Category Archives: PLC Applications

plc

How to maintain a PLC (Programmable Logic Controller)

How to maintain a PLC (Programmable Logic Controller)

As many of us know, PLCs (programmable logic controllers) are staples in the factory automation world. In order to have them running optimally and as efficiently as possible, routine maintenance is imperative. Generally, manufacturers produce PLCs to endure strenuous, unsterilized environments. By adhering to an adequate maintenance schedule, PLCs operating timeframe can be lengthened.

Protect your PLC

Always be on the lookout for corrosive and conductive contaminants that have the potential to become a detriment to a PLCs’ components. By completing visual inspections for black dust and blowing airborne particles from the PLC’s vicinity, you are lowering the likelihood of contamination.

Is power flowing?

A PLC will not operate correctly without adequate power. To avoid any operation bugs, remain vigilant of any surges or shorts.

Calibrate Analog Components

Always refer to the preventative maintenance schedule for any analog input device. Analog inputs need to be cleaned regularly and calibrated as accurately as possible.

 

Take EMI into consideration

EMI (electromagnetic interference) is known to cause horrible issues for PLCs without clearly indicating what the specific issue is or how to go about fixing it. To remain ahead of the game, many perform an audit of the local wiring to pinpoint potential EMI sources before they interfere with the operation of your PLC. Lower-level components and high-current wires often interfere with each other, which wiring designs must take into consideration.

Additional PLC Maintenance Tips

By creating a PLC maintenance checklist and adhering to it strictly, operating errors can likely be avoided. The space between the PLC and the machine it’s controlling should be minimal.

MRO Electric and Supply has new and refurbished Modicon PLC parts available here. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

 

Modicon 140AVI03000

Modicon Quantum 140AVI03000 – Product Spotlight

The 140AVI03000 is a Analog Mixed Current/Voltage Input Modules that is part of the Modicon Quantum series. This Analog In 8 Channel Bipolar Modules accepts a mix of current and voltage inputs. Jumpers are required between the input and sense terminals for current inputs. The 140-AVI-030-00 contains a total of 18 LEDs. The “Active” LED remains on and green when Bus communication is currently present. The “F” indicator will light up red when an error external to the module has been detected. The green LEDs 1 through 8 will turn on when the indicated point or channel is ON. The red 1 through 8 LEDs when light up for two reasons. Either the indicated channel is out of range (1 – 5 Volts), or a broken wire condition has been detected (4 – 20 mA).

To prevent improper fault indications, unused inputs should have the + (plus) and – (minus) inputs tied together and be configured for a bipolar input range. Unwired inputs can cause invalid readings. When configured for voltage inputs (no jumper is installed between Input (+) and ISENSE terminals), a broken field wire can cause readings to be non-zero and unpredictable. The field wiring terminal must not be removed when the module is in operation.

The following figure shows the 140-AVI-030-00 Wiring Diagram.

140-AVI-030-00 wiring diagram
140AVI03000 Wiring Diagram

For external wiring, the user should supply the current and voltage sources, and installation and calibration of the fuses are at the discretion of the user. It is recommended that shielded cables are used, and twisted shielded cables should be used in noisy environments. The shielded cables should be connected to the PLC’s ground. A shield bar should be used to connected the shielded cable to the ground. If you are field wiring the 140AVI03000, the maximum wire size is 1-14 AWG or 2-16 AWG and the minimum wire size is 20 AWG.

MRO Electric and Supply Company carries new and refurbished Modicon 140-AVI-030-00‘s. For more product information or to request a quote on a part, please call 800-691-8511 or email sales@mroelectric.com.
Modicon 140AVI03000
Modicon 140AVI03000
140CPU65150

Modicon Quantum 140CPU65150 – Product Spotlight

The 140CPU65150 is a Unity processor in Schneider Electric’s Modicon Quantum series. It is one of the newer models in the series of processor modules. It joins together the standard functions of the PLC and the diagnostic possibilities of a web server. It communicates using an RJ-45 connection. The module is in a double-width standard Quantum housing which requires two sequential slots in a Quantum rack. Because its web server functions are diagnostic only, software must be used to configure its services.

It has a clock frequency of 166 Mhz and has two local racks. It has 63 distributed I/O stations, 1 rack, and 3 distributed networks. It has 8000 discrete inputs and outputs of discrete in a distributed network, and 31744 discrete inputs and inputs in a remote system.  As far as application specific I/O, it can be used for time stamping, as a counter, for high-speed interrupt inputs, and as a serial link.

There are 6 optional modules that can be used with the 140CPU65150. These include, Ethernet, Modbus, Modbus Plus, Profibus DP, and Sy/Max. In a local AS interface, the module has an unlimited maximum number of connections. It also has 4 integrated connection types – Ethernet TCP/IP, Modbus, Modbus Plus, and USB. It has an expandable 8 MB of file storage, 7168 kB or expandable programming, and 768 kB of RAM. The 140CPU65150 uses a key switch memory port for on/off functionality.

The 140CPU65150 has a data rate of 10/100 Mbps. For a medium, a user should used a shielded twisted pair cable. The module has a number of services, including standard web service, Modbus TCP messaging, I/O scanning services, global data, FDR client, SNMP management, and SMTP services (email). It is compatible only with the Unity Pro software.

MRO Electric and Supply carries the 140CPU65150. For more product information or to request a replacement module, email sales@mroelectric.com or call 800-691-8511.

140CPU65150
140CPU65150

Modicon 140CRA31200 RIO Drop E/IP Adapter – Product Spotlight

The 140CRA31200 is a Ethernet RIO drop adapter in the Modicon Quantum series. It has 3 ports and uses the Ethernet IP/Modbus TCP communication port protocol. It can handle two integrated connection types: the Ethernet IP/Modbus TCP through the service port or through the device network. It is compatible with the 140CRP31200.

The 140CRA31200 has a number of local signalling channels. 1 green LED for RUN, 1 green/red LED for module status, 1 green/red LED for network communication status, and 1 red LED for I/O. This adapter module consumes one slot in the main (first) rack of the in Quantum remote drops. The extended (second) rack in a Quantum remote I/O drop does not require an adapter.

To set the location of the Ethernet remote I/O drop on the network, use the rotary switches on the front of the 140CRA31200 before you apply power to the module and before you download the application. The values that are set are applied during a power cycle. If the switch settings are change after the module has powered up, the Mod Status LED is activated and a mismatch message is logged in the module’s diagnostic system.

Because new values on the rotary switches are implemented on at the next power cycle, it is recommended that you set the values before starting the module. Valid values are from 00 to 159. These rotary switches can be manipulated on the 140CRA31200 with a small flat tipped screwdriver, and no software is required to configure or enable the rotary switches. Do not use the Stored and Clear IP settings on the Ones rotary switch, and keep in mind that the functionality of these settings do not apply to remote I/O installations.

MRO Electric and Supply carries new and refurbished Modicon 140CRA31200s. For more product information or to request  quote, email sales@mroelectric.com or call 800-691-8511.

140cra31200
140cra31200

Modicon 140CPS11420 – Product Spotlight

The Schneider Electric / Modicon 140CPS11420 is a Power Supply Module in the Quantum automation platform. It can use a summable or standalone power supply type. The module has an internal output overvoltage and overload protection. It comes in a standard module format and weights 0.65 kg. When in a standalone configuration, the 140CPS11420 uses a maximum current of 11 amps. In a summable configuration, the module has a maximum current of 20 amps. Its internal power dissipation is less than 12 watts at a full load.

A normally closed relay contact rated at 220 volts AC, 6 amp / 30 volts DC, 5A is available on terminals 1 and 2 of the power terminal strip. This contact set may be used to signal input power Off. The relay will de-energize when input power drops below 70 volts AC, when the input voltage is set to 115 volts AC, or 140 volts AC when the input is set to 230 volts AC. Its output to the Bus is 5.1 volts DC. No minimum current is required. The module’s input frequency can range from 47 – 63 Hz. the 140CPS11420’s input voltage total harmonic distortion is less than 10% of the fundamental root mean square value. The input power interruption is no less than 1 second when in a 1/2 cycle at full load, and at the minimum rated line voltage and frequency.

Remove the power line prior to insertion or removal of the module.Use only compatible combinations of summable and standalone power supplies in the Quantum back plane as stated above. If these precautions are not taken, serious injury and/or equipment damage could occur.

MRO Electric and Supply Company stocks new and refurbished 140CPS11420 modules.  For more information or to request a quote, call 800-691-8511 or email sales@mroelectric.com.

140CPS11420
140CPS11420
HMI-STU-855

Modicon Magelis HMI-STU-855 (HMISTU855) Product Spotlight

The Schneider Electric / Modion HMI-STU-855 is a 5.7 inch touch panel screen with a Magelis operating system and CPU ARM9 processor. It uses a QVGA TFT color touchscreen with a pixel resolution of 320 x 240 pixels. It uses an external supply source of 24 volts and consumes 6.8 watts of power. It has 16 MB of application battery with 64 kB available to back up data. The HMISTU855 is able to download a number of protocols including Modbus, Modbus TCP/IP, Uni-TE, and 3rd party protocols.  When using the HMISTU855, all connections to the communication ports on the bottom and sides of the unit must not put large amounts of stress on the ports. Be sure to securely attach communication cables to the panel or cabinet. Use only RJ45 cables with a functioning locking tab.

Critical detected alarm indicators and systematic function require independent and redundant protection hardware or mechanical interlocks. It is important that when power is cycled, the user waits at least 10 seconds before restoring power. Switching the power on and off quickly can damage the unit. The interface is connected to remote equipment using a RS232C or RS-485 cable. The connector that is used is a RJ45-8 pin type. The using a long PLC cable to connect the unit, a difference of electric potential can be observed between the cable and the ground, even when connected to a ground. The serial port on the HMI-STU-855 is not isolated. The signal ground and frame ground terminals are connected inside the unit. When setting up the RS-485 communication, the cable diagram for some equipment may need polarization on the terminal side. This terminal does not need any special setting because it can handle polarization automatically.

MRO Electric and Supply Company stocks many Modicon Magelis HMIs and panels, including the HMI-STU-855. For for information or to request a quote, please email sales@mroelectric.com or call 800-691-8511.

HMI-STU-855
HMI-STU-855

TSX PLCs – Compact, Flexible, Cost-Effective

TSX PLCs
TSX Nano PLCs are easy to set up and have numerous built in functions, such as memory for storing programs, battery-backed RAM, and real-time clocks for modules with 16 and 24 I/O’s. They can be installed easily on a mounting rail or base plate in the vertical or horizontal position. TSX PLCs are programmed in lists of instructions using the FTX 117 programming terminal, in Ladder or Instruction list language using software on an FT 2000, FTX 517 terminal or PC compatible. They can be used to augment extendable TSX PLCs using a single extension per base. Depending on the model they have

16 I/O : 9 inputs + 7 outputs
24 I/O : 14 inputs +10 outputs.

The following types of inputs and outputs are used:

Inputs : 24 Volts
Outputs : Relay outputs for models with ~ 100… 240 Volt power supply, transistor outputs with positive logic for models with 24 Volt power supply.

I/O Extension

Each TSX Nano base PLC can be extended using an I/O extension. This extension is created by one of the PLCs with 10, 16, or 24 i/o. The function of each PLC is defined by the position of the coding selector switch:
Position 0 : base PLC
Position 1 : I/O extension

Peer PLCs

Up to 3 peer TSX PLCs, communicating via common words, can be connected to the base PLC. In this case, only the base PLC can receieve an I/O extension. The function of each PLC is defined by the position of the coding selector switch. I/O addressing of peer PLCs is identical to that of the base TSX PLC. The extension link cable between the base PLC and PLC extensions is shielded, twisted pair  and is no more than 200 meters long.  Each PLC has 2 reserved (IW) and 2 reserved (QW) words for exchanging data between PLCs. These exchange words are updated automatically. For each PLC, the user program is only able to write to the 2 %QW output words and read the 2 %IW input words.

MRO has many Modicon PLCs available. For more information, please email sales@mroelectric.com or call 1-800-691-8511.

Modicon TSX PLCs
Modicon TSX PLCs

Human Machine Interface (HMI) Retrofitting

At MRO Electric and Supply, we are experts at retrofitting older HMIs with a new interface that is clean, modernized, and still works with your system.

Take this older Fanuc HMI as an example. The old CRT display has begun to fade out, making its use inefficient and none user-friendly. Old CRT screens are also prone to overheating, and they take up a lot of much needed space.

Fanuc HMI
Fanuc HMI Pre-Retrofit

A new LCD retrofitted screen can give you more accessibility, brighter displays, and user-friendly colors. MRO Electric can quickly update your HMI at a fraction of the cost of replacing your whole HMI. You also don’t have to rewrite your programming, or waste time and resources replacing your whole system.

Fanuc HMI next to LCD Retrofit
Fanuc HMI next to its LCD Retrofit

Below is a fully retrofitted Fanuc HMI with an LCD monitor. This lighter, energy-efficient replacement adds years of life and service to existing legacy equipment, and eliminates potential future downtime. In addition, all of our HMI repairs come standard with a 12 month warranty.

Newly Retrofitted Fanuc HMI
Newly Retrofitted Fanuc HMI

Get in touch with us today to learn more about this cost effective solution for your HMIs. You can request a quote by calling 1-800-691-8511 or by emailing sales@mroelectric.com.

140CPU43412A Error Codes and Hot Standby

Our previous blog post on the 140CPU43412A describes the 140CPU43412A Configuration and Setup. 

140CPU43412A Hot Standby

You cannot create a Quantum Hot Standby configuration running one 140CPU53414A PLC with Unity firmware and one with NxT firmware. When using an NxT configuration in hot standby, both PLCs must have NxT firmware. When using a Unity Quantum hot standby configuration, only specific hot standby controllers can be used. The 140CPU43412A and 140CPU53414A PLCs are not supported in Unity Hot Standby configurations.

140CPU43412A Error Codes

The following are the error codes for the 140CPU43412A:

140CPU43412A Error Codes
140CPU43412A Error Codes
140CPU43412A Error Codes
140CPU43412A Error Codes
140CPU43412A Error Codes
140CPU43412A Error Codes

For ordering info or for a 140CPU43412A price quote you can call 1-800-691-8511 or email sales@mroelectric.com.

140CPU43412A Firmware Part II

Phase 1 of firmware restoration is described in our previous blog post on the 140CPU43412A firmware.

140CPU43412A Firmware Part II

Restoring a 140CPU43412U (Unity) to 140CPU43412A (Concept):

Phase 2

During the download:

• Do not power OFF the PLC

• Do not power OFF the PC

• Do not disconnect the cable

• Do not shut down OS loader

Any loss of communication during the update procedure can cause severe damage to the CPU or NOE module. Failure to follow these instructions can result in injury or equipment damage.

Reset the PLC

Once the download of the intermediate binary file has completed, the PLC has to be initialized. This task can be performed by one of the two following actions:  Reset the PLC by pushing on the Restart button located on the CPU (for more information, refer to the PLC technical documentation).  Power OFF then ON the PLC. Once the PLC has restarted, go to Phase 3: download the final Concept OS.

Phase 3

Presentation

The final binary file “q5rv135E.bin ” (140CPU34312 in our example) has to be downloaded. For that, follow the same procedure as the one described in the Phase 1.

Checking Version (optional)

If needed, you can check the new CPU version. For that  Open the OS loader tool.  Select the communication protocol.  Click on “Connect.” Then Click on “Properties.”

For ordering info or for a 140CPU43412A price quote you can call 1-800-691-8511 or email sales@mroelectric.com.

140CPU43412A
140CPU43412A FIrmware