6/13/2021 Motor Speed Control using VFD and PLC Programming | Ladder Logic

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Motor Speed Control using VFD and PLC

Programming
BACnet Modbus Converter
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This is PLC Program to control motor speed using VFD drive.

Motor Speed Control

A VFD drive controls the motor speed. The VFD can be controlled remotely by using
PLC/DCS systems.

The PLC has to give set point for VFD drive to control the motor speed, this can
achieved either automatically from the PLC or by the operator action from the HMI.

Piezo Motion
Rapid response time: 10μs. Open and closed-loop options available

nonmagnetic

learn.piezomotion.com OPEN

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6/13/2021 Motor Speed Control using VFD and PLC Programming | Ladder Logic

According to set point value, PLC willX control the drive

PLC Program for Food Processing Industry
speed and VFD drive finally
T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S
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controls
P LC TU TO RI Athe
LS motor speed. Write PLC program for this
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PLC Program Food Processing Industry This is PLC
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Program to detect burned chips and remove them by
flip flop in PLC using ladder diagram progra…
using PLC. Problem Description Potato chips are mad…

Problem Diagram

Problem Solution
For controlling we used here PID function so according to set point it will
automatically control drive speed.
As per name, PID controller consists main three coefficients: proportional,
integral and derivative.
For VFD drive control explanation, we will use setpoint for drive from the PLC
(50RPM). PID function will maintain the speed as per setting.
According to set point PID will generate output and the VFD drive receives the
PLC input and maintains the required motor speed.

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6/13/2021 Motor Speed Control using VFD and PLC Programming | Ladder Logic

Here we are considering 4-20mA

PLC Program for Food Processing Industry
X signal for VFD drive input (required speed
T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S
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setpoint from PLC) and feedback from the Tdrive

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also 4-20mA
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List of inputs/outputs
Digital Inputs/Analog Inputs

PID Enable :- I0.0

Manual Enable :- I0.1
PID reset :- I0.2
4-20mA signal form drive :- IW64

Digital outputs/Analog output

Analog output for drive :- QW80

M memory

Set point PID :- MD500

PID output for drive :- MW762
Run mode by startup :- M0.3

PLC Ladder diagram to control Motor Speed

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6/13/2021 Motor Speed Control using VFD and PLC Programming | Ladder Logic

X X
PLC Program for Food Processing Industry T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S

P LC TU TO RI A LS T Flip Flop Logic using PLC This is PLC Program to

implement T flip flop. Problem Description Implement T
PLC Program Food Processing Industry This is PLC
flip flop in PLC using ladder diagram progra…
Program to detect burned chips and remove them by
using PLC. Problem Description Potato chips are mad…

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6/13/2021 Motor Speed Control using VFD and PLC Programming | Ladder Logic

X X
PLC Program for Food Processing Industry T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S

P LC TU TO RI A LS T Flip Flop Logic using PLC This is PLC Program to

implement T flip flop. Problem Description Implement T
PLC Program Food Processing Industry This is PLC
flip flop in PLC using ladder diagram progra…
Program to detect burned chips and remove them by
using PLC. Problem Description Potato chips are mad…

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6/13/2021 Motor Speed Control using VFD and PLC Programming | Ladder Logic

X X
PLC Program for Food Processing Industry T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S

P LC TU TO RI A LS T Flip Flop Logic using PLC This is PLC Program to

implement T flip flop. Problem Description Implement T
PLC Program Food Processing Industry This is PLC
flip flop in PLC using ladder diagram progra…
Program to detect burned chips and remove them by
using PLC. Problem Description Potato chips are mad…

Program Description
For this application we use S7-1200 PLC and TIA portal software for programming. We
can implement this logic by using other PLC also.

Network 1:- 

In network we configured standard parameters for PID function.

“Drive PID”.sRet.r_Ctrl_Gain:- saved proportional gain or P gain for PID (1.0).

“Drive PID”.sRet.r_Ctrl_Ti:-Saved integral time or I gain for PID (20s).

Network 2:-

“Drive PID”.sRet.r_Ctrl_Td:-Saved derivative time or D gain for PID (0s).

Network 3:-

Here we have taken drive PID max output limit and minimum output limit. We have
considered here max limit for PID output 100 and minimum limit is 0.

Network 4 :-

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6/13/2021 Motor Speed Control using VFD and PLC Programming | Ladder Logic

Sampling time of the PID_Compact instruction

X
PLC Program for Food Processing Industry
r_Cycle is determined automatically and
T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S
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usually
P LC TU TO RIequivalent
A LS to the cycle time of the calling OB. Consider
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Flop Logic using Thisthis
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Program to
implement T flip flop. Problem Description Implement T
PLC Program Food Processing Industry This is PLC
flip flop in PLC using ladder diagram progra…
Program to detect burned chips and remove them by
using PLC. Problem Description Potato chips are mad…
Network 5 :-

When PID enable (I0.0) is pressed PID block will be executed. As per SET point
(MD500) it will generate output (0-27648) and according to speed drive will give
feedback (IW96) to PID.Manual enable (I0.1) is for manual operation and PID reset
(I0.2) is for resetting the PID.

Network 6 :-

Activate Mode after CPU restart If sb_RunModeByStartup = FALSE, the controller will
remain inactive after a CPU startup. After a CPU startup and if sb_RunModeByStartup =
TRUE, the controller will return to the most recently active operating mode.

Network 7 :-

When PID enable switch (I0.0) is pressed, Drive (Q0.0) will be enabled.

Network 8 :-

Moving PID output (MW762) to Analog channel (QW96) of the expansion module of
the PLC.

Set 50 RPM form the HMI and enable PID so PID will generate output according to set
point. After getting output from PID drive will run on 50 RPM and it will generate mA
according to speed. After reaching set point PID will maintain 50 RPM.

In above application we have considered S7-1200 PLC. There are two on board analog
inputs (Voltage) in this CPU. So for this application we need consider one more

$expansion module which has analog input facilities with current

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6/13/2021 Motor Speed Control using VFD and PLC Programming | Ladder Logic

X X
PLC Program for Food Processing Industry T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S

P LC TU TO RI A LS T Flip Flop Logic using PLC This is PLC Program to

implement T flip flop. Problem Description Implement T
PLC Program Food Processing Industry This is PLC
flip flop in PLC using ladder diagram progra…
Program to detect burned chips and remove them by
using PLC. Problem Description Potato chips are mad…

In TIA portal software, select analog output type > current and range > 4-20mA

Note :- Above application may be different from actual application. This example is
only for explanation purpose only. We can implement this logic in other PLC also. This
is the simple concept of drive speed control using PID.

All parameters considered in example are for explanation purpose only, parameters
may be different in actual applications.

For PID we need to configure so many parameter, here we configured parameters only
for our application. Hence all parameters are not configured here.

Runtime Test Cases

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6/13/2021 Motor Speed Control using VFD and PLC Programming | Ladder Logic

X X
PLC Program for Food Processing Industry T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S

P LC TU TO RI A LS T Flip Flop Logic using PLC This is PLC Program to

implement T flip flop. Problem Description Implement T
PLC Program Food Processing Industry This is PLC
flip flop in PLC using ladder diagram progra…
Program to detect burned chips and remove them by
using PLC. Problem Description Potato chips are mad…

Author : Bhavesh

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P LC TU TO RI A LS T Flip Flop Logic using PLC This is PLC Program to
implement T flip flop. Problem Description Implement T
PLC Program Food Processing Industry This is PLC
flip flop in PLC using ladder diagram progra…
Program to detect burned chips and remove them by
Reply
using PLC. Problem Description Potato chips are mad…

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PLC Program for Food Processing Industry T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S

P LC TU TO RI A LS T Flip Flop Logic using PLC This is PLC Program to

implement T flip flop. Problem Description Implement T
PLC Program Food Processing Industry This is PLC
flip flop in PLC using ladder diagram progra…
Program to detect burned chips and remove them by
using PLC. Problem Description Potato chips are mad…

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PLC Program for Food Processing Industry T Flip Flop PLC Ladder Diagram P LC TU TO R IA L S

P LC TU TO RI A LS T Flip Flop Logic using PLC This is PLC Program to

implement T flip flop. Problem Description Implement T
PLC Program Food Processing Industry This is PLC
flip flop in PLC using ladder diagram progra…
Program to detect burned chips and remove them by
using PLC. Problem Description Potato chips are mad…
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