ELECTRICAL ENGINEERING

ELECTRICAL INSTALLATIONS
ELECTRONICALLY CONTROLLED
INDUSTRIAL SYSTEMS
Panel mod. C-IID/EV

The applications of this panel are optimized when it is used together with
the panel for testing industrial installations in wired logic mod. C-IIC/EV

PLC 1214 & HMI KTP700 Basic

Inverter VFS-15
Soft Starter ADXC

TEACHER /STUDENT handbook

© COPYRIGHT BY ELETTRONICA VENETA

CIID$$$301E0
 CONTENTS

CONTENTS

Safety standards ............................................................................................................... page 1

Introduction .................................................................................................................... page 3

Description of the panel .................................................................................................. page 4

Presence, asymmetry and sequence phase relay ............................................................. page 5

Soft starter ...................................................................................................................... page 7

Inverter for three-phase asynchronous motor ................................................................ page 10

PLC and Operator Panel (Touch panel) ........................................................................ page 14

Safety warnings in control circuit of machines ............................................................. page 18

Identification codes ....................................................................................................... page 19

Exercise 1: System for powering three-phase power consuming devices with

presence asymmetry and sequence phase relay.............................................................. page 26

Exercise 2: Controlling a three-phase asynchronous motor by PWM inverter,

V/f – vector control, acceleration and braking ramps ................................................... page 33

Exercise 3: Controlling a three-phase asynchronous motor by PWM inverter, with

selection of direction of rotation, control of RMP with voltage of 0-10 Vdc ............... page 39

Exercise 4: Gradual start-stop of a three-phase asynchronous motor by soft starter ..... page 45

Exercise 5: Connections and configuration of PLC and of HMI in Profinet ............... page 48

Exercise 6: Start-stop control of a motor by PLC and HMI panel ................................. page 88

Exercise 7: Pulse / start-stop control of a motor by PLC and HMI panel ..................... page 96

Exercise 8: Separate control of two motors by PLC and HMI..................................... page 104

Exercise 9: Reversing contactor for three-phase asynchronous motor controlled by

PLC and HMI panel .................................................................................................... page 112

Exercise 10: Reversing contactor for three-phase asynchronous motor with limit
switches, control by PLC and HMI panel .................................................................... page 121

Exercise 11: Star-delta starting by PLC and HMI panel .............................................. page 130
CONTENTS

Exercise 12: Starting via stator resistors controlled by PLC and HMI panel .............. page 139

Exercise 13: Starting a TAM by autotransformer, sequence control by PLC and

HMI panel ................................................................................................................ page 148

Exercise 14: Starting via rotor resistors by steps, control by PLC and HMI panel .... page 157

Exercise 15: Remote pole changing switch for single-winding (Dahlander) motors,
controlled by PLC and HMI panel ............................................................................... page 167

Exercise 16: Reverse current braking of a three-phase asynchronous motor,

Controlled by PLC and HMI panel .............................................................................. page 176

Exercise 17: Sequential start of motors controlled by PLC and HMI panel ................ page 185

Exercise 18: Controlling a three-phase asynchronous motor by PWM inverter,

PLC and HMI, for forward-reverse sequences and different speeds .......................... page 195

Setting panel mod. C-IID/EV at work ........................................................................... page 204

Appendix A - Lay-out of panel mod. C-IID/EV .......................................................... page 206

Appendix B – Meanings of variables and diagram of PLC and HMI ........................... page 210

As regards the design, transfer of program, setting at work of PLC and of the operator panel,
consider also what indicated in the respective original hardware and software handbooks of
the manufacturer.
 SAFETY STANDARDS

SAFETY STANDARDS

The directions of this handbook must be read carefully as they supply important
indications on the safety of installation, use and maintenance.

Keep this handbook for any further reference.

This operational handbook describes the operation of the panels for testing industrial electric
systems mainly used in buildings of industrial use and generally in premises of production
activities.
As regards the characteristics and operation of the devices and the necessary connections for
their operation, refer to this handbook.

UNPACKING
After the packaging has been removed, set all accessories so that they are not lost and check
the equipment integrity. In particular, check that the equipment and its accessories are integral
and they show no visible damage

Before connecting the equipment with the mains, make sure that the rating corresponds to that
of the mains (the rated value of the supply voltage is indicated on the apparatuses).

Power cords must be set so that they cannot be trodden upon nor squeezed by objects. In case
of incompatibility between the outlets and the plugs of the apparatuses, the outlets must be
changed with the suitable ones by highly qualified personnel. These engineers must check that
the cable sections of outlets are sized according to the power absorbed by the apparatuses.
The use of adapters or multiple outlets is not recommended; when these are used they must
comply with the safety regulations in force.

On the equipment, sometimes there are some slots or opening for ventilation; they must not be
blocked nor covered to ensure a reliable operation and to protect the apparatuses from
overheating.

Never set these panels on unstable trolleys, supports, tripods, brackets or tables. They could
fall causing injuries to the collided persons, or they can damage themselves. Any installation
of these apparatuses must follow the manufacturer’s directions and it must be carried out with
recommended accessories.

These apparatuses must be employed only for the use they have been conceived, i.e. as
educational equipment, and they must be used under the direct supervision of expert
personnel. Any other use is illegitimate and therefore dangerous.

The manufacturer cannot be held responsible for any damages due to illegitimate,
wrong or unreasonable uses.

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SAFETY STANDARDS

PRECAUTIONS!
In order to safeguard the operator’s safety and the good operation of the apparatuses, the use
of electrical equipment requires the compliance with some fundamental rules. In particular the
following standards of use must be complied with:

Ambient temperature: from 0 to 45C.

Relative humidity: from 20 to 80 %.
Avoid any sudden shift of temperature and humidity.
These apparatuses must be used in a place without or distant from: dust, humidity, high heat,
objects radiating heat, objects producing a strong magnetic field (HI-FI loudspeakers, etc…),
liquids or corrosive substances.

Power supply: refer to what specified on each panel

Fuses: only those indicated in the corresponding electrical diagrams.

To prevent contact with electrical parts, do not open the apparatuses; in case of need, only
qualified personnel can do it. Before carrying out any maintenance operation, disconnect the
panels from the mains.
In case of fault and/or malfunction, switch the apparatuses off immediately and do not tamper
with them. In case of repairs, refer to the after-sales service or request exclusively original
spare parts. If these conditions are not respected, the apparatuses can be jeopardized.
All the necessary connections for the exercises must be carried out with equipment off and via
proper cables with safety plugs of 4 mm.
In case the protection fuses have to be changed, first of all remove the power cord from the
mains outlet.
In case of penetration of objects or liquids inside the apparatuses, disconnect the power cord
and have them checked by qualified personnel before using again.
CLEANING THE APPARATUSES
Use a soft and dry cloth to clean the cases and the schematic diagrams. Never use pesticides
nor chemical products or solvents for cleaning.

VIBRATIONS OR COLLISIONS
Be careful not to cause vibrations or collisions.

These apparatuses and all their parts will be disposed of separately from
the other wastes. At the end of their lifetime, these apparatuses will be
conveyed to the proper centres of separate collection of waste.
A proper separate collection ensures that the eliminated apparatuses
will undergo the necessary treatment and recycling for preventing any
negative effect on the environment and on men’s health.
Illegal disposal of the product by the user involves the application of
administrative sanctions referred to Italy, in D.Lgs. no. N. 152/2006 art.
255 and 256, as amended; and directive 2008/98/EC of the european
parliament and of the council of 19 November 2008.
For states outside the European Union comply with local law.

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 INTRODUCTION

Introduction

Automation process has undergone a deep evolution in industrial

buildings since the 70s of the last century and now it extends
gradually to the sector of services, office and shops, and it is also
spread in the sector of civil buildings. At present the growing
complexity and the high number of technological systems included
in facilities require an efficient control as automatic as possible,
for a safe and rational management of energy resources.

Companies have integrated their automation and organization

sectors with powerful data storage equipment to improve
efficiency and productivity and to attain a target of flexible
production also matching market variability.

Assembling electromechanical components controlled by

electronic circuits enables to construct small automation systems
for the needs of a specific machine; these components perform
some specific functions; examples of these components are: relays
for controlling sequence and symmetry of supply voltage,
programmable sequence control relays, gradual motor starting and
stopping devices, panels for the indication of the operational state
of a machine with messages of normal operation, alarm states,
etc...
On the contrary assembling some components with specific
functions, coordinated and controlled by Programmable Logic
Controller (PLC) units enables to construct big automation
systems allowing to carry out the so-called Computer Integrated
Manufacturing (CIM). PLCs can be considered as intermediate
devices in the operating process: actually they are the interface
between the machine (and consequently the process) and the
planning environment with general control.

The components installed in the testing panel, designed for

industrial automation systems and controlled electronically, are
devices with a high content of electronics or of microelectronics
which perform functions of specific automation. The educational
target is just the possibility of assembling and testing the
installations that include these devices controlled electronically,
besides the traditional industrial installations. And the aim is to
understand the utility and enrichment of functions they can carry
out.

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DESCRIPTION OF THE PANEL

PANEL mod. C-IID/EV

Fig. 1 - Panel for testing electrical industrial installations controlled electronically.

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 DESCRIPTION OF THE PANEL

3-PH SWITCH (Q9)

Three-pole switch / circuit breaker - In=16 A Un= 400 V (AC1).
This switch can be used for the control / breaking of a three-phase or
single-phase power-consuming device, when this is directly connected
manually.

Fig. 2 – Three-pole switch – circuit breaker.

1–3-5 Power terminals of three-phase line 3 x 400 V.

2–4-6 Line output terminals
The two warning lights signal that some voltage is available across the
output terminals.

PRESENCE, ASYMMETRY and SEQUENCE FAILURE PHASE RELAY (K4)

This relay will determine the right sequence of phases, the total or
partial failure of a phase and asymmetry of the three voltages
L1 – L2 – L3 are the leading terminals of the three-phase line 3 x 400
Vac having to be checked.
NO – COM – NC are the output terminals of the alarm relay (relay
with potential free exchange contacts of 250 Vac - 10 A).
A trimmer (Asymmetry ) available on the fore part of the relay
enables the percent adjustment of asymmetry allowed in the three-
phase line, within the range of 5…15 % Ue; it is reset automatically as
soon as the asymmetry value drops three points below the set point.
Then another trimmer (Reset) enables to adjust the reset time from 0.1
s to 30 s.
Alarm relay works in positive safety: relay energized with powered
device and correct line conditions; a wrong sequence, the failure of a
phase and an asymmetry of voltages higher than the set percentage
extending beyond the delay time will lead to release the alarm relay.

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DESCRIPTION OF THE PANEL

Fig. 3 - Presence, asymmetry and phase sequence relay.

L1-L2-L3 Power terminals of three-phase line 3 x 400 V

COM Common terminal of output relay
NC Terminal of the normally closed contact of output relay
NO Terminal of the normally open contact of output relay
Green LED: the green LED on indicates that the relay is powered and
everything is OK, the three phases are available, the
sequence is correct and the asymmetry is lower than the
adjusted percentage; the output relay is active
Green LED the green and red LEDs are flashing alternately:
Red LED that indicates that the phase sequence is wrong; the
output relay is deenergized instantaneously

Green LED: when flashing the green LED signals that a phase is
missing or that a phase has dropped below 30 % of Ue;
the output relay is deenergized instantaneously

Red LED when flashing the red LED signals that the symmetry of
the three voltages is not within the limits set by the
corresponding trimmer. If this asymmetry continues over
the set time, the output relay is deenergized and the LED
is kept on, but it stops flashing.

When the voltages, the phase sequence and the asymmetry are again
within the set limits, the red LED goes out and the green LED starts
flashing for the time assigned by trimmer Reset; after this time, the
output relay will trip, the green LED is kept on, but it stops flashing.
Caution ! This device works in positive safety; as it is shown in the
schematic diagram, the state of relay contacts changes when the relay
is powered with the three phases in right sequence and asymmetry
within the adjusted value.

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 DESCRIPTION OF THE PANEL

SOFT STARTER (T1)

Device for soft start and stop of three-phase asynchronous squirrel-
cage motor; main characteristics:
– built-in by-pass relay for the total exclusion of semiconductors
– maximum voltage rating: 400 Vac - 50 Hz
– rated current: 12 A.
– start/stop input: 24 Vac/dc
– control of acceleration/deceleration with voltage ramp on 2 phases
– setting the acceleration time: 1...20 seconds
– setting the deceleration time: 0...20 seconds
– setting the starting torque: 0...85 %.
– three LEDs of state indication.
The electric system must include a switch or circuit breaker. It must
be connected very near the device and it must easily be reached by the
operator. It must be marked as breaker of the equipment: IEC/EN
61010-1 § 6.11.2.1.
The by-pass relays of the main circuit can be in a undefined state
because of transport. Therefore, first of all it is better to carry out a
cycle when the motor is not connected yet, to reset the by-pass relay
correctly. Otherwise the motor could carry out a false start.

Fig. 4 – Static soft starter for three-phase asynchronous squirrel-cage

motors.

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DESCRIPTION OF THE PANEL

L1-L2-L3 (3x400 V POWER SUPPLY) Input terminals of

supply voltage
PE Terminals for connecting the earth conductor from the
power line to the motor
U/T1-V/T2-W/T3 Output terminals of the device for a three-phase
asynchronous motor with voltage of 400 V and
power up to 0,75 kW.
COMMON INPUT Common terminal for the input of control signal
24 V~/= Input terminal for the starting signal with voltage
ranging between 24 V. The starting voltage can be
either in alternating current and in direct current

Fig. 5 – Adjustment performed on static soft starter.

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 DESCRIPTION OF THE PANEL

Fig. 6 – Wiring diagram of the static soft starter.

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DESCRIPTION OF THE PANEL

3-PH MOTOR PWM DRIVE (T2)

 Drive for three-phase asynchronous squirrel-cage motor; main
characteristics:
 PWM sine-wave control adjustable in the range of 2.0 to 16.0 Hz
(default: 12 kHz)
 Voltage/frequency characteristics: constant V/f, variable couple,
automatic couple increase, vector control, automatic energy saving,
dynamic control, PM control of motor
 Output frequency from 0.5 to 500.0 Hz, default setting: from 0.5 a
80 Hz,
 Frequency references, potentiometer on fore panel, input from
external potentiometer (1–10 kΩ), 0…10 Vdc (input impedance:
VIA/VIB=30 kΩ)
 Three frequencies can be set from 0 up to the maximum threshold
frequency
 Main control functions, PID control, setting proportional gain,
integral gain, differential gain and control waiting time.
 Acceleration/deceleration times: from 0.0 to 3200 s.
 Direct-current braking, regenerative braking, integrated braking
chopper, (optional) external braking.
 (Programmable) input terminals: selection among 66 functions
 (Programmable) output terminals: 58 functions that will be
assigned to the output terminals of relay FLA-FLB-FLC and RY-
RC, or to OUT-NO open collector output
 Run/Stop via RUN and STOP buttons on the fore panel, switching
forward/reverse run from inputs in terminal board
 Automatic alarm reset: if line voltage were missing temporarily, the
inverter is able to keep all its functions active by using the
regenerative energy of the motor
 Drop function: when two or more inverters are used to control two
motors having the same load, this function prevents the load from
concentrating on one of the two motors for an unbalance
 Functions for preventing motor from stalling, overload protection
with electronic thermal function, protection against output short
circuit, protection from overvoltage, minimum voltage, accidental
earth fault, output phase failure
 Historical alarm inventory where the data on the four last alarms
are stored
 Display of free unit: arbitrary unit (e.g. r.p.m.) corresponding to
output frequency.

Further characteristics are described in the electronic operational

handbook (CD) supplied together with drive.

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 DESCRIPTION OF THE PANEL

Fig. 7 – Three-phase INVERTER 400 V – 0,75 kW, power and auxiliary connections.

Fig. 8 - Three-phase INVERTER 400 V – 0,75 kW.

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DESCRIPTION OF THE PANEL

Fig. 9 - Diagram of the electric connections of the INVERTER included in the panel.

L1-L2-L3 (3x400 V POWER SUPPLY) Terminals for powering

the inverter.

PE Terminals for connecting the earth conductor from the

power line to the motor under test

U1-V1-W1 (for a motor with voltage of 400 V) Output terminals of

inverter for three-phase asynchronous motor of 0.75 kW

ALARM OUTPUT Exchange contacts of the relay for signalling

inverter in alarm.

RESET it resets the inverter after an alarm condition; it resets the

state of the contacts of alarm relay

CC Common terminal of input circuits with voltage of 0 Vdc

P24 Common terminal of input circuits with positive voltage of

24 Vdc

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 DESCRIPTION OF THE PANEL

PP Terminal (OUTPUT B) with voltage 10 Vdc -10 mA max.

for powering any external potentiometer for the control of
the frequency output by the inverter

VIA Input terminal (INPUT A) for voltage of 0-10 Vdc or for

current of 4-20 mA of inverter control

VIB Input terminal (INPUT B) for voltage of 0-10 Vdc of

inverter control

F Terminal (FORWARD) for enabling forward run

R Terminal (REVERSE) for enabling reverse run

S1 Input terminal with programmable functions (for instance,

setting the first r.p.m. value). Input enabling contact must
be referred to terminal P24.

S2 Input terminal with programmable functions (for instance,

setting the second r.p.m. value). Input enabling contact
must be referred to terminal P24.

S3 Input terminal with programmable functions (for instance,

setting the third r.p.m. value). Input enabling contact must
be referred to terminal P24.

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DESCRIPTION OF THE PANEL

PROGRAMMABLE LOGIC CONTROL PLC (K3)

PLC Siemens S7 1200 CPU 1214 C with:
14 digital inputs of 24 Vdc six of which at high frequency (100 kHz),
2 analog inputs 0…10 Vdc,
10 digital transistor outputs of 24 Vdc 0,5 A, including relay interface
with potential free contacts of 10 A,
1 analog output 0…10 Vdc

Fig. 10 - PLC S7 1200 with 14 DI, 10 DO, 2 AI, 1 AO.

When using the outputs with fast processes, the switch OUTPUTS RELAYS OFF enables to
deenergize the coils of the relays connected with the same outputs.

Fig. 11 – Diagram of the electrical connection of the PLC included in the panel.

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 DESCRIPTION OF THE PANEL

24 V= Input terminals of the supply voltage of 24 Vdc. The supply

voltage is output by the regulated power supply unit (OUT 24
V= - 3 A).

I0.0…1.5 Terminals of PLC digital inputs (24 Vdc). The common

terminal for these inputs is the terminal +24 V=

AI0…1 Terminals of PLC analog inputs (0…10 Vdc). The

reference terminal of the voltage across the analog inputs
is the terminal -

Q0.0…1.1 Terminals of PLC digital outputs of 24 Vdc – 0.5 A. Note:

besides the transistor outputs, some potential free contacts
are available for each output.
The relays used in this PLC have an operating voltage of
250 V~ / 24 V= and a maximum current of 10 A

AQ0 Terminal of PLC analog output (0…10 Vdc). The

reference terminal of the voltage across the analog output
is still the terminal -

TOUCH PANEL (P5)

Operator panel - HMI touch screen with 8 function keys, Liquid
Crystal Display LCD-TFT of 7” - 65536 colours.

Fig. 12 – Operator panel with function keys.

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DESCRIPTION OF THE PANEL

Fig. 13 – Terminals for the supply voltage of 24 Vdc powering the

operator panel, and LAN connector for the connection with PLC

24 V= Input terminals of the supply voltage of 24 Vdc

LAN RJ45 connector for the connection with the SWITCH, via
patch cables, to assemble the network PLC – Operator
panel - PC.

Fig. 14 - Terminals for the supply voltage of 24 Vdc powering the

SWITCH for networking PLC, Touch Panel and PC in Profinet (LAN).

24 V= Input terminals of the supply voltage of 24 Vdc

P1…4 RJ45 connector for networking PLC, T. P. and PC. via
patch cables

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 DESCRIPTION OF THE PANEL

Simulator of analog and digital states

Fig. 15 - Simulator for analog and digital signals.

2 Outputs 0…10 V= Voltage adjustable with continuity between 0

and 10 Vdc by potentiometer. As regards the
operation of analog outputs, enable output OUT
24 V=. The terminal -0V is the common
reference of the two analog outputs, and it is the
same of the power supply unit described here
below.
3 selectors Two-way selector with central zero, provided with
potential free contacts for generating ON/OFF variables
for PLC and sending commands to the soft starter or to
the inverter.

Power supply unit of 24 Vdc – 3 A, input 120…230 Vac

Fig. 16 – Power supply unit of 24 Vdc.

AUX LINE Connector for auxiliary power supply of 100…240 V~

50-60 Hz
OUT 24 V= Output terminals of the regulated voltage of 24 Vdc – 3
A max. for powering the PLC and the components of
the LAN.

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 SAFETY WARNINGS IN CONTROL CIRCUITS OF MACHINES

SAFETY WARNINGS
Although there are also other methods, control circuits of machines
use extra low voltage. In this case it is better to use PELV (Protection
Extra Low Voltage) systems where a point of the secondary winding
of the transformer is connected with the earth system of the
installation and the other point is protected by the protection device
against over currents (fig. 17a).
Earthing a point of the secondary winding of the power supply is
necessary so that the protection device (available on the other wire)
can trip in case of first earth fault and avoid that, if a first earth fault is
not detected (fig. 17b), the second fault short circuits the NC stop
contact (fig. 17c), thus the machine cannot be stopped; very serious
trouble!

Fig. 17a - Control circuit powered by PELV system with a point earthed and the other point
connected with the protection device against over currents. Correct circuit.
Fig. 17b - First fault not detected by the protection device in PELV circuit not earthed. Wrong
circuit because the fault cannot be seen, but it may exist.
Fig. 17c – Another fault too is not detected, but the stop button does not open the circuit any
more. Wrong circuit with serious consequences because the machine cannot be stopped!

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 SAFETY WARNINGS IN CONTROL CIRCUITS OF MACHINES

An analogous device must also be carried out when the control board
of the machine and the actuators are powered in direct current; PLC,
micro PLC or logic modules. In this case the point having to be
earthed is the negative pole coming out of the rectifying bridge.

Fig. 18 - Control circuit powered in DC with a point earthed and the other point connected with
a protection device against over currents. Correct circuit.

If there are two PELVs of 24 Vac and 24 Vdc, two transformers, or a

transformer with two separate secondary windings, are necessary to
earth the two systems. Fig. 19 shows that there are two earthed points:
one in the AC circuit (fig. 17a) and the other in DC circuit (fig. 18).

Fig. 19 - Control circuit powered partially in AC and partially in DC. Correct circuit.
N.B.: the fuses installed at the input of the rectifying bridge protect the secondary winding of the
transformer in case of any fault on diodes (diodes in short circuit).

IDENTIFICATION CODES
A good principle consists in identifying the components of an electric
system with a code.
An identification code can consist of letters and figures; letters will be
those of Latin alphabet, written in capital characters (A-Z), figures
will be Arab numerals. Avoid using vowels I and O that could be
confused with figures 1 and 0.

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SAFETY WARNINGS IN CONTROL CIRCUITS OF MACHINES

Standard CEI EN 61346-1 (CEI 3-43) derived from IEC 1346-1 states
that the components of an electric system can be described by their
own code with a prefix according to three different aspects referring
to:
- what this component does (function) prefix =
- where it is installed (position) prefix +
- how it has been assembled (product) prefix -
Standard EN 61346-2 (CEI 3-47) derived from IEC 61346-2 specifies
the letter code to classify the elements of the electric system (refer to
table 1).

Function codes concern the functional aspect of the element, that is

the aim or task assigned to the element; the letter of code is preceded
by prefix = and followed by the digits of the progressive numbering.
For instance, =T1 and =T2 indicate two transformers.

Position codes enable to locate the physical position of elements, such

as the physical place considered as building, floor, room, or as part of
the system: switchboard or one of its panels; alphanumeric code is
preceded by prefix +.
Generally these codes consists of mnemonic abbreviations or
acronyms chosen by designers and explained in a legend.
For instance: +PLA1+CAB2+T1 or +PLA.CAB2.T1 can indicate
transformer 1 (T1) in cabin 2 (CAB2) of plant 1 (PLA1). It is a
convention that when the signs of prefix after the first one are equal
(+, in this example) can be replaced by a dot.

Product codes classify each element apart from the function and
position it has in the system; code letters indicated in table 1 are
preceded by prefix – and followed by the digits of progressive
numbering.
For instance, -Q2 and -F1 indicate switch No. 2 and fuse No. 1 of a
wiring diagram.

Identification codes of connection terminals can be numeric, literal or

alphanumeric, they are preceded by prefix : and they are coupled to
product codes usually.
For instance, -X1:1 and -X3:7 indicate the specific terminals of
terminal boards X1 and X3.

The electric leads of an alternating current system are identified by:

Phase 1 L1; Phase 2 L2; Phase 3 L3; Neutral N; protection conductor
PE.
The electric leads of a direct current system are identified by:
Positive L+; Negative L-; Median point M.

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 SAFETY WARNINGS IN CONTROL CIRCUITS OF MACHINES

Table 1 - Letter references for the identification of the materials being used to draw diagrams of
electric systems. Standard EN 61346-2 (CEI 3-47) adopted by IEC 61346-2

Letter Type of material Examples of mechanical Examples of electric products

products
A Two or more aims or tasks / Touch screen

B Conversion of an input variable Calibrated flange Buchholz relay

(physical property, condition or event) (for measurement) Detector
into a signal for subsequent processing Sensor Fire detector
Gas detector
Measuring element
Measuring relay
Measuring shunt
Measuring transformer
Microphone
Movement detector
Photocell
Control contact
Position contact
Proximity contact
Proximity sensor
Protection relay
Sensor
Smoke sensor
Tachogenerator
Temperature sensor
Thermal overload relay
Video camera

C Storing materials, energy or Barrel Storage buffer

information Buffer Buffer battery
Tank Capacitor
Vessel Event recorder *
Accumulator of hot water Hard disk
Support for coils of paper Storage
Pressure accumulator RAM
Steam accumulator Storage battery
Reservoir Tape recorder *
Container Video recorder *
Voltage recorder *
* mainly used for storing
functions

D Reserved for future standardizations / /

E Supply of thermal or radiating energy Boiler Boiler

Freezer Fluorescent lamp
Heater Heater
Gas lamp Lamp
Heat exchanger Bulb lamp
Nuclear reactor Laser
Radiator Lights
Refrigerator Maser
Radiator

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 SAFETY WARNINGS IN CONTROL CIRCUITS OF MACHINES

Letter Type of material Examples of mechanical Examples of electric products

products

F Direct protection of a flow of energy, Airbag Anode of cathode protection

signals, personnel, or of apparatuses Buffer Faraday cage
from dangerous or undesired Fence Fuse
conditions. Systems with protective Shelter Miniature switch
functions Valve for pipe breaking Protector
Breaking disk Thermal overload breaker
Safety belt
Safety valve
Shield
Thermionic tube

G Production of a flow of energy or of Blower Dry battery

material Machine for inserting Direct-current generator
Generating signals used to send components Fuel cell
information, or as reference source Conveyor belt (in operation) Generator
Production of a new type of energy, Breaker Power generator
material or product Fan Rotary generator
Mixer Function generator
Pump Solar cell
Vacuum pump Wave generator

/ /
H Reserved for future standardizations

/ /
I Do not use

/ /
J Reserved for future standardizations

K Processing (reception, processing and Feedback control of fluids “All-or-nothing” relay

supply) of signals or information, Pilot valve Analog integrated circuit
excluding the objects with protective Valve positioner Device of automatic parallel
functions, refer to code F Binary integrated circuit
Auxiliary relay
CPU
Delay element
Delay line
Thermionic tube
Cathode-ray tube
Feedback controller
Filter
Induction mixer
Microprocessor
Process computer
Programmable controller
Synchronization device
Timing relay
Transistor

/ /
L Reserved for future standardizations

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 SAFETY WARNINGS IN CONTROL CIRCUITS OF MACHINES

Letter Type of material Examples of mechanical Examples of electric products

products

M Supply of mechanical energy Combustion engine Actuator

(mechanical, rotating or linear Actuator for fluids Control coil
movement) for driving function Hydraulic cylinder Electric motor
Thermal engine Linear motor
Mechanical actuator
Spring actuator
Turbine
Hydraulic turbine
Wind turbine

/ /
N Reserved for future standardizations

/ /
O Do not use

P Supply of information Sound signalling device Sound signalling device

(Weighing) balance Ammeter
Bell Bell
Clock Clock
Display unit Continuous recorder
Flowmeter Display unit
Gas meter Electromechanical indicator
Level pipe Event counter
Pressure gauge Geiger-Müller counter
Mechanical indicator LED
Printer Loudspeaker
Sight glass Visual signalling device
Thermometer Printer
Water meter Recording voltmeter
Pilot lamp
Buzzer
Synchroscope
Voltmeter
Wattmeter
Watt-hour meter

Q Controlled variation or switching of a Brake Switch

flow of energy, signals or of materials Control valve (Power) contactor
Clutch Breaking device
Port Switch with fuse
Baffle Breaker with fuse
Gate valve Starter
On-off valve Power transistor
Shutter Short-circuit device with sliding
Closing contacts
Key device (Power) switch
Thyristor

- 23 -
 SAFETY WARNINGS IN CONTROL CIRCUITS OF MACHINES

Letter Type of material Examples of mechanical Examples of electric products

products

R Limitation or stabilization of Blocking device Diode

movement or of a flow of energy, Check valve Inductor
information or materials Attenuator Limiter
Brake Resistor
Interlocking device
Locking device
Modulating flange (for limiting
the flow)
Pressure relief valve
Reducer
Bumper
Silencer
Free-trip mechanism

S Conversion of a manual operation into Push-button valve Control switch

a signal to be processed Selector Discordance switch
Keyboard
Optical pen
Mouse
Pushbutton
Selector
Set-point controller

T Converting energy into energy of the Amplifier for fluids AC/DC converter
same type Gear Amplifier
Converting a defined signal preserving Measurement transducer Antenna
the information content Measurement transmitter Demodulator
Converting the shape of a material Pressure amplifier Frequency converter
Torque converter Measurement transducer
Die-casting machine Measurement transmitter
Cold forging machine Modulator
Grinding wheel (size reduction) Power transformer
Lathe Rectifier
Saw Conversion unit
Signal converter
Signal transformer
Telephone set
Transducer

U Keeping objects in a defined position Beam Insulator

Bearing, ball bearing
Block
Cable conductor
Via cable
Console
Corbel
Equipment
Foundation
Hook
Insulator
Assembly plate
Assembly frames
Tower

- 24 -
 SAFETY WARNINGS IN CONTROL CIRCUITS OF MACHINES

Letter Type of material Examples of mechanical Examples of electric products

products

V Processing of materials or products Centrifugal machine Filter

(including preparation and finishing) Degreaser
Dehydrator
Filter
Grinding wheel (surface
treatment)
Packing machine
Rake
Separator
Sieve
Painting machine
Vacuum cleaner
Washing machine
Wetting machine

W Guiding or transport of energy, Conveyor belt (not driven) Omnibus bar

signals, materials or products from Conduit Cable
place to place Tube Conductor
Ladder Information bus
(Mechanical) connection Fibre optic
Mirror Bushing insulator
Roller table (not driven) Waveguide
Pipe
Shaft
Shuttle

X Connection of objects Flange Connector

Hook Male connector
Pipe fitting Terminal
Oil pipeline fitting Terminal strip
Quick-releasing connection Terminal plate
Shaft coupling
Connection block

Y Reserved for future standardizations / /

Z Reserved for future standardizations / /

- 25 -
EXERCISE 1: System for powering 3-phase power consuming devices with phase presence and sequence relay

Exercise 1 – System for powering three-phase power consuming

devices with presence asymmetry and sequence failure phase
relay

OBJECTIVE 1
The first aim of this exercise consists in assembling the electric
system of a machine with one or more three-phase asynchronous
motors controlled by presence, asymmetry and sequence failure phase
relay. The machine cannot start if a phase is missing or the phase
sequence is not correct; that prevents motors from running in opposite
direction to that required; in this case, invert two wires of the power
supply of the machine.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV.
1 Panel mod. C-IIC/EV with start and stop pushbuttons and contactors
1 fixed single-phase power supply unit of 220-230 Vac for auxiliary
circuits
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
Remark: if panel mod. C-II/CEV is not available, however it is
possible to connect the presence asymmetry and sequence failure
phase relay, considering the LEDs of its fore panel and the contact of
the internal relay, and to analyse its operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that it/they is/are perfectly
stable. Connect the various electrical components according to the
wiring diagram shown in fig. 1.1, or carry out the connections as
indicated in the lay-out shown in fig. 1.2.

DISCUSSION
The principle for setting and developing the diagram, that will be
applied to all the exercises, is indicated here below:
POWER CIRCUIT,
CONTROL CIRCUIT,
SIGNALLING CIRCUIT.

N.B.: contact COM – NO is used in control and sequence phase

relay; this contact is indicated as normally open in the diagram
and this looks like a contradiction for an electric consent, but
actually that expresses the concept of positive safety. This contact
changes its state and closes only if the conditions of the checked

- 26 -
EXERCISE 1: System for powering 3-phase power consuming devices with phase presence and sequence relay

three-phase line are correct; in all the other cases, this contact is
open and it must be kept in this condition.

Students are invited to plot the connections among the electrical

devices using the lay-out of the panels available in Appendix A, as a
first step.

TESTING
Before powering the system assembled as described above, it is better
to carry out a visual check (also using the tester prearranged for
measurements of continuity) to detect any error in the connections.

It is a good rule not to power the power circuit immediately, but first
of all enable and check the control and signalling circuits: only if these
last circuits are OK, the power circuit will be enabled and the final
testing of the system will be carried out.

Make sure that the machine does not start when the phase sequence is
not correct.
Check that if a phase is missing, the machine cannot start, although
the sequence is correct, and it stops, if it is switched on.
Checking whether the relay trips in a line with asymmetric phases will
require the reduction of the voltage of one of the three leads below the
value set in ASYMMETRY % Ue, for instance, and to wait for the
time set in DELAY.

- 27 -
EXERCISE 1: System for powering 3-phase power consuming devices with phase presence and sequence relay

Fig. 1.1 - - Control of a machine with presence asymmetry and sequence failure phase relay.

- 28 -
 EXERCISE 1: System for powering 3-phase power consuming devices with phase presence and sequence relay

Fig. 1.2 – Connections on the panels for the control of a machine with presence asymmetry and sequence failure relay.

The machine cannot start if a phase is missing, if phase sequence is not correct and if the asymmetry of the three voltages is higher than the set percent value.

- 29 -
EXERCISE 1: System for powering 3-phase power consuming devices with phase presence and sequence relay

OBECTIVE 2
The second target of this exercise consists in assembling the electric
system of a machine with one or more three-phase asynchronous
motors controlled by presence, asymmetry and sequence failure phase
relay, but in this case phase sequence is automatically corrected if it
does not match the machine.

DISCUSSION
The operation of this circuit only considers the control of phase
sequence as the relay can set the normal condition: as a logical
consequence, if this condition is not set, that means that the phase
sequence is not correct; then the contactor is enabled for phase
inversion.
This use of the protection relay does not consider the asymmetry of
voltages, nor any failure of a phase; therefore it will work only as
corrector of the sequence of three-phase line.

PREPARING THE EXERCISE

Position the panel/s on the working top so that it/they is/are perfectly
stable. Connect the various electrical components according to the
wiring diagram shown in fig. 1.3, or carry out the connections as
indicated in the lay-out shown in figures 1.4a and 1.4b.

Fig. 1.3 – Automatic change of line phase sequence if this does not comply.

- 30 -
 EXERCISE 1: System for powering 3-phase power consuming devices with phase presence and sequence relay

Fig. 1.4a – Connections of the power circuit for the control of a machine with phase sequence relay for the automatic change of line phase if they do not comply.

- 31 -
EXERCISE 1: System for powering 3-phase power consuming devices with phase presence and sequence relay

Fig. 1.4b - Connections of the control circuit for the control of a machine with phase sequence relay for the automatic change of line phase if it does not comply.

- 32 -
 Exercise 2: Controlling a three-phase asynchronous motor by PWM inverter

Exercise 2 - Controlling a three-phase asynchronous motor by PWM

inverter, in V/f – vector control mode, with acceleration and braking
ramps

OBJECTIVE
Assemble the electric control system of a three-phase asynchronous
squirrel-cage motor of 0.3-0.75 kW with electronic drive (PWM
inverter). Start and stop buttons are available on the operational panel,
frequency is set by the potentiometer included in the inverter.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for auxiliary
circuits
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor of 0.3-1 kW mod. M-
4/EV or P-4/EV
Remark: if panel mod. C-IIC/EV is not available, however it is
possible to connect the inverter and to analyse its operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Connect the various electrical components according to the
wiring diagram shown in fig. 2.2, or carry out the connections as
indicated in the lay-out shown in fig. 2.3.

DISCUSSION
The “heart” of the control of a TAM (Three-phase Asynchronous
Motor) is represented by the inverter: this device will output voltage
and frequency that vary according to a precise standard.
The necessary data for electric installers that use it “blindly” (the
electronic circuits of inverters are not dealt with in this handbook) are:
 rated power of TAM
 type of input power supply (single-phase, three-phase)
 three-phase voltage rating output by the inverter.
The data mentioned above are interlinked because inverters for TAMs
of small power (generally up to 2.2 kW) are produced with single-
phase supply voltage of 220-230 V, consequently their three-phase
output voltage rating will be equal to 230 V (TAM 230/400 will be
connected in delta configuration). In the other cases (higher power
and three-phase power supply of 380-400 V) three-phase output
voltage rating reaches 400 V (TAM 230/400 will be connected in star
configuration).

- 33 -
Exercise 2: Controlling a three-phase asynchronous motor by PWM inverter

When setting the inverter-motor assembly at work, carry out the

proper modifications of control parameters to obtain an optimum
operation of the machine (programming the inverter).

Fig. 2.1 - Connection diagram of an inverter with three-phase power supply

As it is shown in fig. 2.1, the input supply circuit is three-phase at 400

V. The TAM will be connected with 400 V (star configuration), at the
inverter output, according to the output voltage rating.
The output frequency and consequently the motor RPM can be
controlled by the potentiometer or by the buttons of the panel (if
accessible), or they can be remote controlled by a voltage or by a
current loop (voltage output by a potentiometer, for instance).
The main adjustments/optimizations having to be carried out are
indicated here below:
 type of response curve: V/f, vector, etc…
 maximum output frequency (maximum speed of rotation of TAM
with respect to the number of pole pairs)
 acceleration time
 deceleration or braking time
 internal, external reference of frequency control
 direction of rotation
 setting different fixed RPM values (frequencies)
 adjusting the rated current of the motor, if its power is lower than
the rated power of inverter
 stopping the inverter when a phase of the connected TAM is cut-off.

- 34 -
 Exercise 2: Controlling a three-phase asynchronous motor by PWM inverter

Fig. 2.2 - Controlling a three-phase asynchronous motor by inverter.

Students are invited to plot the connections among the electrical

devices using the lay-out of the panels available in Appendix A, as a
first step.

TESTING

Before powering the system assembled as described above, it is better

to carry out a visual check to detect any error in the connections.

- 35 -
Exercise 2: Controlling a three-phase asynchronous motor by PWM inverter

Fig. 2.3 - Connections of the panels for the control of a three-phase asynchronous motor by inverter.

- 36 -
 Exercise 2: Controlling a three-phase asynchronous motor by PWM inverter

Setting the parameters

Standard parameters are programmed when inverters are
manufactured.
Parameters are divided into 4 main categories.
 Basic parameters: parameters having to be programmed before the
inverter is used for the first time
 Extended parameters: parameters for special and detailed setting
 User parameters (function of automatic search): they are the
different parameters from those standard of setup and default. They
are used to check and modify the setting
 Historical parameter inventory: it displays the last five parameters
modified, in reverse chronological order. This function is useful
when an inverter is programmed repeatedly with the same
parameter.

Range of adjustment for parameters

- HI = an attempt of assigning a higher value than that of the
programmable range has been carried out. Or the modification of
other parameters has led to the result that the programmed value of
the parameter, currently selected, exceeds the maximum threshold
- LO = an attempt of assigning a lower value than that of the
programmable range has been carried out. Or the modification of
other parameters has led to the result that the programmed value of
the parameter, currently selected, drops below the lower threshold.
If the aforesaid alarm signals start blinking, no value being equivalent
or higher than HI nor equivalent or lower than LO can be set.

Programming parameters
All the parameters can be programmed according to the sequence of
buttons indicated here below:
[MODE] it switches to parameter setting mode
[Turning Left/Right] Selecting the parameter having to be modified
[ENTER] Reading the current parameter setting [Center of the dial]
Turning Left/Right] Modifying the parameter setting
[ENTER] Saving the modified parameter [Center of the dial]
In case of any error during these operations, press button [MODE] to
return to indication 0.0

Programming and/or checking the parameters for the exercise’s

objective.
Refer to the tables of complete parameters (chapter 7 of the
operational handbook included in the CD of the inverter).

Modify or check parameter CNOd = 1 (Selection of start/stop control

mode on the inverter panel).
Modify or check parameter FNOd = 0 (Selection of speed setting
mode on the potentiometer included in the inverter).

- 37 -
Esercitazione 2 Controllo di un motore asincrono trifase mediante azionamento elettronico

Name Function Range of adjustment

CNOd Selecting start/stop control mode 0: Terminal board
1: Panel
FNOd Frequency setting mode 0: Setting the internal potentiometer
1: VIA
2: VIB
3: Operational panel
4: Series communication
5: Up/down external contacts
6: VIA+VIB (summation of inputs)

Adjusting parameter ACC = 1.0 enables to set the acceleration time at

1 s.
Adjusting parameter dEC = 2.0 enables to set the deceleration time at
2 s.
Adjusting parameter UL = 60.0, for instance, enables to set the
maximum threshold frequency at 60 Hz. It is important that parameter
FH too is set equal to / or higher than UL.

Symbol Function Range of adjustment Default setting

ACC Acceleration time (s) 0.0 – 3200 s 10 s
dEC Deceleration time (s) 0.0 – 3200 s 10s
FH Maximum frequency (Hz) 30.0 – 500.0 Hz 80.0 Hz
UL Maximum threshold frequency (Hz) 0.5 - FH 50. 0 Hz
LL Minimum threshold frequency (Hz) 0.0 – 30.0 Hz 0. 0 Hz

DO IT YOURSELVES
Although the TAM connected with the inverter, free of mechanical
load, does not show any trouble in acceleration and deceleration
phase, change and verify the operation with different response curves
(V/f, vector, etc…).
Enable the detection of motor phase failure output by the inverter,
modify parameter F605 (selection from 1 to 5).

Name Function Range of adjustment

Pt Selecting V/F 0: V/F constant
control mode 1: Variable torque
2: Automatic control of torque increase
3: Vector control
4: Energy saving
5: Dynamic energy saving (for fans and pumps)
6: PM motor control
F605 Motor output 0: Disabled
phase failure 1: At the start (only once, after the power supply has been switched on)
2: At the start (every time)
3: During the run
4: At the start and during the operation
5: Detecting failures on output side

- 38 -
 EXERCISE 3: Controlling a three-phase asynchronous motor by PWM inverter

Exercise 3 - Controlling a three-phase asynchronous motor by

PWM inverter, with selection of direction of rotation, control of RPM
with voltage of 0-10 Vdc

OBJECTIVE
Assemble the electric system for controlling a three-phase
asynchronous squirrel-cage motor of 0.3-0.75 kW with PWM inverter,
selector for the reversal of rotation and a potentiometer for adjusting
the r.p.m. (control of frequency with voltage input of 0-10 Vdc).

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for auxiliary
circuits
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor of 0.3-1 kW mod. M-
4/EV or P-4/EV (if available)
Remark: if panel mod. C-IIC/EV is not available, however it is
possible to connect the inverter and to analyse its operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that it/they is/are perfectly
stable. Connect the various electrical components according to the
wiring diagram shown in fig. 3.1, or carry out the connections as
indicated in the lay-out shown in fig. 3.2.

DISCUSSION
The inverter was used in the last exercise with the only resources of
the equipment and it enabled to carry out the following
adjustments/optimizations:
 type of response curve: V/f, vector, etc…
 maximum output frequency (maximum speed of rotation of TAM
with respect to the number of pole pairs)
 acceleration time
 deceleration or braking time
 internal reference of frequency control
 stopping the inverter when a phase of the connected TAM is cutoff.
The adjustments/optimizations that can be carried out in this exercise
are:
 reversal of rotation
 external references of frequency control
 setting different fixed RPM values (frequencies)

- 39 -
EXERCISE 3: Controlling a three-phase asynchronous motor by PWM inverter

Fig. 3.1 - Control of a three-phase asynchronous motor with inverter,

selector of direction of rotation and potentiometer for r.p.m. control.

Students are invited to plot the connections among the electrical

devices using the lay-out of the panels available in Appendix A, as a
first step. The potentiometer is not included in the panels.

TESTING
Before powering the system assembled as described above, it is better
to carry out a visual check to detect any error in the connections.

- 40 -
 EXERCISE 3: Controlling a three-phase asynchronous motor by PWM inverter

Fig. 3.2 - Connections on the panels for the control of a three-phase asynchronous motor with inverter, selector of direction of rotation and r.p.m.-control potentiometer.

- 41 -
EXERCISE 3: Controlling a three-phase asynchronous motor by PWM inverter

Setting the parameters

Standard parameters are programmed when inverters are
manufactured.
Parameters are divided into 4 main categories.
 Basic parameters: parameters having to be programmed before the
inverter is used for the first time
 Extended parameters: parameters for special and detailed setting
 User parameters (function of automatic search): they indicate the
different parameters from those standard of default setup. They are
used to check and modify the setting
 Historical parameter inventory: it displays the last five parameters
modified, in reverse chronological order. This function is useful
when an inverter is programmed repeatedly with the same
parameter.

Range of adjustment for parameters

- HI = an attempt of assigning a higher value than that of the
programmable range has been carried out. Or the modification of
other parameters has led to the result that the programmed value of
the parameter, currently selected, exceeds the maximum threshold
- LO = an attempt of assigning a lower value than that of the
programmable range has been carried out. Or the modification of
other parameters has led to the result that the programmed value of
the parameter, currently selected, drops below the lower threshold.
If the aforesaid alarm signals start blinking, no value being equivalent
or higher than HI nor equivalent or lower than LO can be set.

Programming parameters
All the parameters can be programmed according to the sequence of
buttons indicated here below:
[MODE] it switches to parameter setting mode
[Turning Left/Right] Selecting the parameter having to be modified
[ENTER] Reading the current parameter setting [Center of the dial]
Turning Left/Right] Modifying the parameter setting
[ENTER] Saving the modified parameter [Center of the dial]
In case of any error during these operations, press button [MODE] to
return to indication 0.0

Programming and/or checking the parameters for the exercise’s

objective.
Refer to the tables of complete parameters (chapter 7 of the
operational handbook included in the CD of the inverter).

Modify or check parameter CNOd = 0 (start/stop control from external

device connected with the terminal board).
Modify or check parameter FNOd = 2 (setting the frequency by signal
from external potentiometer).
- 42 -
 EXERCISE 3: Controlling a three-phase asynchronous motor by PWM inverter

Name Function Range of adjustment

CNOd Selecting start/stop control mode 0: Terminal board
1: Panel 1
FNOd Frequency setting mode 0: Setting the internal potentiometer
1: VIA
2: VIB
3: Operational panel
4: Series communication
5: Up/down external contacts
6: VIA+VIB (summation of inputs)

N.B.: assigning the same value of FH also to parameters F204 and

F213 will enable to reach the same value of frequency (r.p.m. of
TAM) output by the potentiometer of the panel and set with parameter
FH, even with an external signal (0-10 Vdc).

Adjusting parameter UL = 60.0, for instance, enables to set the

maximum threshold frequency at 60 Hz. It is important that parameter
FH too is set equal to / or higher than UL.

Symbol Function Range of adjustment Default setting

ACC Acceleration time (s) 0.0 – 3200 s 10 s
dEC Deceleration time (s) 0.0 – 3200 s 10s
FH Maximum frequency (Hz) 30.0 – 500.0 Hz 80.0 Hz
UL Maximum threshold frequency (Hz) 0.5 - FH 50. 0 Hz
LL Minimum threshold frequency (Hz) 0.0 – 30.0 Hz 0. 0 Hz

DO IT YOURSELVES
The control of forward/reverse run realized in the exercise described
above via the toggle switch is of permanent type; when motor is
powered again after an interruption of the supply voltage, the motor
will restart and that can lead to dangerous situation as this restart has
not been programmed.
Modify the wiring diagram so that the controls of forward/reverse run
are realized via pushbuttons: thus only pressing the start button
enables to restart the TAM when it is powered again after an
interruption of the supply voltage.
Advice: assemble the control circuit of a reversal of rotation of a
three-phase asynchronous motor with lockout on pushbuttons; use a
normally open contact of each contactor, instead of toggle switch, to
enable the F/R input of the inverter.

- 43 -
EXERCISE 3: Controlling a three-phase asynchronous motor by PWM inverter

Enabling different speeds of rotation of the motor.

Combining the 3 inputs S1…S3 of the inverter will enable to retrieve
the seven available RPM memories in binary logic.

Symbol Function Range of adj. Default value

Sr1…Sr7 Preset frequency, retrieval coupled to memory 1…7 from LL to UL 0.0

Example of programming:
Symbol Setting S1 S2 S3
Sr1 Program at 10 Hz X
Sr2 Program at 20 Hz X
Sr3 Program at 30 Hz X X
Sr4 Program at 40 Hz X
Sr5 Program at 50 Hz X X
Sr6 Program at 60 Hz X X
Sr7 Program at 70 Hz X X X
N.B.: sending also the command of forward run or of reverse run
(being the parameter CNOd = 0) will enable a preset RPM value: the
frequency of 70 Hz is possible only if parameter UL (maximum
frequency threshold ) is set as equal or higher.

Fig. 3.3 - Control of a three-phase asynchronous motor with inverter,

selectors of direction of rotation and of preset r.p.m. values.

- 44 -
 EXERCISE 4: Gradual start-stop of a three-phase asynchronous motor by soft starter

EXERCISE 4 – Gradual start-stop of a three-phase asynchronous

motor by soft starter

OBJECTIVE
When RPM must not be modified, but the three-phase asynchronous
motors included in a machine (such as conveyor belts, water pumps,
fans, etc…), must start and stop “softly”, some phase choking devices,
commonly known as soft starters, can be used

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor of 0.3-1 kW mod. M-
4/EV or P-4/EV (if available)
Remark: if panel mod. C-IIC/EV is not available, however it is
possible to connect the soft starter and to analyse its operation.

PREPARING THE EXERCISE

Position the panels on the working top so that they are perfectly
stable. Connect the various electrical components according to the
wiring diagram shown in fig. 4.1, or carry out the connections as
indicated in the lay-out shown in fig. 4.2.

DISCUSSION
The machine of exercise 1 including one or more three-phase
asynchronous motors was controlled by a presence asymmetry and
sequence failure phase relay.
The main aim of that exercise was to prevent the machine from
starting if phase sequence was not correct.
In this exercise the presence asymmetry and sequence failure phase
relay will protect the soft starter to guarantee the “quality” of the three
voltages powering the motor; the aim consists in preventing the failure
of a phase and/or strong unbalances of the three voltages that provoke
superheating of electronic phase choking devices, during the starting
phases. At the end of the starting phase a relays acts as by-pass of the
current that does not cross the electronic devices any longer.
There are various modes for controlling a soft starter: the extra low
voltage of 24 Vac is used in this exercise because this voltage is
available and used by the control circuits of contactors.
An alternative could be represented by the control voltage of 24 Vdc,
if a PLC is available, because this voltage is normally used in its input
circuits.

- 45 -
EXERCISE 4: Gradual start-stop of a three-phase asynchronous motor by soft starter

Another possibility consists in using the control with voltage of 230

Vac (phase – neutral) or of 400 Vac (phase – phase) of the mains.

Fig. 4.1 - Application of a Soft Starter with control of 24 Vac

Students are invited to plot the connections among the electrical

devices using the lay-out of the panels available in Appendix A, as a
first step.

TESTING
Before powering the system assembled as described above, it is better
to carry out a visual check (also using the tester prearranged for
measurements of continuity) to detect any error in the connections.
Make sure that the phase sequence is correct (the consent signal has
been received from the presence asymmetry and sequence failure
phase relay), then start the motor.
Check and adjust the times of ramps and the starting torque with the
trimmers available on the fore panel of the soft starter.

- 46 -
 EXERCISE 4: Gradual start-stop of a three-phase asynchronous motor by soft starter

Fig. 4.2 – Connections on the panels for a Soft Starter with control of 24 Vac.

- 47 -
EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

EXERCISE 5 - Connections and configuration of PLC and of HMI in

Profinet

OBIETTIVI
This exercise enables to learn how a PLC, specifically a PLC S7 1200,
and a HMI operator panel, specifically the Touch Panel with LCD-
TFT of 5.7”, can be connected so that they communicate with each
other and with the programming PC via LAN ports (PROFINET).
It also includes an example of PLC programming and the creation of a
page in HMI for a graphic representation of system state.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 fixed single-phase power supply unit of 220-230 Vac for auxiliary
circuits
1 set of leads with safety plugs with diameter of 4 mm.
1 Personal computer with software TIA Portal step 7 already installed

DISCUSSION
PROFINET is an open and innovatory standard for Industrial Ethernet
(IEC 61158/61784) being used for industrial automation.
PROFINET enables to network apparatuses starting from the field
level up to the company management.
PROFINET guarantees a homogeneous communication, with an
engineering extended to the whole system, and it uses IT standards for
diagnostics up to the field level. Existing bus systems (e.g.:
PROFIBUS) can be integrated without any modification of the
equipment and of the application software already installed..
PROFINET is based on Industrial Ethernet and it uses the Transport
Control Protocol / Internet Protocol (TCP/IP) for parameterization,
configuration and diagnostics of the devices. Real-time
communication for the transmission of I/O variables runs through the
same Ethernet cable, but without using TCP/IP.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Fig. 5.1 – Wiring diagram of a PROFINET with a SWITCH for connecting a PLC with a
HMI (Touch Panel) and for connecting the PC with the programming software.

The wiring diagram shown in fig. 5.1 can be used as basic model for
assembling industrial applications with the PLC installed in the panel.
Notice that a PC is absolutely necessary for the phase of writing and
transfer of the program into the PLC and the HMI. The SWITCH with
4 ports will network the communicating units in PROFINET; it is not
necessary if only the PLC or HMI must be programmed, but in this
case the connection of the programming PC depending on CPUs can
require a networking patch cable with crossed wires. The SWITCH
automatically upgrades the wires (auto-crossing), therefore it is
possible to use networking cables with point-to-point or crossed wires
indifferently and to leave all the communicating units connected
without disconnecting and connecting the networking cables again, as
they are identified by the IP address.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Fig. 5.2 – Connections on the panel; PROFINET with SWITCH for connecting the PLC with
HMI and for connecting the PC for programming.

At the end of programming, if the testing of the installation of PLC

and HMI has given a positive result, the SWITCH can be removed
and the two devices can be connected with each other.
Of course, if programming must undergo some modifications, the
devices must be connected alternately, or networked via Switch, to
download the corresponding modifications.

The following sections will supply a step-by-step description of the

operations being carried out with software TIA Portal to configure the
PLC and the HMI, to write and download the apps into the
corresponding CPUs and to start the program in the PLC and /or in
simulation.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

The path for organizing the New project is indicated here below.

Open the software to program the PLC and HMI by clicking once on
icon TIA Portal V[…] available on the desktop.

Wait… for software uploading.

Select Create new project then confirm by clicking on button [Create]

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Instead of creating a new project, an existing project can be opened with the command Open
an existing project : select the desired project from the list available on the right and
confirm by clicking on button Open .

Wait for software uploading.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

After selecting New project , select Devices & Networks .

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Select Add new device .

Search the PLC that must be included in the project, in the column on the right: search the
exact commercial model indicated in the same PLC by the manufacturer.

In this example : CPU 1214 DC/DC/DC and specifically 6ES7 214-1AG31-0XB0

If different, write down the model: CPU . . . . . . and specifically 6ES7 . . . . .

Click twice on the corresponding model to insert in the project.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Wait... Then the opening window will include the selected PLC.

The PLC includes a module with an analog output, click on the central box of PLC. Before
enabling the module, search the exact commercial model indicated in the module of analog
output AQ, in the column on the right.

In this example: AQ1 x 12 bit and specifically 6ES7 232-4HA30-0XB0

If different, write down the model: AQ . . . . . . . . and specifically 6ES7 . . . . . . . . . . . . . . .

Click twice on the corresponding model to insert in the PLC.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

After the module has been inserted, the box will show the model of the installed device.

The configuration of PLC is finished with this operation.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Then repeat analogous steps for the definition of the HMI.

Remove the tick  from box Filter, in the column on the right, to display all the products.
Then select HMI from the list.

Include the Touch Panel in the project: open folder HMI , open Display of 6” in family
SIMATIC Basic Panel, then search the specific model.

In this example: KPT600 Basic PN

If different, write down the model: KPT . . . . . . . . . . . . .

The selected HMI cannot be inserted in the window View of devices, it is necessary to pass
to the window View of network.
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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Click twice on the corresponding model to insert in the project.

Wait… After this model has been inserted, the window View of network also displays the
HMI (Touch panel) just defined, besides the PLC.

Then assemble the subnet between PLC and HMI.

Click on the square identifying the communication port of PLC, keeping the left key of the
mouse pressed, and drag the connection up to the square identifying the communication port
of HMI, then, when the link is completed, release the mouse.

If that were not successful, the prohibition signal is displayed. Periodically Save project

Clicking with the right key of the mouse, as shown above, enables to remove the link.
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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

As it was already mentioned in section “Discussion” at the beginning of this exercise,

PROFINET standard is based on Industrial Ethernet and it uses the Transport Control
Protocol / Internet Protocol (TCP/IP) for parameterization, configuration and diagnostics of
devices.
Now the TCP/IP addresses must be assigned to the networked apparatuses.
These addresses have already been assigned to the networked devices to facilitate this
function and also to test the PLC and HMI installed in panel mod. C-IID/EV; refer to these
addresses in this new project and in all the future exercises on this panel.

The TCP/IP of the Personal computer must have its first 3 fields equal to those of PLC and of
HMI, but the last field must be different (do not use 1 and 2 for the PC because they are or
will be used by the devices). For instance, use:
PC IP ADDRESS: 192 . 168 . 0 . 3 Subnet mask 255 . 255 . 255 . 0

TCP/IP addresses of the devices can be seen on the fore panel of each device and they are:
PLC IP ADDRESS: 192 . 168 . 0 . 1 Subnet mask 255 . 255 . 255 . 0
TOUCH IP ADDRESS: 192 . 168 . 0 . 2 Subnet mask 255 . 255 . 255 . 0

Verify or change the IP address of the Personal Computer as it is shown here below:

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Verify or upgrade the TCP/IP address of the PLC and of HMI as indicated here below:
Make sure or enable Devices & networks , in the column on the left.
Click on PLC_1, open the central lower window, named PLC_1 [ CPU 1214C DC/DC/DC ],
suitably.

Remaining always in the central lower window, called PLC_1 [ CPU 1214C DC/DC/DC ]
and suitably enlarged, select “PROFINET interface” on the left column; scroll down the
image with the right side bar until the fields with IP address are displayed; verify or introduce
192 . 168 . 0 . 1 in IP Address, and 255 . 255 . 255 . 0 in Subnet mask

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Now click with the mouse on HMI_1, in the central lower window named HMI_RT [ KT600
Basic PN ]; select “PROFINET interface” on the left column; scroll down the image with the
right side bar until the fields with IP address are displayed; verify or introduce 192 . 168 . 0 .
2 in IP Address, and 255 . 255 . 255 . 0 in Subnet mask

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Operations for creating a program and downloading in the PLC.

Open the folders in the left column up to folder Show all variables, click twice on this folder
with the mouse. The window for the insertion of the variables being used to create the
program, will open in the centre of the screen

Open the folders in the left column up to folder Main [OB1], click twice with the mouse on
this folder. The window for the insertion of program segments, will open in the centre of the
screen

 
Passing from the window of Table of variables to window Main [OB1] and vice versa, will
b made easier by the keys available in the lower line of the screen.
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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Now the subject having to be expounded (as example) with the PLC is:
 to enable an output when two inputs are active (& function), and
 to enable another output when at least one of the two inputs is active (OR function).
Then it is necessary to state which I (Inputs) and which Q (Quit = outputs) of the PLC must
accomplish this task; a Name, the type of data item it represents, the address, etc… must be
assigned to each “variable”, as it is explained above.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

PREPARING THE EXERCISE

Position the panel on the working top so that it is perfectly stable.
Connect the various electrical components according to the wiring
diagram shown in fig. 5.3, or carry out the connections as indicated in
the lay-out shown in fig. 5.4. Draw up the list of the necessary
variables for the exercise.

Fig. 5.3 - Wiring diagram with example of application of PLC.

Meaning of the variables of the PLC and of the HMI

Name Type of data Address Description
1 Input 1 Bool %I0.0 Logic state No.1
2 Input 2 Bool %I0.1 Logic state No.2
3 Output 1 Bool %Q0.0 Signalling logic state AND operation
4 Output 2 Bool %Q0.1 Signalling logic state OR operation
5

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Fig. 5.4 – Connections on the panel with example of application of PLC.

N.B.: refer to the LEDs available on the fore panel of the PLC to display the state of its
outputs.
An alternative consists in connecting two warning lights of panel mod. C-IIC/EV, referred to
terminal – of of the power supply of 24 Vdc of the PLC, with transistor outputs Q0.0 and
Q0.1, as it is shown in the wiring diagram.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

After the task has been assigned, the table of PLC Variables becomes:

Open the window Main [OB1] by clicking on the key in the lower line of the screen.
Drag the symbol representing the reading of a logic state over the line of segment 1, then
release the mouse in the position looking possible.

If the line with the graphic symbols is not displayed, make sure that the option Display
bookmarks also in editor is active (icon with yellow star).

The symbol is positioned in the segment with some question marks above, to indicate that it is
not assigned to anyone of the defined variables.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Click on the question marks, then click on the box on the right, in the small window enabled,
to open the list of the defined variables. Select and insert the requested variable.

The sequence of the operations has enabled to assign the variable from which the logic value
is taken, to the symbol.

Observe that now two pieces of information are available for the symbol: in the upper part the
physical address preceded by character %, and in the lower part the Name assigned to the
variable, indicated between “inverted commas”.

Complete the insertion of the variables according to the subject assigned.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

At the end of the programming, two segments are available; immediately under them there is
the list of the variables of the same segments.

Save the program clicking on the icon Save project in the upper left part of the screen.

Execute the compilation from the drop-down menu Modify , then click on Compile to
check whether there is not any error in the program.

Selecting Information and Compile enables to display the result in the window at Main
[OB1].

Then the program must be transferred into the CPU of PLC.

Click on the icon Upload in the device highlighted in the following figure: the window
Advanced uploading will open.
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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Continue as indicated here below by selecting:

Type of PG/PC interface PN/IE
PG/PC interface INVIDIA… (the card of PC)
Connection with subnet PN/IE_1
in the boxes marked by 

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

At the end of these operations the window Upload preview will open.

Confirm by clicking on button Upload and then on button End .

Return to the window of program.

Now the program has been transferred into the CPU of PLC and it is being executed.
It is possible to carry out some checks of its correct operation.
Besides showing the operation of the downloaded application, the LEDS on the fore panel of
PLC enable to start the mode Connect online to control the logic states of input operands
and of outputs versus the state of inputs and of the programmed logical operations.
Click on button “Connect online” highlighted in the figure here below.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Once established the online connection, click on the button “with spectacles” highlighted in
the following figure.
The different colours of graphic signs enable to analyse the program operation in depth.

Important considerations for the supervision (pages) by HMI TOUCH PANELS

Touch panels enable to display the state of process variables with the option of Simple
objects , but using their option Elements can also enable controls such as Pushbuttons .
Pushbuttons must never be used to supervise the outputs of the PLC because they could be
“controlled”, even accidentally, by a simple touch on the screen.
Use exclusively Simple objects , to indicate the logic state of variables Q (quit) and M
(memories).

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Steps for drawing up a program for HMI and downloading it into HMI
When continuing from the previous section, starting from folder HMI_1, in the left column,
open the folders up to Pages , the click twice on folder Add a new page . Thus page_1
will be displayed, click twice on it with the mouse. The page of the Touch panel where the
graphic objects must be inserted, will be displayed in the centre of the screen.

If the project is resumed later, enable software TIA Portal V[…] by clicking on its icon
available on the desktop. Select the project in the list of existing projects and confirm by
clicking on button Open .

Wait… Then click on box Design a HMI page , in the window opened on the screen.

That enables the window which includes all the resources for programming the TOUCH
PANEL.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Click twice on icon Global page with the mouse.

Open the folder of Pages ; if page_1 is not available, create it by clicking twice on
Add a new page. Then click twice on Page_1 : the window with “page_1” will open in the
centre of the screen; the graphic objects which are included in the various folders of the right
column, will be inserted in this page.

The window underlying the Touch page enables to assign / modify the Properties of the
page and of the objects inserted in it.

Now the subject (as example) having to be dealt with by the HMI is indicated here below:
 the logic state of the two inputs must be shown by two icons of different colour which
identifies their logic state : for instance, green will indicate low signal, whereas red will
indicate high signal (equivalent to open/closed contact)
 a two-coloured icon, with text string AND, must represent the result of “series” operation
 a two-coloured icon, with text string OR, must represent the result of “parallel” operation.
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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

The same “variables” of the PLC program are used, therefore they have been defined as
Visible in HMI and Accessible from HMI . Refer still to the wiring diagram of fig. 5.3,
and to the lay-out of fig. 5.4, for the connections.
Take the “Rectangle” from the window of Simple objects on the right and drag it to any
position in the Touch page.

The window underlying the Touch page enables to assign / modify the Properties of the
page and of the objects that must be inserted in it.

The object dragged and laid down in the Touch page needs some parameterizations. Click on
the object (selecting it). Going to Properties , Shaping , in the window Properties of
Rectangle_1, will enable to modify the colour and the (compact / transparent) pattern of
object background.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Going to Properties , Representation , in the window Properties of Rectangle_1, will

enable to modify the position and dimensions, as well as the radius of curvature of the corners
of the rectangle.

Then go to Animations , General view , in the window Properties of Rectangle_1, and

click on Enable colours and flashing as it is highlighted in the following figure.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

The window Shaping opening after the last operation, enables to associate the variable to
the object, as well as the colours it will take according to the logic states 0 (zero) and 1.
Associate the variable by clicking on the button of tag Name: highlighted in the figure
here below.

The table of variables written for the PLC and shared by the HMI, will be opened.
Select the line with the variable that must be associated to the object, that is INPUT 1, in this
case.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

The window of Shaping also enables to define the colours the object will take according to
its logic state 0 (zero) or 1. Define the colour/s by clicking twice on “Add” in column
“Area”: that will open two lines that enable to assign the colour/s to the two possible states of
the associated variable.

Then drag Text box from the window of Simple objects with the mouse and release it in the
rectangle that has become the variable “INPUT 1”.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Select the text object just inserted and go to Properties , General (in the window
Properties of Text Box_5) where the proposed text can be modified with that having to be
represented: in this case, write INPUT 1.

Now the rectangle will become green / red according to the logical value 0 / 1 of the variable
to which it has been associated, and include a fixed text identifying it.

Other similar objects can be realized: it is sufficient to repeat all the steps described above, or
to make copies. Realize other objects by selecting the existing objects one at a time, and
execute copy – paste commands.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Of course these copies are exactly like the originals; the object can be made different, but in
this case the process variable must be modified and the object must be associated to the
specific variable, that is INPUT 2, in this case.

The copy of Text box too must be modified. Write INPUT 2, in this case.

Then go on creating the icons representing (as example) the logic state of the two outputs.
Take the “Circle” from the window of Simple objects on the right and drag it into the page.

The window underlying the Touch page enables to assign / modify the Properties of the
objects that must be inserted in it.
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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

The object dragged and laid down in the Touch page needs some parameterizations. Click on
the object (selecting it). Going to Properties , Shaping , in the window Properties of
Circle_1, will enable to modify the colour and the (compact / transparent) pattern of object
background.
Going to Properties , Representation , in the window Properties of Circle_1, will enable to
modify the position & dimensions, as well as the Radius of the circle.

The window Shaping opening after the last operation, enables to associate the variable to
the object, as well as the colours it will take according to the logic states 0 (zero) and 1.
Associate the variable by clicking on the button of tag Name: highlighted in the figure
here below.

The table of variables written for the PLC and shared by the HMI, will be opened.
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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Select the line with the variable that must be associated to the object, that is OUTPUT 1, in
this case.
The window of Shaping also enables to define the colours the object will take according to
its logic state 0 (zero) or 1. Define the colour/s by clicking twice on “Add” in column
“Area”: that will open two lines that enable to assign the colour/s to the two possible states of
the associated variable.

Then drag Text box from the window of Simple objects with the mouse and release it on
the circle; or carry out a copy – paste operation of a text written before. Select the text object
just inserted and go to Properties , General (in the window Properties of Text Box_5)
where the proposed text can be modified with that having to be represented: in this case, write
AND OPERATION.

Save the program by clicking on icon Save project in the upper left part of the screen.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Now the circle will become green / red according to the logical value 0 / 1 of the variable to
which it has been associated, and include a fixed text identifying it.
Other similar objects can be realized: it is sufficient to repeat all the steps described above, or
to make copies. Realize other objects by selecting the existing objects one at a time, and
execute copy – paste commands.
Of course these copies are exactly like the originals; the object can be made different, but in
this case the process variable must be modified and the object must be associated to the
specific variable, that is Output 2, in this case.

The background colours are those of the original object copied, but it is always possible to
check their correctness and / or modify them.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

The copy of Text box too must be modified. Write OR OPERATION, in this case..

Save the program by clicking on icon Save project in the upper left part of the screen.

Execute the compilation from the drop-down menu Modify , then click on Compile to
check whether there is not any error in the program.

Selecting Information and Compile enables to display the result in the window at Main
[OB1].

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

Now the program must be transferred into the HMI.

Click on the icon Upload in the device with the mouse: the window Advanced uploading
will open. At the end of these operations the window Upload preview will open.

Confirm by clicking on button Upload and then on button End .

Wait for the end of the uploading operation. Then return to the window of Page_1.

Now the program has been transferred into the HMI and it is being executed. The result of
these transfer operations is displayed in the window of Information.

Carry out the functional checks of the system.

Clicking once on X in the upper right part of the screen, with the mouse, will quit program
TIA.

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EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

This exercise must be considered as a method for writing the programs of the PLC and
of the HMI for all the following exercises.

The program in KOP (by contacts) is available in each exercise (from 6 to 18) and the CD
supplied together with panel also includes a global project containing all these exercises. This
project has been saved under the name C-IID_EV.

Downloading the program in the CPU of the PLC and in the HMI (only once) enables to carry
out all the exercises.

Touching the buttons [Exercise …] in the HMI enables to browse among the various
exercises.
The button with the house enables to return to the main page.
The button with the flag enables to choose the language between Italian and English.

Function keys F1…F6 cannot be enabled in this program.

When an exercise has been enabled, the HMI allows the change of the page with the wiring
diagram and the icons explaining the circuit, whereas the PLC allows to skip, besides
processing the specific subroutine.

The section “Example of program” of every exercise indicates the subroutine [FC…] that is
executed by the PLC and the page uploaded in the HMI.

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 EXERCISE 5: Connections and configuration of PLC and of HMI in Profinet

The addresses of the tables of PLC variables consist of the indication of operand area and of
the address of this area.
Addresses must be univocal in the whole CPU. If an address already assigned to another
variable, is introduced, this address is highlighted in yellow in both positions and an error
message is sent.
Operand areas
The following table indicates the possible operand areas. The types of available data depend
on the used CPU:

Operand area Explanation Type of data Addressing area:

International German Format S7-1200 S7-300/400
mnemonic mnemonic
I E Input bit BOO I x.y 0.0..1023.7 0.0..65535.7
E x.y
BYTE, CHAR, SINT, IB x
IB EB Incoming byte 0..1023 0..65535
USINT EB y
WORD, INT, UINT, IW x
IW EW Input word 0..1022 0..65534
DATE, S5TIME EW y
DWORD, DINT,
ID x
ID ED Input double word UDINT, REAL, TIME, 0..1020 0..65532
ED y
TOD
Q x.y
Q A Output bit BOOL 0.0..1023.7 0.0..65535.7
A x.y
BYTE, CHAR, SINT, QB x
QB AB Output byte 0..1023 0..65535
USINT AB y
WORD, INT, UINT, QW x
QW AW Output word 0..1022 0..65534
DATE, S5TIME AW y
DWORD, DINT,
Output double QD x
QD AD UDINT, REAL, TIME, 0..1020 0..65532
word AD y
TOD
M M Merker bit BOOL M x.y 0.0..8191.7 0.0..65535.7
M M Merker bit LREAL M x.0 0.0..8190.0
BYTE, CHAR, SINT,
MB MB Merker byte MB x 0..8191 0..65535
USINT
WORD, INT, UINT,
MW MW Merker word MW x 0..8190 0..65534
DATE, S5TIME
DWORD, DINT,
Merker double
MD MD UDINT, REAL, TIME, MD x 0..8188 0..65532
word
TOD
Time function
T T (only for S7- Timer Tn - 0..65535
300/400)
Counting function
Zn
C Z (only for S7- Counter - 0..65535
Cn
300/400)

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EXERCISE 6: Start-stop control of a motor by PLC and HMI panel

EXERCISE 6 - Start-stop control of a motor by PLC and HMI Panel

OBJECTIVE
Achieve the start-stop control system of a three-phase asynchronous
motor provided with motor protector, by the PLC, and draw up a page
on the HMI to indicate the state of its operation. Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor mod. M-4/EV or P-
4/EV (if available)
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 6.1, for the automation with the PLC; power circuit does
not change.
N.B.: the wiring diagram is extracted from exercise 2 of the handbook
of industrial systems mod. C-II/EV; consequently, refer to the relevant
chapter of this handbook for any in-depth examination and functional
description of the circuit.

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,

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 EXERCISE 6: Start-stop control of a motor by PLC and HMI panel

 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 6.2, or in carrying out the
connections as shown in the lay-out of fig. 6.3.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- supply voltages for PELV auxiliary circuits,
- stop control via a NC pushbutton as in the case of wired logic,
- protection device against over currents with NC contact connected in
series with the contactor coil, and NO contact connected with an input
of the PLC,
- interrogation of the operational state of the contactor via a NO
contact connected with an input of the PLC.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vac. After the positive testing of the
(Hardware and Software) control section, enable also the power
supply of power circuit and complete the testing.

- 89 -
EXERCISE 6: Start-stop control of a motor by PLC and HMI panel

Fig. 6.1 – Wiring diagram of the traditional start-stop control of a motor.

- 90 -
 EXERCISE 6: Start-stop control of a motor by PLC and HMI panel

Meaning of the variables of PLC and of HMI panel

Name Type of data Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 Stop pushbutton
3 S2 NO %I0.2 Holding start button
4 Q1_C NO %I0.3 Auxiliary contact of Q1
5 Q1 Coil of 24 Vac %Q0.0 Coil of contactor
6 P1 24 V %Q0.1 Warning light of standstill motor
7 P2 24 V %Q0.2 Warning light of running motor
8 P3 24 V %Q0.3 Warning light for overload

Fig. 6.2 - Start-stop control of a motor by PLC and HMI.

- 91 -
EXERCISE 6: Start-stop control of a motor by PLC and HMI panel

Fig. 6.3a - Connections on the panels for the electric start-stop control system of a motor by PLC and HMI. Connections of power circuit at 400 V and PLC outputs at 24 Vac.

- 92 -
 EXERCISE 6: Start-stop control of a motor by PLC and HMI panel

Fig. 6.3b - - Connections on the panels for the electric start-stop control system of a motor by PLC and HMI. Connections of auxiliary power supply of PLC and HMI, PLC inputs at 24 Vdc.

- 93 -
EXERCISE 6: Start-stop control of a motor by PLC and HMI panel

Example of program for the start-stop control of a motor by PLC and HMI.
Filename: [C-IID_EV] PLC Exercise 6 [FC1], HMI page Exercise 6

- 94 -
 EXERCISE 6: Start-stop control of a motor by PLC and HMI panel

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 95 -
EXERCISE 7: Pulse / start-stop control of a motor by PLC and HMI

EXERCISE 7 – Pulse / start-stop control of a motor by PLC and

HMI Panel

OBJECTIVE
Carry out the connections and the necessary program of the PLC and
of HMI panel for managing the pulse / start-stop control system of a
three-phase asynchronous motor. Also a protection against over
currents and an emergency stop button with mechanical holding are
included. Furthermore this system must also be equipped with
signalling circuit with:
 warning light indicating motor in rest conditions
 warning light indicating motor enabled by instantaneous control
pulse; flashing at frequency of 1 Hz the same warning light will
indicate the motor enabled by permanent control
 warning light indicating the tripping of the protection against over
currents; flashing at a different frequency from the previous one the
same warning light will indicate that the emergency button has
been pressed.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor mod. M-4/EV or P-
4/EV (if available)
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 7.1, for the automation with the PLC and HMI; power
circuit does not change.

- 96 -
 EXERCISE 7: Pulse / start-stop control of a motor by PLC and HMI

N.B.: the wiring diagram is extracted from exercise 3 of the handbook

of industrial systems mod. C-II/EV; consequently, refer to the relevant
chapter of this handbook for any in-depth examination and functional
description of the circuit.

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write the program and enable PLC and HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 7.2, or in carrying out the
connections as shown in the lay-out of figs. 7.3a and 7.3b.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop control via a NC pushbutton as in the case of wired logic,
- emergency stop control of hardware type via a NC contact connected
in series with the coils of contactors, and another NC contact, or via a
NO contact connected with an input of the PLC,
- NC contact of the protection device against overcurrents connected
in series with the contactor coil, and NO contact connected with an
input of the PLC,
- interrogation of the operational state of the contactor via a NO
contact connected with an input of the PLC;
- any warning light must be shunted before the emergency button, so
that they can indicate the state of the machine apart from the position
of the emergency pushbutton.

- 97 -
EXERCISE 7: Pulse / start-stop control of a motor by PLC and HMI

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vac. After the positive testing of the
(Hardware and Software) control section, enable also the power
supply of power circuit and complete the testing.

Fig. 7.1 - Wiring diagram for the control of a traditional pulse / start-stop contactor.

- 98 -
 EXERCISE 7: Pulse / start-stop control of a motor by PLC and HMI

Meaning of the variables of PLC and of HMI panel

Name Type of data Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 Stop pushbutton
3 S2 NO %I0.2 Holding start button
4 S4 NO %I0.3 Pulse start button
5 Q1_C NO %I0.4 Auxiliary contact of Q1
6 S5 NC %I0.5 EMERGENCY pushbutton
7 Q1 Coil of 24 Vac %Q0.0 Coil of contactor
8 P1 24 V %Q0.1 Warning light of contactor in rest condition
9 P2 24 V %Q0.2 Warning light of pulse/permanent run
10 P3 24 V %Q0.3 Warning light of Emergency/overload

Fig. 7.2 - Control of a pulse / start-stop of contactor by PLC and HMI.

- 99 -
EXERCISE 7: Pulse / start-stopo control of a motor by PLC and HMI

Fig. 7.3a – Connections on the panels for the electric control system of a pulse / start-stop contactor by PLC and HMI Panel. Power connections at 400 V, PLC outputs at 24 Vac.

- 100 -
 EXERCISE 7: Pulse / start-stop control of a motor by PLC and HMI

Fig. 7.3b – Connections on the panels for the electric control system of a pulse / start-stop contactor by PLC and HMI Panel. Aux. power supply of PLC and HMI, PLC inputs at 24 Vdc.

- 101 -
EXERCISE 7: Pulse / start-stop control of a motor by PLC and HMI

Example of program for the pulse / start-stop control of a motor by PLC and HMI.
Filename: [C-IID_EV] PLC Exercise 7 [FC2], HMI page Exercise 7

- 102 -
 EXERCISE 7: Pulse / start-stop control of a motor by PLC and HMI

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 103 -
EXERCISE 8: Separate control of two motors by PLC and HMI

EXERCISE 8 – Separate control of two motors by PLC and HMI

OBJECTIVE
Carry out the connections and start the program of the PLC and of
HMI panel to manage the control and signalling system, referred to a
machine with two small three-phase asynchronous motors controlled
separately from each other.
The system will be completed with a signalling circuit with:
 warning light indicating motors in rest condition
 warning light indicating motor A running
 warning light indicating motor B running
 warning light indicating the tripping of thermal protections
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
2 three-phase asynchronous squirrel-cage motors mod. M-4/EV or P-
4/EV (if available)
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 8.1, for the automation with the PLC and HMI; power
circuit does not change.
N.B.: the wiring diagram is extracted from exercise 5 of the handbook
of industrial systems mod. C-II/EV; consequently, refer to the relevant
chapter of this handbook for any in-depth examination and functional
description of the circuit.

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),

- 104 -
 EXERCISE 8: Separate control of two motors by PLC and HMI

 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 8.2, or in carrying out the
connections as shown in the lay-out of figs. 8.3a and 8.3b.

Remember that the two contactors Q1 and Q2 are interlocked

mechanically; if they must be used in this exercise, remove the
mechanical interlock, or use contactors Q1 and Q3.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- emergency stop control of hardware type via a NC contact connected
in series with the coils of contactors, and another NC contact, or via a
NO contact connected with an input of the PLC,
- protection devices against overcurrents with NC contacts connected
in series with the contactor coils, and NO contacts connected with
inputs of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC;
- the warning lights of standstill motors and of motor overload must be
shunted before the emergency button, so that they do not depend on
the position of the emergency pushbutton.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vdc and the auxiliary supply voltage of
24 Vac. After the positive testing of the (Hardware and Software)
control section, enable also the power supply of power circuit and
complete the testing.

- 105 -
EXERCISE 8: Separate control of two motors by PLC and HMI

Fig. 8.1 – Traditional wiring diagram for the separate control of two motors.

- 106 -
 EXERCISE 8: Separate control of two motors by PLC and HMI

Meaning of the variables of the PLC and of HMI panel

Name Type of data Address Description
1 S5 NC %I0.0 Emergency pushbutton
2 F1 NO %I0.1 Motor protector of motor M1
3 S1 NC %I0.2 Stop button of motor M1
4 S2 NO %I0.3 Start button of motor M1
5 Q1_C NO %I0.4 Auxiliary contact of Q1
6 F2 NO %I0.5 Motor protector of motor M2
7 S3 NC %I0.6 Stop button of motor M2
8 S4 NO %I0.7 Start button of motor M2
9 Q2_C NO %I1.0 Auxiliary contact of Q2
10 Q1 Coil of 24 Vac %Q0.0 Coil of contactor of motor M1
11 Q2 Coil of 24 Vac %Q0.1 Coil of contactor of motor M2
12 P1 24 V %Q0.2 Warning light of motor M1 running
13 P2 24 V %Q0.3 Warning light of motor M2 running
14 P3 24 V %Q0.4 Warning light of standstill motors
15 P4 24 V %Q0.5 Warning light of motor overload

Fig. 8.2 – Wiring diagram for the separate control of two motors by PLC and HMI.

- 107 -
EXERCISE 8: Separate control of two motors by PLC and HMI

Fig. 8.3a – Connections on the panels for the electric system of separate control of two motors by PLC and HMI Panel. Power connections at 400 V, PLC outputs at 24 Vac.

- 108 -
 EXERCISE 8: Separate control of two motors by PLC and HMI

Fig. 8.3b - Connections on the panels for the electric system of separate control of two motors by PLC and HMI Panel. Aux. power supply of PLC and HMI, PLC inputs at 24 Vdc.

- 109 -
EXERCISE 8: Separate control of two motors by PLC and HMI

Example of program for the separate control of two motors by PLC and HMI.
Filename: [C-IID_EV] PLC Exercise 8 [FC3], HMI page Exercise 8

- 110 -
 EXERCISE 8: Separate control of two motors by PLC and HMI

Example of a page of HMI panel for displaying the state of two motors: standstill, M1
running, M2 running, overload.

- 111 -
EXERCISE 9: Reversing contactor for three-phase asynchronous motor controlled by PLC and HMI

EXERCISE 9 – Reversing contactor for three-phase asynchronous

motor controlled by PLC and HMI panel

OBJECTIVE
Use the PLC to assemble a system for obtaining the reversal of
rotation of a three-phase asynchronous motor via contactors, the
control of forward run-stop-reverse run and relevant signal lamps.
Then create a page of HMI to indicate the state of the motor.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor of 0.3-1 kW mod. M-
4/EV or P-4/EV (if available)
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 9.1, for the automation with the PLC and HMI; power
circuit does not change.
N.B.: the wiring diagram is extracted from exercises 6, 7 and 8 of the
handbook of industrial systems mod. C-II/EV; consequently, refer to
the relevant chapters of this handbook for any in-depth examination
and functional description of the circuit.

OPERATIONAL MODE
Describing this very important application for its wide range of uses
(lifts, freight elevators, gates, cranes) requires a preliminary remark. A
three-phase asynchronous motor will reverse the direction of its
rotation when two power phases of stator winding exchange; if the
two contactors are not prevented from working simultaneously, a
bolted short circuit will occur between two phases.

- 112 -
 EXERCISE 9: Reversing contactor for three-phase asynchronous motor controlled by PLC and HMI

Remember that contactors Q1 and Q2 are interlocked

mechanically, but that does not prevent from carrying out also the
electrical interlock.

Students are invited:

 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 9.2, or in carrying out the
connections as shown in the lay-out of figures 9.3a, 9.3b and 9.3c.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- protection device against over currents with NC contact connected in
series with the contactor coils, and NO contact connected with an
input of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC;
- the electric interlock between the two contactors will be carried out
not only via software, but also via NC physical contacts; mechanical
interlock is optional or additional.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vdc and the auxiliary supply voltage of
24 Vac. After the positive testing of the (Hardware and Software)
control section, enable also the power supply of power circuit and
complete the testing.

- 113 -
EXERCISE 9: Reversing contactor for three-phase asynchronous motor controlled by PLC and HMI

Fig. 9.1 – Reversing contactor for a traditional three-phase asynchronous motor.

- 114 -
 EXERCISE 9: Reversing contactor for three-phase asynchronous motor controlled by PLC and HMI

Meaning of the variables of the PLC and of HMI panel

Name Type of data Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 Motor stop button
3 S2 NO %I0.2 Forward running button
4 S4 NO %I0.3 Reverse running button
5 Q1_C NO %I0.4 Auxiliary contact of Q1
6 Q2_C NO %I0.5 Auxiliary contact of Q2
7 Q1 Coil of 24 Vac %Q0.0 Coil of forward running contactor
8 Q2 Coil of 24 Vac %Q0.1 Coil of reverse running contactor
9 P1 24 V %Q0.2 Warning light of standstill motor
10 P2 24 V %Q0.3 Warning light of running motor
11 P3 24 V %Q0.4 Warning light for overload

Fig. 9.2 – Wiring diagram for reversing contactor controlled by PLC and HMI.

- 115 -
EXERCISE 9: Reversing contactor for three-phase asynchronous motor controlled by PLC and HMI

Fig. 9.3a - Connections on the panels for the reversing contactor of a three-phase asynchronous motor, controlled by PLC and HMI Panel. Power connections at 400 V, aux. power supply of PLC and HMI at 24 Vdc.

- 116 -
 EXERCISE 9: Reversing contactor for three-phase asynchronous motor controlled by PLC and HMI

Fig. 9.3b - Connections on the panels for the reversing contactor of a three-phase asynchronous motor, controlled by PLC and HMI Panel. Connections of PLC outputs at 24 Vac.

- 117 -
EXERCISE 9: Reversing contactor for three-phase asynchronous motor controlled by PLC and HMI

Fig. 9.3c - Connections on the panels for the reversing contactor of a three-phase asynchronous motor, controlled by PLC and HMI Panel. Connections of PLC inputs at 24 Vdc.

- 118 -
 EXERCISE 9: Reversing contactor for three-phase asynchronous motor controlled by PLC and HMI

Example of program for reversing contactor for three-phase asynchronous motor; control by
PLC and HMI. Filename: [C-IID_EV] PLC Exercise 9 [FC4], HMI page Exercise 9

- 119 -
EXERCISE 9: Reversing contactor for three-phase asynchronous motor controlled by PLC and HMI

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 120 -
 EXERCISE 10: Reversing contactor for three-phase asynchronous motor with limit switches, PLC and HMI

EXERCISE 10 – Reversing contactor for three-phase asynchronous

motor with limit switches, control by PLC and HMI Panel

OBJECTIVE
Use a PLC and the HMI to assemble a reversing contactor for a three-
phase asynchronous motor of forward-reverse running for conveyor
belt, with control pushbuttons and limit switches in the two extreme
positions; include also the overload protection and the warning lights
for signalling forward running, reverse running and tripping of
thermal relay. Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor of 0.3-1 kW mod. M-
4/EV or P-4/EV (if available)
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 10.1, for the automation with the PLC and HMI; power
circuit does not change.
N.B.: the wiring diagram is extracted from exercises 9 and 10 of the
handbook of industrial systems mod. C-II/EV; consequently, refer to
the relevant chapters of this handbook for any in-depth examination
and functional description of the circuit.

OPERATIONAL MODE
Describing this very important application for its wide range of uses
(lifts, freight elevators, gates, cranes) requires a preliminary remark. A
three-phase asynchronous motor will reverse the direction of its
rotation when two power phases of stator winding exchange; if the
two contactors are not prevented from working simultaneously, a
bolted short circuit will occur between two phases.

- 121 -
EXERCISE 10: Reversing contactor for three-phase asynchronous motor with limit switches, PLC and HMI

Remember that contactors Q1 and Q2 are interlocked

mechanically, but that does not prevent from carrying out also the
electrical interlock.

Students are invited:

 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 10.2, or in carrying out the
connections as shown in the lay-out of figures 10.3a, 10.3b and 10.3c.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- NC limit switches, connected in series, as in the case of wired logic,
- protection device against over currents with NC contact connected in
series with the contactor coils, and NO contact connected with an
input of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC;
- the electric interlock between the two contactors will be carried out
not only via software, but also via NC physical contacts; mechanical
interlock is optional or additional.
TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vdc and the auxiliary supply voltage of
24 Vac. After the positive testing of the (Hardware and Software)
control section, enable also the power supply of power circuit and
complete the testing.

- 122 -
 EXERCISE 10: Reversing contactor for three-phase asynchronous motor with limit switches, PLC and HMI

Fig. 10.1 – Reversing contactor for three-phase asynchronous motor with limit switches.

- 123 -
EXERCISE 10: Reversing contactor for three-phase asynchronous motor with limit switches, PLC and HMI

Meaning of the variables of the PLC and of HMI panel

Name Type Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 Motor stop button
3 S2 NO %I0.2 Forward running button
4 S4 NO %I0.3 Reverse running button
5 Q1_C NO %I0.4 Auxiliary contact of Q1
6 Q2_C NO %I0.5 Auxiliary contact of Q2
7 B1 NC %I0.6 Limit switch of Forward run
8 B2 NC %I0.7 Limit switch of Reverse run
9 Q1 Coil of 24 Vac %Q0.0 Coil of contactor for Forward run
10 Q2 Coil of 24 Vac %Q0.1 Coil of contactor for Reverse run
11 P1 24 V %Q0.2 Warning light of motor Forward running
12 P2 24 V %Q0.3 Warning light of motor Reverse running
13 P3 24 V %Q0.4 Warning light for motor overload

Fig. 10.2 – Wiring diagram for reversing contactor for three-phase asynchronous motor,
control by PLC and HMI Panel.

- 124 -
 EXERCISE 10: Reversing contactor for three-phase asynchronous motor with limit switches, PLC and HMI

Fig. 10.3a - Connections on the panels for the reversing contactor of a three-phase asynchronous motor with limit switches, PLC and HMI. Power connections at 400 V, aux. power supply of PLC and HMI at 24 Vdc.

- 125 -
EXERCISE 10: Reversing contactor for three-phase asynchronous motor with limit switches, PLC and HMI

Fig. 10.3b - Connections on the panels for the reversing contactor of a three-phase asynchronous motor with limit switches, PLC and HMI. Connections of PLC outputs at 24 Vac.

- 126 -
 EXERCISE 10: Reversing contactor for three-phase asynchronous motor with limit switches, PLC and HMI

Fig. 10.3c - Connections on the panels for the reversing contactor of a three-phase asynchronous motor with limit switches, PLC and HMI. Section of PLC inputs at 24 Vdc.

- 127 -
EXERCISE 10: Reversing contactor for three-phase asynchronous motor with limit switches, PLC and HMI

Example of program for reversing contactor for three-phase asynchronous motor, with limit
switches, PLC and HMI.
Filename: [C-IID_EV] PLC Exercise 10 [FC5], HMI page Exercise 10

- 128 -
 EXERCISE 10: Reversing contactor for three-phase asynchronous motor with limit swiches, PLC and HMI

Example of a page of HMI panel for displaying the state of a motor: forward run, reverse run,
overload.

- 129 -
 EXERCISE 11: Star-delta starting by PLC and HMI

EXERCISE 11 - Star-delta starting by PLC and HMI Panel

OBJECTIVE
Assemble an electric system including power, control and signalling
circuits for the Star - Delta starting of a three-phase asynchronous
motor controlled by PLC and HMI. This system must be completed
with warning lights signalling:
- motor in rest condition
- motor started and motor in starting phase (flashing light)
- tripping of protection against overloads.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor of 0.3-1 kW mod. M-
4/EV or P-4/EV (if available). N.B.: if the available supply voltage is
380-400 V, a Y/D motor with voltage of 660-690 / 380-400 V is
necessary.

Remark: if panel mod. C-IIC/EV is not available, however enabling

the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 11.1, for the automation with the PLC and HMI; power
circuit does not change.
N.B.: the wiring diagram is extracted from exercise 13 of the
handbook of industrial systems mod. C-II/EV; consequently, refer to
the relevant chapter of this handbook for any in-depth examination
and functional description of the circuit.

- 130 -
 EXERCISE 11: Star-delta starting by PLC and HMI

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 11.2, or in carrying out the
connections as shown in the lay-out of figs. 11.3a, 11.3b and 11.3c.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- protection device against over currents with NC contact connected in
series with the contactor coils, and NO contact connected with an
input of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC;
- the electric interlock between the star and delta contactors will be
carried out not only via software, but also via NC physical contacts;
mechanical interlock is optional or additional.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vdc and the auxiliary supply voltage of
24 Vac. After the positive testing of the (Hardware and Software)
control section, enable also the power supply of power circuit and
complete the testing.

- 131 -
EXERCISE 11: Star-delta starting by PLC and HMI

Fig. 11.1 - Star – delta starter for a traditional three-phase asynchronous motor.

- 132 -
 EXERCISE 11: Star-delta starting by PLC and HMI

Meaning of the variables of the PLC and of HMI panel

Name Type of data Address Description
1 S1 NC %I0.0 Stop pushbutton
2 F1 NO %I0.1 Motor protector
3 S2 NO %I0.2 Start pushbutton
4 Q1_C NO %I0.3 Auxiliary contact of Q1
5 Q3_C NO %I0.4 Auxiliary contact of Q3
6 Q4_C NO %I0.5 Auxiliary contact of Q4
7 Q1 Coil of 24 Vac %Q0.0 Coil of Line contactor
8 Q3 Coil of 24 Vac %Q0.1 Coil of Star (Y) contactor
9 Q4 Coil of 24 Vac %Q0.2 Coil of Delta (D) contactor
10 P1 24 V %Q0.3 Warning light of standstill motor
11 P2 24 V %Q0.4 Warning light of running motor
12 P3 24 V %Q0.5 Warning light for overload

Fig. 11.2 – Wiring diagram of a star-delta starter for three-phase

asynchronous motor controlled by PLC and HMI Panel.
.
- 133 -
EXERCISE 11: Star-delta starting by PLC and HMI

Fig. 11.3a – Connections on the panels for a star-delta starter of a three-phase asynchronous motor, controlled by PLC and HMI. Power connections at 400 V, aux. power supply of PLC and HMI at 24 Vdc.

- 134 -
 EXERCISE 11: Star-delta starting by PLC and HMI

Fig. 11.3b - Connections on the panels for a star-delta starter of a three-phase asynchronous motor, controlled by PLC and HMI. Connections of PLC outputs at 24 Vac.

- 135 -
EXERCISE 11: Star-delta starting by PLC and HMI

Fig. 11.3c - Connections on the panels for a star-delta starter of a three-phase asynchronous motor, controlled by PLC and HMI. Section of PLC inputs at 24 Vdc.

- 136 -
 EXERCISE 11: Star-delta starting by PLC and HMI

Example of program for the star-delta starter of a three-phase asynchronous motor, controlled
by PLC and HMI. Filename: [C-IID_EV] PLC Exercise 11 [FC6], HMI page Exercise 11

- 137 -
EXERCISE 11: Star-delta starting by PLC and HMI

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 138 -
 EXERCISE 12: Starting via stator resistors controlled by PLC and HMI

EXERCISE 12 - Starting via stator resistors controlled by PLC

and HMI panel

OBJECTIVE
Use a PLC and HMI to assemble an electric system including power,
control and signalling circuits for the starting of a three-phase
asynchronous motor with resistors connected in series with stator.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor of 0.3-1 kW mod. M-
4/EV or P-4/EV (if available)
1 three-phase rheostat 3 x 50  3 x 500 W (position the slider at the
centre to obtain two almost equal resistive sectors), if available.
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 12.1, for the automation with the PLC and HMI; power
circuit does not change.
N.B.: the wiring diagram is extracted from exercise 14 of the
handbook of industrial systems mod. C-II/EV; consequently, refer to
the relevant chapter of this handbook for any in-depth examination
and functional description of the circuit.

OPERATIONAL MODE
Students are invited:

- 139 -
EXERCISE 12: Starting via stator resistors controlled by PLC and HMI

 to fill in the table of PLC - HMI variables (make a photocopy of

the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 12.2, or in carrying out the
connections as shown in the lay-out of figs. 12.3a, 12.3b and 12.3c.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- protection device against over currents with NC contact connected in
series with the contactor coils, and NO contact connected with an
input of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vdc and the auxiliary supply voltage of
24 Vac. After the positive testing of the (Hardware and Software)
control section, enable also the power supply of power circuit and
complete the testing.
This exercise requires the removal of the mechanical interlock
between contactors Q3 and Q4.

- 140 -
 EXERCISE 12: Starting via stator resistors controlled by PLC and HMI

Fig. 12.1 - Traditional two-step starting of a three-phase asynchronous motor via stator
resistors.

- 141 -
EXERCISE 12: Starting via stator resistors controlled by PLC and HMI

Meaning of the variables of the PLC and of HMI panel

Name Type of data Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 Stop pushbutton
3 S2 NO %I0.2 Start pushbutton
4 Q1_C NO %I0.3 Auxiliary contact of Q1
5 Q3_C NO %I0.4 Auxiliary contact of Q3
6 Q4_C NO %I0.5 Auxiliary contact of Q4
7 Q1 Coil of 24 Vac %Q0.0 Coil of contactor Q1
8 Q3 Coil of 24 Vac %Q0.1 Coil of contactor Q3
9 Q4 Coil of 24 Vac %Q0.2 Coil of contactor Q4
10 P1 24 V %Q0.3 Warning light of standstill motor
11 P2 24 V %Q0.4 Warning light of running motor
12 P3 24 V %Q0.5 Warning light for overload

Fig. 12.2 – Wiring diagram for two-step starting of a three-phase asynchronous motor via
stator resistors controlled by PLC and HMI Panel.

- 142 -
 EXERCISE 12: Starting via stator resistors controlled by PLC and HMI

Fig. 12.3a - Connections on the panels for the two-step starting of a three-phase asynchronous motor via stator resistors, controlled by PLC and HMI. Power connections at 400 V, aux. power supply of PLC and
HMI at 24 Vdc.

- 143 -
EXERCISE 12: Starting via stator resistors controlled by PLC and HMI

Fig. 12.3b - Connections on the panels for the two-step starting of a three-phase asynchronous motor via stator resistors, controlled by PLC and HMI. Connections of PLC outputs at 24 Vac.

- 144 -
 EXERCISE 12: Starting via stator resistors controlled by PLC and HMI

Fig. 12.3c - Connections on the panels for the two-step starting of a three-phase asynchronous motor via stator resistors, controlled by PLC and HMI. Section of PLC inputs at 24 Vdc.

- 145 -
EXERCISE 12: Starting via stator resistors controlled by PLC and HMI

Example of program for starting with stator resistors of a three-phase asynchronous motor,
controlled by PLC and HMI.
Filename: [C-IID_EV] PLC Exercise 12 [FC7], HMI page Exercise 12

- 146 -
 EXERCISE 12: Starting via stator resistors controlled by PLC and HMI

Continuation of file: [C-IID_EV] PLC Exercise 12 [FC7], HMI page Exercise 12.

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 147 -
EXERCISE 13: Starting a TAM by autotransformer, control by PLC and HMI

EXERCISE 13 – Starting a TAM by autotransformer, sequence

control by PLC and HMI Panel

OBJECTIVE
Implement the automation for the control of the starting of a three-
phase asynchronous squirrel-cage motor by autotransformer. The
system will also include a signalling circuit with:
 warning light indicating motor in starting phase,
 warning light indicating motor already started,
 warning light indicating the tripping of the protection against
overload.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor of 0.3-1 kW mod. M-
4/EV or P-4/EV (if available)
1 three-phase autotransformer for starting motor mod. SA-M/EV or
SA-P/EV (if available).
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation
.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 13.1, for the automation with the PLC and HMI; power
circuit does not change.
N.B.: the wiring diagram is extracted from exercise 15 of the
handbook of industrial systems mod. C-II/EV; consequently, refer to
the relevant chapter of this handbook for any in-depth examination
and functional description of the circuit.

- 148 -
 EXERCISE 13: Starting a TAM by autotransformer, control by PLC and HMI

DISCUSSION
Examining this circuit leads to infer that the “sequence” having to be
implemented in the logic module looks like the starting by stator or
rotor resistors.

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 13.2, or in carrying out the
connections as shown in the lay-out of figs. 13.3a, 13.3b and 13.3c.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- protection device against overcurrents with NC contact connected in
series with the contactor coils, and NO contact connected with an
input of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vdc and the auxiliary supply voltage of
24 Vac. After the positive testing of the (Hardware and Software)
control section, enable also the power supply of power circuit and
complete the testing.

- 149 -
EXERCISE 13: Starting a TAM by autotransformer, control by PLC and HMI

This exercise requires the removal of the mechanical interlock

between contactors Q3 and Q4.

Fig. 13.1 - Traditional starting of a three-phase asynchronous motor by autotransformer.

- 150 -
 EXERCISE 13: Starting a TAM by autotransformer, control by PLC and HMI

Meaning of the variables of the PLC and of HMI panel

Name Type of data Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 Stop pushbutton
3 S2 NO %I0.2 Start pushbutton
4 Q1_C NO %I0.3 Auxiliary contact of Q1
5 Q3_C NO %I0.4 Auxiliary contact of Q3
6 Q4_C NO %I0.5 Auxiliary contact of Q4
7 Q1 Coil of 24 Vac %Q0.0 Coil of contactor Q1
8 Q3 Coil of 24 Vac %Q0.1 Coil of contactor Q3
9 Q4 Coil of 24 Vac %Q0.2 Coil of contactor Q4
10 P1 24 V %Q0.3 Warning light of standstill motor
11 P2 24 V %Q0.4 Warning light of running motor
12 P3 24 V %Q0.5 Warning light for overload

Fig. 13.2 – Wiring diagram for starting a three-phase asynchronous motor by

autotransformer; control by PLC and HMI Panel.

- 151 -
EXERCISE 13: Starting a TAM by autotransformer, control by PLC and HMI

Fig. 13.3a – Connections on the panels for starting a three-phase asynchronous motor by autotransformer; control by PLC and HMI. Power connections at 400 V, aux. power supply of PLC and HMI at 24 Vdc.

- 152 -
 EXERCISE 13: Starting a TAM by autotransformer, control by PLC and HMI

Fig. 13.3b - Connections on the panels for starting a three-phase asynchronous motor by autotransformer; control by PLC and HMI. Connections of PLC outputs at 24 Vac.

- 153 -
EXERCISE 13: Starting a TAM by autotransformer, control by PLC and HMI

Fig. 13.3c - Connections on the panels for starting a three-phase asynchronous motor by autotransformer; control by PLC and HMI. Section of PLC inputs at 24 Vdc.

- 154 -
 EXERCISE 13: Starting a TAM by autotransformer, control by PLC and HMI

Example of program for starting a three-phase asynchronous motor by autotransformer; control by

PLC and HMI. Filename: [C-IID_EV] PLC Exercise 13 [FC8], HMI page Exercise 13

- 155 -
EXERCISE 13: Starting a TAM by autotransformer, control by PLC and HMI

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 156 -
 Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

EXERCISE 14 – Starting via rotor resistors by steps, control by

PLC and HMI Panel

OBJECTIVE
Assemble an electric system including power, control and signalling
circuits for the starting of a three-phase asynchronous wound-rotor
motor. Automation is implemented by a PLC and HMI that control the
exclusion of two sets of resistors.
This system must be completed with three warning lights:
- warning light P1 on = standstill motor,
- warning light P2 on = motor started; flashing = motor still in
starting phase
- warning light P3 on = tripping of the protection against overloads.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor mod. M-5/EV or P-
5/EV (if available)
1 three-phase rheostat 3 x 50  3 x 500 W (position the slider at the
centre to obtain two almost equal resistive sectors), if available.
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 14.1, for the automation with the PLC and HMI; power
circuit does not change.
N.B.: the wiring diagram is extracted from exercise 17 of the
handbook of industrial systems mod. C-II/EV; consequently, refer to
the relevant chapter of this handbook for any in-depth examination
and functional description of the circuit.

- 157 -
Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 14.2, or in carrying out the
connections as shown in the lay-out of figs. 14.3a, 14.3b and 14.3c.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- protection device against overcurrents with NC contact connected in
series with the contactor coils, and NO contact connected with an
input of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vdc and the auxiliary supply voltage of
24 Vac. After the positive testing of the (Hardware and Software)
control section, enable also the power supply of power circuit and
complete the testing.
This exercise requires the removal of the mechanical interlock
between contactors Q3 and Q4.

- 158 -
 Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

Fig. 14.1 - Traditional two-step rotor starting of a three-phase asynchronous motor.

- 159 -
Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

Meaning of the variables of the PLC and of HMI panel

Name Type of data Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 Motor stop button
3 S2 NO %I0.2 Start pushbutton
4 Q1_C NO %I0.3 Auxiliary contact of Q1
5 Q3_C NO %I0.4 Auxiliary contact of Q3
6 Q4_C NO %I0.5 Auxiliary contact of Q4
7 Q1 Coil of 24 Vac %Q0.0 Coil of contactor Q1
8 Q3 Coil of 24 Vac %Q0.1 Coil of contactor Q3
9 Q4 Coil of 24 Vac %Q0.2 Coil of contactor Q4
10 P1 24 V %Q0.3 Warning light of standstill motor/overload
11 P2 24 V %Q0.4 Warning light of running motor

Fig. 14.2 - Wiring diagram for two-step rotor starting of a three-phase asynchronous motor
controlled by PLC and HMI Panel.

- 160 -
 Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

Fig. 14.3a – Connections on the panels for the two-step rotor starting of a three-phase asynchronous motor controlled by PLC and HMI. Power connections at 400 V, aux. power supply of PLC and HMI at 24 Vdc.

- 161 -
Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

Fig, 14.3b - Connections on the panels for the two-step rotor starting of a three-phase asynchronous motor controlled by PLC and HMI. Connections of PLC outputs at 24 Vac.

- 162 -
 Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

Fig. 14.3c - Connections on the panels for the two-step rotor starting of a three-phase asynchronous motor controlled by PLC and HMI. Section of PLC inputs at 24 Vdc.

- 163 -
Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

Example of program for starting a three-phase asynchronous motor via rotor resistor; control by
PLC and HMI. Filename: [C-IID_EV] PLC Exercise 14 [FC9], HMI page Exercise 14.

- 164 -
 Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

Continuation of file: [C-IID_EV] PLC Exercise 14 [FC9], HMI page Exercise 14.

- 165 -
Exercise 14: Starting via rotor resistors by steps; control by PLC and HMI

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 166 -
 EXERCISE 15: Remote pole changing switch for Dahlander motors controlled by PLC and HMI

EXERCISE 15 – Remote pole changing switch for single-

winding (Dahlander) motors, controlled by PLC and HMI Panel

OBJECTIVE
Assemble an electric system including power, control and signalling
circuits for the control of a three-phase asynchronous squirrel-cage
motor with two speeds and only one winding (Dahlander). This
system must be completed with a signalling circuit with:
 warning light indicating motor running slowly
 warning light indicating motor running fast
 warning light indicating the tripping of protection against
overloads.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor mod. M-6/EV or P-
6/EV (if available)
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section of the wiring diagram
shown in fig. 15.1, for the automation with the PLC and HMI; power
circuit does not change.
N.B.: the wiring diagram is extracted from exercise 20 of the
handbook of industrial systems mod. C-II/EV; consequently, refer to
the relevant chapter of this handbook for any in-depth examination
and functional description of the circuit.

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),

- 167 -
EXERCISE 15: Remote pole changing switch for Dahlander motors controlled by PLC and HMI

 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 15.2, or in carrying out the
connections as shown in the lay-out of figs. 15.3a, 15.3b and 15.3c.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- protection device against over currents with NC contact connected in
series with the contactor coils, and NO contact connected with an
input of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vdc and the auxiliary supply voltage of
24 Vac. After the positive testing of the (Hardware and Software)
control section, enable also the power supply of power circuit and
complete the testing.
In this exercise it is better that contactors Q1 and Q2 are
interlocked mechanically.

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 EXERCISE 15: Remote pole changing switch for Dahlander motors controlled by PLC and HMI

Fig. 15.1 - Remote pole changing switch for a single-winding (Dahlander) motor.

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EXERCISE 15: Remote pole changing switch for Dahlander motors controlled by PLC and HMI

Meaning of the variables of the PLC e and of HMI panel

Name Type of data Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 Motor stop button
3 S2 NO %I0.2 Slow running button
4 S4 NO %I0.3 Fast running button
5 Q1_C NO %I0.4 Auxiliary contact of Q1
6 Q2_C NO %I0.5 Auxiliary contact of Q2
7 Q3_C NO %I0.6 Auxiliary contact of Q3
8 Q1 Coil of 24 Vac %Q0.0 Coil of contactor Q1
9 Q2 Coil of 24 Vac %Q0.1 Coil of contactor Q2
10 Q3 Coil of 24 Vac %Q0.2 Coil of contactor Q3
11 / / %Q0.3 Available
12 P2 24 V %Q0.4 Warning light of slow run
13 P3 24 V %Q0.5 Warning light for tripping of motor protector
14 P4 24 V %Q0.6 Warning light of fast run

Fig. 15.2 - Remote pole changing switch for a single-winding (Dahlander) motor, controlled
by PLC and HMI Panel.
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 EXERCISE 15: Remote pole changing switch for Dahlander motors controlled by PLC and HMI

Fig. 15.3a – Connections on the panels for remote pole changing switch for a single-winding (Dahlander) motor, controlled by PLC and HMI. Power connections at 400 V, aux power supply of PLC and HMI at 24 Vdc.

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EXERCISE 15: Remote pole changing switch for Dahlander motors controlled by PLC and HMI

Fig. 15.3b - Connections on the panels for remote pole changing switch for a single-winding (Dahlander) motor, controlled by PLC and HMI. Connections of PLC outputs at 24 Vac.

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 EXERCISE 15: Remote pole changing switch for Dahlander motors controlled by PLC and HMI

Fig. 15.3c - Connections on the panels for remote pole changing switch for a single-winding (Dahlander) motor, controlled by PLC and HMI. Section of PLC inputs at 24 Vdc.

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EXERCISE 15: Remote pole changing switch for Dahlander motors controlled by PLC and HMI

Example of program of a remote pole changing switch of a Dahlander three-phase asynchronous

motor; controlled by PLC and HMI.
Filename: [C-IID_EV] PLC Exercise 15 [FC10], HMI page Exercise 15.

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 EXERCISE 15: Remote pole changing switch for Dahlander motors controlled by PLC and HMI

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

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EXERCISE 16: Reverse current braking of a three-phase asynchronous motor, controlled by PLC and HMI

EXERCISE 16 – Reverse current braking of a three-phase

asynchronous motor, controlled by PLC and HMI Panel

OBJECTIVE
Use PLC and HMI Panel to assemble an electric system including
power, control and signalling circuits for controlling the braking of a
three-phase asynchronous squirrel-cage motor. When the motor is
running, pressing the emergency stop button must enable a circuit that
reverses the rotation of the motor only for the time required to reduce
its RPM near zero. Motor RPM will be controlled by a specific
braking relay. Pressing the normal stop button must not enable any
braking. This system controlled by PLC must be provided with a
unique warning light signalling what indicated here below:
- warning light out = standstill motor
- warning light on = motor started
- warning light flashing slowly = tripping of protection against
overloads
- warning light flashing fast = emergency braking phase.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor mod. M-4/EV, 1
braking relay mod. FRC-1/EV and 1 three-phase rheostat for limiting
the braking action 3 x 50  - 3 x 500 W, if they are available.
Remark 1: adjust the rheostat for a more or less strong braking.
Remark 2: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panel/s on the working top so that they are perfectly
stable. Complete/modify the control section (use only one warning
light) of the wiring diagram shown in fig. 16.1, for the automation
with the PLC and HMI; power circuit does not change.
N.B.: the wiring diagram is extracted from exercises 21, 22 of the
handbook of industrial systems mod. C-II/EV; consequently, refer to
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 EXERCISE 16: Reverse current braking of a three-phase asynchronous motor, controlled by PLC and HMI

the relevant chapter of this handbook for any in-depth examination

and functional description of the circuit.

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 16.2, or in carrying out the
connections as shown in the lay-out of figs.16.3a, 16.3b and 16.3c.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- protection device against over currents with NC contact connected in
series with the contactor coils, and NO contact connected with an
input of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC;
- the electric interlock between the two contactors will be carried out
not only via software, but also via NC physical contacts; mechanical
interlock is optional or additional.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vdc and the auxiliary supply voltage of
24 Vac. After the positive testing of the (Hardware and Software)
control section, enable also the power supply of power circuit and

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EXERCISE 16: Reverse current braking of a three-phase asynchronous motor, controlled by PLC and HMI

complete the testing.

Fig. 16.1 - Reverse current braking of a traditional three-phase asynchronous motor.

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 EXERCISE 16: Reverse current braking of a three-phase asynchronous motor, controlled by PLC and HMI

Meaning of the variables of the PLC and of HMI panel

Name Type of data Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 Motor stop button
3 S2 NO %I0.2 Start pushbutton
4 R FRE NO %I0.3 Enabling the braking relay (*)
5 S5 NC %I0.4 Emergency stop button
6 Q1_C NO %I0.5 Auxiliary contact of Q1
7 Q2_C NO %I0.6 Auxiliary contact of Q2
8 Q1 Coil of 24 Vac %Q0.0 Coil of contactor for running motor
9 Q2 Coil of 24 Vac %Q0.1 Coil of contactor for braking
10 P1 24 V %Q0.2 Warning light for various signalling
(*)use the contact closing when motor is running, and opening with standstill motor.

Fig. 16.2 - Wiring diagram for reverse current braking of a three-phase asynchronous motor,
controlled by PLC and HMI Panel.
- 179 -
EXERCISE 16: Reverse current braking of a three-phase asynchronous motor, controlled by PLC and HMI

Fig. 16.3a – Connections on the panels for the reverse current braking of a three-phase asynchronous motor controlled by PLC and HMI. Power connections at 400 V, aux power supply of PLC and HMI at 24 Vdc.

- 180 -
 EXERCISE 16: Reverse current braking of a three-phase asynchronous motor, controlled by PLC and HMI

Fig. 16.3b - Connections on the panels for the reverse current braking of a three-phase asyinchronous motor controlled by PLC and HMI. Connections of PLC outputs at 24 Vac.

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EXERCISE 16: Reverse current braking of a three-phase asynchronous motor, controlled by PLC and HMI

Fig. 16.3c - Connections on the panels for the reverse current braking of a three-phase asyinchronous motor controlled by PLC and HMI. Section of PLC inputs at 24 Vdc.

- 182 -
 EXERCISE 16: Reverse current braking of a three-phase asynchronous motor, controlled by PLC and HMI

Example of program for reverse current braking of a three-phase asynchronous motor; control
by PLC and HMI. Filename: [C-IID_EV] PLC Exercise 16 [FC11], HMI page Exercise 16

- 183 -
 EXERCISE 16: Reverse current braking of a three-phase asynchronous motor, controlled by PLC and HMI

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 184 -
 EXERCISE 17: Sequential start of motors controlled by PLC and HMI

EXERCISE 17 - Sequential start of motors controlled by PLC

and HMI Panel

OBJECTIVE
Use PLC and HMI panel to assemble the electric control system
concerning a machine with sequential control of 4 motors.
Suppose to carry out the following start optimized for handling of
goods on conveyor belts.
Pressing the start button will start the sequence
- starting belt 1 (motor 1)
- after time “t”, starting belt 2 (motor 2) and stopping belt 1
- after time “t”, starting belt 3 (motor 3) and stopping belt 2
- after time “t”, starting belt 4 (motor 4) and stopping belt 3
- after time “t”, stopping belt 4 (motor 4)
- sequence can restart.
Pressing the stop button will stop belts only at the end of the
sequence.
Pressing the emergency button will immediately stop all belts (all
the motors).
This system will also include a warning light that starts flashing to
signal process in progress.
Process will be checked on message display that indicates its phases
(standstill machine, belt 1, belt 2, etc…).
When the protections against overload of motor/s trip, sequence will
stop and the message display will show a flashing message of faulty
motor/s.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for control
circuit
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
Remark: assemble only the circuit of outputs at 24 Vac and of inputs
at 24 Vdc to PLC and HMI; use the contacts of the two limit switches
included in mod. C-IIC/EV to simulate the two missing motor
protectors; motors are optional, the sequence can be seen on
contactors.

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EXERCISE 17: Sequential start of motors controlled by PLC and HMI

PREPARING THE EXERCISE

Position the panel on the working top so that it is perfectly stable.
Assemble the wiring diagram shown in fig. 17.1, for the automation
with the PLC and HMI.

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,
 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the wiring diagram of fig. 17.2, or in carrying out the
connections as shown in the lay-out of figs. 17.3a and 17.3b.

SAFETY WARNINGS
The operation of the system controlled by programmable logic will be
the same of that controlled by wired logic.
Make sure that the auxiliary power supply units of HMI panel and of
PLC, as well as their digital inputs, must use direct voltage (24 Vdc)
output by a different power supply unit from that powering the digital
relay outputs that operate at 24 Vac.

It is extremely important for the safety of the equipment and of people

that the control program and the circuit being assembled include:
- stop controls via NC pushbuttons as in the case of wired logic,
- emergency control via NC pushbutton connected in series with the
coils of contactors, and via another contact connected with the PLC
input,
- protection devices against over currents with NC contacts connected
in series with the contactor coils, and NO contacts connected with
inputs of the PLC,
- interrogation of the operational state of contactors via NO contacts
connected with inputs of the PLC and of HMI panel.

TESTING
First of all enable the operation of the PLC and HMI with the
auxiliary supply voltage of 24 Vac.

- 186 -
 EXERCISE 17: Sequential start of motors controlled by PLC and HMI

Fig. 17.1 - Sequential start of 4 motors; electric power diagram.

- 187 -
EXERCISE 17: Sequential start of motors controlled by PLC and HMI

Meaning of the variables of the PLC and of HMI panel

Name Type of data Address Description
1 S1 NC %I0.0 STOP button
2 S2 NO %I0.1 START button
3 S5 NC %I0.2 EMERGENCY button
4 F1 NO %I0.3 Motor protector 1
5 F2 NO %I0.4 Motor protector 2
6 F3 NO %I0.5 Motor protector 3 (*)
7 F4 NO %I0.6 Motor protector 4 (*)
8 Q1_C NO %I0.7 Auxiliary contact of Q1
9 Q2_C NO %I1.0 Auxiliary contact of Q2
10 Q3_C NO %I1.1 Auxiliary contact of Q3
11 Q4_C NO %I1.2 Auxiliary contact of Q4
12 Q1 Coil of 24 Vac %Q0.0 Coil of contactor of motor 1
13 Q2 Coil of 24 Vac %Q0.1 Coil of contactor of motor 2
14 Q3 Coil of 24 Vac %Q0.2 Coil of contactor of motor 3
15 Q4 Coil of 24 Vac %Q0.3 Coil of contactor of motor 4
16 P1 24 V %Q0.4 Warning light of conveyor belts running
17
18
(*) Use the contacts of the two limit switches instead of the contacts of motor protectors F3
and F4.

- 188 -
 EXERCISE 17: Sequential start of motors controlled by PLC and HMI

Fig. 17.2 – Wiring diagram for the control of a machine by PLC and HMI Panel concerning the
sequential start of 4 motors.

- 189 -
EXERCISE 17: Sequential start of motors controlled by PLC and HMI

Fig. 17.3a – Connections on the panels for the sequential start of 4 motors controlled by PLC and HMI Panel. Power connections at 400 V, auxiliary power supply of PLC and HMI at 24 Vdc.

- 190 -
 EXERCISE 17: Sequential start of motors controlled by PLC and HMI

Fig. 17.3b - Connections on the panels for the sequential start of 4 motors controlled by PLC and HMI Panel. Connections of PLC outputs at 24 Vac.

- 191 -
EXERCISE 17: Sequential start of motors controlled by PLC and HMI

Fig. 17.3c - Connections on the panels for the sequential start of 4 motors controlled by PLC and HMI Panel. Section of PLC inputs at 24 Vdc.

- 192 -
 EXERCISE 17: Sequential start of motors controlled by PLC and HMI

Example of program for sequential start of 4 motors, controlled by PLC and HMI.
Filename: [C-IID_EV] PLC Exercise 17 [FC12], HMI page Exercise 17

- 193 -
EXERCISE 17: Sequential start of motors controlled by PLC and HMI

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 194 -
 EXERCISE 18: Controlling a TAM by PWM inverter, PLC and HMI for forward-reverse sequences

EXERCISE 18 – Controlling a three-phase asynchronous motor by

PWM inverter, PLC and HMI for forward - reverse sequences and
different speeds

OBJECTIVE
Assemble the electric control system of a three-phase asynchronous
squirrel-cage motor of 0.3-0.75 kW driven electronically (PWM
inverter), including PLC and HMI for the control of an operational
sequence with different directions of rotation and speeds.
As the automatic sequence starts, the TAM must run in clockwise
direction for 10 s at slow speed (10 Hz), then it will stop for 2 s and it
will start turning in counterclockwise direction at high speed (33 Hz)
for 3 s; after 5 s repeat the cycle.
Operational phases:
 wire the electric system of power circuit,
 wire the control circuit and the warning lights controlled by PLC
(PLC inputs and outputs),
 write and transfer the program into the PLC and HMI.

NECESSARY EQUIPMENT
1 Panel mod. C-IID/EV
1 Panel mod. C-IIC/EV for control and protection devices
1 fixed single-phase power supply unit of 220-230 Vac for auxiliary
circuits
1 fixed three-phase power supply unit of 380-400 Vac for power
circuit
1 set of leads with safety plugs with diameter of 4 mm.
1 three-phase asynchronous squirrel-cage motor of 0.3-1 kW mod. M-
4/EV or P-4/EV (if available)
Remark: if panel mod. C-IIC/EV is not available, however enabling
the PLC inputs suitably will allow to program the PLC and HMI and
to analyze the circuit operation.

PREPARING THE EXERCISE

Position the panels on the working top so that they are perfectly
stable. Assemble the wiring diagram shown in fig. 18.1, for the
automation with PLC and HMI.

OPERATIONAL MODE
Students are invited:
 to fill in the table of PLC - HMI variables (make a photocopy of
the blank table available in Appendix B),
 complete the wiring diagram of the PLC and of HMI panel (make a
photocopy of the connection diagram of the PLC and of HMI panel
available in Appendix B),
 write and transfer the program into the PLC,
 write and transfer the graphic page into the HMI,

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EXERCISE 18: Controlling a TAM by PWM inverter, PLC and HMI for forward-reverse sequences

 plot the connections among the electrical devices using the lay-out
of the panels available in Appendix A, as a first step; it is better to
make two photocopies and draw the connections of power circuit 3
x 400 V, together with the PLC outputs of 24 Vac, and draw the
power section and the inputs of PLC and of HMI at 24 Vdc,
separately.

An alternative consists in connecting the various electric components

according to the lay-out of figures18.2a and 18.2b.

Fig. 18.1 - Controlling a three-phase asynchronous motor by inverter, with forward-reverse

sequences and different speeds managed by PLC and HMI.

Meaning of the variables of the PLC and of HMI panel

Name Type of data Address Description
1 F1 NO %I0.0 Motor protector
2 S1 NC %I0.1 STOP button
3 S2 NO %I0.2 START button
4 F 24 Vdc %Q0.0 Enabling clockwise rotation
5 R 24 Vdc %Q0.1 Enabling counterclockwise rotation
6 VEL1 24 Vdc %Q0.2 Retrieving speed 1
7 VEL2 24 Vdc %Q0.3 Retrieving speed 2
8 P1 24 Vdc %Q0.4 Sequence enabled
9 P2 24 Vdc %Q0.5 Motor protector tripping

- 196 -
 EXERCISE 18: Controlling a TAM by PWM inverter, PLC and HMI for forward-reverse sequences

Fig. 18.2a – Connections on the panels for the control of a TAM by inverter, forward-reverse sequences and different speeds managed by PLC and HMI. Power connections at 400 Vac and auxiliary power supply of
PLC and HMI at 24 Vdc.

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EXERCISE 18: Controlling a TAM by PWM inverter, PLC and HMI for forward-reverse sequences

Fig. 18.2b - Connections on the panels for the control of a TAM by inverter, forward-reverse sequences and different speeds managed by PLC and HMI. Connections of aux power supply of PLC and HMI, inverter
inputs and controls at 24 Vdc.

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 EXERCISE 18: Controlling a TAM by PWM inverter, PLC and HMI for forward-reverse sequences

Setting the parameters of inverter

Standard parameters are programmed when inverters are
manufactured.
Parameters are divided into 4 main categories.
 Basic parameters: parameters having to be programmed before the
inverter is used for the first time
 Extended parameters: parameters for special and detailed setting
 User parameters (function of automatic search): they indicate the
different parameters from those standard of default setup. They are
used to check and modify the setting
 Historical parameter inventory: it displays the last five parameters
modified, in reverse chronological order. This function is useful
when an inverter is programmed repeatedly with the same
parameter.

Range of adjustment for the parameters of inverter

- HI = an attempt of assigning a higher value than that of the
programmable range has been carried out. Or the modification of
other parameters has led to the result that the programmed value of
the parameter, currently selected, exceeds the maximum threshold
- LO = an attempt of assigning a lower value than that of the
programmable range has been carried out. Or the modification of
other parameters has led to the result that the programmed value of
the parameter, currently selected, drops below the lower threshold.
If the aforesaid alarm signals start flashing, no value being equivalent
or higher than HI nor equivalent or lower than LO can be set.

Programming the parameters of inverter

All the parameters can be programmed according to the sequence of
buttons indicated here below:
[MODE] it switches to parameter setting mode
[Turning Left/Right] Selecting the parameter having to be modified
[ENTER] Reading the current parameter setting [Center of the dial]
Turning Left/Right] Modifying the parameter setting
[ENTER] Saving the modified parameter [Center of the dial]
In case of any error during these operations, press button [MODE] to
return to indication 0.0

Programming and/or checking the parameters for the exercise’s

objective.
Refer to the tables of complete parameters (chapter 7 of the
operational handbook included in the CD of the inverter).

Conditions of use, adjustments/optimizations of the inverter:

Modify or check parameter CNOd = 0 (control of forward/reverse run
from external device connected with terminal board F-R).
Modify or check parameter FNOd = 0 (setting the frequency by signal
from internal potentiometer).

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EXERCISE 18: Controlling a TAM by PWM inverter, PLC and HMI for forward-reverse sequences

Name Function Range of adjustment

CNOd Selecting start/stop control mode 0: Terminal board
1: Panel 1
FNOd Frequency setting mode 0: Setting the internal potentiometer
1: VIA
2: VIB
3: Operational panel
4: Series communication
5: Up/down external contacts
6: VIA+VIB (summation of inputs)

Adjusting parameter UL = 60.0, for instance, enables to set the

maximum threshold frequency at 60 Hz. It is important that parameter
FH too is set equal to / or higher than UL.

Modify or check parameter ACC = 2.0 (acceleration time of 2 s) and

parameter dEC = 0.3 (deceleration or braking time of 0.3 s).

Symbol Function Range of adjustment Default setting

ACC Acceleration time (s) 0.0 – 3200 s 10 s
dEC Deceleration time (s) 0.0 – 3200 s 10s
FH Maximum frequency (Hz) 30.0 – 500.0 Hz 80.0 Hz
UL Maximum threshold frequency (Hz) 0.5 - FH 50. 0 Hz
LL Minimum threshold frequency (Hz) 0.0 – 30.0 Hz 0. 0 Hz

Enabling different speeds of rotation of the motor. Combining the

three inputs S1…S3 of inverter will enable to retrieve the 7 available
RPM memories in binary logic.

Symbol Function Range of adjust. Default value

Sr1…Sr7 Preset frequency, corresponding retrieval of memory 1…7 Da LL a UL 0.0

Modify or check parameter Sr1 = 10.0 (output frequency at 10 Hz)

and parameter Sr2 = 33.0 (output frequency at 33 Hz).

Example of programming:
Symbol Setting S1 S2 S3
Sr1 Program at 10 Hz X
Sr2 Program at 33 Hz X

N.B.: the RPM preset in parameter CNOd = 0 can be enabled only

after the command of forward run or reverse run has also been sent.

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 EXERCISE 18: Controlling a TAM by PWM inverter, PLC and HMI for forward-reverse sequences

Example of program for the control of a TAM by inverter, forward - reverse sequences and
different speeds controlled by PLC and HMI.
Filename: [C-IID_EV] PLC Exercise 18 [FC13], HMI page Exercise 18

- 201 -
EXERCISE 18: Controlling a TAM by PWM inverter, PLC and HMI for forward-reverse sequences

Exercise 18 continues [FC13]

- 202 -
 EXERCISE 18: Controlling a TAM by PWM inverter, PLC and HMI for forward-reverse sequences

Example of a page of HMI panel for displaying the state of a motor: standstill, run, overload.

- 203 -
 SETTING THE PANEL AT WORK AND SERVICING OPERATIONS

SETTING PANEL mod. C-IID/EV AT WORK

 Power the panel using a single-phase power supply unit of 230 V with
protection earth, frequency of 50-60 Hz for the auxiliary services, and
a three-phase power supply unit 3 x 400 V for the presence asymmetry
and sequence failure phase relay and for the inverter.

 Carry out the electrical connections of both power and control circuits,
being the power supply disconnected.

 As regards the functional description of the panel and the

programming of the devices, refer to the section of exercises of this
handbook.

The applications of this panel are optimized when it is used together with
the panel for testing industrial installations in wired logic mod. C-
IIC/EV: thus control buttons, limit switches, motor protectors and
contactors coupled with the electronic devices included in the panel, can
be used to assemble applications with the PLC, the soft starter and the
inverter.

- 204 -
 SETTING THE PANEL AT WORK AND SERVICING OPERATIONS

Elettronica Veneta S.p.A. EQUIPMENT SERVICING FORM

Panel mod. CIID/EV Serial number: all Date of production: from January 2013

Manufacturer: Elettronica Veneta S.p.A.

Address: Via Postumia No. 16 - Motta di Livenza (TV – Italy)
After-sales service: at Elettronica Veneta’s premises
Reference documents: □ Operational handbook □ Wiringt diagrams

It is recommended to carry out the servicing operations at least every four months.
Considering a normal school year, make that the two servicing cycles coincide with the
beginning of the two four-month periods.
If apparatuses are used even beyond the classic school period, it would be better to carry out
also a third servicing cycle to cover the residual time.

Checking and servicing schedule

Operator
Object Check Action
(date and
signature)
Cleaning Presence of dust Remove with a dry and ……………..
soft cloth
……………..
Visual check of Check that these parts are Replace the parts
……………..
electric parts intact and well fixed onto damaged or removed.
the panel Tighten and lock all the ……………..
loosened parts
Electric operation General functional test. Signal or replace any ……………..
Refer to the exercises faulty device
proposed in the operational ……………..
handbook
Kit of accessories Check that leads of 4 mm Replace the leads not ……………..
are intact complying with the
safety standards ……………..

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APPENDIX A - LAY-OUT OF PANEL mod. C-IID/EV

- 206 -
APPENDIX A - LAY-OUT OF PANEL mod. C-IIC/EV

- 207 -
APPENDIX A - LAY-OUT OF PANELS mod. C-IIC/EV & C-IID/EV

Reference: Name: Form: Date:

APPENDIX A - LAY-OUT OF PANELS mod. C-IIC/EV & C-IID/EV

Reference: Name: Form: Date:

APPENDIX B - LIST OF MEANINGS OF VARIABLES AND DIAGRAM OF PLC

Meaning of the variables of PLC and of HMI

Name Type of data Address Description

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

Reference: Name: Form: Date:

 Connections and configuration of PLC and of HMI in Profinet

Diagram of connections of PLC

Reference: Name: Form: Date:

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