MOTOR CONTROL

WITH
BASIC PLC PROGRAMMING
Presented by: JS Moreno
 LEARNING OBJECTIVES
▪ Understand and wire a wide range of devices (pushbuttons, relays, contactors, thermal
overload, timers etc) and their principle of operation.
▪ Design and wire electric motor starters from scratch (DOL and Wye/Delta Motor Starter)
▪ Use circuit diagram as an aid to design, replacement and maintenance
▪ Practice safe working methods on electrical systems
▪ Introduce the basic hardware and software components of a Programmable Logic Controller
(PLC).
▪ Learn the basic Programming techniques and logic designs using the ladder logic
▪ Learn the operating features of the PLC, the advantages of the PLC over hard-wired control
systems and practical applications using simulation software.
▪ To provide an experience in motor control and PLC as close to the ‘real thing’ as possible using
the CADe SIMU and RSL0gix 500 simulation software.
 COURSE CONTENTS
Part 01: Motor Control
› Overview of Motor Control
› Common Components in Motor Control
› Set-up using MCCB vs MPCB
› Purpose of Motor Control Component
› Major Circuits in Motor Control
› Circuit layout, Connections, and Symbols
 COURSE CONTENTS
Part 02: Basic PLC
› Introduction to PLCs - What is PLC › Example of PLC - Input and Output Devices
(IO devices)
› Advantages of PLCs
› PLC Examples
› Disadvantages of PLCs
› PLC hardware connection of Motor Control
› Leading Brands of PLC
› Ladder Logic for Basic Gates (Truth Table)
› Areas of Application
› Difference between Current-Sourcing and
› PLC Sizes
Sinking
› Major parts of PLC
› PLC Operation Sequence
› PLC Programming Language
 OVERVIEW OF MOTOR CONTROL
▪ MOTOR CONTROL – is a device that will energize and de-energizes the circuit of the motor so
that it can start and stop. It might include an automatic or manual means in starting and
stopping the motor. In this webinar we will focus on motor control for induction motors as it is
widely used in most of industries.
▪ INDUCTION MOTOR – An induction motor (also known as an asynchronous motor) is a commonly
used AC electric motor. The electric current required to create torque in an induction motor is
produced by electromagnetic induction from the rotating field of the stator winding. The rotor
of an induction motor can be a squirrel cage rotor or wound type rotor.

▪ OPERATING CHRACTERISTICS OF MOTOR CONTROLLER:

a. Motor controller are to used start and stop the motor and to protect the motor, machine,
product, and operator.
b. To provide supplementary functions such as reversing, jogging, operating at several speeds or
at reduced levels of current and motor torque.
COMMON COMPONENTS IN MOTOR CONTROL

ADDITONAL COMMON COMPONENT:

MCCB or MPCB

Timer Relay

Pilot Lamp
 SET-UP USING MCCB vs MPCB
Conventional method A method using a MPCB
 PURPOSE OF MOTOR CONTROL COMPONENT
▪ MOULDED CASE CIRCUIT BREAKER (MCCB) is a
type of electrical protection device that is
used to protect the electrical circuit from
excessive current, which can cause overload or
short circuit.

▪ MOTOR PROTECTION CIRCUIT BREAKER (MPCB) –

A motor protection circuit breaker, or MPCB, is
an electromechanical device that performs
three important functions upstream of an
electric motor:
✓ Isolation,
✓ Motor protection against overload, short
circuit, line-to-ground faults and line-to-
line faults ,
✓ Control of the motor (on/off).
Continue. …
▪ MAGNETIC CONTACTOR – Same with typical
relay but with higher ratings and bigger in size.
Its purpose is used as switching.

▪ THERMAL OVERLOAD RELAY – is a

electromechanical protection devices. It is
design to interrupt the circuit when drawn with
high current.
▪ TIMER RELAY - are similar to other control
relays and that they use a coil to control the
operation of some number of contacts. The
difference between a control relay and a timer
relay is that the contacts of the timer relay
delay changing their position when the coil is
energized or de-energized. Timer Relay can
either be On – Delay and Off – Delay Timer Relay
 MAJOR CIRCUITS IN MOTOR CONTROL
▪ POWER CIRCUIT – Show the wiring of motor connected to power source. It has a higher voltage
▪ CONTROL CIRCUIT – the circuit for motor controller. It is used to control the motor to start,
stop, forward, reverse the motor rotation.

STARTING THE INDUCTION MOTORS

Different Starting methods are applied to induction motor since they draw high starting current.
There are two distinct starting method in induction motors, namely:
• Across the Line Starting – Manual Motor Starter and Magnetic Motor Starter- (Direct-On-Line)
• Reduced Voltage Starting - Solid State Starter, Primary Resistance Starters, Autotransformer
Starters, Part Winding Starter and Wye-Delta Starter

For the activities Direct On Line (DOL) and Wye-Delta Starter will be used.
CIRCUIT LAYOUT, CONNECTIONS, and SYMBOLS
▪ NEMA ▪ IEC
Direct-On-Line Motor Starter Reduced Voltage Starting - Wye-Delta Starter
 PART 02

~ BASIC PLC ~
 INTRODUCTION TO PLCs
What is PLC
PLC (Programmable Logic Controller) is a digital
computer used in industrial automation to
automate different electromechanical processes. It
was introduced to eliminate problems such as high
power consumption caused by the use of relays to
control the manufacturing process. It consists of a
programmed microprocessor whose program is
written on the computer and then downloaded to
the PLC via a cable. The program is stored in non-
volatile PLC memory.
 INTRODUCTION TO PLCs
What is PLC
❑ Developed on late 1960’s by Bedford associates (founded by: Richard E. Morley)
❑ Designed a computing device known as the Modular Digital Controller
(MODICON).
❑ Used as a replacement electromechanical relay of for General Motors
❑ The first PLC, model 084, was invented by Dick Morley in 1969
❑ MODICON is using the Boolean statements as programming technique.
 ADVANTAGES OF PLCs
❑ Less wiring.
❑ Very fast
❑ Wiring and Space of the control system is tremendously reduced
❑ Easier and faster to make changes.
❑ Low power consumption
❑ Energy savings as power consumption is greatly reduced
❑ Trouble shooting aids make programming easier and reduce downtime.
❑ Counter, timer and comparator can be programmed
❑ Small physical size, shorter project time
❑ Reliable due to absence of moving parts
 DISADVANTAGES OF PLCs
▪ Expensive
▪ PLCs are propitiatory, which means software and parts one manufacturer can’t be
easily combine with part of another manufacturer.Power consumption is high
▪ Machine downtime is usually long.
▪ Engineering drawings is not usually updated due to any change and modification.
 LEADING BRANDS OF PLC
1. Siemens – Simatec PLC
2. Rockwell Automation (Allen Bradley) – Allen Bradley PLC
3. Mitsubishi – Melsec PLC
4. Schneider Automation – Modicon PLC
5. ABB - AC500, X20 & X90 PLC
6. Omron – Sysmac PLC
7. Emerson Electric (GE) - RX3i & VersaMax (GE Fanuc)
8. Yokogawa - Vitesse & Stardom PLC
9. Phoenix Contact - AXC
10. Eaton - XC & EasyE4 (Cutler-Hammer)
 AREAS OF APPLICATION
❑ Manufacturing
❑ Packaging Machines
❑ Food / Beverage
❑ Automatic Assembly
❑ Power
❑ Mining
❑ Petrochemical / Chemical
❑ Material handling
❑ Machine Tools
❑ Conveyor system etc.
❑ And in general, any type of application that requires
electrical controls can use a PLC.
 PLC SIZES
1. FIXED/INTEGRATED/COMPACT
✓ Fixed number of INPUT and OUTPUT
✓ Input module, Output module and control unit in one
house.it covers units with up to 128 I/O’s. - These
PLC’s are capable of providing simple to advance
levels or machine controls.
2. MODULAR
✓ Installed separately from the CPU, Input and Output
is mounted on a rack and can be substituted with a
specific module if needed.
✓ Can be classified into small, medium and large
✓ Module are connected to each other through system
bus
 MAJOR PARTS OF PLC
PLC generally having five (5) parts, namely:
i. POWER SUPPLY - provides the voltage
needed to run the primary PLC components
ii. I/O MODULES Provides signal conversion and
isolation between the internal logic level
signals inside the PLC and the field’s high (Digital Input (Digital Output

level signal. Signal) Signal)

iii. PROCESSOR - provides intelligence to

command and govern the activities of the
entire PLC systems.
iv. PROGRAMMING DEVICE used to enter the
desired program that will determine the
sequence of operation and control of
process equipment or driven machine.
 PLC OPERATION SEQUENCE
1. SELF TEST: Testing of its own hardware and software faults.
2. INPUT SCAN: If there are no problems, PLC will copy all the inputs and copy
their values into memory.
3. LOGIC SOLVE/SCAN: - Using inputs, the ladder logic program is solved once
and output are updated.
4. OUPUT SCAN: While solving logic the output values are updated only in
memory when ladder scan is done, the outputs will be updated scan is
done, the outputs will be updated using temporary values in memory.
 PLC PROGRAMMING LANGUAGE
▪ Graphical languages:
1. Ladder logic diagrams – most widely used
2. Function block diagrams – instructions composed of operation blocks that
transform input signals
▪ Text-based languages:
1. Instruction list - low-level computer language
2. Structured text – looks very similar to BASIC or C programming
▪ Sequential function charts – series of steps and transitions from one state to
the next (Europe)
 PLC PROGRAMMING LANGUAGE
Ladder Logic diagram Function block diagrams
 PLC PROGRAMMING LANGUAGE
Structured text Instruction list
PLC PROGRAMMING LANGUAGE
Sequential function charts
EXAMPLE OF PLC – INPUT and OUTPUT DEVICES
(IO Devices)
DIGITAL INPUT DEVICES PROGRAMMABLE LOGIC DIGITAL OUTPUT DEVICES
CONTROLLER

EXECUTE / PROCESS
DETECT
OUTPUT
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 PLC EXAMPLES
Power Supply
Processor or CPU(Logix5572)
Ethernet I/P Communication Link
Redundancy Card IO Cards (DI, & DO)

Power Supply
Processor or CPU (S7-400)
Communication Link IO Cards (DI, DO, AO, & AI)

Ewon (Ethernet Switch) 27

RECALL THE MOTOR CONTROL CONNECTION

ADDITONAL COMMON COMPONENT:

MCCB or MPCB

Timer Relay

Pilot Lamp

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PLC HARDWIRE CONNECTION OF MOTOR CONTROL

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LADDER LOGIC FOR BASIC GATES (TRUTH TABLE)
AND Gate NAND
NANDGate
Gate

A B C A B C
0 0 0 0 0 1
0 1 0 0 1 1
1 0 0 1 0 1
1 1 1 1 1 0

OR NOR
NORGate
Gate
ORGate
Gate
A B C A B C
0 0 0 0 0 1
0 1 1 0 1 0
1 0 1 1 0 0
1 1 1 1 1 0

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DIFFERENCE BETWEEN CURRENT-
SOURCING AND SINKING

Current Sourcing Current Sinking

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 PART 03: ACTIVITIES
EXAMPLES:
▪ Example: Implement DOL motor starter using the CADe Simulation software.
▪ Example: TON, TOF, and Bit Functions

ACTIVITIES:
▪ Forward/reverse motor starter with interlock using the CADe Simulation software.
▪ Implement DOL motor starter WITH joG CIRCUIT in CADe Simulation software
▪ Wye/Delta motor starter with interlock using the CADe Simulation software.
▪ Implement a ladder logic in below circuits using the RSLogix 500 simulation software
❖ JOG circuit for DOL motor starter
❖ Forward/Reverse motor starter with interlock
❖ Wye/Delta motor starter
❖ Control a bulb in two(2) and (10) different location
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 Thank You!

Happy Learning