Electric Power / Controls

PLC S7 – 300 Applications Wind Turbine

1-800-Lab-Volt www.labvolt.com

85303-30

Job Sheets - Instructor

Electric Power / Controls

PLC S7 – 300 Applications

Wind Turbine

Job Sheets - Instructor

85303-30

ELECTRIC POWER / CONTROLS

PLC S7 – 300 APPLICATIONS WIND TURBINE

by the Staff

of Lab-Volt Ltd.

Copyright © 2009 Lab-Volt Ltd.

All rights reserved. No part of this publication may be reproduced, in any form or by any means, without the prior written permission of Lab-Volt Ltd.

Legal Deposit - Second Trimester 2009

ISBN 978-2-89640-332-5

FIRST EDITION, JUNE 2009

Printed in Canada June 2009

To the Instructor

Lab-Volt's Programmable Logic Controller, Basic Principles Using the Programming Software student manual (P/N 36017) allowed the reader to become familiar with PLCs and ladder programming. This was accomplished with the help of Lab-Volt's Programmable Logic Controller Training System (Model S7 - 300). The aim of the present series of PLC applications is to integrate the basic principles previously acquired by designing small-scale systems that can be found in the real world. Through practical examples, students will gain a strong knowledge of the PLC field of study. Each manual of the PLC applications series concentrates on a specific example of PLC application that evolves along a path of increasing complexity. With each manual, new components are added to the PLC module to create different opportunities to learn. This Instructor Guide provides the instructor with complete solutions to all procedure questions found in the corresponding student manual. The instructor should be familiar with PLCs to recognize erroneous results. It is advised that a complete run- through of each job sheet be included in the instructor's preparation for class. Each Job Sheet has several performance objectives. The instructor should ensure that each student understands them. The Analog I/O Expansion is necessary to perform the manipulations pertaining to the wind direction measurement and the subsequent control on the orientation of the nacelle. Optional modules can be added to the electrical circuits: - The Wiring modules (P/N 3205) are used to practice wiring skills, to include a

different PLC, or to interface the Analog I/O. - An Emergency Switch (P/N 3204) instantly stops the system in case of

malfunction.

III

IV

Job Sheet 1 Job Sheet 2 Job Sheet 3 Job Sheet 4

Table of Contents

Familiarization with the Wind Turbine . . . . . . . . . . . . . . . . . . 1 Wind Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Complete Nacelle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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PLC Applications - Wind Turbine

JOB SHEET 1 FAMILIARIZATION WITH THE WIND TURBINE ANSWERS TO PROCEDURE STEP QUESTIONS

3.

4.

Figure 1-1. Measurement of the Wind Speed.

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PLC Applications - Wind Turbine

There are many other indicators which can be of interest. Among them are: - A pilot light indicating an unsteady wind (wind speeds must then be

compared over time). - A pilot light indicating the wind is in the normal operating range. - A pilot light indicating a command is contradictory (such as asking for

clockwise and counter-clockwise rotations at the same time). - Etc...

6.

Figure 1-3. Ladder Program of Job Sheet 1.

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PLC Applications - Wind Turbine

Figure 1-4. Ladder Program of Job Sheet 1 (cont'd).

JOB SHEET 2 WIND TRACKING To attach the expansion module to the PLC, be sure to follow the instructions in the user guide. The wind vane installed on the Nacelle Simulator has been calibrated in such a way that, when the tail of the wind vane is aligned with the rear of the nacelle, the output voltage is 5.00 V (or about 16380 out of 32760 on a reading of I:1.0 using RSLogix 500). This sets the discontinuous transition from 10 V to 0 V at the back of the nacelle. This is done in order to avoid discontinuities in the program's logic. The wind vane should remain well calibrated but you can perform a recalibration by simply inserting an Allen key (Hex key) in the small hole in the cap of the wind vane to unscrew it. Adjust the potentiometer under the cap to perform the calibration, then replace the cap and screw it snugly. ANSWERS TO PROCEDURE STEP QUESTIONS 2.

Note to the Instructor: The Analog I/O can be used in current or voltage modes. To switch from one mode to another, simply set the relevant switch to the required position. Switch 1 pertains to channel 0 and switch 2 to channel 1. The "ON" position is for the current mode and the "OFF" position is for voltage mode. Voltage mode is the mode to use for this series of Job Sheets on Wind Turbine control with PLCs.

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PLC Applications - Wind Turbine

8.

Figure 2-4. Ladder Program of Job Sheet 2.

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PLC Applications - Wind Turbine

Figure 2-5. Ladder Program of Job Sheet 2 (cont'd).

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PLC Applications - Wind Turbine

Figure 2-6. Ladder Program of Job Sheet 2 (cont'd).

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PLC Applications - Wind Turbine

JOB SHEET 3 COMPLETE NACELLE OPERATION ANSWERS TO PROCEDURE STEP QUESTIONS 4. It prevents the registration of multiple counts if the yaw motor is

stopped and started many times while the turn detector is still in a true state.

Figure 3-1. Counting Block.

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PLC Applications - Wind Turbine

7.

Figure 3-4. Ladder Program of Job Sheet 3.

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PLC Applications - Wind Turbine

Figure 3-5. Ladder Program of Job Sheet 3 (cont'd).

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JOB SHEET 4 TROUBLESHOOTING ANSWERS TO PROCEDURE STEP QUESTIONS 2.

Note to the Instructor: Provide the program of your choice to your students. You may choose to provide the program of Figure 3-4 of the Instructor Guide for the guided part and a modified version containing faults for the non-guided troubleshooting part.

4. Yes.

The motor does not rotate in the clockwise direction when it should do so.

5. The answers should be Yes for all questions.

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PLC Applications - Wind Turbine

6. Yes.

Yes. b. Electrical.

- A mechanical failure of the motor is unlikely, especially as it works fine in the other direction.

7. The problem is located in the clockwise motor control wiring of the

nacelle.

The problem likely originates from a faulty connection inside the nacelle (open-circuit) or a defective motor. Investigate further the electrical connection inside the nacelle. Determine if the motor is in need of repairs. Perform the required reparations.

9. Choose a fault or two from the list provided below. You can also supply a different ladder program containing programming faults.

10. Electrical faults can be:

# FAULT DESCRIPTION

1 Opens the PLC input 0 circuitry 2 Disables PLC inputs 4 to 9 by opening their

DC COM terminals

3 Short-circuits PLC inputs 7 and 8 4 Opens the circuitry of the second analog

input [IV2(+)]

5 Opens the PLC output 4 circuitry 6 Disables PLC outputs 2 to 5 by opening

their DC 24V+ circuitry

7 Opens the PLC output 1 circuitry 8 Removes power from the ten 24-VDC input

switches of the trainer front panel

Table 4-1. Fault description (PLC trainer, Model S7 - 300).

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PLC Applications - Wind Turbine

# 1 2 3 4 5 6

7 8

9

10 11 12

FAULT DESCRIPTION

Opens the circuitry to PLC input 0 Opens the circuitry to PLC input 2 Opens the circuitry to PLC input 3 Opens the circuitry to PLC input 5 Opens the circuitry to PLC input 9 Creates a short circuit between the circuitry to PLC inputs 11 and 12 Opens the circuitry to PLC input 13 Removes power from the 24-VDC input switches of the trainer front panel Opens the PLC output 0 circuitry Opens the PLC output 4 circuitry Opens the PLC output 7 circuitry Opens the PLC output 9 circuitry

Table 4-2. Fault description (PLC trainer, Model S7 - 300).

# FAULT DESCRIPTION

1 Opens the circuitry of the Turn Counter NO Contact

2 Opens the circuitry of the Wind Direction Output

3 Opens the circuitry of the Clockwise Motor Control

4 Opens the circuitry of the Wind Speed Output

Table 4-3. Fault description (Nacelle Simulator, Model 3297).

Programming faults can be: - Changing instruction types (e.g. NC for NO or TON for TOF). - Mixing the addresses of the inputs and outputs. - Logic errors.

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PLC Applications - Wind Turbine

ANSWERS TO POST-TEST 1. c.; 2. b.; 3. d.; 4. a.; 5. c.; 6. b.; 7. d.; 8. d.; 9. d.; 10. b.

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