAND
START
JOG
FWD/REV
STOP
4-20mA
FWD/REV
PID CONTROL
P501 P GAIN
P502 I GAIN
RL1A
RL1B
User
Relay R
0 NONE
1 HEALTH
2 TRIPPED
3 RUNNING
4 AT ZERO
5 AT SPEED
OP31 RELAY
OP01 ANOUT
0 NONE
1 DEMAND%
2 CURRENT%
3 PID ERROR%
4 RAISE/LOWER%
EASY TUNING FOR SETPOINT/
FEEDBACK CONTROL APPLICATIONS,
REGULATING VOLUME OR PRESSURE,
SUCH AS AIR HANDLING OR PUMPING
0 = CONSTANT TORQUE
1 = VARIABLE TORQUE
P7 BASE FREQ
P13 V BOOST
P11 V/F SHAPE
60Hz base frequency
*BLUE is DEFAULT
P1 APPLICATION = 5
d1 Frequency Hz
d2 Speed Setpt %
d3 DC Link Volts V
d4 Motor I A
DIAGNOSTICS
p1 Application
p2 Max speed
p3 Min Speed
p4 Accel time
p5 Decel time
p6 Motor rated current
p7 Base frequency
p8 Jog setpoint
p9 Stop mode
p11 V/F shape
p12 HVAC ratings
p13 Fixed boost, (VF only)
p99 Password
STANDARD PARAMETERS

108. 1011011001010101001101010111010101
Serial
Interface

109. PLC Overview

110. • What is a PLC
PLC stands for Programmable
Logic Controller
A PLC is a ‘automation controller’
with a simple yet robust operating
system.
PLC Overview

111. • PLC Manufacturers
– Allen Bradley
– Siemens
– Omron
– Mitsubishi
– Toshiba
– Koyo
PLC Overview

112. PLC basically does three things
–Reads Inputs
–Solves Logic
–Writes Outputs
PLC Overview

113. PLC Overview
• Inputs
– An input is any device that provides a
signal to a PLC.
•Auto-switch / Limit switch
•Pushbutton switch
•Pressure switch
– Inputs are wired directly to an input
module of a PLC

114. PLC Overview
• Outputs
– An output is any device that is
controlled directly by the PLC
•Lamp
•Relay
•Solenoid valve
– Outputs are wired directly to an
output module of a PLC.

115. PLC Overview
• Programming
– PLC’s are programmed using ladder
logic.
Ladder logic uses the same graphical
representation that electricians call
ladder diagrams with the same types
of symbols they have been looking at
for generations.

116. PLC Overview
• A 'brick' PLC has a
block shaped case
(hence a 'brick')
with terminal strips
on it. They can be
panel or DIN rail
mounted but come
in a model-number-
determined set of
I/O capabilities

117. PLC Overview
• A 'Rack' PLC has one
or more 'card racks'
that individual circuit
cards slide into so
you can pick and
choose your I/O to
whatever number
and/or type you
need.

118. Conventional Wiring
• D-Sub Manifold
– On a solenoid manifold,
each solenoid must be wired
to an output terminal.
– An 8-station, double
solenoid manifold would use
one complete output module
(16 outputs)

119. Conventional Wiring
• D-Sub wiring example:
– Assume four 8-station, double solenoid
manifolds were to be installed just 30 m
from the PLC.
•16 solenoids + 1 common = 17 wires
•4 manifolds x 17 wires = 68 wires
•68 wires x 30 meters = 2,040 meters
•2,040 = over 2 Km of wire!!

120. Conventional Wiring
• To install the manifolds in this example
the customer would need:
– 2.04 Km of wire
– 4 output modules
– Conduit, Junction boxes, terminal
strips
– Lots of patience for wiring and
troubleshooting.

126. MMI Interface for Standalone Applications
E-NODE (Ethernet 802.3) Maximum 64 Stations
Intelligent Field Devices
DH via / Serial
KTX Card
Ethernet
PLC Interfaces
Applications Workstation 70
• Utilizing Latest NT V 4.0
• 10 Years of Control Software Development
• Updated Graphics Builder
• Advanced Alarm Management
• Advanced Trending & Historian
• IT Ready via OLE DDE ODBC Connections
AP
WP
Direct Connect
I/O Modules
Fieldbus
CP
DDE I/O Gateway
Ethernet
Serial
Foreign Devices
Support for 100’s
of DDE compliant
device drivers.
DI
OPC
Server
Devices

127. System Architecture
Plant Information
Network
X-Terminal and
Workstations
Fault-Tolerant Nodebus
Triconex
Tricon TMR
Field bus
Control
Processor
Allen-Bradley
Modicon
Triconix
GE Fanuc
Siemens
Custom
Device
Integrator
AB Station
PLC-5/X
Fieldbus I/O
Distributed Design
Comm.
Processor
Printers
Terminals
Carrierband LAN
Workstations
X-Terminals
and Servers
Personal
Computers
Computers
and Servers
Personal
Computer
AB PLC-5/XE
GE 90 Series
Remote PC
Micro
I/A
I/O-
Fieldbus
General Electric
Allen Bradley
Modbus
Etc.

128. 12
MICRO-
PLC
6 7
1
LAN
DC Drive Servos & Bookshelf
1 2 6 7
SIMATIC
S7
4
1
SIMATIC
M7
SIEMENS
6SE7016- 1EA30
W
R 2,2 kW
Nr. 467321
SIMO
VERT SC
SIEMENS
6SE7016- 1EA30
W
R 2,2 kW
Nr. 467321
SIMO
VERT SC
AC Drive.
Centralized
technology
Distribute
d
technology
Master
Control
MV Large Drive
SIMADYN D
Centralized or distributed technology:
T400

129. WinCC
Master-controllevel
Open- and
closed-loop
controllevel
Drivelevel
SINEC L2-DP
(1,5MBaud)
Incoming
supply
ET
ET
ET
SINEC L2-DP (1,5MBaud)
CP
C C
P
U
C
P
U
D
E
D
A
A
E
IM IM
PIC PIC PIC PIC PIC PIC PIC
PT
PT
PT
PT
PT
PT
PT
DC bus
RU
I I I I I I I I I I
SIMATIC S7
SINEC
L2-DP
(1,5MBaud)
3AC
M
~
M
~
M
~
M
~
M
~
M
~
M
~
M
~
M
~
M
~
M
~
M
~
M
~
Draw-in Stretching
machine 1
Stretching
machine 2
Stretching
machine 3
Calander 1/2/3 Tow
stacker
Dancer
roll
Crimper Tensioning
stands
Cutter Auxiliary drives
RU = Rectifier unit
I = Inverter
M
~
Sectional Drives

131. 4
Example: Metal processing
Positioning, thickness and synchronous control

132. 5
Example: Basic industries
cascade, rate regulation

133. 6
Example:Hoisting
Positioning, load sharing control

134. 7
Example:Conveyors
Synchronous, load sharing control

135. 8
Example: Paper Industry
Synchronous shaft winder control

136. 9
Example: Textile industry
Tensile control

137. 10
Example:Power plants
Field-current regulator, turbine control

138. T282 - 360 ton

140. • Built in PID controller maintains
constant pressure.
• High switching frequency
ensures low noise.
• Reduced damage to pipe with
controlled ramp rates.
Pumping Application

141. Float Glass