section 40 94 43 – programmable logic controllers

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SECTION 40 94 43.01 – PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
PLCs may enter a project via a contractor, subcontractor (such as a systems integrator), or from an
Original Equipment Manufacturer. Verify that each Original Equipment Manufacturers
specifications have been properly coordinated with this section. This will help to prevent system
compatibility issues during start up.
PART 1 - GENERAL
1.1
RELATED DOCUMENTS
A.
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 1 Specification Sections, apply to this Section.
B.
References:
1.
RFI/EMI Susceptibility: MIL STD 461B CS02
2.
Showering Arc Test: NEMA Pub No ICS2-230.42
3.
Surge Withstand: ANSI C37.90a
4.
IEEE 472
5.
NFPA 70 (NEC)
6.
UL508
7.
RFI Immunity: IEC 801-3
8.
Ground Continuity: IEC 801-5
9.
Electrostatic Discharge: IEC 801-2
10. Electromagnetic Field (IEC 61000-4-3)
11. Fast transients (IEC 61000-4-4)
12. Programming Languages IEC 61131-3
1.2
SUMMARY
A.
This Section includes Programmable logic controllers for control of process equipment, process
oriented machinery, and process systems.
B.
Related Sections include the following:
1.3
1.
Section 40 94 33.10 “Operator Interface Terminals”
2.
Section 40 94 33.20 “SCADA Software and Hardware”
DEFINITIONS
A.
AI: Analog Input
B.
AO: Analog Output
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
40 94 43.01 - 1
C.
Fixed: A PLC style consisting of a fixed number of I/O, a processor, and a power supply all in
one enclosure. Some fixed PLCs have limited expansion ability.
D.
CPU: Central Processing Unit
E.
DI: Digital Input
F.
Distributed I/O: Hardware that has been specially designed to function as Remote I/O.
G.
DO: Digital Output
H.
HMI: Human-Machine Interface
I.
I/O Input and/or Output
J.
Modular: A PLC style consisting of cards that are assembled to comprise a complete unit. All
I/O, CPU, and Power Supply are dedicated cards. Typically, these cards are inserted into a
chassis.
K.
Master/Slave: Communication between devices in which one device, the master, controls all
communications. The other devices, the slaves, respond only when queried by the master.
Typically used in a Remote I/O application.
L.
Peer to Peer: Communication between two or more devices, typically PLC’s, in which each
device can control the communication exchange.
M.
PID: Control action, proportional plus integral plus derivative.
N.
PLC: Programmable Logic Controller
O.
Remote I/O: Remote I/O is any and all I/O that is located remotely from the processor. Remote
I/O can be over a variety of communication protocols and can use standard rack based I/O, or
special Remote I/O hardware referred to as Distributed I/O.
P.
SCADA: Supervisory Control and Data Acquisition
1.4
SUBMITTALS
A.
Product Data: For each type of PLC include dimensions, mounting arrangements, and weights.
Also include, manufacturer's technical data on features, performance, electrical ratings,
characteristics, terminal connections, and finishes.
B.
Operation and Maintenance Data: Provide for each PLC component literature detailing routine
maintenance requirements (if any).
C.
Each submittal shall have a check sheet for each PLC type. This check sheet shall be an
acknowledgement of all criteria in this specification. The check sheet will consist of three
columns. The leftmost column will indicate the referenced section of the specification. The
middle column will indicate rather the indicated specification criteria is met, not met, or has a
variance. The rightmost column will be used to describe reasons for variances or not meeting
the specified criteria. Each row on the check sheet will be for a dedicated spec section or sub
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
40 94 43.01 - 2
section. Each organization delineation will have its own dedicated row. For instance, you
cannot accept section 1.5B and its corresponding subparagraphs in a single row. You must
accept 1.5B in a row, and 1.5B1 in another row.
1.5
QUALITY ASSURANCE
Change mileage to reflect actual distance required. Locations in the southwest part of the United
States may need to increase the distance, while locations in the northeast may be able to decrease
that requirement.
A.
Manufacturer Qualifications: A qualified manufacturer shall maintain, within [100 miles (160
km)] of Project site, a facility, system integrator, or panel shop capable of providing training,
parts, and coordination of emergency maintenance and repairs.
Retain first paragraph and subparagraph if an independent testing agency’s approval (such as UL)
is required for quality assurance, or inspection requirements. The first paragraph specifies
29 CFR 1910.7 or other more specific criteria (e.g., NETA). 29 CFR 1910.7 defines a nationally
recognized testing laboratory as it applies to testing and inspecting for safety, and lists, labels, or
accepts equipment and materials that meet certain OSHA criteria.
B.
Testing Agency Qualifications: An independent agency, with the experience and capability to
conduct the testing indicated, that is a member company of the InterNational Electrical Testing
Association or is a nationally recognized testing laboratory (NRTL) as defined by OSHA in
29 CFR 1910.7, and that is acceptable to authorities having jurisdiction.
1.
Testing Agency's Field Supervisor: Person currently certified by the InterNational
Electrical Testing Association or the National Institute for Certification in Engineering
Technologies to supervise on-site testing specified in Part 3.
C.
Source Limitations:
1.
Provide all PLCs from a single manufacturer. If the PLC manufacturer has authorized
third party vendors to provide modules that are compatible with their platforms, then
products manufactured by these authorized third party vendors will be acceptable.
2.
To insure reliability and compatibility with all aspects of the control system, all PLC
equipment shall be from the same vendor as the SCADA software, Operator Interface
Terminals, and Power Distribution Equipment.
D.
Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70,
Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for
intended use.
E.
Comply with NFPA 70.
PLCs with the same functional characteristics may vary in length, width, and depth among
manufacturers. If installation space is limited, show maximum dimensions on Drawings, ensure
that equipment is available to fit, and retain paragraph below; delete if space is not a concern.
F.
Product Selection for Restricted Space: Drawings indicate maximum dimensions for PLCs,
minimum clearances between PLCs, and adjacent surfaces and other items. Comply with
indicated maximum dimensions and clearances, or with PLC vendors required distances if they
are greater then the distances indicated.
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1.6
DELIVERY, STORAGE, AND HANDLING
A.
Deliver PLC components in packaging designed to prevent damage from static electricity, and
physical damage..
B.
Store PLCs according to manufacturers’ requirements. As a minimum, store indoors in clean,
dry space with uniform temperature to prevent condensation. Protect PLCs from exposure to
dirt, fumes, water, corrosive substances, and physical damage. Also, protect the PLC from all
forms of electrical and magnetic energy that could reasonably cause damage.
1.7
PROJECT CONDITIONS
A.
Environmental Limitations: Rate equipment for continuous operation, capable of driving full
load without derating, under the following conditions, unless otherwise indicated:
1.
2.
3.
4.
1.8
Ambient Temperature: 0 to 55 deg C.
Humidity: Less than 95 percent (noncondensing).
Altitude: Not exceeding 6500 feet (3000 m).
<Insert unusual service conditions.>
PRODUCT PROTECTION
A.
Control panel designer shall provide independent line fuses or circuit breakers, per the
manufacturer’s recommendation, for each power Supply, Input Module, Output Module, and
other modules with separately derived power requirements.
B.
Control panel designer shall insure that communication signals, 4-20mA signals, embedded
HART signals, are properly conditioned for the PLC and protected from all sources of radiated
energy or harmonics.
1.9
SPARE I/O
A.
1.10
A.
Each PLC will be sized to handle the required I/O plus a percentage of spares. When
calculating spare I/O count, all fractional I/O points will be rounded up to the next whole I/O
point. The resultant I/O count will be rounded up to next whole I/O card. When configuring
spare I/O counts, use the following criteria:
1.
Analog Inputs (AI): Required for the PLC plus [15] [Insert a number]%.
2.
Analog Ouputs (AO): Required for the PLC plus [15] [Insert a number]%.
3.
Digital Inputs (DI): Required for the PLC plus [15] [Insert a number]%.
4.
Digital Outputs (DO): Required for the PLC plus [15] [Insert a number]%.
SPARE PARTS
Furnish spare parts as described below for each type of PLC. Material shall be packaged for
long term storage and identified with labels describing contents. Coordinate with each PLCbased control panel vendor to optimize the amount of spares that are provided.
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1.
2.
3.
4.
5.
6.
I/O Cards: Provide as a minimum a spare of each type of card identified. Provide an
additional spare for every [ten] <Insert number> cards of a specific type installed.
Processors: Provide as a minimum a spare for each type of CPU identified.
PLC oriented Power Supplies: Provide as a minimum a spare of each type of power
supply identified. Provide an additional spare for every [ten] <Insert number> power
supplies of a specific type installed.
Memory Cards: Provide as a minimum a spare of each type of card identified. Provide an
additional spare for every [ten] <Insert number> cards of a specific type installed
Specialty Modules: Provide as a minimum a spare of each type of module identified.
Provide an additional spare for every [ten] <Insert number> modules of a specific type
installed
“Fixed” PLCs: Provide as a minimum a spare of each type of PLC identified. Provide an
additional spare for every [ten] <Insert number> PLCs of a specific type installed.
PART 2 - PRODUCTS
2.1
MANUFACTURERS
A.
Available Manufacturers: Subject to compliance with requirements, manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the following:
B.
Qualified Manufacturers:
1.
Only manufacturers that have been selling PLCs for a minimum of [35 thirty-five]
[choose a number] years will be considered acceptable.
C.
Basis-of-Design Product: Square D - Schneider Electric; Programmable Controllers.
2.2
PROGRAMMABLE LOGIC CONTROLLERS
Several factors must be considered when choosing a PLC platform(s). Failure to properly analyze
the platforms can have a significant impact on project cost and control system performance. Two
main philosophies exist when selecting a PLC platform. Which philosophy is applicable will
depend on project requirements. One philosophy is to utilize a single platform throughout the
project. This will allow for unification of spare parts, but may impact total project cost. The other
philosophy is to utilize multiple platforms. This philosophy can minimize project cost, but does not
allow for unification of spare parts. Delete unused PLCs from the following.
A.
GENERAL:
1.
The PLC shall collect data, perform process control functions, communicate with other
PLCs, and distribute process information along the local area network.
2.
The PLC shall be able to have its program downloaded from a remote workstation over
the local area network, and be locally programmed from a portable laptop computer.
3.
The executive firmware of all intelligent modules shall be stored in Flash memory and
shall be able to be updated in the field using standard programming tools. Executive
firmware files shall be readily available via a public web site.
4.
The PLC shall have provisions for communicating unsolicited messages (report by
exception) to an operator interface to reduce network traffic.
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5.
6.
7.
8.
9.
B.
The PLC shall be field expandable to allow for the expansion of the system by the simple
addition and configuration of hardware.
Each component shall include a clearly visible faceplate with appropriate data such as the
manufacturer’s model number and a brief description of the component’s function.
All cables and connectors shall be as specified by the manufacturer. Cables shall be
assembled and installed per the manufacturer’s recommendations.
Each discrete point shall have a light emitting diode on the face of the module to indicate
point status. Green shall indicate that the point is logic level “1”, also reffered to as “on”
or “high”.
The PLC shall utilize Ethernet protocols that meet the following:
a.
Protocols that are assigned to port 502 of the TCP/IP stack by the IANA (Internet
Assigned Numbers Authority).
b.
Protocols that are supported by the Open DeviceNet Vendors Association (ODVA)
c.
Programming software will have embedded network configuration tools that utilize
FDT/DTM technologies. PLC systems that have the PLC programming and
network configuration tools in separate software will not be acceptable.
d.
Will not rely on third party vendors to meet the above criteria.
PLC PROGRAMMING REQUIREMENTS:
1.
All specified PLC platforms will be programmed using the same programming software
package. PLCs that use multiple software programming packages under similar trade
names will not be accepted. The programming software will have the following:
a.
Use of all textural and graphic languages specified in IEC 61131-3.
b.
An additional language dedicated to organization of the PLCs programs and
function blocks. This language shall be in Sequential Function Chart (SFC)
format.
c.
The software shall allow the program to be subdivided into two large functional
areas. One are is for normal program execution, the other is for process that must
be executed on a periodic, or very rapid, basis. Each area shall allow multiple
subsections of programming code. Each subsection can contain be of any
language type supported by IEC 61131-3 or SFC.
d.
Addressing shall be as follows.
1)
Digital and Analog I/O will be mapped to fixed addresses.
2)
Processor status will be mapped to fixed addresses
3)
Internal words and other internal data can eithier be unmapped, or mapped
to fixed addresses. If unmapped, the programming software will determine
the location.
4)
Internal words, I/O and other non processor status data will be able to be
addressed by an alpha numeric pneumonic. This name will be used in
unmapped variables, and in lieu of the address for mapped variables.
e.
Ability to store and retrieve instruction comments, program comments, rung
comments, and other comments and notes in the PLC processor.
f.
Ability to convert from one supported PLC platform to another supported
platform. Conversion shall be accomplished by exporting the program code, and
importing to a new program with the desired PLC platform and configuration.
g.
Textual syntax of the IL and ST languages, as specified in Annex B.2 and B.3 of
IEC 61131-3, 2nd Edition, including all directly and indirectly referenced
productions out of Annex B.1.
h.
The PLC programming software shall have the following tools for monitoring and
troubleshooting the PLC program.
1)
Power flow animation for graphical languages.
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2)
i.
j.
C.
A breakpoint capability to automatically halt the program just before a
certain sequence is initiated.
3)
Ability to advance the program step by step to insure proper operation.
4)
Ability to create watch points for desired variables. These watch points will
display the real time value of the variable.
5)
Monitoring of step activity times within the SFC language.
6)
The use of color to indicate execution progress.
7)
The ability to create HMI like screens for enhanced troubleshooting and
program monitoring.
8)
Ability to create a table that will track a chosen variety of variables.
The PLC programming software shall allow creation of standard programming
blocks. The blocks will be as follows:
1)
The programmer will see each instance of a given block. To reduce PLC
memory size, and increase processing speed, the programming software will
use one instance for each type of DFB. The PLC will automatically manage
calls and execution to insure proper code execution.
2)
The programming blocks will contain programming sections. Each
programmer added section can be designated as any of the four IEC
languages.
3)
The programming block will be able to be inserted into all four of the IEC
languages in the main program. This ability will not be dependent on the
languages used inside the block.
4)
An internal database using unmapped variables. The variables associated
with this block will be separate from the PLC database to prevent mapping
conflicts.
5)
Each block will appear to be a single instruction in the programming
environment. The designer of the block will be able to designate pin
assignments and names. These pins will be used to connect to the PLC
database.
Programming software shall have integrated tools for network configuration, and
communication capabilities.
PLC’s that use separate programming,
communication, and network configuration software shall not be accepted.
PLC ENVIRONMENTAL REQUIREMENTS:
1.
The PLCs must meet or exceed the following environmental requirements:
a.
Minimum temperature range:
1)
Operating: 0-55o C (+32 to +131oF)
2)
Storage: -25 to +70o C (-13 to +158oF)
b.
Relative humidity:
30 to 95% non condensing.
c.
Altitude:
1)
Operation 0-6,500 feet minimum
2)
Storage 0-9,800 feet minimum
d.
Degree of protection:
NEMA 1 (IP20)
e.
Vibration resistance in accordance with at least one of the following:
1)
Installed rating:
a)
DIN rail mounted PLC:
10-57 Hz, amplitude 0.075 mm,
acceleration 25-100 Hz, and
b)
Panel or plate mounted PLC: 2-25 Hz, amplitude 1.6mm, acceleration
25-200 Hz.
2)
In compliance with IEC 60068 and IEC 61131.
f.
Shock resistance: 147m/s2 for 11ms.
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D.
WEB SERVICES:
1.
Description: The PLC’s shall be designed for connection to the World Wide Web. These
PLC’s will have standard and customizable web pages.
2.
Standard web pages: The PLC shall have a standard web page integral with the
processor. This page shall display all internal status points, status registers, and alarm
word. Also, the status of each I/O point will be accessible.
3.
Customizable web pages: The PLC shall have the ability to store, operate, and display on
a standard web browser custom configured web pages. These pages shall be created by
the programmer to display the actual process or machine being operated.
4.
The PLC shall be capable of::
a.
ModbusTCP messaging: The web services shall use Modbus TCP messaging over
port 502 of the TCP packet. Protocols reliant on UDP will not be acceptable.
b.
I/O scanning service: I/O scanning will allow the PLC to control I/O scanning
capable I/O located remotely from the main panel.
c.
Fast Device Replacement (FDR): The PLC shall act as a faulty device replacement
client/server. This will enable the PLC to automatically download IP address and
configuration to FDR client devices.
d.
SNMP Network Management: The PLC shall manage the different components
through a SNMP connection. This will allow the PLC monitor network, and
device integrity.
e.
Global Data: The PLC shall use Global Data service to ensure real time
communication between stations in the same distribution group while minimizing
network loading. Global Data servicing will use Real-Time Publisher Subscriber
producer consumer based protocol.
f.
NTP Time synchronization service: The PLC shall be capable of synchronizing
from its internal clock from a reference clock on a NTP server. This time can then
be used to time stamp internal events.
g.
SMTP: The PLC shall be capable of SMTP email transmission service.
h.
Bandwidth monitoring service: The PLC shall be capable of monitoring the
bandwidth to determine load level.
5.
Interconnection: The PLC web services shall be compatible with other devices that
utilize port 502, or ODVA supported Ethernet protocols for communication. This
includes power equipment, HMI, switches, and VFD’s.
E.
SMALL PLC:
1.
Description: A chassis mount PLC designed for up to 1024 points of I/O.
2.
The PLC shall:
a.
Collect data, perform process control functions, communicate with other PLCs,
and distribute process information along the local area network.
b.
Be able to have its program downloaded from a remote workstation over a
network, or locally programmed from a portable laptop computer.
c.
Allow for the expansion of the system by addition and configuration of hardware.
3.
Executive firmware shall be stored in Flash memory and can be updated in the field
using standard programming tools. Executive firmware files shall be readily available
via a public web site.
4.
Each discrete point shall have a light emitting diode to indicate point status. Green
shall indicate that the point is logic level “1”, also referred to as “on” or “high”.
5.
The PLC shall utilize Ethernet protocols that meet the following:
a.
Protocols that are assigned to port 502 of the TCP/IP stack by the IANA (Internet
Assigned Numbers Authority).
b.
Protocols that are supported by the Open DeviceNet Vendors Association (ODVA)
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c.
Programming software will have embedded network configuration tools that utilize
FDT/DTM technologies. PLC systems that have the PLC programming and
network configuration tools in separate software will not be acceptable.
d.
Will not rely on third party vendors to meet the above criteria.
6.
Processors:
Pick one, or more, of the following processors depending on project conditions. See manufacturers’
literature for more information. When a project requires multiple PLCs of a specific type, be sure
to indicate which processor is intended for each machine/process. Remove unwanted processors
from the list.
a.
Each General Processor shall have a USB terminal port for programming. The
processor shall accept an 8Mb SD memory card. This card shall be capable of
storing, at a minimum application files, data files, PDF files, CAD files, Microsoft
office files. Processor performance shall be rated at least 6,900 instructions per
millisecond at a program make up of 65% Boolean and 35% numerical.
Acceptable processors are detailed below:
The Specialty Processor was originally designed as a Distributed I/O Interface Module. Processing
capability was added so that a logic routine could be executed upon loss of communications.
However, the embedded processor can also be used to execute logic routines that are independent of
communication state. Thus, this serves as a low cost processor in some small applications.
1)
Specialty Processor:
a)
400Kb of internal user Ram. Processor shall have a single Ethernet
port.
b)
Processor shall support one additional rack mounted Ethernet card.
The General Processor is for all applications.
2)
General Processors
a) 2,048 Kb of internal user RAM. Processor shall have a multi-protocol
serial port.
b) 4,096 Kb of internal user RAM. Processor shall have a multi-protocol
serial port, and a CANopen master port.
c) 4,096 Kb of internal user RAM. Processor shall have a multi-protocol
serial port, and an Ethernet port.
d) 4,096 Kb of internal user RAM. Processor shall have an Ethernet port,
and a CANopen master port.
b.
Upon power loss, the PLC shall insure memory is transferred to flash memory
before PLC RAM powers down. PLCs with a battery backup will not be accepted.
c.
The PLC shall have on board status lights to indicate the following various
functions:
1)
Green RUN lamp that will illuminate while the program is executing
2)
Red ERR lamp that will illuminate when a fault occurs in the processor
3)
Red I/O Lamp that will illuminate upon an I/O failure or configuration fault.
4)
Yellow SER COM lamp will illuminate when activity is present on the
serial port
7.
Distributed I/O
a.
The PLC platform can also be used as I/O for Distributed I/O applications. The
system will have a small processor with limited memory that can serve as an
intelligent Distributed I/O interface module. The on internal memory will be
400Kb.
b.
The Distributed I/O interface module will be able to support 4 total racks on I/O
including the rack that holds the interface module.
c.
The Distributed I/O interface module will communicate to Modicon Quantum
PLC’s via Ethernet.
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d.
The Distributed I/O interface module will consist of a single Ethernet port.
The I/O cards listed are the most widely used. Other cards, such as combination cards, may be
available. See manufactures literature for more detail. Furthermore, to save room and provide a
cleaner specification, remove the I/O cards that will not be required.
8.
General I/ O Cards: The PLC shall have a series of general I/O cards. They will be as
follows:
a.
Analog Inputs: All Analog input cards will offer isolation between channels.
1)
Four (4) channel +/- 10V, 0-20mA, B,E Thermocouple, Pt 100, Pt 1000, Ni
1000, 2 or 4-wire temperature probes input card.
2)
Four (4) and Eight (8) channel RTD and Thermocouple cards.
b.
Analog Outputs: All analog output cards will offer isolation between channels,
1)
Two (2) channel +/- 10V, 0-20mA output card
c.
Discrete Inputs:
1)
Sixteen (16) channel sink and source 24VDC input cards
2)
Sixteen (16) channel 120VAC input card
3)
Thirty two (32) channel sink 24VDC input card
4)
Sixty four (64) channel sink 24VDC input card
d.
Discrete Outputs:
1)
Sixteen (16) channel 24VDC (0.5A/channel) protected transistor sink and
source output cards
2)
Thirty-two (32) channel 24VDC (0.5A/channel) protected transistor source
output card
3)
Sixty-Four (64) channel 24VDC (0.5A/channel) protected transistor sink
output card
4)
Eight (8) channel 24VDC 24VDC/240VAC isolated relay output card
5)
Sixteen (16) channel 24VDC/240VAC relay output card
6)
Sixteen (16) channel 48-240VAC (1A/channel) triac output card.
9.
Specialized I/O Cards: The PLC shall have a series of application specific I/O cards.
These will be as follows:
a.
High speed counter card: Eight (8) channels at 10 KHz, 16 bits. Two (2) inputs at
24VDC per channel. The card shall also be capable of handling four (4)
incremental encoders in 32 bit.
b.
High performance high speed counter card: 2 channels at 60 KHz at 32 bits. Six
(6) inputs at 24VDC and Two (2) reflex outputs per channel.
10. Communication Capabilities: The PLC shall support the following without the need
for third party modules
a.
10/100Mb Ethernet with fast device replacement (FDR) capability, standard web
page and custom web page capability. A memory card will be available to store
web pages and data.
b.
ASi V2 Master
c.
Serial protocols including Modbus, Unitelway, and ASCII.
d.
DNP3
e.
CANopen
f.
The PLC shall have an Ethernet card with four (4) ports. Each port shall be
capable of communicating both Modbus TCP, and Ethernet I/P simultaneously.
Cards requiring that the port be configured for one protocol will not be accepted.
The card will also support daisy chain wiring.
11. Power Supplies: The PLC shall have chassis mounted power supplies to provide
power for the processor and applicable modules. The power supplies shall be
available in both 24 VDC and 115 VAC models. The available power ratings will be
from 16 to 36W.
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12.
Chassis: The chassis shall come in 4, 6, 8, and 12 position configurations. The cards
will be secured to the chassis via a screw connection.
13. Other:
a.
Programming cable: The PLC shall utilize a USB to Mini B cable for
programming.
This cable shall be compatible with those designed for
downloading digital cameras to USB compatible PC. Accordingly, this cable shall
be available through most traditional retail stores serving the consumer electronics
market.
b.
Alarming: The PLC shall have a configurable alarming capability. Each alarm
point can be configured to display an alphanumeric message in the alarm buffer.
The buffer can be displayed via a web page, or on an operator interface screen.
c.
I/O Connector cables:
1)
Unterminated connector cables shall have one end terminated to HE10
terminal block modules. The other end shall be unterminated to allow
custom interface to panel devices.
2)
Terminated connector cables shall have one end terminated to interface to
terminal block, or FCN socket, cards. The other end shall be terminated to
interface with HE10 terminal block modules.
14. Basis of Design: The basis of design is the Modicon M340 platform by Schneider
Electric.
F.
MEDIUM PLC:
1.
Description: A chassis mount PLC designed for up to 2048 points of I/O. The system
will execute logic in a single processor module. Systems capable of multiple processors
in a single rack will not be accepted.
2.
The PLC shall:
a.
Collect data, perform process control functions, communicate with other PLCs,
and distribute process information along the local area network.
b.
Be able to have its program downloaded from a remote workstation over a
network, or locally programmed from a portable laptop computer.
c.
Allow for the expansion of the system by addition and configuration of hardware.
3.
Executive firmware shall be stored in Flash memory and can be updated in the field using
standard programming tools. Executive firmware files shall be readily available via a
public web site.
4.
Each discrete point shall have a light emitting diode to indicate point status. Green shall
indicate that the point is logic level “1”, also referred to as “on” or “high”.
5.
The PLC shall utilize Ethernet protocols that meet the following:
a.
Protocols that are assigned to port 502 of the TCP/IP stack by the IANA (Internet
Assigned Numbers Authority).
b.
Protocols that are supported by the Open DeviceNet Vendors Association (ODVA)
c.
Programming software will have embedded network configuration tools that utilize
FDT/DTM technologies. PLC systems that have the PLC programming and
network configuration tools in separate software will not be acceptable.
d.
Will not rely on third party vendors to meet the above criteria.
6.
Processor Features:
Pick one, or more, of the following processors depending on project conditions. Other processors
exist that are not listed. See manufacturers’ literature for more information. When a project
requires multiple PLCs of a specific type, be sure to indicate which processor is intended for each
machine/process. Remove unwanted processors from the list.
a.
Each processor will be capable of being programmed via serial communications
with a PC. The processor will have a display block with colored indicator lamps
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
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for RUN (Green), ERR (Red), I/O (Red), and TER (Yellow). Processors with an
integrated Ethernet port shall have colored indicator lamps for RUN (Green), ERR
(Red), COL (Red), STS (Yellow), TX (Yellow), and RX (Yellow). The processor
shall be programmable through the USB port of a personal computer using a direct
cable scheme. The acceptable processors are detailed below:
1)
96KB of base program and data memory. Also includes an integrated
10BASE-T/100BASE-TX RJ45 Ethernet Port.
2)
96KB of base program and data memory.
3)
160KB of base program and data memory. Also includes an integrated
10BASE-T/100BASE-TX RJ45 Ethernet Port.
4)
160KB of base program and data memory.
Specify the processor in the following paragraph if using the smaller memory redundancy system.
5)
192KB of base program and data memory. Also includes an integrated RJ45
Port.
This port shall be dedicated for Hot Standby processor
synchronization.
6)
192KB of base program and data memory. Also includes an integrated
10BASE-T/100BASE-TX RJ45 Ethernet Port.
7)
192KB of base program and data memory.
8)
320KB of base program and data memory. Also includes an integrated
10BASE-T/100BASE-TX RJ45 Ethernet Port.
9)
320KB of base program and data memory.
Specify the processor in the following paragraph if using the larger memory redundancy system.
10) 440KB of base program and data memory. Also includes an integrated RJ45
Port.
This port shall be dedicated for Hot Standby processor
synchronization.
11) 640KB of base program and data memory. Also includes an integrated
10BASE-T/100BASE-TX RJ45 Ethernet Port.
12) 640KB of base program and data memory.
b.
The PLC shall use a lithium battery to back up the PLC RAM. A BAT light shall
indicate when it is time to replace the battery.
c.
The PLC shall have status lights to indicate the following various functions:
1)
Green RUN lamp will indicate the program is executing
2)
Red ERR lamp that will indicate a fault in the processor
3)
Red I/O Lamp that will indicate an I/O or configuration fault.
4)
Yellow TER lamp will indicate activity on the TER or AUX Terminal Port
5)
Red FIP lamp will indicate activity on the FIPIO bus.
The I/O cards listed are the most widely used. Other cards, such as combination cards, are
available. See manufactures literature for more detail. Furthermore, to save room and provide a
cleaner specification, remove the I/O cards that will not be required.
7.
General I/ O Cards: I/O modules shall be plugged into a backplane. All modules shall be
enclosed in plastic housing. All field wiring shall be to a removable terminal strip that
will permit removal and replacement of a module without disturbing the field wiring or
any other I/O modules. They will be as follows:
a.
Analog Inputs: All analog input cards will offer isolation between channels,
between bus and channels, and between channels and ground.
1)
Four (4) channel +/- 10V, 0-20mA, B,E Thermocouple, Pt 100, Pt 1000, Ni
1000, 2 or 4-wire temperature probes input card.
2)
Eight (8) channel +/- 10V, 0-20mA input card
3)
Sixteen (16) channel +/- 10V, 0-20mA input card.
b.
Analog Outputs: All analog output cards will offer isolation between channels.
1)
Four (4) channel +/- 10V, 0-20mA output card
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
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2)
Eight (8) channel +/- 10V, 0-20mA output card
Discrete Inputs:
1)
Eight (8) channel 24VDC input card
2)
Sixteen (16) channel 24VDC input card
3)
Thirty two (32) channel 24VDC input card
4)
Sixty-four (64) channel 24VDC input card
5)
Sixteen (16) channel 120VAC input card
d.
Discrete Outputs:
1)
Eight (8) channel 24VDC (0.5A/channel) protected transistor output card
2)
Sixteen (16) channel 24VDC (0.5A/channel) protected transistor output card
3)
Eight (8) channel 24VDC/240VAC relay output card
4)
Sixteen (16) channel 24VDC/240VAC relay output card
5)
Sixteen (16) channel 48-240VAC (1A/channel) protected triac output card.
8.
Specialized I/O Cards: The PLC shall have a series of application specific I/O cards.
These will be as follows:
a.
Counter Modules: A four (4) channel 40 KHz counter module will be available.
Each channel will have three (3) 24VDC enable, preset and read inputs; 1 24VDC
line check, or incremental encoder power supply input; and 2 24VDC reflex
outputs per channel.
b.
High Speed Counter Module: A two (2) channel 500 KHz counter module will be
available. Each channel will have two (2) 24VDC preset and read inputs, one (1)
point configurable as an enable input or 24VDC output, two (2) 24VDC reflex
outputs, one (1) 24VDC programmable output, and one (1) encoder power supply
input for 5VDC or 24VDC.
9.
Communication Capabilities: The PLC shall support the following without the need
for third party modules
a.
Ethernet with Fast Device Replacement (FDR) capability,
b.
ASi V1 and V2
c.
Serial protocols including Modbus, and Unitelway.
d.
Profibus DP for up to 126 slaves
e.
Modbus TCP and EtherNet I/P protocols
At least one of the following two paragraphs must be specified if redundancy is required.
Otherwise delete them.
1)
PLC will have an Ethernet card capable of scanning I/O for up to 64
stations. They will also have global data capabilities, and an integrated FDR
server for automatic reconfiguration(BootP/DHCP)
2)
PLC will have an Ethernet card capable of scanning I/O for up to 64
stations. They will also have global data capabilities, and an integrated FDR
server for automatic reconfiguration. Additionally the card will have an
alarm display, a graphic data editor, and handle custom web pages.
f.
Web page based HMI services: The PLC will be capable of handling an alarm
display, a graphic data editor, and the capability to handle custom web pages (8MB
max memory). The PLC will also be capable of email, interpreted math and logic
functions, and connection to relational databases.
10. Power Supplies: The PLC shall have chassis mounted power supplies to power the
chassis backplane, and provide power for the processor and applicable modules. There
shall be a single power supply per chassis. The power supplies shall be available in both
24-48VDC and 100-240VAC models.
11. Chassis: The PLC shall have chassis to mount processors, power supplies, and other
applicable cards. The chassis shall come in 4, 6, and 12 position configurations. The
cards will be secured to the chassis via a screw connection.
c.
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12. Other: The PLC shall have other capabilities as listed below:
Use redundancy for applications where enhanced reliability is desired. Redundancy capabilities of
this PLC is best applied on non-time critical applications such as those found in water, wastewater,
and HVAC. For time critical applications, the Telemecanique Quantum PLC is more applicable.
a.
Redundancy: The PLC shall be capable of redundant operation.
1)
Redundant operation shall be via redundancy capable processors and
modules. Redundant communication between the processors will be via a
fiber optic, or twisted pair copper, cable attached directly to the processor.
2)
Redundant processor shall have a coprocessor to handle communications
between the primary and backup processor. This coprocessor shall allow
communication to occur simultaneously to the program scan. Simultaneous
communications eliminates the need to manage program scan time. Thus,
a)
Controller shall stop execution of the program only to transfer data to
the coprocessor. Controllers that stop program execution to perform
communication transfer to another processor module shall not be
allowed.
b)
Primary to backup communications shall not limit minimum
processor program scan time.
c)
Controllers that rely on scan time management techniques to
minimize scan time shall not be allowed.
d)
Controllers that caution against scan dependent logic are not allowed.
e)
Simultaneous communication and scan technique shall not require
additional tag memory compared to a non-redundant version. Any
processors that require doubling tag count compared to a nonredundant version shall not be allowed.
3)
Redundancy system shall allow for outputs in any file to transition from
primary to backup control without momentary lapse, or bump. PLC’s that
requires outputs to be placed in a single file, or a file with a highest priority
to achieve bumpless control shall not be allowed.
4)
The redundancy system shall allow usage of data shifting and ASCII
instructions. Processors that have ASCII and data shifting instruction
limitations shall not be allowed.
5)
Active messages during a switchover shall not cause a delay, a pause, or
allows the message to become inactive. Processors that have a delay, or
pause for cached or uncached messages shall not be acceptable. Processors
that allow messages to become inactive during switchover are not allowed.
6)
Messages targeted to the redundant controller shall have no impact on
backplane communication. Redundant controllers that stop backplane
communication for diagnostic or switchover purposes shall not be allowed.
7)
Primary and backup processors shall automatically synchronize. Processor
that could require a manual synchronization shall not be allowed.
Processors that allow you to deactivate automatic synchronization are not
allowed.
8)
Redundancy System shall allow Ethernet to be used for communication to
Peer to Peer devices including HMI’s, SCADA, and other PLC’s. During a
switchover, communication to these devices shall not stop. Controllers that
can have message communications outages over Ethernet are not acceptable.
9)
For legal and liability protection, automation suppliers must be very careful
in insuring manuals, and literature accurately represents what the
automation system is capable of. For proper consideration, only automation
suppliers that have the words “Hot Standby” in the title of their redundancy
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
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13.
system user manuals are acceptable. Suppliers that have “Redundancy
System” in the title are not acceptable.
Basis of Design: The basis of design is the Modicon Premium platform by Schneider
Electric
G.
LARGE PLC
1.
Description: A PLC that can accommodate over 62,000 points of I/O. This PLC shall
be a chassis mounted modular system. The CPU will be capable of handling its
backplane, and one additional backplane. Additional I/O will be interfaced to the PLC
via remote I/O or distributed I/O as specified below.
2.
The PLC shall:
a.
Collect data, perform process control functions, communicate with other PLCs,
and distribute process information along the local area network.
b.
Be able to have its program downloaded from a remote workstation over a
network, or locally programmed from a portable laptop computer.
c.
Allow for the expansion of the system by addition and configuration of hardware.
3.
Executive firmware shall be stored in Flash memory and can be updated in the field
using standard programming tools. Executive firmware files shall be readily available
via a public web site.
4.
Each discrete point shall have a light emitting diode to indicate point status. Green
shall indicate that the point is logic level “1”, also referred to as “on” or “high”.
5.
The PLC shall utilize Ethernet protocols that meet the following:
a.
Protocols that are assigned to port 502 of the TCP/IP stack by the IANA (Internet
Assigned Numbers Authority).
b.
Protocols that are supported by the Open DeviceNet Vendors Association (ODVA)
c.
Programming software will have embedded network configuration tools that utilize
FDT/DTM technologies. PLC systems that have the PLC programming and
network configuration tools in separate software will not be acceptable.
d.
Will not rely on third party vendors to meet the above criteria.
6.
Processor Features:
Pick one, or more, of the following processors depending on project conditions. Other processors
exist that are not listed. See manufacturers’ literature for more information. When a project
requires multiple PLCs of a specific type, be sure to indicate which processor is intended for each
machine/process. Remove unwanted processors from the list.
a.
The PLC shall have a variety of processors available. Each processor will be
capable of being programmed via Modbus or Modbus Plus with a PC. Modbus
and Modbus Plus shall be available through processor embedded ports.
Acceptable processors are detailed below:
1)
A single slot processor capable of 420KB of base program and data
memory, with a maximum of 40 programmable channels suitable for
process control.
2)
A single slot processor capable of 928KB of base program and data
memory, with a maximum of 80 programmable channels suitable for
process control.
3)
A single slot processor capable of 2716KB of base program and data
memory, with a maximum of 100 programmable channels suitable for
process control.
4)
A dual slot processor capable of 640KB of base program and data memory
(7168MB after expansion), with a maximum of 60 programmable channels
suitable for process control.
In addition to the above specified
communications capabilities, the processor shall have an integrated Ethernet
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
40 94 43.01 - 15
TCP/IP port capable of Modbus TCP communications, and a USB port
dedicated for PLC programming.
5)
A dual slot processor capable of 768KB of base program and data memory
(7168MB after expansion), with at least 60 programmable channels suitable
for process control. In addition to the above specified communications
capabilities, the processor shall have an integrated Ethernet TCP/IP port
capable of Modbus TCP communications, and a USB port dedicated for
PLC programming.
Use the following processor if hot standby redundancy is required.
6)
A dual slot redundancy ready processor capable of 768KB of base program
and data memory (7168MB after expansion), with at least 60 programmable
channels suitable for process control. In addition to the above specified
communications capabilities, the processor shall have an integrated fiber
based Ethernet TCP/IP port dedicated to redundant communications, and a
USB port dedicated for PLC programming.
b.
The PLC shall use lithium battery to back up the PLC RAM. A BAT light shall
indicate when it is time to replace the battery. The battery shall be accessible from
the front of the CPU. It shall be possible to change the battery while the CPU is
running.
c.
The PLC shall have on board status area to indicate the following various
functions:
1)
Single slot processors will have a:
a)
Green RUN lamp that will illuminate while the program is executing
b)
Red ERR lamp that will illuminate when a fault occurs in the
processor
c)
Red I/O Lamp that will illuminate upon an I/O failure or
configuration fault.
d)
Yellow TER lamp will illuminate when activity is present on the TER
or AUX Terminal Port
2)
Dual slot processors will have use a LCD to display messages.
The I/O cards listed are the most widely used. Other cards, such as combination cards, are
available. See manufactures literature for more detail. Furthermore, to save room and provide a
cleaner specification, remove the I/O cards that will not be required.
7.
General I/ O Cards: The PLC shall have a series of general I/O cards. They will be as
follows:
a.
Analog Inputs: All analog input cards will offer isolation between channels.
1)
Eight (8) channel differential +/- 10V, 0-25mA input card.
2)
Eight (8) channel Type B, E, J, K, R, S, T thermocouple input card
3)
Eight (8) channel RTD (2-,3-,or 4-wire), Pt, Ni input card
4)
Sixteen (16) channel differential or single ended +/- 10V, 0-20mA input
card.
b.
Analog Outputs: All analog output cards will offer isolation between channels,
1)
Four (4) channel +/- 10V output card
2)
Four (4) channel 4-20mA output card
3)
Eight (8) channel 0-25mA output card
c.
Discrete Inputs:
1)
Sixteen (16) channel 10-60VDC Sink input card
2)
Sixteen (16) channel 115VAC input card
3)
Thirty two (32) channel 10-64VDC Sink input card
4)
Thirty two (32) channel 24VDC Source input card
5)
Thirty two (32) channel 115VAC input card
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
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6)
Ninety Six (96) channel 24VDC Sink input card.
Discrete Outputs:
1)
Eight (8) channel 150VDC/250VAC (5A/channel) NO/NC relay output card
2)
Sixteen (16) channel 10-60VDC source (2A/channel) output card
3)
Sixteen (16) channel 150VDC/250VAC (2A/channel) NO relay output card
4)
Sixteen (16) channel 24-48VAC (4A/channel) output card
5)
Sixteen (16) channel 24-230VAC (4A@20-132VAC/channel or 3A@170253VAC/channel) output card
6)
Thirty-two (32) channel 5VDC/TTL sink (75mA/channel) output card
7)
Thirty two (32) channel 24VDC source (0.5A/channel) output card
8)
Thirty two (32) channel 24VDC sink (0.5A/channel) output card
9)
Thirty two (32) channel 24-230VAC (1A/channel) output card
10) Thirty-two (32) channel 10-30VDC source (0.5A/channel) verified output
card
11) Ninety-Six (96) channel 19.2-30VDC (0.5A/channel) output card
Other specialized I/O cards are available. Some are available only through third party vendors.
Check with manufacturer and third party vendors to see if other solutions exist. Furthermore, to
save room, delete cards that are not used in the application.
8.
Specialized I/O Cards: The PLC shall have a series of application specific I/O cards.
These will be as follows:
a.
Intrinsically Safe I/O: Intrinsically safe I/O will be available in the following
configurations:
1)
Eight (8) channel RTD, Thermocouple (J, K, E, T, S, R, B), Platinum, and
Nickel analog input card
2)
Eight (8) channel 0-25mA analog input card
3)
Eight (8) channel 0-25mA analog output card
4)
Eight (8) channel 8VDC no load voltage discrete input card
5)
Eight (8) channel 24VDC(open) discrete output card
b.
Counter Modules:
1)
The PLC will have a five (5) channel 100 KHz at 5VDC, or 20 KHz at
24VDC. Each channel will have a resolution of 32 bits. Each module will
also have eight (8) 24VDC outputs.
2)
The PLC will have a five (5) channel 500 KHz at 5VDC. Each channel will
have a resolution of 32 bits. Each module will also have four (4) 24VDC
outputs.
c.
Latch/Interrupt Module: The PLC will have a sixteen (16) channel latch interrupt
module. This module will utilize 24VDC. The module will have an Interrupt
Handling mode, an Automatic Latch/Unlatch mode, and a High speed input mode.
d.
Motion Control: The PLC will have the servomotor motion control modules. The
following types will be available.
1)
Two (2) channel 5VDC incremental encoder with (RS 422). The card will
have a +/- 10VDC 12 bit encoder feedback. The card shall be capable of
controlling one real axis and a remote axis (for master signal).
2)
A SERCOS link module capable of handling 8 real axes, 4 imaginary axes,
4 remote axes, 4 coordinate sets (with linear interpolation 8 axes maximum),
4 follower sets, and cam profiles. The card shall be capable, with
manufacturers’ support, of being expanded to handle up to 16 real axes, or
22 axes/axis sets.
3)
A SERCOS link module capable of handling 8 real axes, 4 imaginary axes,
4 remote axes, 4 coordinate sets (with linear interpolation 8 axes maximum),
4 follower sets, and cam profiles. The card shall be capable, with
d.
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
40 94 43.01 - 17
manufacturers’ support, of being expanded to handle up to 22 real axes, or
32 axes/axis sets.
Delete capabilities not used for an application.
9.
Communication Capabilities: The PLC shall support the following.
a.
10/100Mb Ethernet with Fast Device Replacement (FDR) capability,
b.
ASi V2 Master
c.
Profibus DP V1 Protocol
d.
Rockwell Automations RIO Protocol
e.
DevicNet
f.
Serial protocols including Modbus RTU and Modbus ASCII.
g.
Modbus Plus
h.
DNP3
i.
Modbus TCP
j.
The PLC shall an Ethernet card capable of communicating both Modbus TCP, and
Ethernet I/P simultaneously. Cards requiring that the port be configured for one
protocol will not be accepted.
Remote I/O and Distributed I/O are very similar. However, there are some speed and high end
deterministic differences between the two. For some markets, such as oil and gas, these differences
are critical. For other markets, these differences may not be as important. The biggest difference
is in the devices supported. In remote I/O the devices are limited to I/O located in remote chassis.
Distributed I/O will communicate to I/O located in remote chassis, or to other devices such as HMI,
drives, etc.
k.
The PLC shall be capable of communicating to Remote and Distributed I/O.
Remote and Distributed I/O shall be capable of being configured in redundant and
non redundant configurations. Remote and Distributed I/O shall be over one of the
following.
1)
Remote I/O utilizing S908 communication network with quad shield coaxial
cable.
2)
Distributed I/O using Modbus Plus communication network over twisted
shielded pair cabling.
3)
Remote and Distributed I/O over Ethernet utilizing either EtherNet I/P,
Modbus TCP, or a combination of both.
The following power supplies represent the full range available. They may not all be applicable to a
given application. To save room, delete the cards that are not required.
10. Power Supplies: The PLC shall have chassis mounted power supplies to power the
chassis backplane, and provide power for the processor and applicable modules plus
30%. The power supplies shall be as follows:
a.
Standalone card capable of handling a 100-276VAC input. The card shall be
capable of handling 3.0A output.
b.
Standalone card capable of handling a 20-30VDC input. The card shall be capable
of handling 3.0A output.
c.
Standalone card capable of handling a 100-150VDC input. The card shall be
capable of handling 3.0A output.
d.
Summable/standalone card capable of 93-138VAC, or 170-264VAC. The card
shall be capable of handling 11.0Amp in standalone mode or 20.0A output in
Summable mode.
e.
Summable card capable of 20-30VDC. The card shall be capable of handling 8.0A
in standalone mode or 16.0 A output in Summable mode.
f.
Summable card capable of 48-60VDC. The card shall be capable of handling 8.0A
in standalone mode or 16.0 A output in Summable mode.
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
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g.
Redundant card capable of 93-138VAC, or 170-264VAC. The card shall be
capable of handling 8.0Amp output.
h.
Redundant card capable of 93-138VAC, or 170-264VAC. The card shall be
capable of handling 11.0Amp output.
i.
Redundant card capable of 20-30VDC. The card shall be capable of handling
8.0Amp output.
j.
Redundant card capable of 48-60VDC. The card shall be capable of handling
8.0Amp output.
k.
Redundant card capable of 100-150VDC. The card shall be capable of handling
8.0Amp output.
11. Chassis: The PLC shall have chassis to mount processors, power supplies, and other
applicable cards. The chassis shall come in 2, 3, 4, 6, 10, and 16 position
configurations.
12. Other: The PLC shall have other capabilities as listed below:
a.
Redundancy: The PLC shall be capable of redundant operation.
1)
PLCs requiring separate redundancy cards shall not be allowed. Redundant
communication between the PLC’s will be via a fiber optic cable attached
directly to the processor. The primary processor shall automatically transfer
its program to the standby upon replacement. Systems that require
programming software, physical media, or manually initiated methods to
load the program into the standby will not be acceptable.
2)
Redundant processors shall have a coprocessor to handle communications
between the primary and backup processor. This coprocessor shall allow
communication to occur simultaneously to the program scan. Simultaneous
communications eliminates the need to manage program scan time. Thus,
a)
Controllers that stop program execution to perform communications
transfer to the backup processor module shall not be allowed.
b)
Primary to backup communications shall not limit minimum
processor program scan time.
c)
Controllers that rely on scan time management techniques to
minimize scan time shall not be allowed.
d)
Controllers that caution against scan dependent logic are not allowed.
e)
Simultaneous communication and scan technique shall not require
additional tag memory compared to a non-redundant version. Any
processors that require doubling tag count compared to a nonredundant version shall not be allowed.
3)
Redundancy system shall allow for outputs to transition from primary to
backup control without momentary lapse, or bump. Outputs placed in any
main program shall be bumpless. Processors whose bumpless integrity
requires outputs to be placed in a single file, or a file with a highest priority
shall not be allowed.
4)
The redundancy system shall allow usage of all available instructions
including data shifting and ASCII instructions. Processors that have
instruction limitations shall not be allowed.
5)
Active messages during a switchover shall not cause a delay, a pause, or
allows the message to become inactive. Processors that have a delay, or
pause for cached or uncached messages shall not be acceptable. Processors
that allow messages to become inactive during switchover are not allowed.
6)
Messages targeted to the redundant controller shall have no impact on
backplane communication. Redundant controllers that stop backplane
communication for diagnostic or switchover purposes shall not be allowed.
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
40 94 43.01 - 19
7)
Primary and backup processors shall automatically synchronize. Processor
that could require a manual synchronization shall not be allowed.
Processors that allow you to deactivate automatic synchronization is not
allowed.
8)
Redundancy System shall allow Ethernet to be used for communication to
Peer to Peer devices including HMI’s, SCADA, and other PLC’s. During a
switchover, communication to these devices shall not stop. Controllers that
can have message communications outages over Ethernet are not acceptable.
9)
For legal and liability protection, automation suppliers must be very careful
in insuring manuals, and literature accurately represents what the
automation system is capable of. For proper consideration, only automation
suppliers that have the words “Hot Standby” in the title of their redundancy
system user manuals are acceptable. Suppliers that have “Redundancy
System” in the title are not acceptable.
b.
Programming cable: The PLC shall be capable of using standard USB cables for
connection between the PLC and programming terminal. The USB cable shall
have a USB A connection on one end, and a USB B connection on the other.
PLC’s relying on vendor supplied cables will not be accepted.
13. Basis of Design: The basis of design is the Telemecanique Modicon Quantum by
Schneider Electric.
Distributed I/O hardware can be used with a variety of networks to gather data from points located
remotely from the Main PLC rack. This can result in significant saving in both material and time
over traditional I/O methods. However, this may not be applicable for all applications. Examine to
see if adopting this hardware can reduce wiring and time. Otherwise delete.
H.
DISTRIBUTED I/O
1.
Programmable Distributed I/O:
a.
Description: A dedicated line of I/O designed to be located remote from the main
PLC rack. This I/O system is designed to communicate to the PLC over a variety
of networks. In the event of a communication failure, the I/O shall be capable of
setting outputs to a predetermined position, or executing a simple Boolean routine
that sets the outputs based on the state of local inputs. The distributed I/O system
shall be capable of communicating with up to 31 I/O modules. Each I/O and
module will reside in a dedicated mounting base. Mounting bases will be DIN rail
mountable and will to a power distribution module. Power distribution modules
will allow divert I/O power to the I/O modules. The Power distribution module
will reside in a mounting base and will interface to the network interface module.
The I/O cards listed are the full range of product. See manufacturer’s literature for more detail.
Furthermore, to save room and provide a cleaner specification, remove the I/O cards that will not
be required.
b.
General I/ O Cards: The distributed I/O hardware platform shall have a series of
general I/O cards. They will be as follows:
1)
Analog Inputs: All Analog input cards will offer field to bus, and channel to
channel isolation. The cards will be as follows:
a)
Two (2) channel +/- 10V with 9 bit+sign resolution card
b)
Two (2) channel +/- 10V with 11 bit+sign resolution card
c)
Two (2) channel 0-10V with 10 bit+sign resolution card
d)
Two (2) channel 0-20mA with 12 bit resolution card
e)
Two (2) channel 4-20mA with 10 bit resolution card
f)
Two (2) channel Thermocouple (B,E,J,K,R,S,and T), Pt 100, Pt 1000,
Ni 100, Ni 1000, Cu10, +/- 80Mv with 15 bit +sign resolution card
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
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2)
c.
d.
Analog Outputs: All analog output cards will offer field to bus, and channel
to channel isolation. The cards will be as follows:
a)
Two (2) channel +/- 10V with 9 bit+sign resolution card
b)
Two (2) channel +/- 10V with 12 bit, or 11 bit+sign resolution card
c)
Two (2) channel 0-10V with 10 bit resolution card
d)
Two (2) channel 0-20mA with 12 bit resolution card
e)
Two (2) channel 4-20mA with 10 bit resolution card
3)
Discrete Inputs:
a)
Two (2) channel sink 24VDC input card
b)
Four (4) channel sink 24VDC input card
c)
Six (6) channel sink 24VDC input card
d)
Two (2) channel sink 115VAC input card
e)
Two (2) channel sink 230VAC input card
4)
Discrete Outputs:
a)
Two (2) channel 24VDC 0.5A source output card
b)
Two (2) channel 24VDC 2A source output card
c)
Four (4) channel 24VDC 0.5A source output card
d)
Four (4) channel 24VDC 2A source output card
e)
Six (6) channel 24VDC 0.5A source output card
f)
Six (6) channel 24VDC 2A source output card
g)
Two (2) channel 115/230 VAC triac output card
h)
Two (2) Form C relays with 2 A per contact output card
i)
Two (2) Form A/B relays with 7A per contact output card
Specialized I/O Cards: The Distributed I/O hardware platform shall have a series
of application specific I/O cards. These will be as follows:
1)
U-Line Interface Module: This card will allow network interface to up to
four (4) Telemecanique U-Line IEC starters. The card has four (4) RJ45
connectors.
2)
Counter Module: 1 channel at 40 KHz at 16 bits. One 24VDC input
channel and Two (2) digital outputs.
Communication Cards: The PLC shall have a series of communication modules.
They shall be as follows:
1)
Ethernet Module: Compliant with 10 Base T communication standards.
Equipped for embedded web (configuration, diagnostics, and access to
variables), SNMP agent, and Modbus TCP/IP.
2)
CANopen Module: Compliant with CAN field bus protocol. Equipped for
Process Data object, Service Data Object, Special function Object, and
Network management.
3)
Modbus Plus network: Compliant with Modbus Plus standard. Equipped to
handle global data, peer-to-peer, and peer cop.
4)
Fipio Module: Compliant with FIP field bus standard. Equipped to handle
periodic I/O exchanges, Peer-to-peer messaging, use of FRD/FSD/and FED
standard profiles.
5)
InterBus: Compliant with the Generation 4 InterBus Industrial Field bus
protocol. Equipped to handle data process implicit exchange, logical
addressing, and diagnostics.
6)
Profibus DP: Compliant with Profibus DP V.0. Equipped to handle slave
configuration, configuration control, and read/write slave data.
7)
DeviceNet: Compliant with v.2.0 of the Open DeviceNet Vendor
Association (ODVA). Equipped to handle DeviceNet object (class ID3),
connection object (class ID5), Island Bus object (class ID101)
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
40 94 43.01 - 21
e.
Power Distribution Module: The Distributed I/O hardware platform shall utilize
power distribution modules to divert power to the I/O cards. The system shall
consist of cards capable of 24VDC input and 115/230VAC input.
If the Distributed I/O is being used with a non-micro PLC platform then leave the following
paragraph. Otherwise delete.
f.
Programming Software: The Distributed I/O shall be programmed via the
common PLC programming software.
If the Distributed I/O is being used either with the micro PLC, or on its own, then leave the
following paragraph. Otherwise delete.
g.
Programming Software: The Distributed I/O shall be programmed/configured via
a dedicated programming package.
h.
Basis of Design: The basis of design is the Telemecanique Advantys STB by
Schneider Electric.
2.
Non-Programmable Distributed I/O
a.
Description: A dedicated line of I/O designed to be located remote from the main
PLC rack. This I/O system is designed to communicate to the PLC over a variety
of networks. The DIN rail mounted distributed I/O Network Interface Modules
(NIM) shall contain 20 I/O and can be expanded up to 256 I/O with addition of
Modicon Twido I/O modules.
The I/O cards listed are the full range of product. See manufactures literature for more detail.
Furthermore, to save room and provide a cleaner specification, remove the I/O cards that will not
be required.
b.
General I/O Cards: The PLC shall have a series of general I/O cards. They will
be as follows:
1)
Analog I/O: All analog I/O shall have photocouple isolation between
channels and ground. The following cards shall be available.
a)
Four (4) point input 0-10 V(non differential), 4-20mA(differential), or
Pt 100/1000 Ni 100/1000 card
b)
Eight (8) point input 10 V(non differential), 4-20mA(differential), or
PTC/NTC card
c)
One (1) point output 0-10V, or 4-20mA card
d)
Two (2) point output +/- 0-10V card
2)
Discrete Inputs:
a)
Eight (8) point input 85-132VAC card
b)
Sixteen (16) point input 20.4-28.8VDC card
3)
Discrete Outputs:
a)
Sixteen (16) point output Normally Open Relay, 20.4-28.8 transistor
sinking, or 20.4-28.8 transistor sourcing cards.
c.
Communication Options in the NIMs: The Distributed I/O NIMs shall have a
series of communication modules. They shall be as follows:
1)
Ethernet TCP/IP Module: Compliant with 10/100 Base T communication
standards. .
2)
CANopen Module: Compliant with CAN field bus protocol. Equipped for
Process Data object, Service Data Object, Special function Object, and
Network management.
3)
Modbus Serial Module: Compliant with Modbus standard.
d.
Power: The Distributed I/O hardware platform shall accept a 24VDC supply
voltage.
e.
Basis of Design: The basis of design is the Telemecanique Advantys OTB by
Schneider Electric.
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
40 94 43.01 - 22
PART 3 - EXECUTION
3.1
EXAMINATION
A.
Examine areas, surfaces, and substrates to receive PLCs for compliance with requirements,
installation tolerances, <Insert Project-specific conditions,> and other conditions affecting
performance.
B.
Proceed with installation only after unsatisfactory conditions have been corrected.
3.2
APPLICATIONS
Delete this Article if PLCs and their types are delineated on Drawings.
A.
Select PLC based upon I/O, memory, communication, expansion, and other criteria. If multiple
PLC panels from different vendors will be supplied, coordinate with other vendors to insure that
PLCs are of similar brand and are equipped to utilize identical communication networks.
3.3
INSTALLATION
Coordinate this Article with Drawings.
Add requirements for special anchorage and seismic restraint if applicable.
A.
Anchor PLCs within enclosures as recommended by the PLC manufacturer.
B.
Provide spacing around PLC as required by the PLC manufacturer to insure adequate cooling.
Insure that the air surrounding and penetrating the PLC has been ambiently conditioned to
maintain the required temperature and humidity range of the PLC.
C.
Wires entering and exiting PLC components shall be sized to comply with the PLC
manufacturers requirements. Doors on all components shall be able to be fully closed when all
the wires are installed.
D.
Ventilation slots shall not be blocked, or obstructed by any means.
E.
For chassis mounted PLCs, no wiring, wire ducts, or other devices shall obstruct the removal of
cards from the rack.
F.
PLC lights, keys, communication ports, and memory card slots shall be accessible at all times.
Lights shall be visible at all times when enclosure door is opened.
3.4
IDENTIFICATION
A.
Identify PLC components, and wiring according to all applicable codes, standards and contract
document sections.
B.
Each I/O point shall be identified on the door of PLC I/O cards or on the surface of each
“Fixed” or “Fixed” style PLC.
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3.5
FIELD QUALITY CONTROL
A.
Field Service: The PLC based control panel supplier shall provide a qualified service
representative to perform the following:
1.
2.
3.
B.
Inspect PLCs, wiring, components, connections, and equipment installation.[ Test and
adjust supplied programmable controllers, components, and equipment.]
Assist in field testing of equipment[ including pre-testing and adjusting of controllers
and its associated application program if necessary.].
Report results in writing.
DEMONSTRATION
1.
Control panel supplier shall provide a qualified service representative to train Owner's
maintenance personnel to adjust, operate, and maintain PLCs. Manufacturer’s standard
training will be sufficient unless specified elsewhere.
END OF SECTION 40 94 43
PROGRAMMABLE LOGIC CONTROLLERS (Long Version)
40 94 43.01 - 24
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