International Journal on Recent and Innovation Trends in Computing and Communication ISSN: 2321-8169

Volume: 2 Issue: 10 3092 – 3098

______________________________________________________________________________________________
Monitoring and Control of a Variable Frequency Drive Using PLC and SCADA
Rinchen Geongmit Dorjee
Advanced Technical Training Centre
Bardang, Singtam, East Sikkim
[email protected]

Abstract— Programmable Logic Controller (PLC) and Supervisory Control And Data Acquisition (SCADA) are two new approaches to control
a Variable Frequency Drive (VFD) whose output is fed to a three-phase induction motor and driving a conveyor belt. The conveyor belt has
three sensors are inputs which senses a passing object and carries out the necessary instructions programmed in ladder logic programming of the
PLC through the medium of a personal computer (PC). The SCADA software installed in the PC in turn enables the human operator to control
the entire operation away from the plant and just by using the virtual inputs designated on his computer screen. The results have been verified
with a validating experiment.

Keywords- Variable Frequency Drive, Programmable Logic Controller, Supervisory Control And Data Acquisition, RS-Logix, Intouch Software
9.5
__________________________________________________*****_________________________________________________

I. INTRODUCTION C. Supervisory Control And Data Acquisition Systems

(SCADA)
A. Variable Frequency Drive (VFD)
A Variable Frequency Drive is used for applications SCADA is a system which exercises supervisory
wherein speed control is of an essential importance due to control of a particular device from a remote location and the
load changes wherein the speed needs to be increased or human operator is able to monitor and control the device from
decreased accordingly. Traditional methods in existence have his computer screen without being physically present near the
addressed this issue, each with their own drawbacks such as device.
high motor starting current, lower power factor, energy losses, A PLC based control system was set up comprising of an
etc. To address these problems, VFD provides a flexible Allen-Bradley PLC, an Allen-Bradley PowerFlex 4M
approach as compared to traditional methods of speed control Variable Frequency Drive, a three-phase induction motor and
especially for certain applications which do not require a workstation (personal computer) has been delivered,
constant speed at all times. To name an example, a pump configured and integrated together for the monitoring and
delivering cooling liquid supply may require peak load control of a motor driving a conveyor load.
operation only for a requisite period of time and may require Various control schemes have been used to operate the
only much less amount during the remainder of the day. VFD induction motor in speed and position control modes of
will allow the speed of the pump to run at a lower rate in such operation using PLC programming developed on the
case thereby enabling energy saving benefits. workstation.
Figure 1 shows the real time control set up which was
B. Programmable Logic Controller (PLC) configured and tested for the experiment.

With the advent of technology and availability of motion

control of electric drives, the application of Programmable Figure 1 The real time control set up
Logic Controllers with power electronics in electrical
machines has been introduced in the manufacturing
automation systems. The use of PLC in automation processes
increases reliability and flexibility and also reduces
production costs. To obtain accurate industrial electric drive
systems, it is necessary to use PLC interfaced with power
converters, personal computers and other electric equipment.
A PLC based control system was set up comprising of an
Allen-Bradley PLC, an Allen-Bradley PowerFlex 4M
Variable Frequency Drive, a three-phase induction motor and
workstation ) has been delivered, configured and integrated Figure 1 The real time control set up
together for the monitoring and control of a motor driving a
conveyor load. II. RELATED WORKS
Various control schemes have been used to operate the
A few selected research papers related to PLC and Variable
induction motor in speed and position control modes of
Frequency Drive has been done to study the various
operation using PLC programming developed on the
methodologies used by the researchers.
workstation. J Ahir et al. [2] in their research have worked on the
design and development of PLC and SCADA based control
panel of monitoring of three-phase induction motor. They have
continuously monitored measurements of voltage, current,
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International Journal on Recent and Innovation Trends in Computing and Communication ISSN: 2321-8169
Volume: 2 Issue: 10 3092 – 3098
______________________________________________________________________________________________
temperature and speed for protection purposes. It was found interfacing to the induction motor through an Ethernet
that PLC was able to achieve optimum accuracy with a connection. W J Weber et al. [9] discussed about the advent
virtually power factor along with easy error detection and of the VFD system and its benefits, such as greater reliability,
correction, along with being more reliable than traditional smaller size, lower production costs, better performance and
methods. The monitoring of three-phase induction motor increased automation potential as compared to conventional
driven by VFD, with PLC as a controller provided high methods of control by which it allows continuous control of
accuracy in the regulation of its speed. Maria G. Ioannides et motor speed and torque, thereby increasing efficiency and
al. [3] has developed a PLC based continuously monitoring flexibility. Various processes are sensed and fed back to the
and control of a three-phase induction motor. Various types of central plant controller, which after receiving inputs from an
sensors were used for monitoring the parameters such as speed operator via the Human Machine Interface (HMI). The
and current. With the help of PLC ladder logic programming, controller then instructs the VFD to maintain optimum
it was proven that speed control of motor was achieved with performance according to the desired inputs. The basic
high accuracy as well as efficiency. It was found that at high function of VFD is to synthesize the voltages and frequency
speeds and loads, the efficiency of the system was increased up applied to a motor so as to control and achieve desired speed
to 10 to 12%. In brief this paper proved that PLC was a and/or torque. A R Al-Ali et al. [14] proposed a power factor
versatile and efficient control tool in industrial electric drives controller for a three-phase induction motor using PLC to
applications. N D Ramesh [5] presented a study on PLC improve the power factor of a three-phase induction motor. For
which uses a programmable memory for implementing the purpose of attaining maximum torque, its voltage to
specific functions such as logic sequencing, timing, counting, frequency ratio is kept constant. A three-phase squirrel cage
and arithmetic control through digital or analog input/output induction motor is coupled with a dc shunt generator and an
modules. The functions of PLC include on-off control, electronic conditioning circuit. Features like interlocking, i.e.,
sequential control, feedback control and motion control, to disabling the controller until it detects currents, voltage,
name a few. Industrial PLCs normally operate at an input- frequency and power factor angles, switch failure detection,
output voltage supply of 24V DC. Physical connections from monitoring voltage to frequency ratio constant during
the real world to the PLC are designated inputs such as limit correcting the power factor, independent control of reactive
switches, push button switches, sensors or basically anything currents in each phase and maximum compensation even when
that works on the principle of “switching” a signal on or off. switch failure occurs, have been incorporated. Cristina Anita
Outputs of a PLC are usually solenoids, lamps, contactors, Bejan et al. [16] presented a method of practical laboratories
relays, etc. The number of digital input/outputs can be for teaching purpose in SCADA system which is focused to
increased by adding additional digital input/output modules. develop applications using an integrated automation system
One of the most common methods of PLC programming is from Siemens - Totally Integrated Automation Democase with
also known as Ladder Logic programming which is a language distributed peripheral employing Profibus and Ethernet
using relay symbols as a base in an image similar to a hard- communications. The final application is targeted to control an
wired relay sequence. It looks like a ladder, whose sides are induction motor with associated frequency touch-screen
the power rail on the left and ground rail on the right. The human machine interface to program the motor speed and to
rungs of the ladder consist of virtual relay components which show variables, trends and alarms. Mihai Iacob et al. [17]
perform certain tasks based on the instructions given in the presented the design and implementation of a SCADA system
program. S. Da'na [4] has discussed the design and for a central heating and power plant meant to supervise and
implementation of a platform to remotely monitor and control control field distributed electric devices using Siemens
PLC-based processes over TCP/IP or by using the GSM software and equipment. The old equipments were replaced by
network. The platform is built using industry-standard off-the- using PLCs, servers, modern approaches regarding network
shelf PLCs. Integrated with each PLC are communication equipments and topologies and flexible monitoring stations.
processors that can be used for connectivity to the network and Remote actions and uninterrupted monitoring were made
to a GSM modem. The communication processor module possible due to redundant servers and web-based applications
(Ethernet module) used in this work, provides an industrial via web server. The system was shown to have various
compatible protocol over TCP/IP that achieves the same advantages like remote and safe operation and monitoring
functionality as Profinet but at a much higher bandwidth from anywhere in the world, evolution charts for one week,
(10/100 Mbps). Additionally, a mobile-based communication archives, easy to interpret alarm system and most importantly-
protocol that facilitates remote monitoring and control of PLCs flexibility, scalability and powerful modular structure. Mini J.
using SMS messages has also been developed. The intent here Thomas et al. [18] presented a report about the design,
is to provide system users with a back-up communication commissioning and functioning of a state-of-the-art SCADA
mechanism in case of a network failure. M Zajmovic et al. [6] laboratory facility at Jamia Milia Islamia, New Delhi, India
presented a paper on the management of induction motors which has been designed with a purpose to function as a
using PLC which executes instructions according to the research and training center for utilities, faculty members and
programmed logic and sends signals to the Variable Speed students. This lab provides hands on learning experience on
Drives, from which it receives feedback of the motor speed so SCADA system, and its applications to the management,
as to control its speed by modulation of voltage and frequency. supervision and control of an electric power System. One of
A Zelio PLC was used with the help of a frequency the unique features of the SCADA laboratory, that makes it the
transformer which controlled a 5.5 kW asynchronous induction only one of its kind, is the use of a distributed processing
motor at a speed of 1500 rpm. A windows XP operating system, which supports a global database. Various research
system with SCADA software from DAQFactory was used for activities like adaptive and intelligent control of integrated
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International Journal on Recent and Innovation Trends in Computing and Communication ISSN: 2321-8169
Volume: 2 Issue: 10 3092 – 3098
______________________________________________________________________________________________
power systems, preprocessing of data at the RTU level using induction motor supplied directly from the main supply.
Fuzzy Logic and Fuzzy-Genetic algorithm, substation
automation etc. are already being supported by this laboratory.

Having reviewed some of the work being done in the field

of VFD, PLC and SCADA, the next chapter explains about the
objectives of this present work and the research methodology
being used.

III. OBJECTIVES AND OVERVIEW OF THE PROPOSED

MECHANISM

A. Objectives
A PLC-SCADA based monitoring and control system for
a Variable Frequency Drive system was developed which Figure 2 Torque speed characteristics of induction motor
controls a three-phase induction motor attached to a conveyor
belt, having three proximity sensors serving as inputs to the The base speed of the induction motor is directly proportional
PLC's ladder logic programming. . PLC was introduced in the to the supply frequency and the number of poles of the motor.
1970's for the automotive manufacturing industry to provide a Since it is not possible to change the number of poles, the
replacement for large relay based control panels. With the only option to change the speed of the induction motor is by
advent of the microprocessor, PLCs have been enhanced to changing the supply frequency.
accomplish more complex industrial applications over the
years. SCADA is a type of industrial control system which The torque developed by the induction motor is directly
are computer-controlled systems for monitoring and control of proportional to the ratio of the applied voltage and the
industrial processes. A distinct advantage of SCADA lies in frequency of supply. By changing the voltage and the
the control ability of large scale processes which includes frequency, but by keeping their ratio constant, the torque
multiple sites and large distances. developed can be kept constant throughout the speed range.
This is the main focus of V/f method of speed control. Figure
The integration of PLC and SCADA for industrial 3 shows the torque-speed characteristics of the induction
automation comprises of: a human-machine interface which is motor with VF control.
the device presenting processed data to a human operator,
who monitors and controls the process; a Remote Terminal
Unit collects the information by connecting to sensors in the
process, converting sensor signals to digital data and sending
digital data to the supervisory system after which that
information is displayed on a number of operator screens;
PLC used as field devices for their economical, versatile,
flexible and configurable attributes.
This integrated system provides a platform for developing
the concepts for thorough understanding of how an industrial
automated system works comprising of all the above Figure 3 Torque speed characteristics of induction motor
components.
A constant V/f ratio produces a constant maximum torque,
B. V/f method of speed control except at low speeds or frequencies. The maximum torque
The motor speed can be controlled by varying supply will have lower value in motoring operation and larger value
frequency. Voltage induced in stator is directly proportional to in braking operation due to reduction in flux during motoring
product of supply frequency and air-gap flux. If stator drop is operation and increase in flux during braking operation.
neglected, terminal voltage can be considered proportional to
product of frequency and flux. V1 α f.Φ Effect of supply The advantages of this method are:
frequency change without terminal voltage change: 1. Speed control of motor
1. Reduction of supply frequency without change in 2. Starting current required is lower.
terminal voltage will cause an increase in the air gap 3. Stable operating region of the motor is increased.
flux thereby saturating the motor. This will cause the 4. At base speed, the voltage and frequency
increase in magnetizing current, core loss and stator achieve their rated values.
copper loss and cause distortion in line current and 5. Acceleration and deceleration of the motor can
voltage and produce high-pitch noise. be controlled by controlling the change of
2. Increase of supply frequency without change in supply frequency to the motor with respect to
terminal voltage will cause decrease in flux therefore time.
leading to reduction of torque capability of the C. Overview of the proposed mechanism
motor. A Variable Frequency Drive is a device used in a drive
Figure 2 shows the Torque-Speed characteristics of an system consisting of the following three main sub-systems:
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International Journal on Recent and Innovation Trends in Computing and Communication ISSN: 2321-8169
Volume: 2 Issue: 10 3092 – 3098
______________________________________________________________________________________________
AC motor, main drive controller assembly, and drive operator
interface. The AC electric motor used in a VFD system is a
three-phase induction motor which is generally the most
economical motor choice. The VFD controller is a solid state
power electronics conversion system consisting of three
distinct sub-systems: a rectifier bridge converter, a direct
current link, and an inverter. In a VSI drive, the DC link
consists of a capacitor which smoothens out the converter's
DC output ripple and provides a stiff input to the inverter.
This filtered DC voltage is converted to quasi-sinusoidal AC
voltage output using the inverter's active switching elements. Figure 4 System layout diagram
VSI drives provide higher power factor and lower harmonic
distortion than phase-controlled Current Source Inverter. IV. EXPERIMENTAL WORK
VFD control has been chosen specifically because they A. Experimental setup
provide the advantages of energy savings, low motor starting 1. The Allen-Bradley PowerFlex 4M AC drive is the
current, reduction of thermal and mechanical stresses on smallest and most cost effective drive which provides
motors and belts during starts, simple installation, high power powerful motor speed control in a compact, space
factor and lower KVA. saving design.
A PLC-SCADA based control system has been set up
comprising of an Allen-Bradley PLC, an Allen-Bradley Table 1 shows the VFD specifications used in the
PowerFlex 4M Variable Frequency Drive, a three-phase experiment.
induction motor and the workstation has been developed,
configured and integrated together for the monitoring and Table 1 VFD specifications
control of the motor driving a conveyor belt load.
Various control schemes have been used to operate the Rated Output 0.75 kW (1 Hp)
induction motor in Speed and Position control modes of Rated Voltage 240 V AC, single phase
operation using PLC programming and through animated
SCADA screens developed on the workstation. Rated Current 4.2 A
Variable Frequency Drives are generally required because Rated Torque 3.5 kg
many applications are not run at the same speed all of the time
due to surrounding circumstances. The revolutions per minute
of the driven shaft need to be increased or decreased 2. The PLC used in this project was Allen Bradley
depending on load changes, application requirement or other MicroLogix 1400 series. The basic parts of a 1400
circumstances. series PLC are Power Supply, CPU, Discrete Input
The PLC has been connected to control and monitor a VFD Module and Discrete Output Module.
which is the acts as a go-between the three-phase induction
motor and the PLC. A conveyor load is connected to the Table 2 shows the PLC specifications used in the
induction motor and three proximity sensor inputs are experiment.
connected uniformly across the conveyor. The forward
direction of the motor is controlled by the first sensor, the Table 2 PLC specifications
second sensor directs the motor to pause for a given period of
Sl Description Details
time and the reverse direction of the motor is controlled by the
third sensor. 1 Dimensions HxWxD 90 x 180 x 87 mm
The sensor inputs are fed to the PLC which processes the
inputs according to the ladder logic programming and initiates 2 Weight 0.9 kg
corresponding output to the VFD. The VFD in turn once again
processes the PLC input to it and accordingly controls the 3 Number of I/O 24 inputs (20 digital 4
speed and position of the three-phase induction motor. Ladder analog) and 14 outputs (12
logic programming is carried out in RS-Logix in the personal digital 2 analog)
computer.
SCADA elements are written into the ladder logic program 4 Power supply voltage 24V DC
itself by assigning a tag or point which represents a single Power supply inrush
5 24V DC:
input or output value monitored or controlled by the system. Current
With the help of SCADA system, labour costs are reduced by 15 A for 20 ms
minimizing site visits for inspection, data collection and
making rectifications. User defined controls such as start, stop 6 Power consumption 50W
are developed on the software window in order to control the
system remotely.
Figure 4 shows the system layout diagram.

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International Journal on Recent and Innovation Trends in Computing and Communication ISSN: 2321-8169
Volume: 2 Issue: 10 3092 – 3098
______________________________________________________________________________________________

 Three proximity sensors to detect motion of

3. Input Variables taken: this input within the drive and finally controls the speed
and position of the motor. The ladder logic programming

 Frequency parameter of VFD to control output

object on conveyor belt is shown in Figure 5

4. Output response – speed and position of three-phase

induction motor driving a conveyor belt load.

B. Conduction of Experiments
Allen-Bradley PLC, Allen-Bradley PowerFlex 4M
Variable Frequency Drive, a three-phase induction motor
driving a conveyor belt load controlled by ladder logic
software and Intouch 9.5 software was connected for the
conduction of the experiment in which for various values of
input supply frequencies, the corresponding values of motor
speed in rpm were obtained as shown in Table 3.

Table 3 Frequency input vs. speed output

Input supply Motor speed in

frequency in Hz rpm

0 0

5 250

10 620

15 940

20 1240

25 1495

30 1809

35 2100

40 2350

45 2590

50 2800
Figure 5 Ladder logic programming for VFD control of induction
55 3200
motor

60 3450
B. Frequency vs. speed graph

V. RESULT AND DISCUSSION By varying the frequency of the VFD from 0 to rated
frequency, the speed control of the motor was increased
A. Ladder Logic Programming accordingly. In this way, speed control of the motor was
achieved by varying the frequency. With the help of ladder
The experiments were conducted based on ladder logic programming, motor position was controlled in the
logic programming which is a software installed on a forward and reverse direction as per the object passing
personal computer according to which the PLC takes the through the first and third sensor accordingly.
sensor inputs, processes them according to the program
and gives the output to the VFD which again processes

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International Journal on Recent and Innovation Trends in Computing and Communication ISSN: 2321-8169
Volume: 2 Issue: 10 3092 – 3098
______________________________________________________________________________________________
Figure 6 shows the graph for the experiment conducted
VI. CONCLUSION
4000
3500
3000
Input
2500 supply
2000 frequenc
1500 y in Hz
1000
500
0
Figure 7 SCADA screen shot of animation of real-time control setup
1 4 7 10 13
VI. CONCLUSION
Figure 6 Frequency input vs. speed output The present work was motivated to develop a scheme to
monitor and control a Variable Frequency Drive using PLC. A
C. SCADA program output thorough study of all the hardware components was done
including their specifications, functioning and overall
The SCADA program was also written using ladder logic performance. Software platform namely AllenBradley ladder
and then run simultaneously from the SCADA screen logic programming RS Linx was comprehended, analysed and
developed by Intouch Software Edition 9.5 The SCADA implemented.
software enables human operator to control the entire A 0.75 KW three-phase induction motor was fully
operation away from the plant and just by using the virtual automated using a Variable Frequency Drive and PLC. The
inputs designated on his computer screen. Table 4 shows the drive used in this set-up offered various control modes of
input-output address of the SCADA program. Figure 7 shows motor operation. The configuration and settings to run the
the SCADA screen shot of animation of the plant which was motor in two control modes viz., speed and position were
previously controlled by the ladder logic program. This type done systematically A ladder logic program was developed
of motor control is helpful when the operator has to control and verified in RS Linx software which enabled the motor to
the motor from a remote location directly through the screen obtain two different positions in succession with a specified
of the workstation. time interval between the positions. A complete study and
practical hands on the PLC and the drive operation have
Table 4 Input-output address of SCADA program imparted a fairly good idea about the industrial automation
TAG ACCESS
systems.
NAME TAG TYPE NAME TAG LINK
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International Journal on Recent and Innovation Trends in Computing and Communication ISSN: 2321-8169
Volume: 2 Issue: 10 3092 – 3098
______________________________________________________________________________________________
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