You are on page 1of 49

*

PREFACE

As a part of the curriculum prescribed for Bachelors Degree of Engineering by University of Rajasthan, Jaipur a total of 24 days practical training has to be taken after third year completion. Thus being a student of engineering I have completed my training at VIDEOCON INDUSTRIES LIMITED SHAHJAHANPUR.

Practical training is one of the major tasks for any professional course. The real place where an professional person faces and tackles the problems was able to get familiar to various processes in the industry. I was given a project on UTILITY in the duration of 24 days.

ACKNOWLEDGEMENTS
I am highly thankful to Mr. Manpreet Sing Oberoi, Mr. Ranjan Jaiswal and Mr. Yogesh Gupta, for providing me the opportunity to work on the current project i.e."PLC" with their prestigious organization and Mr. Sunil Joshi, Mr. M.K. Agarwal and Mr. Dhirendra Mathur who allowed me to take my training as per the curriculum of the Bachelors Degree of Engineering, as prescribed by University of Rajasthan, Jaipur. I am deeply indebted to Yogesh Gupta for assigning the project, and also grateful to Mr. Ram kumar Gutpa for sharing his views and giving total insight into the minor details of the project as well as that of the organization and grateful to him for helping me in preparing my Training Report. The help rendered by Mr. Surendra Jingar from time to time is also thankfully acknowledged. The keen Interest shown by Mr. Yogesh Gupta during the course of the final project and these investigations is creditable.

CONTENTS:-

1. Introduction to company 2. Company profile 2.1. Background of AB Electrolux 2.1.1. Details of shahjahanpur plant 3. Name of plant shops 3.1. Process Flow chart 4. Function of different departments 4.1. Production Department 4.2. Plant Engg. Department 4.3. Quality Assurance Department 4.4. Material Department 4.5. Design & Development Department 4.6. Manufacturing Engg. Department 4.7. HR Department 4.8. Commercial Department 4.9. Maintenance Department

Introduction of the Company


Electrolux Kelvinator Limited ,was established in the Electrolux Kelvinator Limited, India is a leading manufacturer and distributor of consumer white goods under the brands of Electrolux Kelvinator, Electrolux and Allwyn.With an annual turnover of over 1 billion Swedish Krona (SEK), they employ approximately 3700 people and the head office is located in Gurgaon, Haryana, India .The Company consists of five manufacturing plants in India. They are Shahjahanpur (Refrigerator Rajasthan State, Butibori (Washing Machine) and Warora (refrigerator) -maharashtra state and Nandalur (refrigerator) and Sanathnagar (Compressor) Andhra Pradesh State.The sales function operates through four business units (BU) located at Gurgaon (north BU), Pune (west BU), Calcutta (East BU) and Chennai (south BU). In addition, there are eighteen market units spread across all over India .They have a Electrolux Technical Center situated in Butibori about 30 Kms from Nagpur city (state of maharashtra).

COMPANY PROFILE
The company was incorporated as a public limited company in August 1989 and was originally promoted by Maharaja International Ltd. to produce washing machine, refrigerator, and dishwasher. It started its commercial production in March 1992 at Shahjahanpur in Distt. Alwar. In February 1995, the company became a 51% subsidiary of AB Electrolux of Sweden and at present AB Electrolux is holding a stake of 75% in the equity share capital of the company and the company affairs being managed by Electrolux Management.

Background of AB ELECTROLUX
AB Electrolux was formed in 1919 by the merger of LUX and

ELECTROMEKANISKA, AB of SWEDEN, AB Electrolux is a Multinational company registered in Stockholm, Sweden. It is one of the worlds leading manufacturers of Household Appliances operating in 60 countries and Employing 111,000 people worldwide. Its product range include Refrigerators, Washing machine, Vacuum cleaners, Microwave ovens, Airconditioners, Dishwashers, Lawn movers Garden Tractors, And Aluminum product for industrial Application etc. It owns several global brand names which Include ELECTROLUX, WHITE WESTINGHOUSE, FRIGDAIRE, KELVINATOR, EUREKA ZANUSSI, AMERICOLD AND AEG.

AB Electrolux is providing Electrolux Kelvinator Ltd. (EKL) the latest technology, developed and presently used in the Electrolux Groups European facilities. This technology is environment friendly and energy efficient. Maharaja International Ltd. was renamed to ELECTROLUX KELVINATOR Ltd. with effect from 8th Feb 1999. The company is at present engaged in the manufacturing of Domestic Refrigerators under famous brand name of KELVINATOR.

Details of Shahjahanpur Plant


The existing plant has a land covering an area of 81085 sq. meters and is free from Encumbrances and has a clear title. The companys existing Factory, Building includes total Refrigerator production facility, Utility Block, Stores, D&D with Auto-Cad Design Facility, Canteen and Administrative block and has a covered area of 27000 sq. meters. It employs approx.1000 persons. It manufactures 3 different models of domestic refrigerators (i.e.165, 175L single door, 195/210/220L single door and 315L double door. At present the company is producing approx. 4 lacks refrigerators per year. The Company is catering the needs of domestic and neighboring countries. The plant received ISO 9001 certificate in February 2000, by D.N.V, B.V. Netherlands for manufacturing and design of refrigerators.

Plant Profile

Home Slide

Shahjahanpur, Rajasthan Kelvinator Refrigerators History

Geographical Location

Production Flow Chart


Raw Materials

Freezer Section

Vacuum Forming

Press Shop

Paint shop

Pre -Assembly

Assembly

PU Foaming

Finished Goods

Testing
Home Slide

Today Electrolux - European market leader in white goods Worlds largest producer of floor-care products, absorption refrigerators, and compressors.

H is to ry A B E le c tro lu x - S w e d is h W h ite G o o d s G ia n t H e a d q u a rte re d a t S to c k h o lm 1 9 1 9 - AL u xm e rg e d w ith c tr o m e k a n is k fo rm B E le to a E le c tro lu x B e g a n w ith m o d e ls o f v a c u u m c le a n e rs . E x p a n d e d o u ts id e S w e Me n beyrs & A c q u is itio n s d e rg

Electrolux- The W orlds Number One Choice HOME A P R A C T IC E IT F O L L O W S E V E N T O D A Y

E le c tro lu- xT h e W o rld s N u m b e r O n e C h o ic e

HO M E

In te rn a tio n a l P ro d u c t L in
(2 0 0 0 )
R e frig e ra to rs V a c u u m c le a n e rs W a s h in g m a c h in e s C o o k e rs D is h w a s h e rs A ir c o n d itio n e rs L ig h t d u ty c h a in s a w s & g a rd e n e q u ip m e n t

CONSUMER CONSUMER DURABLES DURABLES

P R O F E S S IO N A L P R O F E S S IO N A L PRODUCTS PRODUCTS

F o o d s e rv ic e e q u ip m e n t V e n d in g S y s te m B a k in g & D y n a m ic p re p a ra tio n L a u n d ry S y s te m s C o m m e rc ia l re frig e ra tio n C h a in s a w s L a n d s c a p e m a in te n a n c e e q u ip m e n t

E le c tro lu- xT h e W o rld s N u m b e r O n e C h o ic e

HOME

C onsum er D urables
W hite goods
M arket leader in E urope,
third largest producer in the US

Floor-care products
W orld leader G lobal m arket share - 20%

Inventor of A bsorption R efrigerator

G arden Equipm ent W orlds largest producer


- law n m owers, garden tractors, law n trim m ers 10 m illion freezers & refrigerators m ade every year!!!

W orlds LAR G E ST producer of Com pressors Rangers/C ookers Vacuum cleaners


HOME

Electrolux The W orlds N um ber O ne C hoice -

Professional Products
Food service equipment
Market leader in Europe Worlds second largest producer

Laundry equipment
World leader in equipment for laundry rooms, hotels & institutions

Worlds Leading suppliers of Professional Kitchens

Leisure appliances World leader inabsorbtion


refrigerators for caravans & hotel rooms

Forestry equipment
Leading brands for professional chainsaws

Components
Worlds largest producers
of compressors

Electrolux- The Worlds Number One Choice

HOME

Organisation Structure - 2000

P C & o P m u

r e m b

s id u

&

n L i c e a g t ai o l n l i c A f f a i r s

C T

o a

n t r o l l i n g , A c T c r o e u a n s tu Oi n r yr g g x e s , A u d it in g , I T & M
C O N S U M
Oo s N P u A P

a a

n n
S

i s a t i o n a l D e v e l o a g e m e n t R e s o
I O N A L P R O D U C T

RP

AR

BO L F E E S S

W O

h it e G W o ho i d t e s G& o u t d o o rE Pu r r o o p d e u c & t N o r t h A m M e a r r i ck ae t s o o b e r t ME a C t so Oo kl a B

d u st d o o r F lo r eo wd u c t Ps r o t s i d e S N m o ra m e r ic a a lm H a n e n g t A n d e r

r c I a n r d e o o r P O r o u dt d u o c ot s r d u c t s & t lh l A p p l i a n c e s S tD r a e bt l ee rf g M B u e n n c g h t o Aw s s o n

r o d

u c t s

n d

e r s s o n

Electrolux - The Worlds Number One Choice

HOM E

Net Sales By Region - 2000


Annual Sales around Annual Sales around US $14.12 billion !!! US $14.12 billion !!!

North America 35.1% Africa 0.9%

Europe 52.8%

Asia 4.4%

55 million Electrolux Latin products sold America worldwide 5.9%

Oceania 0.9%

Electrolux - The Worlds Number One Choice Electrolux - The Global Appliance Company

HOME

Name of Plant Shops

Press shop Paint shop Vacuum forming shop Foaming area Pre-Assembly shop Final Assembly shop

Process Flow Chart

Production Flow Chart


Raw Materials

Freezer Section

Vacuum Forming

Press Shop

Paint shop

Pre -Assembly

Assembly

PU Foaming

Finished Goods

Testing
Home Slide

Function Of different departments

PRODUCTION DEPARTMENT 1. To plan for the monthly & yearly targets of quality production for the year. 2. To co-ordinate with Q.A, Purchase. Maintenance for achieving the targets. 3. To achieve the average demerit value as prescribed for the year 4. To reduce the scrap cost per refrigerator. 5. To reduce the material consumable cost as per the value prescribed for the year. 6. To increase the productivity. 7. To solve day to day problems in production in various shops. 8. To study the process for further improvement & modification for quality & productivity. 9. To educate the Engineers, Staffs & Workers about quality 10. To carry out preventive actions for the non-conformities.

PLANT ENGG. DEPARTMENT 1. Plan for optimum utilization of plant machinery to achieve production targets. 2. Preparation of maintenance budget. 3. Plan & execution of preventive maintenance schedule.

4. To study & improve the working environment & conditions for critical machines. 5. Spare parts planning procuring &in degeneration of critical imported spares.

6. Installation & erection of new machines. 7. Plan & execution of block shut down on annual basis. 8. Maintenance of utilities. 9. Average break down % of plant to be 4.5% for the year. 10.Plan & execute energy conservation in plant. 11.To liaison & co-ordinate with the functionaries of government i.e. Rajasthan State Electricity Board, RIICO, Pollution Control Board & other deptt. 12.To develop the concept of TPM (Total Preventive Maintenance).

QUALITY ASSURANCE DEPARTMENT 1. Process Monitoring through instruction with QA executives. 2. Documenting trends in quality. 3. Control of the non conforming products authorized for taking deviations. 4. Developing & implementation of plans for customer complaint resolution. 5. To reduce call rate. 6. Assessment of preliminary & on going process capability. 7. To reduce de merit value. 8. Monitoring inspection & testing at incoming, in-process & final stage.

9. Co-ordination calibration of equipment. 10.Co-ordination validation of inspection jigs & test status on product. 11.Providing inspection & test status on product. 12.To identity & implement statistical technical for process & product. 13.To verify the effectiveness of corrective & preventing actions.

MATERIALS DEPARTMENT 1. To identify the suitable vendors/suppliers for the procurement of BOM items, production consumables and indented items. 2. Preparation of procurement schedule against P O to different vendors based on monthly material plan. 3. To look after complete stores for the inventory and its proper storage accounting to take preventive measure in case of any shortage/excess. 4. To prepare dispatch schedule plan as per monthly corporate logistic indent to send finished goods at different branches /locations in India. 5. Liaison with private/union transport for in time dispatches 6. To ensure correct physical availability of material finish goods as per book balance. 7. To impart training to subordinate for the development purpose.

DESIGN & DEVELOPMENT DEPARTMENT 1. Design & Development of new products /models. 2. Modification /Upgradation for existing product design. 3. System design /Performance testing of refrigerator. 4. Control of drawing specifications document & release of ECN. 5. Prototype & model making for development /testing.

6. Process support to shop floor. 7. Up gradation of product quality.

MANUFACTURING ENGG. DEPARTMENT 1. To formulate capital budget & investment plan. 2. To identify machine capacity & man power planning. 3. Selection of equipment & identification of suppliers for capital equipment. 4. Procurement of Equipment & machines. 5. Installation & commissioning of new machines. 6. To design & provide material handling equipment for better productivity. 7. To design moulds & tools for optimum production at vendors end.

HR DEPARTMENT 1. To maintain smooth & cordial industrial relation. 2. Man power planning for & present requirement. 3. To co-ordinate performance Appraisal/Review exercise. 4. To organize for identification of training needs of both blue &White collar employees & preparation of Annual Training Calendar & implementation of the same. 5. Organize recruitment as per approved standard force both for staff as well as workmen.

6. To ensure all statutory obligations under the various provisions of the labor laws.

7. To ensure smooth functioning of all welfare activities. 8. Responsible for the implementation of quality systems with regard to training.

COMMERCIAL DEPARTMENT 1. Responsible for Finance, Accounts, Costing, Excise & Administrative control of IT operation. 2. Responsible for finalization of monthly reporting to corporate & Electrolux Corporate Office. 3. Responsible for finalization of annual accounts & tax audit. 4. Responsible for annual budget preparation, monitoring of budget & profit improvement plan. 5. Monthly variance analysis of budget & actual. 6. Handling excise & sales tax.

Maintainance deppt.
1.0 PURPOSE To establish and maintain a system for keeping all the machinery and equipment of plant in good working condition to ensure continuing process capability. 2.0 SCOPE Applicable to all plant machinery and equipment including utilities, electrical installations used in the plant. 3.0 DEFINITION FH (PE) Mnt. 4.0
4.1

: :

Functional Head (Plant Engineering) Maintenance

RESPONSIBILITY:

Functional Head (Plant Engg) is overall responsible for proper functioning of all the machines and equipment of the plant. Respective Incharge (Maintenance) for the activities assists him. Incharge (Mechanical Maintenance), Incharge (Electrical Maintenance) and Incharge (Utilities) are responsible for maintenance related to their area of activities.
4.2

Shift Incharge (maintenance) are responsible for maintenance during any particular shift.
4.3

Individual responsibilities for specific activities are given below in description.


4.4

Identify the key machines / equipments, which affect quality and to be covered under maintenance Maintain a List of the identified machines / equipments Decide the jobs / activities to be carried out and the frequency for the maintenance based on information given in machine manuals and/or previous history of Breakdowns. Discuss the same with respective Incharge(s) of Maintenance.

Decide the jobs / activities to be carried out and the frequency for the maintenance based on information given in machine manuals and/or previous history of Breakdowns. Discuss the same with respective Incharge(s) of Maintenance.

5.1.4 Based on the above, prepare Annual Maintenance Schedule for electrical, mechanical and utilities. 5.1.5 Ensure recording of various checks parameters of DG set, air compressors, thermopac, and RO plant in respective logbooks. The control parameters for each operation are as per specification sheets. 5.1.6 Maintain list checksheets for each category of machines and equipment. 5.1.7 Periodically examine Maintenance Schedule and inform the concerned Maintenance Crew for carrying out Preventive Maintenance activities as per relevant checklists. 5.1.8 Get Checklist from respective Incharge (Maint.) and carry out all activities as given in checklist. Technician Nil

5.1.10 If any of the maintenance activities are not carried out as per schedule / checklist, enter the details in maintenance log book/ utilities logbook for inclusion next time. 5.1.10.1 Review the maintenance log book and make necessary arrangement for rescheduling the maintenance activities at next available opportunity. Monitor them for accomplishment. 5.1.11 In case any major replacement / repairs are carried out, enter the details in Machine History Card 5.1.11.1 Review the machine history card once in every six months. If required, change the preventive maintenance frequency and inform respective Incharge (Mnt.) accordingly.

5.2 Predictive Maintenance 5.2.1 Take a round of the plant daily in the General Shift and examine the condition of machines / Equipments. 5.2.2 Inform the abnormality observed if any to concerned Section Incharge and request for sparing the machine for needful 5.2.3 In case the machine can not be spared due to urgency of production but the same can work, record the observations in maintenance log book/utilities log book. -doL01-0910 L02-0910

5.3 Breakdown Maintenance In order to attend the breakdowns in most effective manner & in the shortest possible time the following procedure is adopted. 5.3.1 On receipt of complaint (by verbal / written) from user deptt. Depute technician for carrying out necessary repairs 5.3.2 Identify the nature of defects & arrange repair. 5.3.3 In case of problems beyond control consult shift incharge / Engineer & arrange repair / rectification as directed. 5.3.4 When ever required, procure materials from stores by raising demand & issue slip after getting authorization from shift incharge. 5.3.5 In case of low / no stock raise Purchase Requisition whenever required. 5.3.6 In case the machinery / equipment is to be sent outside the factory for repairs put up the requisition for out going material after authorization from FH (PE).

After completion of repairs and satisfactory operation enter details in maintenance / utilities log book.

5.3.8 Maintain a list of essential spare parts with minimum stock level required for smooth operation. List Authorized by FH (PE) 5.3.9 Interact with maintenance purchase Incharge & maintenance store Incharge to ensure the availability of minimum stock as required. 5.4.2 Compile machine Breakdown time for the month of all area of activities including Breakdown Analysis (i.e. causes). 5.4.3 Discuss the Machine Breakdown Trend Chart in Management Review Meetings and take suitable corrective measures to meet as well as improve upon the laid down objectives. 5.4.4 Submit Monthly Utility Report to management about generation and consumption of energy and fuels. 5.4.5 Submit maintenance overtime report to the management about manpower utilization.

Scope of Study
Study of PLC System at Electrolux, Various Frequency Drives use and their programming, Power Supply, SCADA Package for MIMIC programs used for data transfer to PLC, Communication and Networking of PLC. Following PLC Systems study in respect to their Operating Software, Hardware, and Programming of Small PLC Logic and necessary modification in existing Programs along with trouble shooting in PLC System Siemens PLC with S5 Series Seimens S7 (Micro Series) PLC Series Siemens S7 (Modular Series) PLC series Along with PLC system study of Various Frequency Drive i.e. Micro Master Inverters with following scope of Study Introduction of Frequency Drives Hardware Programming of Frequency drives as per requirement Function and Operation of Frequency drives Application Type of Frequency of Frequency Drives Siemens Micro Master from 0.5 HP to 3.0 HP Siemens Micro Master Vector Drive 3.0 HP Omron Inverter 0.5 HP Power Supply

Brief Description of PLC

Introduction PLC

PLC refers to programmable logic control as the name suggests it is a computer used to control different operations of a machine to which it has been connected. The different operations to be performed are judged in sequence by the PLC as per the prog installed in the PLC PLC generally consists of a CPU, input and output ports. A CPU is of 2 type -: With an i/o device Without an i/o device Different hardware is connected to the PLC so as to handle different operations of the machine which it has been connected. Use of the PLC

PLC is used -: 1) To control different functions done by the machine 2) To provide protection to the people working manually on the machine and to the machin case of some power failure or some cases of short circuit also. 3) To operate the machine automatically.

A program is fed to the PLC to make machines operate as per the requirement for the diffe operations of the machines. Type & make of PLC Different companies which manufacture PLC wchich are generally used are SEIMENS OMRON

ALLEN BRADLEY PLC are manufactured by the SEIMENS in 2 version they are -:

S5 S7 Further S7 has 2 versions -: 200 (Micro Series) 300 (Modular Series) Depending on the number of the input modules connected to the PLC The languages been used LAD-ladder Cascade Statement Function CSF STL statement line We have interfacing of the plc to the pc or vice versa through different modes TTY-text to text interface (interface between single pc to single plc) PPI- point to point interface (connections of different pc to a number of plc) MPI-multiple point interface (connection of number of plc to more than one plc)

Project on S5 Series PLC


At Electrolux one of machine named as MARISTED-1 Used to Cabinet Foaming for Refrigerators having S5 Series PLC used for the Automatic control of the machine.

This machine program required to be modified to avoid accident in machine because of malfunctioning of Input devices (Limit Switches) and to ensure smooth trouble free operation of Machine Machine PLC Details MRSDT1 Power Supply-AC 230V/115V DC 24V 2A SIEMENS S5-100U CPU 103 DI 8X24V DC- 10 in no. DO 8X115/230V AC /0.5 A 10 in no.

Problem
During the transfer of Foamed cabinet fixture from foaming station to inside carriage Insider carriage should be in backward position. But sometimes when this carriage is at forward position and because of Foam or otherwise Limit Switch might got stuck-up in backward position, It will give false input to PLC and both Inputs of Carriage forward & Backward will be available to PLC. This causes fixture transfer without carriage and causes damage to cylinders and major Accident occurs

Introduction of S7 (Micro Series) PLC


The S7-series is a line of micro-programmable logic controllers (micro PLCs) that can control a variety of automation applications. Its a compact design, expandability, low cost and powerful instruction set make the S7-200 controllers a perfect solution for controlling many applications In addition, the wide variety of CPU sizes and voltages provide you with the flexibility you need to solve your automation problems. The S7-212/213/214/215/216 CPUs combine a central processing unit (CPU), power supply, and discrete I/O points into a compact, stand alone device. The CPU executes the program and stores the data for controlling

the automation task or process. The power supply provides electrical power for the base unit and for any expansion module that is connected. The inputs and the outputs are the system control points: the input monitors the signals from the field devices (such as sensors and switches), and the outputs control pumps, motors, or other devices in your process. The communication port allows you to connect the CPU to a programming device or to other devices. Status lights are been provided to provide visual information about the CPU mode (RUN or STOP), the current state of the local I/O, and whether a system fault has been detected. The S7 Micro Series programming software offers powerful programming and debugging tools which make you more effective and this means cost savings. We use the programming in the same manner as the Windows applications User programs are written using simply mouse clicks, tool bars, or simply drag & drop operations .It have the following properties: -

4 or 6 independent hardware counters at the rate of 30 kHz each for interfacing to incremental encoders or high-speed pulse trains. 4 independent interrupt input with 0.2ms input filter times to adjust reaction times for maximum process response. 2 high speed pulse outputs at the rate of 20khz each either pulse width modulation or pulse train output , e.g. for control of stepper motor , drives or temperature . High-speed analog inputs signal conversion with 25micro seconds, 12 bit resolution.

Real time clock. 2 timed interrupts (adjustable from 1ms in intervals of 1 ms) for precise control of processes that change over time.

EEPROM CARTRIDGE A small optional EEPROM cartridge saves significant time and money. We can use it easily copy, update or replace your applications program on your S7-200 CPU. And if required, one can mail a program rapidly and at a low cost, using the cartridge. Simply turn off the power and the user program is updated in a flash.

BATTERY CARTRIDGE To guarantee that applications data are never lost , the optional battery module permits long term backup for typically 200 days beyond the internal backup of 5 days . REAL TIME CLOCK Whether we require it to count operating hours, preheat rooms or provide time stamps for messages; the real time clock of the S7-200 is software controlled to provide exact seconds and dates even taking leap years into account. ANALOG POTENTIOMETERS

With the S7 200 s analog potentiometers we can optimize our process by means of a screwdriver. We can set memory values, timer values, counter presets or other variables without

Work Study On Siemens S7 (200) Series PLC

Introduction of Siemens S7 (Modular Series) PLC


Siemens has introduced a mini PLC in the PLC family. It is an ideal choice when the job calls for something fast and powerful. It has a program memory for up to 16k statements, 1024 digital inputs and outputs and an MPI interface for programming devices and operator panels. The speed of the PLC of CPU, the most powerful one is 0.3ms to process 1024 binary statements It holds an incredible 256 digital i/os in addition to the CPU. Every module has 16/32 isolated channels. The S7-300 needs a 24v DC power supply. This is provided by load current supply modules, which convert the 120/230v AC line voltage to the 24v DC operating voltage. The S7-300 series is the is an advance version of the S5 series .The additions have been made to the programming languages Statement List, Ladder Diagram and Functional block Diagram. The instruction set can be used in all blocks and in all programming languages.

S7-300 has central data storage and a perfectly matched suite of individual functions. This means that we need to enter only the data once, at a single user interface. And we can use the same functions for every task. From configuring and programming to startup and documentation. We can write the program in any language and switch from one to another as we want.

S7-300 consists of the following components-: 1. Power Supply (PS) 2. Central Processing Unit(CPU) 3. Signal Modules(SM) 4. Function Modules(FM) 5. Communication Processor (CP) Power Supply (PS): It converts line voltage (230 V ac/115V ac) into 24v dc which provide power to S7-300 it is switching mode power supply Central processing unit (CPU): It has a central processing unit CPU which takes merely .3ms to process 1024 binary statements and it is equally good at word oriented processing .The system include a number of CPUs FOR different performance requirements. CPU executes the user program provides the 5V supply for the 5v supply for the S7-300 back plane bus. It communicates with other modes by MPI (multi point interface). Communication Processor (CP): It means how to interface PLC to PC or PC to PLC. We also interface other devices to PLC. We can interface it by three ways 1. MPI

2. PPI 3. TTY In S7-300 we use MPI for interfacing. In communication process we use two types of connector: 1. RS485 PLC) 2. RS232 (PC) Every module has 16/32 channels; it can be increased till 250 digital I/O

INVERTER(Frequency drive) Inverter is a frequency drive used to invert the A.C. to D.C. and control the rpm of AC motors by variable frequency. The drive converts the phase from single phase to three phase if the power supplied is in single phase . These inverters are microprocessor controlled A special pulse width modulation with selectable pulse frequency permits extremely quiet motor operation. Microprocessor is available for reliable and flexible control. Remote control capability is also used to control inverters. It has a built in non-volatile memory for storing parameter settings. Output frequency can be controlled by one of the five methods -: Digital frequency setpoint Analogue setpoint Potentiometer Fixed frequency Remote data transmission The inverter has a built in dc injection brake which stops the motor by applying a DC current, this causes heat to be generated in the motor rather than the inverter and holds the shaft stationary until the end of the braking period. Braking is effective for the period of time set. But the frequent use of long periods of DC injection braking can cause the motor to overheat. Automatic load compensation is done by flux current control. The Power supply is supplied in single phase or in three phases and has an output always in three phases, so a 4 core wire is used for connection.

. Following are the specifications of the inverter -: Input frequency 47 Hz to 63 Hz Power factor - >=0.7 Output frequency 0 Hz to 650 Hz Resolution 0.1 Overload capacity 150% for 60 s, related to nominal current Protection against inverter overtemperature Motor overtemperature Overvoltage and undervoltage Additional protection Against short circuit and earth/ ground faults pullout protection Protection against running with no load. Regulation and control FCC (flux current control) voltage /frequency curve Ramp times-0-650s Invert efficiency 97% Operating temperature 0 c to +40c Parameters can be changed and set using the membrane-type buttons to adjust the desired properties -: ParameterP000 Its function is to operate the display. This displays the output selected in P001 .In the event of a faliure the relevant error message is displayed .In the event of a warning the display flashes .If output frequency has ben selected (P001=0) the display alters between the selected frequency and the actual frequency. P001 Its function is to display selection .0-7 Numbers are used for display selection 0-output frequency 1-speed at which inverter is set 2-motor current 3- DC-link voltage 4- motor torque

5-Motor rpm 6-uss status 7-closed loop display mode P002 Ramp up time is the function done by this parameter, which is the time taken by the motor to reach the maximum frequency from the standstill condition, Its range is from 0-650 sec.

P003 Ramp down time, it is the time taken to decelerate from maximum speed to minimum standstill position. P004 Its function is to smooth the acceleration /deceleration of the motor. P005 Digital frequency set point 0-650.00 P006 Frequency set point type selection 0-2 0- digital 1- 1-analogue 2- fixed frequency or motor potentiometer P007 Enable /disable front panel buttons 0-1 0-run, jog and reverse are disabled 1-front panel buttons can be selected P009 Parameter protection setting 0-3

0- only parameters from P001 P009 can be read / set 1- all the parameters can be read and P001-P009 can be set 2- all the parameters can be read /set but P009 is automatically set to zero when power is removed 3- all can be read/set

P010 Display scaling

P011 Frequency setpoint memory 0-1 0-disable 1-enable after switch off P012 Minimum motor frequency 0-650 P013 Maximum motor frequency 0-650 P015 Automatic restart 0-1 0-disable 1- automatic restart P016 Start on the fly 0-4 Allows the inverter to start on to a spinning motor, to avoid overcurrent trip. P017

Smoothing type 1-2 1- continuous smoothing 2- discontinuous smoothing

P018 Automatic restart after fault P021 Minimum analogue frequency 0-650 P022 Maximum analogue frequency 0-650 P023 Analogue input type P024 Analogue setpoint addition P025 Analogue output P031 Jog frequency right (Hz) P032 Jog frequency left (Hz) P033 Jog ramp up time P034 Jog ramp down time P041

1st fixed frequency

P042 2nd fixed frequency P043 3rd fixed frequency P044 4rth fixed frequency P045 Inversion fixed setpoints for fixed frequencies P046 5th fixed frquency P047 6th fixed frequency P048 7th fixed frequency P049 8th fixed frequency P050 Inversion fixed setpoints for fixed frequencies P051 Selection control function , DIN1 P052 Selection control function , DIN2

P053 Selection control frequency,DIN3 P054 Selection control function , DIN4 P055 Selection control function , DIN5 P061 Selection relay output RL1 P062 Selection relay output RL2 P063 External brake release delay P064 External brake stopping time P065 Current threshold for relay P070 Braking resistor duty cycle P071 Slip compensation P072 Slip limit P073 DC injection braking

P074 Motor derating curve as temperature protection P075 Braking resistance P076 Pulse frequency P077 Control mode P078 Continuous boost P079 Starting boost P081 Nominal frequency for motor P082 Nominal speed for motor P083 Nominal current for motor (A) P084 Nominal voltage for motor (V) P085 Nominal power for motor (kW) P086 Motor current limit

P087

Motor PTC enable P088 Automatic calibration P089 Stator resistance P091 Slave address P092 Baud rate P093 Time out P094 Serial link nominal system setpoint P095 USS compatibility P101 Operation for Europe or USA P111 Inverter power rating (kW/hp) P121 Enable /disable RUN button P122 Enable/disable FORWARD/REVERSE button

P123 Enable /disable JOG button

P124 Enable /disable P131 Frequency setpoint P132 Motor current P133 Motor torque P134 DC link voltage P135 Motor RPM P201 Closed loop mode P201 Proportional gain P203 Integral gain P204 Derivative gain P205 Sample interval (x25ms)

P206 Sensor filtering P207 Sensor reading

P211 0% setpoint P212 100% setpoint Minimum frequency mode P720 Special input /output functions P721 Analogue input voltage P722 Analogue output current P723 State of digital inputs P724 Relay output control P910 Local/Remote mode P922 Software version P923 Equipment system number P930 Most recent fault code P931 Most recent warning type P944

Reset to factory default settings P971 EEPROM storage control

You might also like