TEKNIK KONTROL INDUSTRI

INDUSTRIAL
CONTROL TECHNIC
 BUKU
REFERENSI

INDUSTRIAL CONTROL ELECTRONIC’S BY JOHN WEBB AND KEVIN

GRESHOCK

INDUSTRIAL ELECTRONIC’S BY FRANK D. PETRUZELLA

PLC (PROGRAMMABLE LOGIC CONTROLLER) BY FRANK D. PETRUZELLA

Manual PLC
 Materi Mata Kuliah
• Peralatan kontrol industri (EMR, SSR, Timer,
Counter, macam-2 switch, sel valve, sel mover)
• Transducer dan sensor (Thermal, optical,
magnetic/induktif, ultrasonic, kapasitif, force,
mechanical)
• Signal conditioning (ohm/V converter, V/I
converter, I/V converter, I/P conv, F/V conve,
V/F conve)
• Power Suplai Industri (AC dan DC)
 Kontrol motor ac/dc
• Start/stop
• Starting motor (jogging start, Y/D stater,
Rheostat dll)
• F/R control
• Breaking (plugging, antiplugging, dinamic
breaking)
• Speed control (AC: pole changing, slip control,
freq control/VSD/Inverter) (DC: kontrol pada
armatur dan dan kontrol pada kumparan
medan)
 Analog kontroler
• On/off controller DB : dead band
• Proportional controller
• PI controller
• PID controller

• Tuning / metode zegler nichols

 Digital Kontroler
• PLC sebagai kontroler:
• Cara pemrograman (ladder diagram, IL
/mnemonic, boolean languange, BD diagram,
Flowchart, Text language…)
• I/O: Discrete, analog, digital
• Alamat dan fungsi2 instruksi
• Projek PLC: kontrol motor, temp kontrol,
dengan software Ladsim (TL, LIFT, car park,
annuciator, vending machines, packing line)
Segi tiga, 5 level kontrol di industri

SCADA, IT, Sophisticated

EC
TFC DCS, Large PLC

Group kontrol PLC, micro, comp

PLC, micro, comp

Individual kontrol
Manual kontrol Manusia
Kontrol otomatis dibanding human control

• Mengurangi biaya produksi secara keseluruhan

• Computational capabilities
• Respon time yang cepat
• Environmental safety for operating personel
• Prompt emergency recognation and reaction
• General convinient
BAB 1

PERALATAN
KONTROL
INDUSTRI
 PERALATAN KONTROL INDUSTRI
• EMR DAN SSR
• TIMER DAN COUNTER
• SWITCHS
• AC DAN DC POWER SUPPLY
• SIGNAL CONDITIONING
 EMR SSR: Thyristor
Relay, (SCR, Triac,
Perbandingan penggunaan kontaktor, GTO,
EMR dan SSR CB Transistor,
Diode

Arcless switching of the load - +

Effect of temperature + -
Shock and vibration resistance - +
Immunity of transtient + -
Radio frequency switching interference + -
Zero voltage turn on - +
Accoustic noise - +
Respons time - +
Selection of multipole multithrow + -
Voltage drop in load circuit + -
Leakage current + -
Interfacing compatibility - +
Life expectancy - +
General cost + -
EMR
SSR
Timer dan counter
Susunan kontak timer dan counter
Retentive timer
Contact arrangement
 Control Switch
• Control Switch banyak digunakan untuk
keperluan pengontrolan di Industri
• Control Switch adalah berupa; Push Botton,
Cam Switch, TS, Sel Switch dll
Jenis-jenis control switch
Push botton
MBB dan BBM
APLIKASI MBB DAN BBM PADA METER
Pada Ammeter
 Pemilihan jenis switch
• Konfigurasi switch (poles dan throws)
• Tegangan dan arus switching (AC atau DC)
• Kemampuan hantar arus switch
• Kebutuhan life cycles in number of actuation
• Environmental consideration (moisture,
vibration, dll)
• Ukuran fisik
• Option seperti; dilengkapi dengan pilot-lamp
atau kunci
 POWER SUPLAI INDUSTRI
• SUPLAI AC / TRAFO KONTROL
• SUPLAI DC
Trafo kontrol / isolation transformer
 FUNGSI TRAFO ISOLASI
• MENGURANGI/MENGHILANGKAN GANGGUAN DARI
BENTUK GELOMBANG INPUT YANG BERUPA:
• FLICKER, NOISE, SAG, SWELL, MOMENTARY
INTERUPTION, TRANSTIEN, NOTCHING, HARMONIC
DLL
• SEHINGGA TEG SUPLAI KE PERALATAN TETAP BAIK
(SINUSOIDAL)
What’s the Problem?

EMO circuit drops

critical equipment
What’s the Problem?

Desktop computers crashing

31
What’s the Problem?

Data Center Downtime

What’s the Problem?

Manufacturing Downtime
 Jenis-jenis gangguan pada Sistem Tenaga
Listrik yang mempengaruhi kinerja peralatan:
• Transients
• Long Duration Voltage Variations
• Short Duration Voltage Variations
• Interruptions
• Waveform Distortion
• Voltage Fluctuation (Flicker)
• Frequency Variation
• Noise
Transient
 Impulsive Transient

Sebuah gangguan atau disturbance yang tiba-tiba

dengan waktu yang sangat cepat terjadi pada
tegangan, arus atau keduanya.
Frequency Range: >5 kHz (High Frequency)
Duration: 30-200 uSec
 Impulsive Transient
 Causes Lightning
 Impacts Transformer failures
 Arrester failures
 Kerusakan pada Customer equipment yang
disebabkan oleh surge
 Oscillatory Transient
Terjadinya fluktuasi yang temporer pada tegangan ataupun arus.
Low Frequency Transients :
<500 Hz, <30 cycles
Penyebab: Capacitor switching
Impacts :
•Tripping of relays dan peralatan sensitive lainnya
•Voltage magnification at customer capacitors
 Oscillatory Transient
Medium Frequency Transients
500 Hz - 2 kHz, < 3 cycles
Penyebab:
Traveling waves dari lightning impulses
Capacitor dan circuit switching transients
Impacts:
Failure of customer equipment
 Oscillatory Transient
High Frequency Transients
2 kHz, < 0.5 cycle
Penyebab:
Switching pada sistem sekunder
Lightning-induced
Local ferroresonance
Impacts:
Menyebabkan naiknya oscilasi dan gagalnya sistem
power suplai tegangan rendah
Oscillatory Transient
Oscillatory Transient
Long Duration Voltage
Variation
Short Duration Voltage
Variations
 Voltage Sags (dips)

Penurunan antara 0.1 dan 0.9 pu dalam rms tegangan atau

arus pada frekuensinya untuk durasi 0.5 cycles sampai 1 min.
Penyebab:
Local and remote faults (Short circuit di tempat lain)
Starting motor-motor besar
Starting trafo
Impacts:
Dropouts pada sensitive customer equipment
Voltage Sags (dips)
Voltage Sags (dips)
 Voltage Swells (surges)
Kenaikan tegangan atau arus rms antara 1.1 dan 1.8 pu pada
power frekuensi untuk durasi antara 0.5 cycle sampai 1 min.
Penyebab:
Single-line-to-ground faults
Impacts:
Equipment overvoltage
Failure of MOVs forced into conduction
Voltage Swells (surges)
Interruptions
 Interruptions

• Momentary Interruption: 1/2 - 3 secs

• Temporary Interruption: 3 - 60 secs
• Long-Term Interruption (outage): > 1 minute
• Penyebab:
– Temporary Faults
– Lightning stroke
– Tree limb falling across two conductors then dropping clear
– Faults that do not clear
– Impacts: Operation interruption, production losses, dan revenue
losses
Interruptions
Fluktuasi Tegangan
 Flicker

• Pengaruh voltage fluctuation pada lampu adalah seperti kita

mengedipkan mata berulang-ulang. Hal ini disebabkan karena
perubahan beban yang melebihi kontinuitasnya, perubahan
arus yang cepat terutama disebakan karena komponen reaktif
dari beban.
 Flicker
• Penyebab:
– Arc furnaces
– Intermittent loads

• Impacts:
– Lighting flicker
– Misoperation pada sensitive loads
Flicker
Frequency Variation
Noise
 Notching

• Periodic voltage disturbance yang disebabkan oleh

pengoperasian peralatan power electronics ketika
arus dikomutasi dari satu phasa ke phasa yang lain
• Penyebab:
– Pengoperasian peralatan power electronic
• Impacts:
– Misoperation of equipment
– Equipment failure
Notching
 Noise

• Bentuk gelombang yang tidak diinginkan yang mengikuti bentuk

fundamental dengan frekuensi sampai 200kHz. Biasanya terjadi pada
phasa ataupun netral
 Noise
• Penyebab:
– Improper grounding
– Pengoperasian peralatan power electronic
– Arcing devices
– Switching power supplies
• Impacts:
– Disturbing electronic devices seperti
microcomputer and programmable controllers
Waveform Distortion
 Harmonics

• Nonlinear loads, seperti misalnya power electronic equipment,

menghasilkan non-sinusoidal current waveforms meskipun disuplai
dengan sinusoidal voltage. Harmonic currents, dan voltage distortion
dapat mempengaruhi impedansi sistem, dapat mengurangi equipment
operating reliability and service life
Harmonics
 Off - Line Technology UPS
Input Power Present

Xfer Switch
Input Filter Output

Charger Inverter

Battery

67
 Off - Line Technology
Input Power Fail

Xfer Switch
Input Filter Output

Charger Inverter

Battery

68
 On - Line Technology UPS
System Operation

EMI / RFI
INPUT OUTPUT
TVSS

DC / DC
Converter

Charger Battery

Facility Voltage Present

 On - Line Technology Battery Operation

EMI / RFI
INPUT OUTPUT
TVSS

DC / DC
Converter

Charger Battery

No Facility Voltage Present

 Dynamic Voltage Restorer
 Energy storage - DC capacitors
 Rectifier changes the voltage to DC
 Inverter changes the DC back to AC
 AC output waveform is controllable
 ‘Adds’ its output to the utility waveform through the use of a series
transformer
 1 to 4 ms response time
 Practical boost to about 50%
 Manufacturers:

– S&C Electric ($ 2M/5 MVA)

– ABB
 D is trib u tio n P rim a ry F e e d e rs F a u lt o c c u rin g o n
S u b s ta tio n a d ja c e n t fe e d

Line Voltag e C ompensating R estored

With Sag Voltag e Voltag e
T ra n s m is s io n
PU PU PU
S y s te m S w itc h in g
+1 +1 +1
o r F a u lt C le a rin g
0 + 0 = 0

-1 -1 -1

D Y N A M IC
V O LTAG E
RE S TO RE R P ro te c te d
S e n s itiv e L o a d

DVR Application in a Feeder

(Courtesy: Westinghouse)

72
DVR Container
 Dynamic Voltage Restorer
Limitations
• Do not address interruptions
• Limit to boost capability - amplitude and
duration
• Boost effectiveness may depend on load
power factor
 Dynamic UPS (ABB)
Pure Wave UPS (S&C)
 Energy storage is a high energy cranking battery.
 Mitigates sags and outages, providing 100% voltage compensation
 During a sag or outage the system disconnects from the utility.
 Standby system
 4 ms response or less
 Manufacturers:

– S&C Electric
– ABB
 S&C Purewave UPS
 380 V to 34.5 kV voltage applications
 313 kVA to 20 MVA per system
 4 ms response
 More than 98% efficient
 30 second protection at
100% load
 Maintenance free high
performance lead-acid
cranking battery

S&C Purewave UPS at ST Microelectronics Fab in Phoenix, AZ

12.5 MVA @12.47kV
 DVR & DUPS Differences

DUPS
DVR Batteries
Capacitors Shunt Device
Series injection Static Transfer Switch
sags and mom. interruptions
Voltage Sags only
 SVR Principle of Operation (ABB)

Utility Load

1. Booster converter Low Voltage (480 V) Application

2. Charger converter 0.5 – 8 MVA load
3. DC link
4. Charger transformer
ABB Series Voltage Restorer (480 V, 3 –ph, 1.5 MVA)

11 ft
 MV Static Transfer Switches

 Solid State thyristor or GTO (Gate Turn-off thyristor)

switches transfer between independent distribution
sources
 Transfers to a ‘good’ source if one is available
 Transfer time as quick as 2 ms
 Numerous manufacturers, including, among others:
 ABB
 Cyberex
 Silicon Power
 S&C Electric
PowerDigm Sub Cycle Transfer Switch

 Addresses interruptions
and sags
 4 ms response
 Up to 38 kV, 600 A
 No energy storage
 Only as good as sources
 Electronics require cooling
 ~ $350k to $700k each
 Dynamic Sag Corrector®
Soft Switching Technologies: Dr. Deepak Divan

9 kVA ProDySC 1.0 MW DySC

 Provides tool (process) or fab-level protection (0.25 kVA to 3,000

kVA) – Soft Switching Technologies
 Corrects for voltage sags down to 50% for to 2-3 seconds
 Corrects for momentary interruptions up to 12 cycles
 4 ms response
 Proven track record
 DySC® Operation
 Normally static switch is closed
 During a sag, the switch is opened and the inverter is
energized, inserting a PWM signal in series with the
voltage sag
 No stored energy is used for sags down to 50%.
 Electrolytic capacitors are discharged for voltage
sags below 50% (12 cycles max)
Voltage Dip Proofing Inverter (DPI)
Voltage Dip Proofing Inverter

Static
Switch

From
100-120 Vac Bridge
or = Inverter To
200-230Vac Load
Storage
voltage source
Capacitor
~

 Off-line Device.
 Sub-cycle switching time in the event of a sag
 Disconnects the normal supply and serves the load from the internal
stored energy for up to 3 seconds.

 capacitors.
The energy storage is a set of DC

 Protects against voltage sags and momentary

outages.
 Coil Hold-In Devices
 Designed to “Prop Up” individual relays and
contactors
 Holds in relay/contactor down to 25% of nominal
voltage.
 Small Size
 Less than $120
 Size Based on Voltage and Coil Resistance
 Voltage rectification produces an average DC
waveform on device secondary
Konfigurasi sekunder
 Pemilihan trafo isolasi
• Besarnya tegangan primer
• Besarnya tegangan sekunder
• Daya trafo
• Loading effect dari trafo
• Kondisi lingkungan
• Sekunder grounding
• Konfigurasi sekunder
• Fusing sekunder dan primer
 Daya trafo dan loading effect
• Beban normal, standard NEMA 1.15 x VA total

• Beban coil, motor

• (continous VAx2)+(inrushVAx2)
• VA =
• 2
 DC POWER SUPPLY
RECTIFIER (CONVERTER AC – DC)
SINGLE PHASE
 BASIC POWER SUPPLY BLOCK
DIAGRAM AND WAVEFORMS

DC power supply

Voltage
ac input Rectifier Filter
regulator
dc output

Input voltage Rectifier o/p voltage Filter o/p voltage DC o/p voltage

(a) Basic power supply block diagram and waveforms.

DC power supply

Voltage
ac input Transformer Rectifier Filter
regulator
dc output

(b) Basic power supply with a transformer input.

90
HALF-WAVE RECTIFIERS.

VP VS RL VL

VP VS RL VL

91
Output voltage of half wave
rectifier

VP VS RL VL

VL (pk)  VS (pk)  VF
NS
VS (pk)  VP (pk)
NP
Vrms
Vpk   2 Vrms
0.707 92
 AVERAGE (OR DC) VOLTAGE AND
CURRENT
Half-wave rectifier:

Vpk
VL ave    0.318Vpk

2Vac rms  Vhw(pk)
  0.450Vac rms  Vhw(rms)

1 Vhw(ave)
Vac rms   VL ave   2.22VL ave 
0.450
I pk
I L ave    0.318I pk  0.450 I ac rms 

I ac rms   2.22 I L ave 
93
PEAK INVERSE VOLTAGE (PIV)

Peak inverse voltage at dioda. The

Diode should resistance from the
breakdown voltage.

PIV = VS(pk) for half-wave rectifier.

94
FULL-WAVE RECTIFIER TIPE TAP.

F1
Input
Signal
Full-wave
rectifier output
Load

A full-wave rectifier
(center-tap)

95
OPERATION FULL-WAVE RECTIFIER
(CENTER-TAP)
F1

IP
VS (pk )

2
IL VL

F1

IP VS (pk )

2
IL VL

96
 VOLTAGE AND CURRENT
EQUATION
Full-wave center-tap rectifier:
VS (pk)
VL   0.7V
2
2VL (pk)
VL (ave)   0.637VL (pk)  0.9VL (rms) Vfw(pk)
 Vfw(rms)
1 Vfw(ave)
VL (rms)  VL (ave)  1.11VL (ave)
0.9
VL (pk)
I L (pk) 
RL
VL (ave)
I L (ave) 
RL 97
PEAK INVERSE VOLTAGE
F1 +17Vpk D1 (on)

0 34 Vpk
D2(off)
RL
VL
-17Vpk 5.1k
24Vac 34 Vpk

PIV  2VL (pk)

PIV  VS (pk)

Full-wave center-tap rectifier.

98
 Negative full-wave rectifier.

F1
Input
Signal
Full-wave
rectifier output
Load

99
RECTIFIER FULL-WAVE BRIDGE TYPE

F1
D2 D3 Input
Signal
Full-wave
D1 D4 Load rectifier output

100
PRINSIP KERJA BRIDGE RECTIFIER

F1
D2 D3
VS
D1 D4 VL
F1
D2 D3
VS
D1 D4 VL

101
PERHITUNGAN TEGANGAN BEBAN
DAN NILAI ARUSNYA

VL ( pk )  VS ( pk ) (ideal)
VL ( pk )  VS ( pk )  1.4V
VL ( pk )
I L ( pk ) 
RL
VL ( ave )
I L ( ave ) 
RL

102
 PEAK INVERSE VOLTAGE

F1 F1
D2 D3 D2
VS VS VS
D1 D4 D4
RL RL

PIV  VS (pk)

Full-wave bridge rectifier.

103
 CENTER-TAP VS BRIDGE
F1 F1
D2 D3

Load D1 D4 Load

2 diodes 4 diodes
(1 diode in the current path) (2 diodes in the current path)
VS (pk)
VL (pk)  VL (pk)  VS (pk)
2

PIV  VS (pk)  2VL(pk) PIV  VS (pk)  VL(pk)

Current passing through half Current passing through full

of secondary winding at a secondary winding all time.
time.

104
HALF-WAVE VS FULL-WAVE

Vhw(pk) Vfw(pk)
Vhw(rms) Vfw(rms)
Vfw(ave)
Vhw(ave)
Vhw(pk)  V fw(pk)  VS (pk) V fw(rms)  2Vhw(rms)
2Vhw(ave)  V fw(ave) Vhw(pk)  2Vhw(rms)
Vhw(pk) V fw(pk)  2V fw(rms)
Vhw(ave) 

2V fw(pk)
V fw(ave) 
 105
Penyearah setengah gelombang 3 fasa
Penyearah gelombang penuh 3 fasa
 Besarnya tegangan penyearahan
• Single phase full wave:
Vdc = 0,637 Vpeak
• Three phase half wave:
Vdc = 0,827 Vpeak
• Three phase full wave
Vdc = 0,955 Vpeak
FILTERING EFFECT ON HALF-WAVE
RECTIFICATION

Half-wave
Filter
rectifier

Vr

Vr = ripple voltage

110
 CAPACITIVE FILTER
Charge Discharge

F1 F1

C1 RL C1 RL
VS 100F VS 100F
1k 1k

VL
IL

Charge Discharge
Charge
IS
Surge current

111
 RIPPLE VOLTAGE VS FILTER TIME CONSTANT

C1 RL
constant constant
RL = 500  C1 = 150 F

RL = 1 k C1 = 300 F

RL = 1.5 k C1 = 470 F

112
FILTER OUTPUT VOLTAGE
Vr /2 dVC (t )
Vr
Vr /2 I C (t )  C
dt
I C (t ) t I L (ave) t
Vpk Vdc
Equal
slopes C 
t  20 ms (for half-wave rectifier) VC Vr
I L (ave) t
Vr Vr 
C
Vdc Vr
VL ( ave )  VL ( pk ) 
2
t  10 ms (for full-wave rectifier)

113
Dc Filter
 Menentukan besarnya filter L/C
• Kapasitor filter
– Xc = 1 / 2fC nilainya sekitar 5% dari resistansi
beban
• induktor filter
– XL = 2fL nilainya 3 sampai 5 kali dari resistansi
beban
• Reaktansi kapasitor sekitar 5 % dari resistanasi
beban, dimana

–C = 1/2fX

Reaktansi Induktor sekitar 3 sampai 5 kali

resistansi beban

–L = X / 2f