PLC App

Electric Power / Controls
PLC Applications
Wind Turbine
1-800-Lab-Volt
www.labvolt.com
85303-20
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Job Sheets – Student

Electric Power / Controls
PLC Applications
Wind Turbine
Job Sheets – Student

85303-20
A
ELECTRIC POWER / CONTROLS
PLC 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 978-2-89640-331-8
FIRST EDITION, JUNE 2009
Printed in Canada
June 2009
Foreword
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 3240).
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.
We hope that your learning experience with the PLC Training System will be the first
step of a successful career.
III
IV
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Job Sheet 1 Familiarization with the Wind Turbine . . . . . . . . . . . . . . . . 1-1
Introducing the wind turbine system. Measuring the wind speed

using a counter and a timer in a structured ladder program. Scaling
the wind speed measurement. Comparing the wind speed with
preset values. Creating a manual control on the yaw-axis motor of
the nacelle.
Job Sheet 2 Wind Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Measuring wind direction and adjusting its scale. Implementing

conditional tracking of the wind. Creating an automatic or a manual
control of position.
Job Sheet 3 Complete Nacelle Operation . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Counting completed turns. Positional reset of the nacelle when the

rotation limit is reached. Automatic reset in case of wind shortage.
Job Sheet 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Guided and non-guided ways of finding an inserted fault in the Wind

Turbine PLC.
Appendices A Lab-Volt PLC Trainers, Models 3240-2 and 3240-A

B Ladder Program Design
C Boolean Algebra and Digital Logic
D Troubleshooting Procedures
E Post-Test
F Glossary of Terms
We Value Your Opinion!
V
VI
Introduction
Programmable Logic Controllers (PLC's) represent state-of-the-art microprocessor-

based electronics that make up technologically advanced control systems with
applications in virtually every segment of industry where automation is required.
The present manual includes five Job Sheets that introduce students to PLC control
of the Wind Turbine System, Model 8075-50. Throughout the manual, students will
learn how to program, connect, operate, and troubleshoot a simple nacelle control
unit PLC.
The corresponding Lab-Volt Instructor Guide (P/N 85303-30) provides answers to

all questions and activities found in this manual.
Prerequisite
Before performing the Job Sheets in this manual, it is recommended to review Lab-
Volt's Programmable Logic Controller, Basic Principles Using the Programming
Software student manual (P/N 36017), which explains how to use the programming
software and the most common PLC instructions. If any difficulty is encountered
while performing the exercises, the programming software's user guide and help
menu can assist students in problem solving.
Safety Considerations
Control systems can be harmful when not used properly. Before performing any of
the exercises in this manual, make sure that you respect the following general
guidelines:
– Put your safety glasses on.

– Avoid wearing any loose clothing (e.g. tie, long sleeves, jewelry).
– Have your hair tied out of the way if it is long.
– Clean your work area if necessary.
Remember that you should never perform an exercise if you have any reason to
think that a manipulation could be dangerous to you or your teammates.
Equipment Required
The following items are required to perform the exercises in this manual:
1 Personal computer on which the RSLogix 500 software is installed

1 Programmable Logic Controller Trainer, Model 3240-2 (see note)
1 Wind Generator, Model 3213
1 Nacelle Simulator, Model 3297
1 Allen-Bradley Analog Input Module
1 Multimeter
1 Printer
Note: The ladder programs shown in the student's and the instructor's
manuals were written with Rockwell's RSLogix 500 programming software
for use with an Allen-Bradley MicroLogix PLC. However, equivalent ladders
can be written for other PLC models.
VII
Introduction (cont’d)
WARNING!
The nacelle (Model 3297) is designed to rotate around its yaw axis with the
assistance of the electrical motor. Avoid manually turning the nacelle as this
may damage the clutch.
Appendices
Appendix A: Lab-Volt PLC Trainers, Models 3240-2 and 3240-A, provides

information concerning the different parts of the PLC modules.
Appendix B: Ladder Program Design, presents two different methods that can be
employed to program a PLC ladder program.
Appendix C: Boolean Algebra and Digital Logic, shows the logical relationships
that can be employed with normally-open (NO) and normally-closed
(NC) contacts.
Appendix D: Troubleshooting Procedures, is a set of guidelines permitting the

student to locate and correct PLC system failures.
Appendix E: Post-Test, is a list of ten review questions.
Appendix F: Glossary of Terms, defines technical words and expressions

contained in this manual.
VIII
1
FAMILIARIZATION WITH THE WIND TURBINE
The energy needs of the world population are continuously increasing along with the
development of new technologies and the industrialization of emergent countries.
Electricity is one such indispensable resource needed in many aspects of modern
life. It is usually generated in power plants of the thermal type which uses one sort
or another of fuel (coal, petroleum, fissionable elements…) to cause a heat-
generating reaction driving turbines to produce electricity. Each method has its
drawbacks such as environmental pollution, management of dangerous waste and
limited supply of fuel. Power plants using renewable resources are becoming much
more prevalent as the focus is shifting towards environmentally-sound methods of
electricity production. Energy produced by such plants comes from a natural
resource – such as water, sunlight, wind, tide – acting as a substitute to conventional
fuel in the power-generation process.
A wind turbine is a device designed to extract the energy stored in the wind in order
to convert it to electricity. The wind is naturally blowing at various speeds and from
different directions as time passes. Once a location with a good wind potential has
been found, a wind turbine or an array of them can be installed to harness that
energy. The wind will propel the aerodynamically-designed blades of the rotor up to
some angular speed thus driving a power generator inside the nacelle of the wind
turbine to produce electricity.
PLC APPLICATIONS – WIND TURBINE 1-1

Figure 1-1. A Wind Turbine.
1-2 PLC APPLICATIONS – WIND TURBINE

The nacelle is the nerve center of the wind turbine. It typically includes all the
mechanical devices (shafts, gearbox…) necessary to transmit mechanical power
from the hub of the rotor to the generator. It also contains a braking system to slow
or stop the rotor, a system to control the orientation of the nacelle on its yaw axis,
and a control unit automating the operating procedures according to the wind
conditions or the maintenance needs. Other essential parts of the nacelle are the
meteorological instruments required to monitor the speed of the wind (anemometer)
and its direction (wind vane).
Figure 1-2. Schematic of a Nacelle.
Lab-Volt's Wind Turbine System
The Wind Turbine System from Lab-Volt is made of two modules:
• Wind Generator, Model 3213

• Nacelle Simulator, Model 3297
Figure 1-3 shows the Wind Generator from Lab-Volt. It is a device used to produce
a constant wind whose strength, as measured by the anemometer, can be varied
simply by moving the generator towards or away from the measuring instruments of
the nacelle.

Figure 1-3. Wind Generator, Model 3213.
1. Wind Outlet
2. ON/OFF Switch
3. 24 V DC Power Input
Lab-Volt's Nacelle Simulator is shown in Figure 1-4. It is designed to reproduce the

key characteristics of a wind turbine nacelle and to demonstrate the possibilities of
control and automation programming.

Figure 1-4. Nacelle Simulator, Model 3297.
1. Wind Direction Selector 9. Wind Direction Analog Output

2. Nacelle (0 - 10 V DC)
3. Wind Vane 10. Wind Speed Output (Pulse)
4. Anemometer 11. Turn-Counter Output Contacts
5. Turn Counter (NO / NC)
6. Turn-Limit Detector 12. Turn-Limit Output Contacts
7. 24 V DC Power Input (NO / NC)
8. Motor Controls – Clockwise and 13. Fault Panel (On the back panel)
Counter-Clockwise Rotation
Automated Control of a Wind Turbine
The control unit inside a nacelle is effected in the simulation by a PLC module
monitoring the outputs of the instruments to control and optimize the operation of the
wind turbine.

The available outputs of the nacelle module are:
– The speed and direction of the wind.

– A turn counter coupled to a limit detector.
The PLC has control over the yaw motor of the nacelle to track the wind or move
away from it as the situation dictates. The different programs necessary to implement
the control routines proposed in the following job sheets will have to be programmed
on the PLC with the help of a computer running a ladder programming software.
Operation of the Wind Speed Output
The anemometer is the device measuring the speed of the wind as it blows on the
wind turbine. The Wind Speed output is a frequency output, a pulse being generated
every time the anemometer completes a revolution.
Figure 1-5. Time Diagram of the Wind Speed Output.
In the following job sheets it will be required to evaluate the wind speed. This is of
prime importance given that a typical wind turbine starts operating at a wind speed
above 4 m/s (about 15 km/h – 9 mph) and has to cut-off to avoid damaging its
components when the speed gets higher than 17 m/s (about 60 km/h – 37 mph).
Using a timer allows for the calculation of the wind speed when a dividing component
is added to the ladder logic. A counter can be added to the design if the wind speed
is to be averaged over the course of a few revolutions.
Divide Instruction
The Divide (DIV) instruction is a standard mathematical operation used to divide a

number (Source A) by another (Source B). The result is stored in a data file
(Destination), typically in the Float data file (F8). As an example, say we know the
distance travelled by the anemometer to be some value X and the time it took to do
so to be stored in the accumulator of a timer. The average speed can be calculated
and saved in the F8 data file by using a rung similar to the one displayed in
Figure 1-6.

Figure 1-6. A Typical Use of the DIV Instruction.
Precise scaling of the anemometer is not required for the following job sheets. A
value for X (see previous paragraph) must be determined such that the calculated
wind speed in the strongest wind condition attainable – i.e. when the wind generator
is closest to the nacelle – is about 65 km/h (40 mph).

1
OBJECTIVES
• Become familiar with some components of the Nacelle module.

• Create and implement a ladder program using a timer to measure the wind
speed.
PROCEDURE
G 1. The first step in using the wind turbine application is to establish the
requirements of the control routine. The program to be written for this Job
Sheet must allow you to perform the following tasks:
• A toggle switch is used to manually command a rotation of the nacelle

in the clockwise direction. Another one is used to perform a rotation in
the counter-clockwise direction. The nacelle stands still if both switches
are simultaneously activated.
• The wind speed is calculated using a timer and a divider. A pilot light is
energized whenever the wind becomes too weak to drive the wind
turbine (15 km/h – 9 mph) and another one lights up if it becomes too
strong (60 km/h – 37 mph).
The ladder program uses only the following RSLogix instructions:
XIC - XIO - OTE - TON - DIV - GEQ - LEQ - NEQ
G 2. Use these I/O connections:

Figure 1-7. Interface Connections for the PLC Implementation.

PLC
PLC ADDRESS CONNECTED TO / USED AS
TERMINALS
I:0/0 Input 0 Wind Speed Output of the

Nacelle
I:0/3 Input 3 Toggle Switch 4 / Used for

Manual Clockwise Control
I:0/4 Input 4 Toggle Switch 5 / Used for

Manual Counter-Clockwise
Control
O:0/0 Output 0 Motor Control of the Nacelle -

Clockwise Input
O:0/1 Output 1 Motor Control of the Nacelle -

Counter-Clockwise Input
O:0/4 Output 4 - / Pilot Light - Indicates

Dangerous Wind Speeds
O:0/5 Output 5 - / Pilot Light - Indicates a Weak

Wind
Table 1-1. PLC I/0 Connections of Job Sheet 1.
G 3. The manual controls of the motor must be designed in such a way as to

avoid sending a contradictory signal to the motor in the nacelle, i.e. a
command to turn both in the clockwise and in the counter-clockwise
directions at the same time.
What are the boolean equations preventing such a contradictory command?

These equations relate outputs O:0/0 and O:0/1 to inputs I:0/3 and I:0/4.
Refer to Appendix B and C if necessary.
A well-designed system will override illogical commands to always produce

coherent results. Always strive for such designs!
G 4. Think of an efficient ladder design to calculate the speed of the wind. You
should be able to write a program with as few as two rungs using only XIC,
XIO, NEQ, DIV, and TON instructions. The NEQ (Not Equal) instruction is
necessary to avoid division by zero. Such an undefined operation results in
a computational error and must be avoided. The speed value should be
stored in a file as a Float by choosing destination F8:0. Sketch this ladder
program in the space provided.

G 5. Two pilot lights are used to indicate if specific wind conditions are met or
not. Using comparator logic, translate those conditions into a short ladder
program which you can draw in the space provided.
Reminder:
O:0/4 is lit if the wind speed is greater or equal to 60 km/h (37 mph).
O:0/5 is lit if the wind speed is lower or equal to 15 km/h (9 mph).
Can you think of another indicator which might be useful in the context of a
wind turbine operation? How would you proceed to implement it?
G 6. Start RSLogix 500 and compile all the results obtained so far in a single
ladder program.
G 7. Test and comment your ladder.
G 8. Demonstrate the operation of your program to your instructor.
G 9. Print your ladder program.
G 10. Close RSLogix 500 and turn off the PLC.
Disconnect and store all leads and components.
Name: Date:
Instructor's approval:

2
WIND TRACKING
The sailor does not pray for wind, he learns to sail.

Gustaf Lindborg
Wind is an abundant resource which is clean and readily-available. Unfortunately,

it can also be quite changing, even temperamental as experienced sailors can easily
confirm. Anywhere a wind turbine will be deployed, the strength and the direction of
the wind will invariably fluctuate.
Changes in the strength of the wind (a strong gust of wind for instance) will induce
sudden loads on the mechanical components of a wind turbine. As well, abating
winds can quickly bring the rotor to a standstill. This must be taken into account by
the engineers designing wind turbines as they must devise ways to attenuate those
nuisances and their impact on energy production.
A change in wind direction can be as harmful to the efficiency of horizontal-axis wind

turbines as a still wind, but this difficulty can be easily corrected by modifying the
orientation of the rotor with the assistance of the yaw motor. Such corrections must
be made as soon as a significant difference between the orientation of the nacelle
and the direction of the wind occurs. This approach relies on a wind vane to
accurately measure the wind direction and on a control unit to automate the tracking
routine.
This job sheet builds upon the previous one by implementing an automatic tracking
mode on top of the wind speed measurements and manual control of the nacelle
orientation.
The Analog Input Expansion Module
All the operations encountered so far were digital. This means that the different
inputs and outputs were either closed or open: there was no in-between. Not
surprisingly, some devices do require the use of a continuous signal, i.e. analog
signal, to convey information more efficiently. This is the case of the wind vane which
outputs an electrical signal whose tension is proportional to its orientation. A reading
of 0 V out of a possible 10 V means that the wind vane is at its origin (It could be
pointing North if calibrated according to this choice) whereas a reading of 5V would
mean the wind vane is halfway through its cycle (and now pointing South). Of
course, intermediary output levels can be produced, making it possible to
discriminate the orientation of the wind vane up to the precision of the instruments.
Because the PLC is digital, a device must be able to manage analog signals and
translate them for the PLC: This is the role of the analog I/O expansion module. Input
0 of the expansion module will be used to read the input of the wind vane. The result
will be a binary number stored in I:1.0.
Note: Adding the Analog Expansion Module to the PLC requires specifying
in the I/O Configuration of RSLogix 500 that the module is connected to
the PLC. Select the corresponding part in RSLogix's menu.

WIND TRACKING
The Wind Vane of the Nacelle Simulator
The orientation of the incoming wind is chosen by the user by aligning the arrowhead
of the wind vane with the desired direction and locking it in place by snugging up the
knob of the wind direction selector.
This analog apparatus measures the orientation of the incoming wind with respect
to the nacelle’s current position. This means that when the tail of the wind vane is
aligned with the rear of the nacelle (the C-shaped part connected to the yaw motor),
a constant output will be produced. If the wind direction changes in a clockwise
manner, the output voltage will increase until a maximum of 10 V is reached to then
jump discontinuously to 0 V and continue increasing. In a similar manner, a rotation
in the counter-clockwise direction will cause a decrease in the output voltage until
the minimum of 0 V is reached to then jump discontinuously to 10 V and continue
decreasing.
SCP Instruction
The Scale with Parameters (SCP) instruction produces a scaled linear relationship
between the specified input and output. For instance, to convert input I:1.0 having
a value of 500 (minimal input value of 0 and maximal input value of 2000) into a new
scale (minimal scaled value of 0 and maximal scaled value of 10000) one would
proceed as in Figure 2-1. The result, 2500, is stored in L9:0, a file for long integers
(integers with thirty-two bits, four bytes, or two words).
Figure 2-1. The SCP Instruction.

WIND TRACKING
LIM Instruction
The Limit Test (LIM) instruction provides a simple method to test an input (Test)
according to logical conditions. To test whether input F8:0 is larger or equal to 5 (Low
Limit) and smaller or equal to 30 (High Limit) one would proceed as in Figure 2-2.
The result is a true rung if the input is within the specified parameters, a false one
otherwise.
Figure 2-2. The LIM Instruction.

2
WIND TRACKING
OBJECTIVES
• Learn to use an analog device and a PLC to measure the direction of the wind.
• Implement an automatic mode to track the wind.
• Write a coherent and well-documented ladder program.
PROCEDURE
G 1. The control routine of this job sheet is an improvement over the preceding
one. Review the required specifications for this project:
• The analog output of the wind direction output must be read and
rescaled by the PLC (saved in L9:0).
• A limit instruction will test the wind speed to make sure the wind turbine
is in its operating range. This condition will be saved as a control bit (in
B3:0/0).
• An automatic mode must be developed. This mode will override the

manual control of the yaw motor and actuate the angular position of the
nacelle to track the wind if and only if control bit B3:0/0 is set to true (i.e.
the wind speed is adequate). A pilot light (O:0/3) lights up to visually
confirm that the nacelle is tracking the wind.
The ladder program uses only the following RSLogix instructions:
XIC - XIO - OTE - TON - DIV - NEQ - LIM - SCP - GRT - LES -
GEQ - LEQ
G 2. The I/O connections are the same as those of Job Sheet 1 (see Table 1-1)
with the following additions:

WIND TRACKING
PLC ADDRESS PLC TERMINALS CONNECTED TO / USED AS
I:1.0 Analog Input 0 (+/-) Wind Direction Output (+/-)
I:0/5 Input 5 Toggle Switch 6 / Used to Turn

On or Off the Automatic Mode
O:0/3 Output 3 Pilot Light - Indicates

Tracking Mode
CAUTION!
The analog input module which is part of the PLC has two
input modes available. One is for current signals while the
other is for voltages. Only the voltage mode must be used in
the context of this experiment and the upcoming ones. To
avoid damaging the equipment, make sure switches 1 and 2
are both in the OFF position as this corresponds to the
voltage mode. Refer to Figure 2-4.

WIND TRACKING
Figure 2-4. Input Type Selection.
G 3. Start RSLogix 500, open the program of Job Sheet 1 and save it under a
different name.
G 4. Open file I1- INPUT and observe line I:1.0. This string of 0 and 1 is a binary
number related to the angular position of the wind vane relative to the
nacelle. If you prefer a decimal representation, simply choose that option in
the radix pull-down menu in the lower-right corner of the window.
Figure 2-5. The Input I1 data file.
As you turn the wind vane, observe how this number changes. What are its
maximal and minimal values?
Maximum Value:
Minimum Value:

WIND TRACKING
As we will be working with angular positions, it would be more convenient

to rescale the wind measurement to have a reading between 0° and 360°.
Use a SCP instruction to rescale I:1.0 in this range and record the rescaled
output in file L9:0. Test your program and make sure the value in file L9:0
behaves in the requested way.
G 5. Now a LIM instruction must be implemented to make sure the wind

conditions are suitable to the operation of the wind turbine (15 km/h or 9
mph < Wind Speed < 60 km/h or 37 mph). Save the resulting control bit (0
if the rung is false, 1 if it is true) in file B3:0/0. Test your program.
G 6. The wind vane can be used to determine the orientation of the wind with
respect to the nacelle. First, make sure you understand how the value of
L9:0 is modified as the wind or the nacelle changes its orientation.
Experiment with the set-up and make sure you can answer the following
questions:
• What happens to the scaled value as you change the orientation of the
wind vane in the clockwise direction? In the counter-clockwise
direction?
• What value do you obtain when the wind vane is aligned with the
nacelle? Is this value the same whatever the orientation of the nacelle
is?
The point of the previous manipulations is to realize that there is a target

value which must be reached if the nacelle is to be aligned with the wind
vane. Take into account that there are some small uncertainties and
fluctuations in this measurement. Also, the motor cannot stop instantly once
the target is reached. You should consequently design your tracking routine
to neglect deviations smaller than 2 or 3° on either side.
G 7. The automatic mode can now be designed. Implement an automatic mode

respecting the requirements mentioned previously in step 1. Also, remember
to use toggle-switch number six with input I:0/5 to active/deactivate the
automatic mode.
This modification to the ladder program can be written with a few

comparison instructions. Remember to allow a tolerance range of a few
degrees to the automatically-assigned position of the nacelle.
Test your program extensively.
G 8. Demonstrate the operation of the Wind Turbine Application to your

instructor.

WIND TRACKING
G 9. Save and print your ladder.
Name: Date:

DRAWINGS AND CALCULATIONS

3
COMPLETE NACELLE OPERATION
The two precedent job sheets allowed for the programming of a control routine
typical of a wind turbine. However, more parameters must be considered to really
account for the complexity of a wind turbine. In this Job Sheet, emphasis will be
given to the number of turns made by the wind turbine around its yaw-axis as it
tracks the wind during its automated routine.
This seemingly minor parameter becomes crucial when you consider the fact that,
in most models of horizontal-axis wind turbines, power cables run from the power
generator in the nacelle down to the ground where the power is then transferred to
the grid. As the nacelle rotates away from its initial position to track the wind, the
cables are subjected to mechanical stresses. Of course, they are designed to
withstand a few revolutions before the mechanical tension becomes worrisome.
Nonetheless, it is mandatory to keep track of the number of turns made from a
reference position in either the clockwise or counter-clockwise direction to avoid
damaging the cables or components of the nacelle.
A device will keep track of the angular position of the nacelle and a detector will
prevent any further displacement if a predetermined limit is reached. If the limit is
reached while the wind turbine is operating, a shutdown sequence will be initiated.
This procedure stops the rotor and unwinds the cables until the nacelle is back to its
reference position. Such a sudden shutdown is necessary but its associated
downtime can be costly in terms of energy production. This is why it is much
preferred to have a wind turbine return to its original position whenever it is not in use
or if the wind conditions are not within the operating range.
Turn Counter and Limit Detector
The Nacelle Simulator is equipped with two devices to keep an account of its angular
position:
• A turn-counter sending a signal every time the nacelle passes by the detector.
This allows for a reliable count of the number of turns completed when the signal
is coupled to information about the direction of rotation of the nacelle at the time
the detector was activated.
• A limit-detector sends a signal whenever the cable in the nacelle becomes too
tightly wound. This signal should be used to override standard operation and
initiate a procedure to rotate the nacelle back to its home position.
Both devices can interface with the PLC from the output panel of the nacelle. Based
on the design of your program, you can choose to use the normally closed output or
the normally open output. Do not forget to power up each output you plan to use. It
is important to know that the nacelle simulator is designed to perform a total of about
twelve turns from one end of its course to the other.

Figure 3-1. The Nacelle Rotation Outputs.
CTU / CTD instructions
The Counter Up (CTU) and Counter Down (CTD) instructions are used to increment
or decrement a counter (C5:0 or C5:1). The Done bit (DN) is set to 1 whenever the
accumulated value is greater than or equal to the preset value.
These instructions and others pertaining to counters are described in greater detail
in section 6: Counters of the PLC Basics Programming Principles - Student Manual
(36017-00). Refer to it if you need more information.
MOV Instruction
The Move (MOV) instruction is a polyvalent tool used to assign a value (Source) to
a destination whenever the rung containing the MOV instruction is true. This
instruction can be used to set a timer or a counter to some value. It also works with
input, output, float, and bit files. To set the accumulated value of a counter to 0 with
a MOV instruction, one would proceed as shown in Figure 3-2.
Figure 3-2. The MOV Instruction.

OSR Instruction
The One Shot Rising (OSR) instruction is used to make sure an event is triggered
on a false-to-true transition. The Storage Bit remembers the state of the rung during
the preceding cycle and the Output Bit is set to one on the false-to-true transition for
the duration of a single program scan. This is usually done to trigger an event only
once even if the detector remains true for a few cycles. The OSR is reinitialized when
the rung becomes false. To apply an OSR instruction to input I:0/1 where the storage
bit is B3:0/4 and the output bit B3:0/5, proceed as in Figure 3-3.
Figure 3-3. The OSR Instruction.
JSR Instruction
The Jump to Subroutine (JSR) instruction causes the controller to stop executing its
main program to jump to a different one. A subroutine is useful whenever the logic
of a control routine can be decomposed into a main program and one or more
specific programs which can be called from the main ladder. Such an approach
allows for a modular and structured approach to programming and encourages the
re-use of subroutines whenever the main program has a use for them. It also serves
the purpose of separating a long program into smaller logical elements which are
simpler to grasp.

An example would be a subroutine to compute the summation of input words I:0.0

and I:0.1 if and only if input I:0/0 is true. The first step would be the main program
calling the subroutine with a JSR instruction if I:0/0 is true. The JSR instruction must
specify the file number to be used for the subroutine. Since file 0 and 1 are reserved
for the system and 2 is for the main ladder, the file number for a subroutine must be
between 3 and 255.
Figure 3-4. The JSR Instruction.
Choosing file number 3, the next step is to create a new ladder file by right-clicking
on Program Files and choosing new. Name the new file and assign number 3 to it.
The new file can now be edited as in Figure 3-4, part 3 to implement a summation
subroutine. Return (RET) is the last instruction necessary in this subroutine. It tells
the PLC to go back to the main ladder program to continue where it left off with the
usual program. This constitutes a subroutine which can be called whenever it is
necessary to add two numbers.

3
OBJECTIVES
• Devise a ladder program monitoring the angular position of the nacelle.
• Use a wide range of basic instructions as well as MOV, OSR, and JSR.
• Implement a subroutine taking charge of moving the nacelle back to its home
position.
PROCEDURE
G 1. This job sheet builds upon its predecessors and adds important
functionalities to the control of a nacelle. The improvements and additions
to make to your previous ladder are:
• A section of the ladder program must use a counter to keep track of the
number of completed turns. The counter is initialized to 6 and
increments for every clockwise turn whereas it decrements for every
counter-clockwise turn.
• A soft reset routine must be added to the automatic mode. The soft
reset returns the nacelle to its home position when the automatic mode
is on and if the wind is too weak. Normal operation resumes if the wind
speed becomes acceptable again.
• A homing mode will override all commands and return the nacelle to its
home position where it will resume its operations. This mode will be
triggered by the limit detector if the nacelle reaches its clockwise or
counter-clockwise limit. Because of its specific nature, the homing mode
must be implemented as a subroutine of the main ladder program.
Note: The home position is defined to be reached when the

nacelle is above the turn counter and has completed six turns
starting from its counter-clockwise limit. The maximal number of
turns that can be completed amounts to twelve.
G 2. The I/O connections are the same as those of Job Sheet 2 (see Table 2-1)
with the following additions:

PLC ADDRESS PLC TERMINALS CONNECTED TO / USED AS
I:0/1 Input 1 Turn Counter - NO Contact
I:0/2 Input 2 Limit Detector - NO Contact
O:0/2 Output 2 Pilot Light - Indicates

Homing Mode
Proceed with the connections.
G 3. Start RSLogix 500, open the program of Job Sheet 2 and save it under a
different name for this Job Sheet.
G 4. Design a program to count the number of turns of the nacelle. Use an OSR
instruction to trigger a CTU or a CTD instruction based on the direction of
rotation of the nacelle when the turn-counter detector makes a false-to-true

transition. The counter (C5:0) is initialized to 6 and increments for every

clockwise turn whereas it decrements for every counter-clockwise turn.
Test your program.
Can you explain why an OSR instruction is useful in this context?
G 5. Modify the automatic mode to implement the soft reset procedure described
in step 1.
XIC, GRT, and LES instructions should be sufficient for the requested
changes. Test your program.
G 6. The Homing mode is the last mechanism to implement in this job sheet.
Note: To achieve this task, it is proposed to latch and unlatch the

following control bits:
B3:0/1 Turn Clockwise Request – Homing Mode.

B3:0/2 Turn Counter-Clockwise Request – Homing Mode.
B3:0/3 Homing Mode Status Bit.
Design a subroutine which will behave in the following way:
When the Homing mode is not yet activated and the motor is turning in the
clockwise direction:
– Latch the Homing mode control bit B3:0/3.

– Latch the Turn Counter-Clockwise Request control bit B3:0/2.
– Reset the counter to its clockwise maximum (12).
When the Homing mode is not yet activated and the motor is turning in the
counter-clockwise direction:
– Latch the Homing mode control bit B3:0/3.

– Latch the Turn Clockwise Request control bit B3:0/1.
– Reset the counter to its counter-clockwise minimum (0).
When the turn counter has accumulated a value of 6 (Home position):
– Unlatch the Turn Clockwise Request control bit B3:0/1.

– Unlatch the Turn Counter-Clockwise Request control bit B3:0/2.
– Unlatch the Homing mode control bit B3:0/3.
Pilot light (O:0/2) is energized whenever the Homing mode (B3:0/3) is on.
A RET instruction returns to the main program after each scan of the
subroutine.

You should also modify the main program to include the following elements:
– The control bits should have control over the yaw motor when the
Homing mode is true.
– The pilot light indicating that the Tracking mode is on should not light up
if the Homing mode is on.
– A rung must include a JSR to invoke the subroutine whenever the limit
detector is activated. The same rung should also call the subroutine
back as long as the Homing mode is activated.
G 7. Demonstrate the operation of your ladder programs to your instructor.
G 8. Save and print your ladder.
Name: Date:


4
TROUBLESHOOTING
Like practically any other device, Wind Turbine systems are subject to breakdown
and require maintenance from time to time. A good way to start troubleshooting a
PLC-controlled system is to observe the faulty equipment in order to determine
where the problem is located. The observed symptoms may often point to a single
component or specific part of circuitry, and no further search is necessary.
For example, the automatic mode not behaving in the expected way might point to
a programming problem. If, on the other hand, the PLC does not receive a particular
input signal, this may indicate that an electrical connection is broken.
Once the problem has been related to one branch or to a specific section of the
system, each component in that area can be checked out one at a time. Once a
defective component has been located, you must be cautious before drawing any
conclusions. In certain cases, the problem may be caused by more than one
defective component. Therefore, you must make sure that the malfunction
discovered plausibly explains the observed problem. If not, there is likely another
defective component which would complete the explanation of the problem.
A situation where many errors are likely to surface is during the startup of a new
installation. Under such circumstances, it is not unusual to observe more than one
electrical (e.g. bad connections), programming (e.g. unhandled situation), or
mechanical (e.g. leaking tubing) problem.
Note: You may refer to Appendix D for detailed PLC troubleshooting

techniques.

4
TROUBLESHOOTING
OBJECTIVE
• Identify faults in a PLC-controlled system.
PROCEDURE
G 1. Start RSLogix 500.
G 2. Connect the inputs and outputs as in Job Sheet 3. Download the program
provided by your instructor to the PLC. Run the program and observe
carefully how the system should work when no problem is present.
G 3. Open the fault-panel of the nacelle simulator. Activate fault number three.
Guided Troubleshooting Method
Most problems with the Nacelle Simulator system are electrical or PLC
program related. During this guided troubleshooting method, it is presumed
that you are performing a system startup and that the problem is of unknown
origin.
Observation
G 4. The first logical step is to observe the behavior of the system and determine
if there are any anomalies. Operate the system and compare it to its normal
behavior. Is anything unusual?
G Yes G No
Write down your observations.
Basic Verifications
G 5. Your task is to discover where the problem is located and what is causing
it. Before you invest a lot of time and energy on a thorough investigation of

TROUBLESHOOTING
the system, it might be a good idea to verify a few basic things. Take a look
at the system and answer the following questions. If you answer "No" to any
of the questions, perform changes to remedy the situation.
Is the PLC power on?
G Yes G No
Is the PLC in run mode?
G Yes G No
Are all the electrical leads connected correctly (i.e. as in Job Sheet 3)?
G Yes G No
Is the PLC V1 switch set to 24 V dc mode?
G Yes G No
G 6. The next step is to determine which problem type relates to the observed
malfunction.
Programming Errors
To see if the problem is program related, put RSLogix in Test Continuous

mode. Revise your program, force input bits, and pay attention to the
different output bits status while the program is running. Does the program
function the way it should?
G Yes G No
Note: To force a bit in a PLC memory file, right-click on the

appropriate bit in the ladder program and choose the option
"Force On" or "Force Off".
Put RSLogix in Run mode and force the different I/O bits. Do the indicator
lights on the PLC module light up as they should?
G Yes G No
Based on these observations, which type of problem do you think you are
facing?
a. Programming
b. Electrical
c. Mechanical
d. Other

TROUBLESHOOTING
WARNING!
Maintenance operations should always be done with full

knowledge of the associated risks. Therefore, always shut
down the sources of power when performing continuity
tests. Likewise, make sure to use the appropriate range with
your voltmeter. Damage to your equipment may result from
incorrect utilization.
Electrical Troubleshooting
G 7. Use your voltmeter to verify if logic signals are transmitted to their

destination. Do so for each of the relevant circuit connections. Based on
your observations, where is the electrical problem located?
What would be the most plausible cause of the trouble?
What would you do to fix the problem?
G 8. Remove the inserted fault. Make sure that the system is now working as it
should.
Non-Guided Troubleshooting Method
G 9. Keep the same setup and program. Ask your instructor to insert one or two
faults in the system. The fault(s) may be electrical or program related.
G 10. Locate the fault(s) using a structured method. What conclusion can you
draw from your inquiry concerning the system's problem(s)?

TROUBLESHOOTING
G 11. Show your work to your instructor.
Name: Date:


Appendix A
Lab-Volt PLC Trainers, Models 3240-2 and 3240-A
The Lab-Volt PLC Trainer, Model 3240-2, features an Allen Bradley
MicroLogix 1200 PLC. This PLC can be programmed by using the RSLogix 500
software from Rockwell Software. The PLC has 14 numbered inputs, labeled 0
through 13, and 10 numbered outputs labeled 0 through 9.
Figure A-1 shows the top panel of the trainer.
• PLC inputs 0 through 13 are internally connected, through a PLC input

interface, to 14 pairs of plug-in jacks mounted at the middle bottom of the front
panel. Each pair of jacks permits activation of the corresponding PLC input,
using either a 24-VDC voltage or the AC line voltage from an external PLC input
device. The smaller jacks are rated for a 24-VDC voltage, while the larger jacks
are rated for the AC line voltage. Three momentary pushbutton switches and
four toggle switches, labeled 1 through 7 and mounted at the left bottom of the
front panel, can be used as PLC input devices: when connected to any of the
PLC input jacks, they permit activation of the PLC inputs with a 24-VDC voltage
provided by the built-in source of the trainer.
• PLC outputs 0 through 9 are internally connected, through a PLC output

interface, to 10 pairs of plug-in jacks mounted at the right bottom of the front
panel. The pairs of jacks each correspond to a PLC output, and permit
connection of external PLC output devices, such as relay coils and motors, that
are energized or de-energized as the controller program is being executed. The
pairs of PLC output jacks are hardwired into two groups of five, each of which
can provide either a 24-VDC voltage or the AC line voltage for energizing the
PLC output devices. The smaller PLC output jacks provide a DC voltage of 24 V,
while the larger PLC output jacks provide the AC line voltage. Above each pair
of jacks is a light indicating the status of the corresponding PLC output.
PLC APPLICATIONS – WIND TURBINE A-1

Figure A-1. PLC Trainer, Model 3240-2 (top view).
The features of the trainer front panel are described below (refer to Figure A-1).
1. Access door to the PLC input wiring terminals
2. Memory module expansion spacing: provides access to a 10-pin connector

for installation of an optional memory module and/or real-time clock.
A-2 PLC APPLICATIONS – WIND TURBINE

3. RS-232 communication port (Primary port, or Channel-0 port): used to connect
the PLC to the computer that runs the RSLogix 500 software, using a serial
cable (a 1761-CBL cable). The recommended protocol for this configuration is
DF1 full duplex.
4. Trim pots: permit modification of data in a register of the controller (the

TPI register). Throughout the course, these potentiometers must not be
adjusted or tampered with, as this will modify the content of the TPI register.
5. Access door to the PLC output wiring terminals
6. PLC output wiring terminal
7. PLC output status indicators: LED's indicating the current status (logic state 0
or 1) of the bits associated with PLC outputs 0 through 9 in the output data file
of the PLC.
8. PLC input status indicators: LED's indicating the current status (logic state 0
or 1) of the bits associated with PLC inputs 0 through 13 in the input data file of
the PLC.
9. I/O bus interface connector: used to connect an expansion I/O module to the
controller, through a flat ribbon cable.
10. PLC status indicators: LED's indicating the current status of the controller:
• POWER: this LED is on when the PLC is properly powered. It is off when
there is no input power to the PLC or when a power error condition occurs.
• RUN: this LED is on when the PLC is executing a program in the Run mode.
It is off when no program is being executed.
• FAULT: this LED is off when there is no fault. It is on when the controller
hardware is faulty. It flashes when a major hardware or software fault has
been detected.
• FORCE: this LED is on when one or more PLC inputs or outputs are forced
on or off. It is off when no forces are installed.
• COMM 0: This LED is off when the controller is not transmitting data via the
PLC communication port (channel-0 port). It is on when the controller is
transmitting data via this port.
• DCOMM: This LED is on when the controller is in the default communication

mode. It is off when the controller is in the user-configured communication
mode.
11. Power switch: used to turn the PLC Trainer on and off.
12. Pushbutton switch 1: pushbutton switch of the momentary type with normally-
open (NO) contacts, that can be used as an input device to the PLC. When the
switch pushbutton is pressed, the NO contacts go from open to closed, causing
a DC voltage of 24 V to be present to the plug-in jack next to the switch

pushbutton. When the pushbutton is released, the voltage is removed from the
plug-in jack.
13. Jack of pushbutton switch 1: intended to be connected to any of PLC input

jacks 0 through 13, using a connection lead. If, for example, the jack is
connected to PLC input jack 0, pressing the switch pushbutton will cause a
DC voltage of 24 V to be applied to PLC input jack 0, thereby activating PLC
input 0. Releasing the switch pushbutton will remove the DC voltage, de-
activating PLC input 0.
14. Toggle switch 4: toggle-operated switch with normally-open (NO) contacts, that
can be used as an input device to the PLC. When the switch toggle is moved
upward, the NO contacts go from open to closed, causing a DC voltage of 24 V
to be applied to the plug-in jack next to the switch toggle. When the toggle switch
is moved downward, the voltage is removed from the plug-in jack.
15. Jack of toggle switch 4: intended to be connected to any of PLC input jacks 0
through 13, using a connection lead. If, for example, the jack is connected to
PLC input jack 9, moving the switch toggle upward will cause a DC voltage of
24 V to be applied to PLC input jack 9, thereby activating PLC input 9. Moving
the switch toggle downward will remove the DC voltage, de-activating PLC
input 9.
16. 24-VDC output: internally connected to the 24-VDC source within the trainer.
The common (black) terminal is used for external devices connected to the PLC
output jacks. Also, when external 24-VDC devices are connected to the PLC
input jacks, the common jack must be connected to the common of the external
24-VDC source that powers these input devices.
17. AC-line voltage neutral jack: internally connected to the neutral conductor of
the AC-line voltage source within the trainer. Used as the neutral terminal for
external, AC-line voltage devices connected to the PLC output jacks. Also, when
external AC-line voltage devices are connected to the PLC input jacks, the
neutral jack must be connected to the neutral of the external AC-line voltage
source that powers these input devices.
18. Earth ground jack: internally connected to the ground conductor of the AC-line
voltage source within the trainer. When external AC-line voltage devices are
connected to the PLC input and output jacks, the earth ground jack of the trainer
must be connected to the earth ground of all PLC input and output devices.
19. 24-VDC jack of PLC input 0: permits activation of PLC input 0, using a
DC voltage of 24 V. This voltage can come from one of the seven switches
mounted on the trainer front panel, or from external PLC input devices rated at
24 V DC.
20. AC-line voltage jack of PLC input 0: permits activation of PLC input 0, using
the AC line voltage. This voltage must come from external PLC input devices
rated at the AC line voltage.
Note: Various types of AC-line rated, PLC input devices are available from
the Lab-Volt Industrial Controls Training System, Model 3100: pushbutton
switches, limit switches, float switch, cam switches, magnetic sensors,
photoelectric sensors, etc.

21. V1 toggle switch: used to select the voltage at which the external devices
connected to the first group of PLC output jacks (0 through 4) will be energized:
24 V DC or the AC line voltage. When the switch toggle is set to the upward
(24-VDC) position, a DC voltage of 24 V is applied to those within the lower-
diameter jacks 0 through 4 whose associated PLC output is activated. When the
switch toggle is set to the downward (AC-line voltage) position, the line voltage
is applied to those within the larger-diameter jacks 0 through 4 whose associated
PLC output is activated.
22. V2 toggle switch: used to select the voltage at which the external devices
connected to the second group of PLC output jacks (5 through 9) will be
energized: 24 V DC or the AC line voltage. When the switch toggle is set to the
upward (24-VDC) position, a DC voltage of 24 V is applied to those within the
lower-diameter jacks 5 through 9 whose associated PLC output is activated.
When the switch toggle is set to the downward (AC-line voltage) position, the
line voltage is applied to those within the larger-diameter jacks 5 through 9
whose associated PLC output is activated.
23. PLC output 0 lamp: This lamp is on when PLC output 0 is activated (that is,
when the bit associated with PLC output 0 in the PLC output data file is at
logic 1, or when this bit is forced on). The lamp is off when PLC output 0 is
deactivated (bit associated with PLC output 0 at logic state 0, or forced off).
24. 24-VDC jack of PLC output 0: when PLC output 0 is activated, a DC voltage
of 24 V is applied to this jack if the V1 toggle switch is set to the
24-VDC position. When PLC output 0 is deactivated, there is no voltage applied
to that jack.
25. AC-line voltage jack of PLC output 0: when PLC output 0 is activated, the
AC line voltage is applied to this jack if the V1 toggle switch is set to the AC-line
voltage position. When PLC output 0 is deactivated, there is no voltage applied
to that jack.
26. PLC output 5 lamp: This lamp is on when PLC output 5 is activated (that is,
when the bit associated with PLC output 5 in the PLC output data file is at
logic 1, or when this bit is forced on). The lamp is off when PLC output 5 is
deactivated (bit associated with PLC output 5 at logic state 0, or forced off).
27. 24-VDC jack of PLC output 5: when PLC output 5 is activated, a DC voltage
of 24 V is applied to this jack if the V2 toggle switch is set to the
24-VDC position. When PLC output 5 is deactivated, there is no voltage applied
to that jack.
28. AC-line voltage jack of PLC output 5: when PLC output 5 is activated, the
AC line voltage is applied to this jack if the V2 toggle switch is set to the AC-line
voltage position. When PLC output 5 is deactivated, there is no voltage applied
to that jack.
29. Expansion I/O spacing: Permits the addition of an optional input/output module
(Lab-Volt Model 3244) to the PLC. This module provides two analog inputs and
two analog outputs, both rated at 0-10 V DC or 4-20 mA. Other types of analog
I/O expansion modules are available as options.

Figure A-2 shows the back panel of the trainer. The features of this panel are
described below.
1. 21-pin Jones connector: used to connect the PLC Trainer to the Lab-Volt
Mechanical Process Simulator, Model 3290, via a multiconductor cable. This
simulator, a linear position control system, is used to achieve PLC control of
sequenced production lines in the second level of the Lab-Volt PLC Training
Program.
2. 24-VDC supply terminals (V1 and V2 jacks): permit the connection of

additional 24-VDC sources to the trainer in order to supply more current to
24-VDC devices connected to the PLC output jacks:
• If the devices connected to PLC output jacks 0 through 4 require more

current, an additional 24-VDC source is connected across the V1 jacks. The
V1 toggle switch on the trainer front panel must be set to 24-VDC (switch
toggle upward), otherwise the additional current will not be supplied to the
output devices.
• If the devices connected to PLC output jacks 5 through 9 require more

current, an additional 24-VDC source is connected across the V2 jacks. The
V2 toggle switch on the trainer front panel must be set to 24-VDC (switch
toggle upward), otherwise the additional current will not be supplied to the
output devices.
Figure A-2. PLC Trainer, Model 3240-2 (back view).
3. 24-VDC RESET button: used to reset the breaker of the built-in 24-VDC voltage
source of the trainer.
4. P-SIM to PLC Interface connector: used to connect the PLC Trainer to the P-
SIM to PLC Interface, Model 3243, through a DB-25 flat cable. The interface,
which converts RS-232 signals into PLC signals, and vice-versa, is required for

the second level of the Lab-Volt PLC Training Program. It allows the PLC to
control animated industrial processes on a computer with the P-SIM Simulations
software, Model 91773.
5. AC-line voltage RESET button: used to reset the breaker of the built-in AC-line
voltage source of the trainer.
6. Trainer AC line cord.
The Lab-Volt PLC Trainer, Model 3240-A, features an Allen Bradley

MicroLogix 1100 PLC. This PLC can be programmed by using the RSLogix 500
software from Rockwell Software. The PLC has 10 numbered inputs, labeled 0
through 9, and 6 numbered outputs labeled 0 through 5.
Figure A-3 shows the Micrologix 1100 side and top views.
Figure A-3. Micrologix 1100 PLC.
1. Ethernet Port
2. RS-232 Communication Port (Primary port, or Channel-0 port): used to

connect the PLC to the computer that runs the RSLogix 500 software, using a
serial cable (a 1761-CBL cable). The recommended protocol for this
configuration is DF1 full duplex.
3. LCD: indicating PLC information such as the I/O status.
4. Input Terminal Block
5. Battery

6. I/O Bus Interface Connector: used to connect an expansion I/O module to the
controller, through a flat ribbon cable.
7. Battery Connector
8. Output Terminal Block
9. Memory Module
10. LCD Keypad
11. PLC status indicators: LED's indicating the current status of the controller:
• POWER: this LED is on when the PLC is properly powered. It is off when
there is no input power to the PLC or when a power error condition occurs.
• RUN: this LED is on when the PLC is executing a program in the Run mode.
It is off when no program is being executed.
• FAULT: this LED is off when there is no fault. It is on when the controller
hardware is faulty. It flashes when a major hardware or software fault has
been detected.
• FORCE: this LED is on when one or more PLC inputs or outputs are forced
on or off. It is off when no forces are installed.
Figure A-4 shows the top panel of the trainer.
• PLC inputs 0 through 9 are internally connected to 10 jacks mounted at the

middle bottom of the front panel. Each jack permits activation of the
corresponding PLC input using a 24-VDC signal. Two 0-10 VDC analog inputs
labeled IV1 and IV2 are located at the top left of the front panel. Two rotary
knobs allow adjustment of 0-10 VDC voltage that can be provided to these
analog inputs through jacks Z1 and Z2. Five momentary pushbutton switches
and five toggle switches, labeled 1 through 10 and mounted at the left bottom of
the front panel, can be used as PLC input devices: when connected to any of the
PLC input jacks, they permit activation of the PLC inputs with a 24-VDC voltage
provided by the built-in source of the trainer.
• PLC outputs 0 through 5 are internally connected to 6 jacks mounted at the right
bottom of the front panel. Each jack corresponds to a PLC output, and permits
connection of external PLC output devices, such as relay coils and motor drives,
that are energized or de-energized as the controller program is being executed.
The PLC output jacks are hardwired into two groups of three, each of which can
provide 24-VDC voltage for energizing the PLC output devices. Beside each jack
is a light indicating the status of the corresponding PLC output.

Figure A-4. PLC Trainer, Model 3240-A (top view).
1. Potentiometers Z1 and Z2: two rotary knobs allow adjustment of voltage

(0-10 VDC) at their respective jacks.
2. Analog Inputs IV1 and IV2: these two jacks are connected to the PLC 0-10
VDC analog inputs.
3. NO Pushbutton Switches: pushbutton switches of the momentary type with

normally-open (NO) contacts, that can be used as an input device to the PLC.
When a switch pushbutton is pressed, DC voltage of 24 V is present at the plug-
in jack next to the switch pushbutton. When the pushbutton is released, the
voltage is removed from the plug-in jack.
4. NC Pushbutton Switches: pushbutton switches of the momentary type with

normally-closed (NC) contacts, that can be used as an input device to the PLC.
When a switch pushbutton is pressed, no voltage is present at the plug-in jack
next to the switch pushbutton. When the pushbutton is released, DC voltage of
24 V is present at the plug-in jack.
5. Toggle Switches: toggle-operated switches with normally-open (NO) contacts,

that can be used as input devices to the PLC. When the switch toggle is moved
upward, the NO contacts go from open to closed, causing a DC voltage of 24 V
to be applied to the plug-in jack next to the switch toggle. When the toggle switch
is moved downward, the voltage is removed from the plug-in jack.

6. PLC Inputs: permit activation of the PLC inputs upon DC voltage of 24 V. The
voltage can come from one of the ten switches mounted on the trainer front
panel, or from external PLC input devices rated at 24 V DC.
7. 24-VDC Output: internally connected to the 24-VDC source within the trainer.
8. PLC Output Lamps: these lamps are on when their PLC output is activated
(that is, when the bit associated with PLC output in the PLC output data file is at
logic 1, or when this bit is forced on).
9. PLC Outputs: when PLC outputs are activated, a DC voltage of 24 V is applied

to the jack.
Figure A-5 shows the back panel of the trainer. The features of this panel are
described below.
1. Power Switch: used to turn the PLC Trainer on and off.
2. Fault Switch Panel: This panel conceals the eight fault switches of the PLC
trainer.
Figure A-5. PLC Trainer, Model 3240-A (back view).
Figure A-6 shows the right side panel of the trainer. The features of this panel are
described below.
1. Trainer Reset Button
2. Trainer AC Line Cord

Figure A-6. PLC Trainer, Model 3240-A (side view).

Appendix B
Ladder Program Design
The following appendix presents two different methods that can be employed to write
a PLC ladder program. Note, however, that other approaches exist that may be
employed to achieve proper PLC programming.
Method 1 - State Equations
State Diagram
One way to describe the operation of many systems is to identify the states they go
through. Examples of microprocessor-based state systems are traffic lights, vending
machines, air conditioners, garage doors, and microwave ovens. For instance, a
microwave oven may go through the following four-state sequence, as shown in the
state diagram of Figure B-1:
1- IDLE (S1)
2- PROGRAM (S2)
3- COOK (S3)
4- ALARM (S4)
1- IDLE (S1)
Figure B-1. Normal Microwave Oven Sequence State Diagram.
However, more than one path can exist between the states. For example, the
microwave oven can also go from COOK to IDLE if the CANCEL button is pressed
while cooking, as shown in Figure B-2. All the possible routes between two states
are called transitions and depend on specific conditions like a time delay or an
input. In our example, there are three inputs and six transitions:
Inputs:
• I0: Numeric KEYPAD*

• I1: START button
• I2: CANCEL button
*In this demonstration, only a “10 Seconds Plus” key touch is implemented, to
simplify the case.
PLC APPLICATIONS – WIND TURBINE B-1

Transitions:
• T1: from IDLE to PROGRAM state upon the touch of the KEYPAD.
• T2: from PROGRAM to COOK state upon the touch of the START button.
• T3: from COOK to ALARM state after the cook time has elapsed.
• T4: from ALARM to IDLE state after the alarm time has elapsed.
• T5: from PROGRAM to IDLE state upon the touch of the CANCEL button.
• T6: from COOK to IDLE state upon the touch of the CANCEL button.
Figure B-2. Modified Microwave Oven Sequence State Diagram.
State Table
State tables are a means of detailing the conditions relative to a particular state. In
this way, they complement well the state diagrams. Table B-1 shows what the
microwave state table looks like. Each line represents a different state. Columns
represent the outputs. Zeros mean that the outputs are off, whereas ones show
energized outputs. In our example, there are five outputs:
Outputs:
• O0: Microwave generator

• O1: Turntable
• O2: Beep Sound
• O3: Interior Light
• O4: Time Display (0 = Clock, 1 = Cook Time)
B-2 PLC APPLICATIONS – WIND TURBINE

Outputs
State
O4 O3 O2 O1 O0
Idle 1 0 0 0 0 0
Program 1 1 0 0 0 0
Cook 3 1 1 0 1 1
Alarm 4 0 0 1 0 0
Table B-1. State Table.
Note: State tables can be implemented in PLC data files, where they can
be particularly useful upon a change of state. During the transition period,
an entire word of data can be transferred from the data file to the output
file, hence updating all outputs simultaneously.
Flowchart
A flowchart is another schematic representation of a system. It brings to the fore the

interrelationships between states with the help of symbols and arrows. Figure B-3
is the flowchart equivalent to the microwave state diagram of Figure B-2.

Figure B-3. Complete Microwave Oven Sequence Flowchart.

Symbols have the following meaning:
(Oval): Beginning, end, or interruption of the program.
(Rectangle): Processing steps (or states).
(Diamond): Condition with two possible decisions (Yes / No).
Boolean Equations
Although you can manage building your ladder programs only with the help of the
previous tools, a more structured approach is to convert your state diagram into
Boolean equations. These equations can then be translated into ladder logic.
Note: Appendix C provides information about boolean algebra

and digital logic.
Once the state diagram, state table, and flowchart have been defined, the next step
is to write an equation for each state. Each equation takes into consideration the
conditions upon which the system can be stable in a given state:
– The system stays in its present state or a transition brings the system to that
state.
AND
– No transition occurs to force the system into a different state.
By taking the same example as previously (see Figure B-2), we obtain this first
equation:
Which means that:
• The system can be in state S1 if it already was in that state (Figure B-4).

Figure B-4. Meaning of State Equation 1 (Part 1).
• The system can also get to State 1 if transition T4, T5, or T6 happens
(Figure B-5).
• Transition T1 between states S1 and S2 does not occur (Figure B-6).

The same method can be applied to the other three state equations:
Where,
T1 = Transition 1 = S1 AND KEYPAD

T2 = Transition 2 = S2 AND START
T3 = Transition 3 = S3 AND COOK.DONE
T4 = Transition 4 = S4 AND ALARM.DONE
T5 = Transition 5 = S2 AND CANCEL
T6 = Transition 6 = S3 AND CANCEL
Note: COOK.DONE refers to the condition in which the down counter

accumulated value reaches zero. ALARM.DONE refers to the condition in
which the timer accumulated value reaches the preset value.
If we replace the transition terms, we have:
These state equations cannot yet be implemented in a ladder program because

some NOT operators stand over multiple terms in the equations. Referring to the
DeMorgan's Theorem found in Appendix C, the equations become:

We are now ready to convert these equations into a ladder program. The first thing
we do (Figure B-7a) is to set the system to state S1 (IDLE) and define the down
counter (COOK) and the timer (ALARM). A second timer (T4:1) is also implemented
to produce a pulse for the counter every second during the COOK state. The
KEYPAD input adds 10 seconds to the counter every time it is actuated. Because
the down counter done bit is on unless the accumulated value diminishes under the
preset value, a bit (B3:0/9) is reserved that is the opposite of the done bit.

Figure B-7A. Ladder Program for the State Equations.

Secondly (Figure B-7b), the state equations are translated into ladder logic. OR ("+")
signs imply parallel branching, AND ("•") signs turn into serial branching, and
NOT operators become NC contacts. Intermediate state variables (ending with an
"X") are used to avoid unstable states during calculations.
Figure B-7B. Ladder Program for the State Equations.
Thirdly (Figure B-7c), the states are updated to reflect the changes that have
happened in the previous equations.

Figure B-7C. Ladder Program for the State Equations.
Finally (Figure B-7d), the states are used to turn specific outputs on. This last step
can be accomplished by observing where 1's are located in the state table.
Note: An alternate way to set the outputs would be to move a word of a

data file (representing the state table) to the output file for each state.

Figure B-7D. Ladder Program for the State Equations.
Method 2 - Timing Diagrams
Another method to design a ladder program is with the help of a timing diagram. An
example is presented here to illustrate this method. In this example, a batch heating
process is controlled by a PLC.
Context
You are asked by the manager of a dairy plant to write a PLC program that controls
the process of Figure B-8. In this process, milk is pumped into a reservoir until the
maximum level is reached. After that, the liquid is mixed and warmed up by a heating
element until the thermostat senses 200 °F. At that point, the system stops heating
and a solenoid valve opens to evacuate the milk until the minimum level is reached.

Figure B-8. Milk Heating Process.
The heated milk will then be transferred to other sections of the plant where it will
become yogurt after having been cooled, inoculated with bacterial culture, incubated,
and refrigerated.
Defining the Inputs and Outputs
From the system schematic (Figure B-8), we can deduce the inputs and outputs
present in the system:
Inputs:
• I0: ON switch
• I1: MIN level sensor
• I2: MAX level sensor
• I3: THERMOSTAT
Outputs:
• O0: Pump
• O1: Heating element
• O2: Mixer
• O3: Solenoid valve
Once the inputs and outputs are defined, we are ready to construct a timing diagram.

Timing Diagrams
Timing diagrams show the relationships of the different inputs and outputs on a time
basis. Figure B-9 shows what the timing diagram of the milk heating subsystem can
look like. First, the time axis is drawn and the variables written in a column. Then, the
state (OFF or ON) of the I/O variables upon time is drafted. This operation is
accomplished by portion, because each change in a variable state is likely to have
an impact on other variables. At this time, some time durations can be approximated
since, for example, the exact time to heat the liquid has not yet been tested.
Figure B-9. Timing Diagram.
Note: Timing diagrams, because they show the system sequence, are also
useful for testing purposes, to verify the behavior of the system.

Identifying States
Once the timing diagram is drawn, it is time to observe the relationships between the
different input and output variables. From that inspection, you should be able to
identify the states the system goes through. In our example, we can identify three
different system states:
1- PUMPING when the pump is working (O0 = 1)

2- HEATING when the heating element and mixer are working (O1 = O2 = 1)
3- EMPTYING when the solenoid valve is open (O3 = 1)
Writing the Program
We can now note which inputs and outputs are actuated during a specific state on
the timing diagram. This information will allow us to write the ladder program either
directly or by writing down the three state equations before. The final result is shown
in Figure B-10 below.
Figure B-10. Ladder Program for the Milk Heating Process.
Note: The equations produced from the observation of the timing

diagram are not optimized. Better coding is achieved through
state analysis.

Appendix C
Boolean Algebra and Digital Logic
Boolean algebra is a mathematical way of looking at logic problems. It is based on

problems which have only two outcomes, such as true or false, on or off, 0 or 1, and
opened or closed.
There are three basic operators in Boolean algebra. They are logical NOT, logical
AND and logical OR.
The logical NOT operator inverts a function or variable. The inverse of 1 is 0 and the
inverse of 0 is 1. The logical NOT is indicated by a bar above the function or variable,
such as:
The logical AND operator is performed on two or more variables such as A or B. The
result of "ANDing" two or more variables is a logical 1 if every variable is a logical 1.
The result is a logical 0 if any variable is a logical 0. The logical AND is indicated by
a dot between the variables, such as:
A@B
The logical OR operator is performed on two or more variables, such as A and B.

The result of "ORing" two or more variables is a logical 1 if any variable is a logical 1.
The result is a logical 0 if every variable is a logical 0. The logical OR is indicated by
a plus sign between the variables, such as:
A+B
A Boolean statement is a shorthand method of describing a logic statement using

Boolean operators. The statement A@B + C = Y is read A AND B, OR C equals Y.
This means that the variable Y will be a logical 1 if both A and B are logical 1's, or
if C is a logical 1.
In a Boolean statement, there is an order of precedence for the operators. This is

listed in Table C-1.
1. Statements within brackets and under bars are performed first. A bar over
two or more variables is considered the same as placing the variables
within brackets. In this case, the statement under the bar is performed
first, and then inverted.
2. Perform all NOT (invert) functions on single variables.
3. Perform all AND functions.
4. Perform all OR functions.
Table C-1. Order of Precedence in a Boolean Statement.
PLC APPLICATIONS – WIND TURBINE C-1

Postulates are the basic assumptions from which the properties, rules, and theorems
of a system can be deduced.
The postulates that are the basis for Boolean algebra are listed in Table C-2.
1. X = 0 or X = 1 5. 1@1 = 1
2. 0@ 0 = 0 6. 1@ 0 = 0, 0@1 = 0
3. 1+1=1 7. 1 + 0 = 1, 0 + 1 = 1
4. 0+0=0
Table C-2. Postulates for Boolean Algebra.
The theorems of Boolean algebra are derived from these postulates. Table C-3 lists
the theorems of Boolean algebra.
THEOREM 1. Commutative Law THEOREM 6. Redundance Law

(a) A+B=B+A (a) A+A@B=A
(b) A@B=B@A (b) A@(A+B)=A
THEOREM 2. Associative Law THEOREM 7. (a) 0+A=A
(a) (A+B)+C=A+(B+C) (b) 1+A=1
(b) (A@B)@C=A@(B@C) (c) 0@A=0
THEOREM 3. Distributive Law (d) 1@A=A
(a) A@(B+C)=A@B+A@C THEOREM 8 (a) &
A +A=1
(b) A+(B@C)=(A+B)@(A+C) (b) &
A @A=0
THEOREM 4. Identity Law THEOREM 9. A @B=A+B
(a) A+&
(a) A+A=A (b) A@(&
A +B)=A@B
(b) A@A=A THEOREM 10. DeMorgan's
Theorem
THEOREM 5. Negation Law (a) &
A&+& A @&
B =& B
(a) (A)=&
A (b) &
A &@ &
B =&
A +&
B
(b) (&
A )=A
Table C-3. Boolean Theorems.
Digital logic is a method of implementing Boolean statements in a control circuit or

program. The Boolean operators (AND, OR, and NOT) are performed by logic gates.
A logic gate receives input signals and transmits an output signal. The output signal
will be a function of the input signal. Six common logic gates are: AND, OR, NOT,
NAND, XOR, and XNOR.
C-2 PLC APPLICATIONS – WIND TURBINE

The AND, OR, and NOT gates perform the same function as the AND, OR, and NOT
operators in Boolean algebra. A NAND gate performs the inverse function of an AND
gate. The NOR gate performs the inverse function of an OR gate. The XOR gate has
two inputs; if one input or the other input, but not both, are logical 1s, then the output
is a logical 1 otherwise the output is 0. The XNOR gate performs the inverse function
of an XOR gate. The table of Figure C-1 lists the types of gates, gate symbols, and
truth tables for each gate. The gate inputs are indicated as either A or B, and the
gate outputs are indicated by Y.
Figure C-1. Logic Gates.
PLC APPLICATIONS – WIND TURBINE C-3

Programmable Controllers often use Boolean operators or logic gate functions as

program instructions. These instructions are often used in combination with
programmed NO and NC contacts.
The AND instruction is used to connect programmed contacts or ladder program

sections in series. The OR instruction is used to connect programmed contacts or
ladder program sections in parallel. The NOT instruction changes a NO programmed
contact to a NC programmed contact.
Figure C-2 shows two contacts "ANDed" together.
Figure C-2. Two "ANDed" Contacts.
Figure C-3 shows two contacts "ORed" together.
Figure C-3. Two "ORed" Contacts.
Figure C-4 shows two sets of "ORed" contacts "ANDed" together.
Figure C-4. Two "ANDed" Ladder Program Sections.
Figure C-5 shows two sets of "ANDed" contacts "ORed" together.
Figure C-5. Two "ORed" Ladder Program Sections.
C-4 PLC APPLICATIONS – WIND TURBINE

Appendix D
Troubleshooting Procedures
Introduction
Even the most efficient PLCs used in modern manufacturing are subject to
breakdowns. Determining a system malfunction can be a time-consuming process.
At this point, a skilled troubleshooter is required. Since downtime is costly to most
companies, highly skilled troubleshooting technicians are in great demand.
The skills necessary to troubleshoot equipment quickly and efficiently may be

acquired by learning the principles of electricity and machinery. The skilled
troubleshooter applies logic and a sound knowledge of the equipment to isolate the
problem.
Trouble Identification
The best way to start troubleshooting a system malfunction is to skim through the
manufacturer's instruction manual. The manufacturer's manual will explain what the
equipment does and how it is accomplished. The manual will usually include lists of
typical faults and probable causes. This type of information can be very useful and
time saving.
Unfortunately, the necessary manual is often missing, lost, or the equipment has
been modified to the point where the manual is of little value. Quite often the
technician must troubleshoot the system without a manual, relying only upon training,
experience, and a schematic diagram.
There are two general principles which can be employed as guides for
troubleshooting system malfunctions. The first principle is to understand the normal
equipment operation. The second is to observe and investigate the malfunction
symptoms.
By applying both principles to the system, the general area of the problem can often
be identified quickly. Once the problem area is identified, specific troubleshooting
techniques may be used to isolate the problem.
Isolating the Problem
There are four general techniques which can be applied to troubleshooting:
1- System function (or system pattern). The problem is isolated to specific

equipment in the system by comparing what the system is supposed to do, to
what it is actually doing.
2- Signal (or power) flow tracing. The trouble is narrowed down to a particular
device, such as a processor unit or expansion unit.
PLC APPLICATIONS – WIND TURBINE D-1

3- Voltage and resistance measurement. This technique helps identify the most
probable cause of a system malfunction, such as dirty or welded relay contacts,
an open relay coil, or an input/output problem.
4- Component substitution. By replacing system components with others that are

known to be working well, faulty components can be identified by the process of
elimination.
These four techniques are the tools of the trade by which a system malfunction can
be solved. To summarize the process of isolating a system malfunction, the
technician must:
a. completely understand equipment operation

b. observe the symptoms and ask questions
c. apply the four techniques in order
General Troubleshooting Procedure
A general procedure to follow when troubleshooting is outlined below.
G 1. Analyze the equipment to understand its operation.
G 2. Note all problem symptoms and ask questions to the operator.
G 3. Check all input/output system devices – pilot lamps, switches, solenoids,

motor starters, etc.
G 4. Check to see if there is a smell of burnt materials, unusual noise, or

vibration.
G 5. Analyze the circuit to locate areas where indications and symptoms suggest
there is a problem.
G 6. Check circuit diagrams and/or equipment manuals to see if a detected

symptom has a probable cause and remedy.
G 7. Make voltage checks in the direction of power flow – start at the main
breaker and trace for power through to the final device in the circuit.
G 8. Isolate the problem device – motor starter, fuse, etc.
G 9. Repair or replace the device – many devices, such as contactors and

control relays, have replaceable parts.
D-2 PLC APPLICATIONS – WIND TURBINE

PLC Start-Up Procedure
PLC systems can be particularly troublesome upon start-up. This is especially true
in the case of a new design or after a major maintenance. Therefore, special
attention must be given before and during the first system run. This allows avoidance
of unexpected and undesirable results. The following PLC start-up procedure
involves seven steps, to be performed sequentially, as described below.
G 1. Inspect the installation before power is connected.
G 2. Disconnect motors and other devices which could cause machine motion.
G 3. Test all inputs.
G 4. Test all outputs.
G 5. Enter, verify, and test the ladder program. This step is detailed in the next
section of the appendix.
G 6. Test the system with motors and other motion-causing devices reconnected.
G 7. Go through a dry run.
The chart shown in Figures D-1 through D-3 is a troubleshooting flowchart which
may be used for steps 3, 4, and 5 of a PLC start-up.
Program Testing
Once the ladder program is written in the programming software, you can verify the
program and check for address errors. The most common mistakes in a ladder
program include:
• incorrect address instructions

• omission of an instruction or rung
• mistaken entry
• repetition of the same output instruction and address
After the user program has been entered and verified, use the single scan test mode.
In this mode, the outputs are not energized and the processor unit will complete one
scan of the user program each time single scan is selected. Simulate the input
conditions necessary to make rung 1 true (Force Function of the PLC), and monitor
the input and output instructions to verify correct operation of the user program.
Repeat this procedure for each program rung to verify that the user program is
functioning correctly.

Figure D-1. Troubleshooting Chart.

Figure D-2. Troubleshooting Chart (continued).

Figure D-3. Troubleshooting Chart (continued).

Appendix E
Post-Test
1. Which advantage-drawback pair applies to wind-turbine electricity production?
a. Complements well a hydro power dam by acting as a “water pump” for the
dam’s reservoir / Emits many tons of CO2 per MWh generated.
b. Is always dependable / Is subject to aesthetical criticism.
c. Uses renewable energy / Unsteady Wind Conditions complicate
management of the power grid.
d. Relies on readily available resources / Necessitates management
of radioactive waste materials.
2. Which components of the nacelle simulator are used as inputs by the PLC?
a. Gear box
b. Meteorological instruments
c. Yaw motor
d. Nacelle power input
3. Why is there a control unit in most wind turbines?
a. To continuously optimize its operation according to the environmental

conditions.
b. To increase development costs.
c. To reduce the number of human interventions.
d. a. and c.
e. a. and b.
4. Which ladder instruction allows you to remap linearly a range of data?
a. SCP
b. MOV
c. OTE
d. LIM
5. What kind of signal comes out of the Wind Direction output?
a. A digital pulse signal (24 V)

b. A high-frequency chirp
c. An analog signal ranging from 0 to 10 V
d. A semaphore
PLC APPLICATIONS – WIND TURBINE E-1

Post-Test
6. What is a LIM instruction used for?
a. To limit an input signal below 10 V.

b. To verify if a variable is within specified values.
c. To force the PLC into a liminal state.
d. To find the mathematical limit of a function.
7 Which statement is true about a MOV instruction?
a. It assigns a value to a specified memory block.

b. You cannot use more than one per rung.
c. It can address bits, bytes or words.
d. a. and c.
e. a., b., and c.
8. The use of subroutines in a ladder program promotes:
a. Reusability of programs.
b. Structured programming.
c. Erratic logical jumps.
d. a. and b.
9. A well-designed wind turbine tracks the wind even when:
a. The wind is too strong.

b. The subroutine designed to rotate the nacelle back to its home position is
being executed.
c. The wind speed is below the minimal operational value.
d. The turn-counter switch is activated.
E-2 PLC APPLICATIONS – WIND TURBINE

Post-Test
10. Analyze the program of Figure E-1. What is the value of the accumulator
(C5:0.ACC) if the input (I:0/0) is closed for three seconds and then turned off?
All bits are initialized to zero at the beginning of the program.
Figure E-1. Ladder Program – Question 10.
a. 0
b. 6
c. 7
d. 10
PLC APPLICATIONS – WIND TURBINE E-3

E-4 PLC APPLICATIONS – WIND TURBINE
Appendix F
Glossary of Terms
accumulated (ACC) value – The number of intervals counted by a timer's internal

clock or the number of counter rung transitions.
actuator – Any linear or rotary device converting fluid power into mechanical motion
and force.
address – A reference number which indicates a specific memory location. Each

address has one memory location and each memory location has one address.
alarm – Audible or visual warning of a problem or condition.
analog – Analog circuitry, also called "linear" circuitry, is circuitry that varies certain
properties of electricity continuously and smoothly over a certain range.
analog input module – An input module which converts an analog signal to a digital
signal compatible with the PLC processor.
analog output module – An output module which converts a digital signal from the
PLC processor to an analog output signal.
anemometer – An instrument to measure the speed of the wind.
binary – A number system (base 2) that uses two numerals, 0 and 1, to represent
the two states of a device, such as "on" and "off"; "opened" and "closed".
boolean equation – An algebraic representation of a relationship where the only

possible values are 0 and 1.
bug – Software error which results in unwanted behavior. Typically used to refer to
programming errors.
clear – The removal of data from a single or all memory location(s) resetting it to
initial conditions. (usually "0").
coil (programmed) – A programmed element which represents an external output

from the PLC.
comparison instructions – These functions compare the contents of two memory

locations without altering their contents, and signal whether or not their contents are
the same. It may also send a signal indicating which memory location contains the
largest and/or smallest value.
contact (programmed) – A programmed element which represents an external

input to the PLC or controlled by a programmed coil. It can be either normally closed
(NC) or normally open (NO).
PLC APPLICATIONS – WIND TURBINE F-1

Glossary of Terms
counter (programmed) – A program instruction which replaces electromechanical
counters. Counters can be preset, combined to allow for greater preset values, and
used for controlling other program elements such as PLC output instructions.
CPU (Central Processing Unit) – The part of a programmable controller or

computer which controls the system's activities. This includes the interpretation and
execution of the user program.
debug – The act of locating and eliminating programming errors from a software
program.
downtime – The time that a system is not operating due to required maintenance.
flowchart – A schematic representation of an algorithm or a process.
force ON/OFF – A function which is used to force an input/output address to an

"ON" or "OFF" state regardless of its present state.
hardware – The physical parts and electronic circuitry of a system.
hexadecimal – A number system (base 16) that uses the numbers 0 through 9 and
the letters A through F to represent decimal values ranging from 0 to 15.
input device – A device which supplies input information to the PLC. Some common
input devices are limit switches, pushbuttons, and thumbwheel switches.
input interface – A unit that is used to connect input devices to a logic

programmable controller. The input module converts a given input signal to a logic
level signal that the CPU can recognize.
instruction set – The group of commands that are used to program the PLC. Each
type of PLC has its own instruction set.
interface – The mating of one component in a system to another to form an

operational unit. Example: by itself, a microprocessor can perform few worthwhile
functions; extensive interfacing is required to produce a useful device (such as a
PLC).
I/O – Abbreviation for Input/Output.
ladder program – Program generally used in PLC's. It consists of individual rungs,

each rung containing a set of instructions represented by symbols for logic control
of an operating system.
latching relay (programmed) – A type of programmed coil which is retentive upon

loss of power, a latching relay can only be unlatched by an unlatching relay coil
having the same address.
LED – Abbreviation for Light Emitting Diode.
limit switch – A mechanical, hall effect, or optical sensor used to detect end of
travel on an axis.
F-2 PLC APPLICATIONS – WIND TURBINE

Glossary of Terms
logical continuity – Exists when there is a complete left to right path of true
instructions on a ladder rung. When logical continuity exists, a PLC output is
energized.
logical function – During PLC operation the processor determines the state of the
bit in the data files, evaluates each ladder rung and determines the PLC output
status according to rung logical continuity.
manually operated – Activated by a human operator using a lever, button, foot

pedal, or other mechanical device.
mask – A code which is used to indicate which part of the sequencer data addresses
apply to the sequencer, and which do not.
memory – The program and data storage area in a PLC.
microsecond – A unit of time equal to one millionth of a second (0.000001 seconds,

1 x 10-6), abbreviated as "µs".
millisecond – A unit of time equal to one thousandth of a second (0.001 seconds,

1 x 10-3), abbreviated as "ms".
nacelle – The enclosure at the top of the tower containing the gear box, generator,
and control units. Meterological equipment is usually attached to the nacelle.
NC – Abbreviation for Normally Closed.
NO – Abbreviation for Normally Open.
node – A point in a ladder logic program matrix into which logic elements can be
programmed.
output device – A device which accepts information from the PLC. Common output
devices are: motors, solenoids, and alarms.
output interface – A unit that is used to connect output devices to the PLC. The
output module converts a logic signal from the processor to the required output
signal.
PLC – Abbreviation for Programmable Logic Controller.
preset – The limit specified for a timer or counter to time or count to.
process control – Pertains to ways and means by which conditions (pressure, flow,
temperature, or level) of processes are automatically kept to desired values or within
a required range.
program – A planned set of stored instructions to be executed by the processor for

machine or process control.
proximity detector – A device that detects the presence or absence of a specific

object.
PLC APPLICATIONS – WIND TURBINE F-3

Glossary of Terms
RAM – Abbreviation for Random Access Memory. A type of memory which can be
read-from or written-to in any order.
relay – An electrical switch that opens and closes under the control of another
electrical circuit.
ROM – Abbreviation for Read Only Memory. This is a type of memory containing
data permanently stored at time of manufacture. It usually cannot be written to after
this.
rung – In ladder programs, the set of instructions which control PLC rung outputs.
A ladder program may contain several rungs of programmed instructions.
scan – The continuous sequential examination of all pertinent information required

for the programmable logic controller to perform the task it has been programmed
for. This consists of examining the current status of the I/O's, solving the user
program and updating the status of each I/O.
scan rate – The time required for the processor to completely scan a user program.
sequencer – A program function which controls two or more sets of programmed

contacts in a predetermined sequence.
setpoint – The desired value of the variable being controlled.
software – A set of computer program, procedures, and possibly associated

documentation concerned with the operation of a data processing system.
state – In memory the logic "0" or "1" condition of a single bit of memory. The "ON"
or "OFF" condition of a PLC's input or output.
state diagram – A graphical representation of a finite state machine.
state table – A truth table showing all possible states of a finite state machine.
status – The state of a device such as ON/OFF, or OPEN/CLOSED.
timer – A device which can be preset to control the interval of operation of another
device. (The device can be either a programmed device or an electromechanical
device).
timing diagram – A representation of a set of signals in the time domain where

higher values are of logic one and lower values are of logic zero.
troubleshooting – A systematic search for the source of a problem so that it can be

solved.
wind vane – An analog instrument designed to measure the direction of the wind.
F-4 PLC APPLICATIONS – WIND TURBINE

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Electric Power / Controls

Job Sheets – Student

Job Sheets – Student

Copyright © 2009 Lab-Volt Ltd.

All rights reserved. No part of this publication may be reproduced,

Legal Deposit – Second Trimester 2009

FIRST EDITION, JUNE 2009

Lab-Volt's Programmable Logic Controller, Basic Principles Using the Programming

Each manual of the PLC applications series concentrates on a specific example of

Job Sheet 1 Familiarization with the Wind Turbine . . . . . . . . . . . . . . . . 1-1

Introducing the wind turbine system. Measuring the wind speed

Job Sheet 2 Wind Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Measuring wind direction and adjusting its scale. Implementing

Job Sheet 3 Complete Nacelle Operation . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Counting completed turns. Positional reset of the nacelle when the

Job Sheet 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Guided and non-guided ways of finding an inserted fault in the Wind

Appendices A Lab-Volt PLC Trainers, Models 3240-2 and 3240-A

We Value Your Opinion!

Programmable Logic Controllers (PLC's) represent state-of-the-art microprocessor-

The corresponding Lab-Volt Instructor Guide (P/N 85303-30) provides answers to

– Put your safety glasses on.

1 Personal computer on which the RSLogix 500 software is installed

Appendix A: Lab-Volt PLC Trainers, Models 3240-2 and 3240-A, provides

Appendix D: Troubleshooting Procedures, is a set of guidelines permitting the

Appendix E: Post-Test, is a list of ten review questions.

Appendix F: Glossary of Terms, defines technical words and expressions

FAMILIARIZATION WITH THE WIND TURBINE

PLC APPLICATIONS – WIND TURBINE 1-1

Figure 1-1. A Wind Turbine.

1-2 PLC APPLICATIONS – WIND TURBINE

Figure 1-2. Schematic of a Nacelle.

Lab-Volt's Wind Turbine System

The Wind Turbine System from Lab-Volt is made of two modules:

• Wind Generator, Model 3213

PLC APPLICATIONS – WIND TURBINE 1-3

Figure 1-3. Wind Generator, Model 3213.

Lab-Volt's Nacelle Simulator is shown in Figure 1-4. It is designed to reproduce the

1-4 PLC APPLICATIONS – WIND TURBINE

Figure 1-4. Nacelle Simulator, Model 3297.

1. Wind Direction Selector 9. Wind Direction Analog Output

Automated Control of a Wind Turbine

PLC APPLICATIONS – WIND TURBINE 1-5

The available outputs of the nacelle module are:

– The speed and direction of the wind.

Operation of the Wind Speed Output

Figure 1-5. Time Diagram of the Wind Speed Output.

The Divide (DIV) instruction is a standard mathematical operation used to divide a

1-6 PLC APPLICATIONS – WIND TURBINE

Figure 1-6. A Typical Use of the DIV Instruction.

PLC APPLICATIONS – WIND TURBINE 1-7

• Become familiar with some components of the Nacelle module.

• A toggle switch is used to manually command a rotation of the nacelle

The ladder program uses only the following RSLogix instructions:

XIC - XIO - OTE - TON - DIV - GEQ - LEQ - NEQ

G 2. Use these I/O connections:

PLC APPLICATIONS – WIND TURBINE 1-9

Figure 1-7. Interface Connections for the PLC Implementation.

1-10 PLC APPLICATIONS – WIND TURBINE

I:0/0 Input 0 Wind Speed Output of the

I:0/3 Input 3 Toggle Switch 4 / Used for

I:0/4 Input 4 Toggle Switch 5 / Used for

O:0/0 Output 0 Motor Control of the Nacelle -

O:0/1 Output 1 Motor Control of the Nacelle -