CITY OF FORT WAYNE MASTER
UPDATED: 12/12/2014
SECTION 40 64 00
PROGRAMMABLE LOGIC CONTROLLERS
PART 1 – GENERAL
1.1
DESCRIPTION
A. Scope:
1. CONTRACTOR shall provide all labor, materials, equipment and incidentals as shown,
specified and required to furnish and install a fully functional Programmable Logic
Controller (PLC) system.
2. The hardware and architecture of the system shall be that of a PLC.
3. The hardware required for the PLC is shown on the PLC block diagram and is comprised
of the following types of major monitoring processing and control equipment units:
NTS: Edit equipment as required.
a. Redundant Fiber Optic Data Highway Communication System.
b. Fault tolerant programmable logical controller(s) with local and remote I/O
subsystem.
c. I/O drivers to communicate with PLC’s.
d. Network communication devices.
e. Power Supplies.
f. Telemetry Units.
g. I/O Cards.
h. I/O Chassis and Cabling.
B.
Related Sections:
NTS: List below only sections covering products, construction and equipment that a user might expect to
find in this section, but are specified elsewhere. Do not list administrative and procedural division 01
sections.
1. Section 40 61 13, Process Control System General Provisions
2. Section 40 61 14, Process Control Networks General Provisions
3. Section 40 61 16, Process Control System Narrative
4. Section 40 61 63, Process Control System Training
5. Section 40 61 93, Process Control System Input-Output List
1.2
TERMS
A. The terms listed below are used throughout this Section and are defined as such:
1. Human Machine Interface (HMI): Keyboard Mouse Operator Interface to control
system. Allows operator intervention and monitoring of all systems and subsystems
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Programmable Logic Controllers – 40 64 00-1
2.
3.
4.
5.
6.
7.
8.
9.
1.3
connected to the PLC system; usually a desktop computer or industrial hardened
computer.
Operator Interface Terminal (OIT): Touch Panel Operator Interface to control system.
Allows operator intervention and monitoring of all systems and subsystems connected to
the PLC system; usually mounted in the control panel.
Programmable Logic Controller (PLC): The controlling device used to control and
monitor hardware connected to it by way of networks or I/O cards. May be identified
under different names such as small logic controller, mini or micro.
Backplane: Usually will indicate the I/O chassis that the power supply, PLC and I/O
cards, and network cards reside in.
I/O Cards: Can be either analog or discrete cards that interface between field devices and
PLC.
Network Hub: Data concentrator where one or more networks are integrated.
Server: Computer having one or more CPU’s used for a specific task such as data
depository, web management. Usually connected to the plant network.
Peripheral Devices: Includes, but not limited to, printer(s), display devices and
standalone intelligent devices, such as remote HMI stations.
PLC System: Includes all parts listed above.
QUALITY ASSURANCE
A. CONTRACTOR shall engage the services of a PLC manufacturer to provide all equipment
listed in this Section.
1. Rockwell Automation
2. No substitutes
1.4
WARRANTY
NTS: Include clear and concise special warranty conditions under this section.
1.5
MAINTENANCE
NTS: Include plc spare parts, any special maintenance services and preventive maintenance requirements
under this section.
A. The PLC vendor shall provide recommended preventive maintenance tasks, schedules and
instructions for hardware supplied. The PM documentation must be clear, applicable to
hardware provided, concise and accurate.
1.6
TROUBLESHOOTING
A. The PLC vendor shall provide trouble-shooting procedures for hardware supplied. The
procedures shall be accurate, easy to understand and follow, current, and comprehensive in
scope. If links to vendor website or technical support is necessary the vendor shall provide upto-date phone numbers and links. The vendor shall supply this documentation prior to
awarding of Purchase Order.
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Programmable Logic Controllers – 40 64 00-2
1.7
SUBMITTALS
A. Submit the following:
1. General:
a. Submit Product Data in sufficient detail to confirm compliance with requirements of
this Section. Submit Product Data and Shop Drawings in one complete submittal
package. Partial submittals are not acceptable.
2. Product Data:
a. Catalog cuts and product specifications for hardware specified.
b. Interface terminations and cable data for each module.
c. Hardware manuals (4 sets).
d. Detailed bill of materials with manufacturer’s part numbers for each rack.
3. Shop Drawings:
a. Panel Shop Drawings shall be submitted under Section 40 61 13, Process Control
System General Provisions.
b. Installation and assembly drawings and specifically prepared technical data for
hardware.
c. Wiring Diagrams: Show control connections and distinguish between factory
installed and field installed wiring.
d. Addressing system and card layout, including special configuration rules and
limitations for each rack.
4. I/O Database
a. Include the control system I/O database information for PLC specific submittals.
NTS: Coordinate with Owner type and number of spare parts required.
5. Spare Parts
a. One spare I/O Card of each type.
b. One spare Communication Card of each type.
NTS: Coordinate with Owner “6. through 9.” required.
6. PLC Programming Software
7. Training Vouchers
8. Instrument Management Software
9. Historian Tags
B.
Submit in accordance with Section 01 33 00.
PART 2 – PRODUCTS
2.1
MANUFACTURERS
A. Allen-Bradley 1756 ControlLogix Series.
B.
Allen-Bradley 1769 CompactLogix Series
C.
No Substitutes.
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Programmable Logic Controllers – 40 64 00-3
2.2
GENERAL
A. Perform stand-alone monitoring and control and include following as minimum.
1. Microprocessor based controller (PLC processor) to execute program instructions, store
data, and control data transfer.
2. PLC memory.
3. I/O subsystem interfaces.
4. Power supply, including power conditioning and surge protection.
5. Communication interfaces.
6. Programming interface.
B.
2.3
Must integrate with existing network of PLCs, VFDs, LOIs and HMIs.
CONTROLLOGIX PLC PROCESSORS 1756-L71
A. Features:
1. 10/100Mbps, RJ-45, Ethernet I/P Communication Interface Card mounted in one of the
two available Communication Card Slots in processor chassis.
2. Ladder, sequential function chart (SFC), structured text, and function block programming
ready.
B.
Provide orderly shutdown on power failure, saving register contents with automatic restart on
power restoration.
C.
Interface to programmer unit for maintenance and troubleshooting. Continually update
display when data requested. Provide capability to monitor or change following.
1. Discrete I/O.
2. Analog I/O.
3. Pulsed I/O.
4. Communication parameters.
5. Configuration data.
6. Internal program data values.
D. CONTROLLOGIX PLC POWER SUPPLY 1756-PA72/C or 1756-PA75/B
1. 85-264 VAC.
2. Sizing is responsibility of System Supplier.
E.
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CONTROLLOGIX I/O MODULES
1. I/O modules specifically designed for interfacing of I/O signals to PLC processor.
Screw-type removable wiring arms required for each I/O module are responsibility of
System Supplier.
2. Include sufficient I/O modules to accommodate I/O with provisions for 20% spare I/O
prewired to terminal strips. Where no I/O of a listed type (digital input, digital output,
analog input, analog output) is shown, provide one spare prewired module. Each
processor or I/O chassis must contain a minimum of one spare slot, beyond the required
spare I/O. Provide 1756-N2 filler strips for all empty slots in processor and I/O chassis.
3. 120VAC Digital Input 1756-IA16I
a. 120 VAC individually isolated as required by application.
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4.
5.
6.
2.4
b. 16 points per module.
c. LED indication of on/off status of each point.
120 VAC Relay Output 1756-OW16I
a. 120 VAC as required by application.
b. 16 points per module.
c. LED indication of on/off status of each point.
d. Provide surge protection (MOV) for inductive loads such as solenoids or coils.
Analog Input 1756-IF8I
a. Individually isolated.
b. 8 points per module.
c. Accept 4-20 mAdc or 1-5 vdc inputs as required by application.
Analog Output 1756-OF8I
a. Individually isolated.
b. 8 points per module.
c. Transmit 4-20 mAdc.
CONTROLLOGIX ETHERNET ADAPTER 1756-EN2TR
A. Provides connectivity between PLC processers and Ethernet Remote I/O on Ethernet data
highway.
B.
2.5
10/100 auto-switching.
MODBUS TCP/IP COMMUNICATION MODULE (PROSOFT MVI56E-MNETCR)
A. Provides connectivity between Modbus TCP/IP Network and Allen Bradley ControlLogix
Ethernet/IP Network.
2.6
MODBUS RS232 MASTER/SLAVE COMMUNICATION MODULE (PROSOFT-MVI69-MCM)
A. Provides connectivity between Allen Bradley CompactLogix processor and Modbus RS-232
network.
2.7
COMPACTLOGIX PLC PROCESSORS
NTS: Coordinate with Owner on requirements.
A. 1769-LXX
2.8
WIRING AND TERMINATION SYSTEMS
A. Wiring of PLC I/O modules shall be through cable assemblies and terminal blocks.
B.
A cable assembly shall incorporate an I/O module-specific wiring arm pre-wired to one end of
a multi-conductor or multi-pair connection cable. The other end of the connection cable shall
be pig-tailed for landing at terminal blocks.
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Programmable Logic Controllers – 40 64 00-5
C.
Connection cables shall have overall insulated jacket. Multi-pair connection cables for analog
I/O shall also incorporate overall cable shield in addition to the individually shielded pairs.
D. Terminal blocks shall be organized by I/O module.
E.
2.9
Provide sufficient terminal blocks to accommodate active I/O points, spares, and future
expansion.
COMMUNICATIONS SOFTWARE
A. Communication software and configuration shall meet monitoring and control requirements of
each process in accordance with functional descriptions.
B.
Within each hardware unit communicating over data highway, include executive routines or
traffic controller to control and coordinate activities on communication links. Use integrated,
standard products for communication software to manage transmission protocols, line error
detection, and message switching.
C.
Interface software for transfer of data from one location to another.
D. Expandable systems shall accommodate addition of future equipment as specified elsewhere.
E.
Diagnostic facilities to check performance of communication links and communications
interface portion of devices on data highway.
F.
Include routines to detect transmission errors. Perform automatic reinterrogations and
retransmissions before alarm is sounded. Generate system alarms.
2.10 OPERATOR AND ENGINEERING WORKSTATIONS
A. General:
1. City will furnish HMI (IFIX Viewnode).
2. System supplier shall install operator and engineering workstations.
2.11 OPERATOR INTERFACE TERMINALS
A. General:
1. Operator Interface Terminals (OIT’s) shall be utilized as the human-machine interface in
the field as shown. All stations shall be functionally similar as to display arrangements,
menu selections, command terminology, and data access methods.
2. All OIT’s shall be functionally interchangeable differing only in the application software
installed on each type. All OIT’s shall be capable of accessing typical operator process
control functions. Each station's functional environment shall be password protected for
system security and user identification. Required number of OIT’s shall be provided as
shown.
B.
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The Operator Interface Terminals shall be a flat panel, industrial hardened PC computer.
They shall be rated NEMA 4X panel mountable, industrial PC Workstations designed for
harsh environments, with sealed front panel displays and keyboards. The units shall be
Programmable Logic Controllers – 40 64 00-6
designed and approved for use in hazardous locations Class I, Division 2, Groups A, B, C and
D; Class II, Division 2, Groups F and G. Each station shall be constructed of identical parts
and components and shall be provided with the following minimum features and functions:
1. 2711P-T15C4D8 in-plant locations
2. 2711PC-T10C4D8 remote stations
2.12 CONTROL NETWORK
A. General: Furnish and install a high security, process control network. The network shall be
arranged such that future nodes can be added at any point(s) along the network without
overloading the system or requiring re-routing of the highway cable being installed under this
contract.
B.
Required Features:
1. The network shall be based on open standards and shall provide a redundant backbone
that shall be implemented using ANSI X3T12 requirements.
2. The network shall be a high-throughput network based on Fiber/Copper Distributed Data
Interface (FDDI/CDDI) per ANSI X3T12 or via Fast Ethernet. Ethernet capable
automation (PLC, HMI, OIT, etc.) shall be interconnected and reside on the process
control network.
3. The network shall be commercially available hardware and software compatible with
existing system.
4. Devices residing on the network shall utilize standard Network Interface Cards (NICs).
The network devices shall individually connect to either FDDI/CDDI concentrators or
Ethernet switches through appropriate media.
5. The net effective communications rate shall be nearly 100 MB per second, sufficient to
support the transmission of at least 100,000 periodic data point values each second.
System data shall be automatically available to all devices on the network at all times.
An analog or digital variable shall be input, output, calculated or sent to any device on the
network within 100 milliseconds.
6. CONTRACTOR shall provide cable meeting all transmission requirements for the system
supplied. Since communication protocols vary from supplier to supplier, achieving the
minimum transmission rate specified does not relieve CONTRACTOR from conforming
to all specific performance requirements.
7. The Operator shall be able to verify from the central location, the presence, type and
well-being of all devices on the network.
8. The communications protocol shall be based on the TCP/IP communications standard. If
FDDI/CDDI is utilized, it shall be implemented in accordance with ANSI X3T12 such to
utilize both synchronous and asynchronous modes.
9. Extensive error checking shall be provided to verify that accepted messages contain the
same data that was sent from the original source and to verify that noise or hardware
failure has not incorporated erroneous data in the received message.
10. The communication channel shall operate without failure in presence of 2.5 KV, 1 MHZ
damped sinusoidal signal (IEEE surge withstanding capabilities specification) applied
differentially or to either data line with respect to ground.
11. The communication channel shall withstand without damage 120V RMS at 60 Hz applied
differentially or to either data line with respect to ground.
12. Refer to Division 26 for all data highway cabling.
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Programmable Logic Controllers – 40 64 00-7
13. Label of network connections shall be done at every connection point. All patch cables of
any length shall be labeled.
PART 3 - EXECUTION
3.1
ENVIRONMENTAL CONDITIONS
A. Instrumentation and PLC components shall be suitable for continuous service in the
OWNERS environment.
END OF SECTION
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