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
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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:
Notforactivesale.Fullrepair/
refurbishmentmaybeavailable
forsomeCPUs;somerefurbished
exchangeunitsmaybeavailable
Support Remote I/O Platforms:
S901500,200and
800SeriesI/Osupport
Networks Supported:
Modbus®/ASCII,S901orS908
communicationswithupgrades
upto32remotechannels
Programmed with:
Modsoft®,ProWORX®
Plus/NxT/32software
Max. number of digital I/Os:
Eachchannelsupportsamax.
of128I/O.200series16discrete
I/Omoduleswith16points.500
serieschannelsupport64discrete
I/Omodules4points.800series
128I/Opoints
Max. number of analog I/Os:
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:
Notforactivesale.Fullrepair/
refurbishmentmaybeavailable
forsomeCPUs;somerefurbished
exchangeunitsmaybeavailable
Support Remote I/O Platforms:
200,500and800Series
Networks Supported:
Modbus,ModbusPlus™
communications
Programmed with:
ProWORXPlus/NxT/32and
Modsoftsoftware
Max. number of digital I/Os:
8192anymix
Max. number of analog I/Os:
2048I/O
Modicon 984 Slot MountCPU Part Number Series:
PC-E984-3xx;PC-D984-xxx;
PC-K984-xxx
Actively Sold:
1987–2006
Current Status:
Notforactivesale.Fullrepair/
refurbishmentmaybeavailable
forsomeCPUs;somerefurbished
exchangeunitsmaybeavailable
Support Remote I/O Platforms:
200,500and800Series
Networks Supported:
Modbus,ModbusPlus
communications
Programmed with:
ProWORXPlus/NxT/32
andModsoftsoftware
Max. number of digital I/Os:
16,384I/16,385O
Max. number of analog I/Os:
1088I/O
Modicon Compact 984CPU Part Number Series:
PC-A984-xxx;PC-E984-2xx
Actively Sold:
1991–2007
Current Status:
Notforactivesale.Fullrepair/
refurbishmentmaybeavailable
forsomeCPUs;somerefurbished
exchangeunitsmaybeavailable
Support Remote I/O Platforms:
I/Obus
Networks Supported:
ModbusPlus,InterbusS
communications
Programmed with:
Modsoft,ProWORXPlus/NxT/32,
Concept™(commonplatform
only)software
Max. number of digital I/Os:
256max.discrete+registerI/O
uptototalof32wordsin/out285
upto512wordsinand512out
Max. number of analog I/Os:
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:
Notforactivesale.Fullrepair/
refurbishmentmaybeavailable
forsomeCPUs;somerefurbished
exchangeunitsmaybeavailable
Support Remote I/O Platforms:
LocalI/Oonlyupto4racks,also
parentchildconfiguration
Networks Supported:
ModbusandASCIIcommunications
Programmed with:
Modsoft,ProWORXPlus/
NxT/32software
Max. number of digital I/Os:
BuiltinfixedI/O16I/12O;
expandablewithCompactI/O
upto4racks
Max. number of analog I/Os:
4I/2O
Modicon QuantumCPU Part Number Series:
140CPUxxxxx
Actively Sold:
1994topresent
Current Status:
Activesale.Fullrepair/refurbishment
availableforallCPUs.
Support Remote I/O Platforms:
Upto32remotedrops
NetworksSupported:
Ethernet,Modbus,ModbusPlus,
RTU,ASCII,RIO,Profibus,
InterbusScommunications
Programmed with:
ProWORX32,Concept,
Unity™software
Max. number of digital I/Os:
2048I/Owordsin/2048I/O
wordsout
Max. number of analog I/Os:
2048I/Owordsin/2048I/O
wordsout
Modicon PremiumCPU Part Number Series:
TPCX57xxxx;TSXP57xxxx
Actively Sold:
1998topresent
Current Status:
Activesale.Fullrepair/refurbishment
availableforallCPUs
Support Remote I/O Platforms:
FIPIO
Networks Supported:
Ethernet,ModbusPlus,Modbus,
Fipway,ASi,CANopen,Profibus,
Interbus,Unitelwaycommunications
Programmed with:
PL7orUnitysoftware
Max. number of digital I/Os:
2048inrack
Max. number of analog I/Os:
512inrack
Modicon MomentumCPU Part Number Series:
171CCC7xxxx;171CCS7xxxx;
171CCC9xxxx
Actively Sold:
1998topresent
Current Status:
Activesale.Fullrepair/refurbishment
availableforallCPUs
Support Remote I/O Platforms:
I/Obus
Networks Supported:
ModbusPlus,MBTCPIP,
Profibus,DeviceNet,FIPIO,
IObuscommunications
Programmed with:
ProWORX,Conceptsoftware
Max. number of digital I/Os:
8192I/O(Atotalof8192bitscan
beconfiguredfordiscreteand
analogI/O,anymixuptothe
statedlimits)
Max. number of analog I/Os:
26,048I/O(Atotalof26,048words
canbeconfiguredfordiscreteand
analogI/O,anymixuptothe
statedlimits)
Modicon M340CPU Part Number Series:
BMXP341000,BMXP342010,
BMXP342020,BMXP342030
Actively Sold:
August2007topresent
Current Status:
Activesale.Fullrepair/refurbishment
availableforallCPUs
Support Remote I/O Platforms:
No
Networks Supported:
CanOpen,Ethernet,
Modbuscommunications
Programmed with:
UnityV3.0software
Max. number of digital I/Os:
1024I/Owords(BMXP342xxx)
Max. number of analog I/Os:
256I/Owords(BMXP342xxx)
5
Sample Exercise B: Current Inventory1. SpecificquantityofeachModiconPLCmodelemployedin yourplantorprocess
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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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Looking aheadIt’snevertoosoontostartplanningfortheongoingsuccessofyouroperations.Takethefirststepandmeetwithyourinstalledbaseconsultanttocompletethein-depthinterviewofyourcurrentsituationandfutureobjectives.Youwillthenreceiveyourpersonalized,comprehensivereport,uponwhichyoucanbasesoundbusinessdecisionsforyourcompany’sfuture.
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