Understanding PLCs (Programmable Logic Controllers): A Comprehensive Guide

In today’s highly automated world, machines and industrial processes are controlled by sophisticated electronic devices that ensure efficiency, precision, and safety. One of the key players in this realm is the Programmable Logic Controller (PLC). PLCs are the unsung heroes behind the automation of countless industries, from manufacturing and agriculture to energy production and beyond. In this comprehensive guide, we will delve deep into the world of PLCs to understand how they work, their applications, components, programming, and their significance in modern industrial automation.

Chapter 1: The Basics of PLCs

1.1 What is a PLC?

A Programmable Logic Controller (PLC) is a specialized computer designed to control and automate industrial processes and machinery. Unlike general-purpose computers, PLCs are tailored for reliability, ruggedness, and real-time control. They are commonly used in manufacturing plants, chemical processing, power generation, and various other industries.

1.2 Why Use PLCs?

PLCs offer several advantages over traditional relay-based control systems:

  • Flexibility: PLCs are highly adaptable and can be reprogrammed to handle different tasks without the need for hardware changes.
  • Reliability: PLCs are known for their robustness, with long lifespans and resistance to environmental factors.
  • Real-time Control: They provide precise control over processes with minimal delay.
  • Diagnostics: PLCs offer extensive diagnostic capabilities, making troubleshooting and maintenance easier.
Read More

ATV11-ATV12 Substitution Chart

Below is a chart that shows the direct replacement from ATV11 to ATV12 drives. MRO Electric and Supply carries new & refurbished ATV11 and ATV12 units by Schneider Electric.

ATV11 EUROPAATV11 USAATV11 ASIAATV12
-ATV11HU05F1UATV11HU05F1AATV12H018F1
ATV11HU05M2EATV11HU05M2UATV11HU05M2AАТУ12Н018М2
-ATV11HU05M3UATV11HU05M3AАТУ12Н018М3
-ATV11HU09F1UATV11HU09F1AATV12H037F1
-ATV11PU09F1UATV11PU09F1AATV12P037F1
AN11HU09M2EATV11HU09M2UATV11HU09M2AATV12H037M2
AN11PU09M2EATV11PU09M2UATV11PU09M2AATV12P037M2
-ATV11HU09M3UATV11HU09M3AATV12H037M3
-ATV11PU09M3UATV11PU09M3AATV12P037M3
ATV11HU12M2E--ATV12H055M2
ATV11PU12M2E--ATV12P055M2
-ATV11HU18F1UATV11HU18F1AATV12H075F1
ATV11HU18M2EATV11HU18M2UATV11HU18M2AАTV12H075М2
ATV11PU18M2EATV11PU18M2UATV11PU18M2AATV12P075M2
-ATV11HU18M3UATV11HU18M3AАTV12H075М3
-ATV11PU18M3UATV11PU18M3AATV12P075M3
ATV11HU29М2ЕATV11HU29M2UATV11HU29M2AATV12HU15M2
-ATV11HU29M3UATV11HU29M3AATV12HU15M3
ATV11HU41M2EATV11HU41M2UATV11HU41M2AATV12HU22M2
-ATV11HU41M3UATV11HU41M3AATV12HU22M3

Product Spotlight: Square D EDB34030 Circuit Breaker

The Square D EDB34030 is a three pole, 30 Ampere circuit breaker. At 277V, this miniature breaker is reliable, sustainable, efficient and safe.

Part Number: EDB34030
Item Weight: 3.6lbs
Product Dimensions: 9.7 x 6.1 x 4.5 inches
Voltage: 480V
Amperage: 30A
Trip Rating; 875A
Mounting Mode: Bolt-on
Interruption Rating: 18kA

Square D EDB breakers by Schneider Electric are available in a range of amperages varying from 20A to 60A. This particular model, the EBD34030, is 30A.
This breaker is set apart from other breakers because of its compact size at 9.7 x 6.1 x 4.5 inches, while the typical breaker is around 8 x 8 x 12 inches. As a bolt on mount, it is preferred in commercial and industrial applications where vibrations might be considered an issue. When installing, be sure to use the recommended #12-#6 AWG AI or #14-#6 AWG Cu Lug wire. This breaker is ideal for NF series panel-boards to offer superior overload and short circuit stability by utilizing thermal magnetic protection. It is also HACR rated, UL listed and CSA certified.

MRO Electric and Supply stocks Square D circuit breakers, including the EDB34030. For more information or to request a quote, please contact us at 800-691-8511 or at sales@mroelectric.com.

ATS48 Soft Start Troubleshooting and Introduction

The Altistart 48(ATS48) series of soft starters by Square D and Schneider Electric allows for consistent start/stop rates that are independent of motor loads. These devices are more advanced than the standard drives that cannot control the applied motor torque. Featuring contact wiring and control, the soft starter allows for near-seamless integration with existing operations. Many preset parameters are included with the device and they cover a large spectrum of operations. Additional parameters may also be loaded up to meet specific needs. Available power ratings include:

  • 3 – 200 HP @ 208VAC, 60 Hz
  • 5 – 250 HP @ 230VAC, 60 Hz
  • 10 – 500 HP @ 460VAC, 60 Hz
  • 15 – 600 HP @ 575VAC, 60Hz

The ATS48 series features a dual configuration of two motors which allows for a cascaded start/stop in many operations. Using the Torque Control System(TCS) the unit can minimize wear on gears which allows for less time servicing the unit.

The Altistart 48 series takes advantage of the PowerSuite™ software for programming of your drive or soft starter.  With this software, you will be able to monitor and document all of your operations. Configurations are easily saved via hard disk, CD-ROM, flash memory, etc. Using Ethernet technology, the user is able to configure and monitor operations on the go, and a constant feed of information allows for real-time opportunity to modify and adjust configuration files on the fly.

Troubleshooting can be an issue for people when so many different things are going on. It just isn’t feasible to stop operations every time an error occurs. Below is a list of fault codes for the ATS48 Soft Start series that will help determine most issues:

Fault CodeDescription
nLP
rdY
Soft start without run command and:
• Line power not supplied
• Line power supplied
tbSStarting time delay not elapsed
HEAMotor preheating in progress
(Use SUP menu to set up monitoring
parameter. Factory setting: Motor Current.)
Soft start with run command
brLSoft start braking
StbWaiting for a command (RUN or STOP) in
cascade mode
CFF Invalid configuration on power-up
CFI Invalid configuration
CLFLoss of Control Power
EEFInternal memory fault
EtFExternal fault
ErFLine frequency out of tolerance
InFInternal fault
LrFLocked rotor fault
OCFOvercurrent fault
OHFSoft start overheating fault
OLCCurrent overload fault
OLFMotor overload/ground fault
OtFMotor thermal fault detected by PTC probes
PHFLoss of line or motor phase
PIFPhase reversal fault
SLFSerial link fault
StFExcessive starting time
ULFMotor underload fault
USFLack of AC line power on a run command

MRO Electric and Supply carries all models of this unit and has a fast and easy repair service to get your unit fixed and back into your hands as soon as possible.

Struggling with your ATS48 Soft Starter?

MRO Electric provides the insights and assistance you need to troubleshoot efficiently. Our inventory is stocked with the necessary parts, and our experts are on standby to help you minimize downtime.

Repairing your Modicon Magelis HMI

Any amount of downtime is too much for most companies. Parts will break from time to time, and repairs will be necessary. Here at MRO Electric and Supply we are dedicated to providing the best service making sure that your downtime is minimal. Human Interface Terminals(HMIs) are a crucial part of any automation process nowadays, so it is important to make sure it is working correctly. Along with selling both new and remanufactured products, MRO Electric and Supply offers both repair and exchange services.

modicon hmi

Modicon was the first manufacturer to release programmable logic controllers onto the market, and since have been one of the top brands for PLC’s. MRO Electric and Supply have all the parts necessary to run the Magelis HMI at it full potential, including panels, cables, controllers, adapters and any software that may be needed. Along with repairs, we handle installations and programming of drives and controllers so that you don’t have to.

We also offer the option to retrofit your old machines with newer interfaces for the most up-to-date applications and processes. By fitting existing HMI’s with new interfaces you are able to add years to the life span of your automation set up. It is a lot easier to update and fix your existing displays and HMIs than taking the time and money to purchase and fit new parts.

All of our repairs come with a 12 month guarantee. Our repair service is based on doing the right job, and getting your part back to you as soon as possible. Every part we refurbish is tested to make sure they work the way they are supposed to. Our factory-trained technicians have many years working with Modicon products.

For a free Modicon Magelis HMI repair quote, please email sales@mroelectric.com or call 800-691-8511.  For more information on our Modicon repair capabilities, you can visit our Modicon Repair page.
Schneider Electric / Modicon PLC and HMI Batteries

Schneider Electric / Modicon PLC and HMI Batteries

MRO Electric and Supply has new and refurbished Schneider Electric and Modicon Quantum parts available now, and also offers repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

Schneider Electric / Modicon PLC and HMI Batteries

Product Line Model Type Part Number Manufacturer
140CPUxxxxx
Lithium 3V
990XCP98000
Duracell (DL2/3A)
(soldered connector)
Quantum 140XCP90000 Lithium 990XCP99000
Quantum
141MMS42501
Lithium 3V
990XCP98000 or Duracell (DL2/3A)
43502625 (soldered connector)
Quantum
141MMS53502
Lithium 3V
990XCP98000 or Duracell (DL2/3A)
43502625 (soldered connector)
Compact PC-O984-xxx Lithium 3.6V (long) “O” 60-0576-000 Eternacell (T04/41)
Compact
PC-A984-1xx
Lithium 3.6V (short) “A”
60-0576-100
Saft (LS3)
PC-E984-2xx Maxell (ER3STC)
Momentum
172xNN2xx2
Lithium 3.6V
170XTS15000
Tadiran (TL-5955)
PNN PV:03
JNN PV:01
Momentum 172xNN2xxx2 Alkaline “AAA” Commercially Available
110CPUx1x0x
Lithium 110XCP98000 Duracel (DL2/3A)
Capacitor 110XCP99000 (soldered connector)
Modicon 984 AM-C986-003
(2 cell pack)
MA-9255-000
Modicon 984 AM-C986-004
Modicon 984 AM-M907-1xx
Modicon 984 AM-M909-0xx
Modicon 984 AM-C921-xxx 60-0490-000
Modicon 984 PC-L984-x8x
Lithium 3.6V “AA”
60-0515-000
Eternacell (T06141)
Modicon 984 PC-O984-x8x Maxell (ERGC#5)
Modicon 984 PC-E984-x8x Saft (LS6)
Modicon 984 PC-O984-455 Tadaran (TL-5104)
Modicon 984 PC-O984-351
Modicon 984 AM-C986-004
Modicon 984 AM-C996-80x
Modicon 984 PC-M984-23x
Modicon 984 AS-B984-1xx
Modicon 984 AM-S929-00x
Lithium
MA-8234-000
Modicon 984 AS-B885-00x
Modicon 984 AM-O984-ATX 60-0490-000
Modicon 984 Rechargeable (Qty. 2) 60-0610-000
Modicon 984 100-865 (Qty. 3) 60-0595-000
Modicon 984 AM-O984-MCX 60-0582-000
Modicon 884
Modicon 884
AS-884A-xxx
MA-8234-000
AS-J890-x0x
Modicon 584 AS-506P-xxx Lithium (3 card) MA-0147-001
Modicon 584 AS-509P-xxx Lithium (4 card) MA-0147-002
Modicon 584 AS-M507-00x 60-0481-000
Modicon 584
3 Card Battery Pack
Lithium AS-5284-001
Alkaline AS-5284-002
Modicon 584
4 Card Battery Pack
Lithium AS-5378-002
Alkaline AS-5378-001
Modicon 484
Lithium MA-0147-001
Alkaline 60-0286-000
Modbus Multiplexer
Modbus Multiplexer NW-0278-000 60-0549-000
0085/0185 (Sharp)
0085/0185 (Sharp)
(with connector) PA-0254-000 Sharp
(without connector) PA-0493-000 (UBATN-5001-SCZZ)
Symax
Symax
Model 400
Lithium 3.6V “AA”
60-0515-000 Eternacell (T06141)
Model 450 29576-03688 Maxell (ERGC#5)
Model 600 (SqD Part #) Saft (LS6)
Model 650 Tadaran (TL-5104)
PS25
PS35
8052 MCM713
Symax
PS20/21
Alkaline “D”
Commercially Available
PS30/31
PS50/51
PS60/61
Symax
8005 Model 50
Ram Memory Pack
8005 MP1
8005 MP4
Symax
PS20
Battery Holder
29904-08200
(SqD Part#)
Symax
SCP1xx 8020 SMM115
8040 PCM-110 (SqD Part #)
Symax
M100
29904-08960
(SqD Part #)
Symax
8009 Compact
Lithium 3V (Type BA1)
Sanyo (CR12600SE)
TDI Battery Co. (?)
Otte Controls
(DUNT-521NCZZ)
Symax
Symax 20
8884 SBP20
(SqD Part #)
PanelMate
PanelMate
all models
60-0627-000
Maxell
60-0628-000
PanelMate PM0632400 (Qty. 3) 60-0595-000
PanelMate PA-0285-000
PanelMate MA-024M-000
Telemecanique
TSX Premium TSXP57xxx Lithium 3.6V “1/2 AA” TSXPLP01 Saft (LS3)
TSX Micro TSXP37xxx Single TSXPLP101 Maxell (ER3STC)
TSX Micro Ten Pack
TSX Micro
TSXMRPxxxxx
Lithium 3V “Button” TSXBATM01
Panasonic (BR2325)
Single TSXBATM101
10 Pack
CCX17
TCCX17xxx
Lithium 3.6V “1/2 AA” TSXPLP01 Saft (LS3)
Single TSXPLP101 Maxell (ER3STC)
Ten Pack
FTX117
TFTXRSMxxxxx
Lithium 3V “Button” TSXBATM01
Panasonic (BR2325)
Single TSXBATM101
10 Pack
TSX 17
Lithium 3.6V “1/2 AA”
TSX17ACC1
Saft (LS3)
Maxell (ER3STC)
(Soldered Connectors)
XBTKN
Lithium 3.6V “1/2 AA”
TSX17ACC1
Saft (LS3)
XBTKM Maxell (ER3STC)
(Soldered Connectors)
Series 7
TSX 27xx
2.6 V
AZ1 AQ 0006
2.4 Volt with minimum of 110 mAH
TSX P471x/P472x Shrink-wrapped cells
TSX RAM xx 8 Soldered on board
TSX AXM 162
TSX AXM 171xx/182
TSX SCM 2xxx
UC TSX 27
Series 7
TSX P473xx/P474xx 3.6V
AZ1 AQ 0002
3.6 Volt with minum of 110 mAH
TSX P67xxx Shrink-wrapped cells
TSX 76 x Soldered on board
TSX P871/P872/P874xx
TSX P76 x
TSX P107xxx
TPMX P474xx
TPMX P674xx
TPMX874xx
TPMX P1074xx
TSX T407 x
TSX RAM xxx 16
TSX MEM 4x
TSX P87 30/310 3.6V (Qty. 3)
tsxcusbmbp

Schneider Electric TSXCUSBMBP: Beyond the User Manual

Need a replacement TSXCUSBMBP? Request a Price Quote Now.

The Schneider Electric TSXCUSBMBP is a USB Modbus Plus Communications Adapter. In this guide, we will show you how to install the hardware, configure the driver software, and use the Modbus Plus network diagnostics features of the driver software.

Important: The least versions of the TSXCUSBMBP driver to run on Win Server 2012 R2 are driver versions 8.0 and 8.1.

The TSXCUSBMBP is designed to bridge the gap between a USB connection and the Modbus Plus network. It combines hardware and software together in one simple and single device. The module has its own Modbus Plus node address which can be set through the TSXCUSBMBP driver software. This module allows software applications using the serial Modbus RTU communications to connect on the high-speed Modbus Plus network, as well as provide diagnostic capabilities to the Modbus Plus network.

Most Win32 Applications that support serial Mdubus communications can use a Modicon TSXCUSBMBP to connect on a Modbus Plus network. A VSP (Virtual Serial Port) is what redirects communications from Concept, Unity, ProWorx32 and other programs to the TSXCUSBMBP communications adapter. After the VSP is installed, it will create one serial port with the port reference as defined in the module’s driver software. When configuring the Modbus application software, this port reference is selected as the serial port for the application to use. The routing table is used to associate Modbus Slave IDs with 5-byte Modbus Plus routing paths which allow the application software to communicate with any Modbus Plus device within range on the network.

The TSXCUSBMBP’s hardware consists of a box with a USB cable from one end (which connects to the PC) and a standard Modbus Plus DB9 connector on the other end (for the Modbus Plus network). Local signalling LEDs on the top cover of the device tell you the presence of power from the USB port and the state of the Modbus Plus network – no external power supply is required.

TSXCUSBMBP Installation

To install the TSXCUSBMBP, you will need the following:
– Windows XP Operating System with service pack 2, or Windows 2000 with Service Pack 4 or greater.
– 1 MB of free disk space.
– Minimum of 256 MB of RAM.
– One free USB port or a USB Hub that supports USB 1.1 or greater.

If a previous version of the TSXCUSBMBP was installed, the VSP component of the driver must be manually uninstalled using Device Manager before a new version can be installed. After this, the new driver should be installed before connecting the new TSXCUSBMBP to the PC. After the new driver is installed, connect the TSXCUSBMBP and install using the New Hardware Wizard. After completing the instructions, you should see a message stating “Your new hardware is ready to use.” Restart your computer, and the device should be fully functional. If the driver starts up before the TSXCUSBMBP is connected, then it will be necessary to re-scan for adapters so the driver can detect it.

TSXCUSBMBP Configuration

To configure the module, you will need to do the following:

1. Configure the Modbus Plus Node Address
The communications adapter must be assigned a Modbus Plus node address to communicate on the network. Select “Settings” and then type the address in the appropriate box. When complete, hit “Save”.

2. Configure the Slave Response Timeout
The slave response timeout is used by the module each time it sends a request from an application out on the network to a slave device. Use the manual to determine the appropriate value that should be used with your system. Select “Settings” and then type the value in the appropriate box. When complete, hit “Save”.

3. Configure the Virtual Serial (COM) Port
To do this, select “Virtual Modbus Port.” Select the desired COM port from the list available. When complete, click “Save”.

If you experience any problems while configuring your adapter, please use the table below to determine the appropriate error code given by the LEDs, if applicable. As always, refer to the user manual for more complete information.

TSXCUSBMBP Error Codes
TSXCUSBMBP Error Codes
MRO Electric carries both New and Refurbished TSXCUSBMBP Communication Adapters. For more information on this module or to request a price quote, please call 800-691-8511 or email sales@mroelectric.com.