automation & control planning guide - schneider electric · pdf filem340 plcs – and...

Automation & Control Planning Guide Making Informed Decisions About Your Installed Equipment

Make the most of your energySM

Introduction

• Whataretheassociatedmaintenancecostsofkeepingolderautomationequipmentinservice?

• Inwhatwayscanthesemaintenancecostsbeminimized?

• Besidesmaintenancecosts,whatotherfactorsshouldIconsiderindecidingifIshouldupgrademyequipmentorsustainoperationswithmyexistingequipment?

• Howeasilycanmyengineeringandmaintenanceorganizationsadapttonewertechnologies?

• IfIdoupgrade,canIspreadtheassociatedcostsandscheduleddowntimeoverseveralmonthsoryears,sothatIcanbettermanagetherisks?

Followingeachsectionofthisguideisasampleofthetypeofinformationyourinstalledbaseconsultantwillcollectduringthefirstofatwo-stepconsultationservice.Youcanusethesesamplestocollectdatainpreparationforyourmeetingortodeterminewhoshouldparticipateinthemeeting.Withtheinformationcollectedwithintheseexercises,SchneiderElectricwillcompileacomprehensivepersonalizedreport,whichwillhelpclarifyyourcurrentstateandoutlineyouroptions–positioningyoutomakeeffectivedecisionsnow,forthefutureofyouroperations.

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This guide has been assembled for customers, like you, with an installed base of Schneider Electric equipment, including programmable logic controllers. This tool is designed to provide a structure and framework for making decisions consistent with your intentions for your equipment.

Sample Exercise A: Business Profile1 Whoisourprimarycontactatyourfacilityforthisprocess?2 Whatareyourtopthreeoperationalconcerns?3 Whatvendorsandmodelsofthefollowingequipmenttypesare usedatyourfacility,andwhatistheapproximatequantityofeach? • Programmablelogiccontrollers(PLCs) • Humanmachineinterfaces(HMIs) • Variablefrequency(AC)drives • Servodrives • SCADAsoftware

Whetheryourgoalistoprolongthelifeoftheinstalledautomationequipment,upgradetoSchneiderElectricbrandModicon®PLCsystemsortoplanforfutureprocesschanges/expansions,wecanhelp.WithuseofthistoolandthehelpofyourSchneiderElectriccertifiedinstalledbaseconsultant,youcananswerquestionssuchas:

In1969,BedfordAssociates(Bedford,MA)inventedaspecializedcomputerintendedtomakeAmerica’sindustrialbasemorecompetitiveinanever-expandingglobalmarket.TheoriginalMOdularDIgitalCONtroller,orModicon,featuredaruggeddesign,modularinputs/outputs(I/0)toconnecteasilytoawiderangeoffielddevicesandarevolutionaryprogramminglanguage,calledLadderLogic,thatsimulatedthebehavioroftherelaycontactsandcoilsthatwerealreadyfamiliartoindustrialprocessengineers.Thisnewtechnologyusheredinahugeadvancementinthefieldofindustrialautomation,keepingmanufacturingprofitmarginsupandproductsaffordable,anddirectlycontributingtothesuccessoftheU.S.astheworld’sleadingindustrialeconomy.

Today,what’scommonlycalledtheprogrammablelogiccontrollercanbefoundeverywhere:fromchickenfarmstoamusementparks,factoryfloorstowastewaterplants,andrailroadstationstobattleships.ManyoftheseexistingapplicationsarebasedonthewidelypopularModicon984andModiconCompact984PLCplatforms;thoughthemodel984isnowdecadesold,thissystemstillprovidesitsuserswithreliableoperation.

History of the Modicon PLC

3

Schneider Electric

has continued in

its evolution of

PLC technology

advancements, as

well as keeping

consistent with the

Modicon product

line’s 40+ year

tradition of

innovation and

high quality.

ThroughtheacquisitionsofModicon,Telemecanique®andSquareD®companies,SchneiderElectrichasbroughttogetherthebestofthreeproductlinesintoasingle,cohesiveoffersupportedbyaglobalnetworkoffieldofficesanddistributorpartners.Thisapproachempowersourcustomerswiththeabilitytomaintaintheirlegacysystemswithworld-classservices,whilesimplifyingthetransitiontothelatestautomationtechnologyasbusinessconditionsrequire.

ConsistentwiththeModiconproductline’s40+yeartraditionofinnovationandhighquality,SchneiderElectrichascontinuedinitsevolutionofPLCtechnology.Theseadvancementsincludetheadoptionofadvancedprocessors,functionblockprogrammingandintegratedEthernetwithembeddedwebservers.Today’sflagshipproductsaresoldundertheModiconQuantum™,ModiconMomentum™,ModiconPremium™andModiconM340™PLCs–andrepresenttheindustry’shighestachievementstowardmakingautomatedprocesseseasiertomaintain,moreefficientandmoreaffordabletopurchaseandtointegrate.

Timeline

4

1975 1980 1985 1990

Modicon 484

Modicon 584 Modicon 984 Slot Mount

Modicon 984 Chassis Mount

Modicon Compact 984

Modicon 484CPU Part Number Series:

AS-C484-xxx

Actively Sold:

1977–1983

Current Status:

Notforactivesale.Fullrepair/

refurbishmentmaybeavailable

forsomeCPUs;somerefurbished

exchangeunitsmaybeavailable

Support Remote I/O Platforms:

LocalI/Oonly;

J471I/Oexpander(local)

Networks Supported:

None;upto10channelslocal

Programmed with:

P190programmer

Max. number of digital I/Os:

256I/O

Max. number of analog I/Os:

Nottoexceedtheremainder

ofthe256I/Ofromdigital

Modicon 584CPU Part Number Series:

AS-584A-xxx;AS-584M-xxx;

AS-584L-xxx

Actively Sold:

1979–1984

Current Status:






S901500,200and

800SeriesI/Osupport

Networks Supported:

Modbus®/ASCII,S901orS908

communicationswithupgrades

upto32remotechannels

Programmed with:

Modsoft®,ProWORX®

Plus/NxT/32software


Eachchannelsupportsamax.

of128I/O.200series16discrete

I/Omoduleswith16points.500

serieschannelsupport64discrete

I/Omodules4points.800series

128I/Opoints


Seeabove;cannotexceed

max.foranyoftheseriesofI/O

Modicon 984 Chassis MountCPU Part Number Series:

P1-984X-008;Px-984A-xxx;

Px-984B-xxx

Actively Sold:

1985–1999

Current Status:






200,500and800Series

Networks Supported:

Modbus,ModbusPlus™

communications

Programmed with:

ProWORXPlus/NxT/32and

Modsoftsoftware


8192anymix


2048I/O

Modicon 984 Slot MountCPU Part Number Series:

PC-E984-3xx;PC-D984-xxx;

PC-K984-xxx

Actively Sold:

1987–2006

Current Status:






200,500and800Series

Networks Supported:

Modbus,ModbusPlus

communications

Programmed with:

ProWORXPlus/NxT/32

andModsoftsoftware


16,384I/16,385O


1088I/O

Modicon Compact 984CPU Part Number Series:

PC-A984-xxx;PC-E984-2xx

Actively Sold:

1991–2007

Current Status:






I/Obus

Networks Supported:

ModbusPlus,InterbusS

communications

Programmed with:

Modsoft,ProWORXPlus/NxT/32,

Concept™(commonplatform

only)software


256max.discrete+registerI/O

uptototalof32wordsin/out285

upto512wordsinand512out


Nottoexceedtheremainderof

the256I/Ofromdigital

1990 1995 2000 2005

Modicon Micro

Modicon Quantum

Modicon Premium

Modicon Momentum

Modicon M340

Modicon MicroCPU Part Number Series:

110CPU311xx;110CPU411xx;

110CPU512xx;110CPU612xx

Actively Sold:

1993–2006

Current Status:






LocalI/Oonlyupto4racks,also

parentchildconfiguration

Networks Supported:

ModbusandASCIIcommunications

Programmed with:

Modsoft,ProWORXPlus/

NxT/32software


BuiltinfixedI/O16I/12O;

expandablewithCompactI/O

upto4racks


4I/2O

Modicon QuantumCPU Part Number Series:

140CPUxxxxx

Actively Sold:

1994topresent

Current Status:

Activesale.Fullrepair/refurbishment

availableforallCPUs.


Upto32remotedrops

NetworksSupported:

Ethernet,Modbus,ModbusPlus,

RTU,ASCII,RIO,Profibus,

InterbusScommunications

Programmed with:

ProWORX32,Concept,

Unity™software


2048I/Owordsin/2048I/O

wordsout


2048I/Owordsin/2048I/O

wordsout

Modicon PremiumCPU Part Number Series:

TPCX57xxxx;TSXP57xxxx

Actively Sold:

1998topresent

Current Status:


availableforallCPUs


FIPIO

Networks Supported:

Ethernet,ModbusPlus,Modbus,

Fipway,ASi,CANopen,Profibus,

Interbus,Unitelwaycommunications

Programmed with:

PL7orUnitysoftware


2048inrack


512inrack

Modicon MomentumCPU Part Number Series:

171CCC7xxxx;171CCS7xxxx;

171CCC9xxxx

Actively Sold:

1998topresent

Current Status:


availableforallCPUs


I/Obus

Networks Supported:

ModbusPlus,MBTCPIP,

Profibus,DeviceNet,FIPIO,

IObuscommunications

Programmed with:

ProWORX,Conceptsoftware


8192I/O(Atotalof8192bitscan

beconfiguredfordiscreteand

analogI/O,anymixuptothe

statedlimits)


26,048I/O(Atotalof26,048words

canbeconfiguredfordiscreteand

analogI/O,anymixuptothe

statedlimits)

Modicon M340CPU Part Number Series:

BMXP341000,BMXP342010,

BMXP342020,BMXP342030

Actively Sold:

August2007topresent

Current Status:


availableforallCPUs


No

Networks Supported:

CanOpen,Ethernet,

Modbuscommunications

Programmed with:

UnityV3.0software


1024I/Owords(BMXP342xxx)


256I/Owords(BMXP342xxx)

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Sample Exercise B: Current Inventory1. SpecificquantityofeachModiconPLCmodelemployedin yourplantorprocess

7

Throughoutmostofthehistoryofindustrialautomation,theprogramminginterfaceofeachPLCwasvendor-specific;thatis,aprogrammerormaintenancespecialistofaModiconPLCsystemwasunlikelytobeasefficientonanothercompany’splatform,andviceversa.Thiscausedmostendusersto“standardize”ononebrandoranother–rarelywouldyoufindmultiplePLCbrandsinasinglefacility.InordertoallowformoreflexibilityinselectionofaPLCvendor,aconsortiumofindustrialcustomersestablishedtheIEC61131programmingstandardsin1993.TheseIECstandards,whichmostmajorPLCmanufacturersnowcomplywith,significantlyreducethebarriersforacustomertoemploythebest-in-classautomationarchitectureforagivenapplication.Now,it’scommontoseeautomationproductsfrommultiplemanufacturersinasinglefacilityorprocess,allprogrammedwiththecommonlook,feelandfunctionalityoftheIECstandards.

Industrial customers established the IEC 61131

programming standards in 1993.

History of the IEC Standards

1 Processefficiencyandresourceutilization

2 Maintenancecosts

3 Processmodificationsandexpansions

4 Safetyandsecurity

Decision CriteriaTherearefourprimaryconsiderationsthatindustrialcustomerscitewhenformulatingplansforthefutureoftheirautomatedplantorprocess:

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Productivity

Market Standard

Time

Actual

Aplant’sefforttoincreaseproductivityatamarketstandardratecouldbelimitedbyseveralfactors:

Capacity of equipment: existingmachinesoriginallydesignedforacertainthroughputmayneedtoundergosignificantredesignormayevenneedtobereplacedtomakeanimpactonefficiency.

Manual troubleshooting: olderproductionsystemsneedmoretimetorecoverfromunscheduleddowntimethannewerplantsthatmayemployself-diagnosticandpreventativemaintenancetechnologies.

Inefficient level of spares inventory: assystemsage,therightmixofspareproductionequipmentbecomescritical.Toomuchinventorydrivesupcosts,whiletoolittlecreatesdowntimerisk.

Flexibility of engineering and service personnel: incrementalexpansionsandmodificationsmayemployamixtureofvariouspiecesofequipmentfromseveraldifferentvendors.Thiscouldhaveanegativeimpactontheflexibilityofmaintenancepersonnelandcontrolsengineersthatservicetheentireoperation.

Sample Exercise C1: Production Rate1 Targetandactualproductionrateforentirefacility.2 Totaloperatinghoursperyear,firstshiftandothershifts.

Sample Exercise C2: Lean Manufacturing Technologies1 Whatprocessdoyouusetodispatchmaintenancepersonnel?2 Howeffectiveisthisprocess?

Sample Exercise C3: Spares Assessment1 Howdoyoumanageyourspareparts?2 Whatisyouraverageinventoryturnover,inpartsperyear,ofthe devicetypessuchasprogrammablelogiccontrollers(PLCs), humanmachineinterfaces(HMIs),variablefrequency(AC)drives, orservodrives.

Sample Exercise C4: Adaptability of Personnel1 Whatisthesizeofyourmaintenanceandengineeringstaff?2 Theiraverageyearsofexperience?3 HowmuchofthisexperienceiswithIECorrelatedprogramming anddiagnostics?

Process efficiency resource utilizationInitsearlystages,anindustrialprocessexhibitstremendousgainsinproductivityasnewequipmentisemployed,informationsystemsareintegrated,startupproblemsareresolvedandpersonnelbecomeefficientattheirnewjobs.Eventually,therateofproductivitywillleveloff,asthefocusshiftstowardsincrementalcostreductionandprocessflowimprovement.

Initially,thepaybackagainstthe“marketstandard”benchmarkforproductivityispositive,asthemodernplantorprocessisabletoofferareturnoninvestment.Astheprocessages,however,theproductivityofthemarketbecomeshigherthanthatoftheprocess,tothepointwhereincrementalefficiencygainsmaynotbeenoughtostaycompetitive.

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ExerciseEisintendedtoassessthedegreethataplantorprocesswillundergomodificationsforreasonsotherthanmaintenancecosts.

Sample Exercise D: Potential Maintenance Cost of Sustaining Legacy Equipment1 Whatisthecostperhourofdowntime, bothintermsofmaintenancelabor,as wellasinlostproduction?

Maintenance costsElectronicproductsfromanymanufacturerthatweremanufacturedinthe’80sandearly’90sarebasedoncomponents,suchasmemorychipsandmicroprocessors,whicharenolongeravailableontheopenmarket.Whilesparepartsproductionismaintainedwithsalvageequipment,last-timebuys,anddiscreteredesigns,futureindefinitesupplyofthesecomponentscannotbeassured.Thisreducedavailabilityhasadirectimpactonmaintenancecosts.Movingtoaplatformthatusesmodernelectronictechnologiescansignificantlyreducethecostsofsparepartsandextendtheworkinglifeoftheprocessormachine.

Ifaprocessormachineneedstobefunctionallymodifiedorexpanded,doingsowithalegacyPLCplatformwilllikelyaddcostsandcomplexity:

• OlderPLCplatformsmaynotbeabletointerfacewithtoday’s highperformancenetworkswithoutexpensivebridges andgateways.

• Buyingadditionalracks,I/Ocards,CPUsandother accessoriesforanobsoleteproductlinemaybe cost-prohibitive.

• Addingfunctionalitytoadecades-oldladderlogicprogram, withoutanegativeimpactoncurrentperformance,can requiresignificantengineeringtimeandspecializedtalent.

Sample Exercise E: Non-Financial Motivators1 Weightedjudgmentsonspecific motivatorsthataredifficulttoquantify, suchas: • Isyourindustrygrowing? • Isyourcompanygrowingwithin yourindustry? • Isyourprocesssensitiveto environmentalconsiderations? • Dostartupsandlinechangesneed tobeperformedmorequickly?

Process modifications and expansions

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Sample Exercise F: Safety and Security Assessment 1 Whichplantsafetystandardsareyou requiredtocomplywith?2 SelectamonglistedNFPA-70E requirementsthoseyoualready meettoday.

Safety and securityToday’sbusinessclimatedemandsattentiontoserioussafetyandsecuritythreatssuchasterrorism,identitytheft,workplaceaccidents,industrialsabotage,environmentalandproductliability,publicsafety,processtraceability,andnaturaldisasters.Withproperplanninganddesignofsafeguards,therisksandrecoverycostsoftheseeventscanbeminimized.

Incremental Upgrade Strategy

Ifyourintention,eitherlong-orshort-term,istoupgradeyourautomationequipment,basedonprocessefficiency,maintenancecosts,expansionplansorsecurityconcerns,youhaveseveraloptionstoconsider:

• Shouldyouupgradetheprocessorandkeepthesamesoftware?

• Ifyouupgradethesoftware,whichplatformshouldyouuse?

• WhatchangesarenecessarytotheI/Oarchitecture?

• Whataccommodationsshouldbemadefornetworkconnectivity?

• Whattechnicalattributesofanewplatformwouldyoubenefitmostfrom?

• Whatistheoptimumupgradeschedule?

• Howdoyoumanagebudgetconstraints?

• Howcandowntimebeminimizedduringthechangeover?

Theanswerstoallofthesequestionsdependontheinformationyouwillprovideinyourconsultationwithyourinstalledbaseconsultant,plusyourassessmentofthevaluethatcomesfromupgradingspecificcomponentsinyourautomationsystems.

ExerciseGwillhelptobetterqualifytherecommendationsinyourpersonalizedreport.

Sample Exercise G: Benefit Assessments1 Determinehowimportanteach ofthefollowingbenefitsaretoyou, inconsideringanupgradeofyour automationequipment: • Increasedsystemperformance: speed,memorycapacity,etc. • Laborversatility:diagnostic tools,intuitiveprogramming environment,etc. • Systemflexibility:communication networks,I/Oselection,etc.

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DocumentNumber0140BR0901 07-09lh

Put our experience to work for youFormoreinformation,contactyourlocalSchneiderElectricsalesrepresentative,automationdistributor,orvisitusonlineathttp://www.schneider-electric.us

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9SchneiderElectricAllRightsReserved

Looking aheadIt’snevertoosoontostartplanningfortheongoingsuccessofyouroperations.Takethefirststepandmeetwithyourinstalledbaseconsultanttocompletethein-depthinterviewofyourcurrentsituationandfutureobjectives.Youwillthenreceiveyourpersonalized,comprehensivereport,uponwhichyoucanbasesoundbusinessdecisionsforyourcompany’sfuture.

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AutomationandControlCenterofExcellence8001KnightdaleBlvd.Knightdale,NC27545Tel:919-266-3671www.Schneider-Electric.us

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