AutoMate - Programmable Logic Controllers
Contents
1. 2 Channel Out 610350 610346 610366 0 10 VDC 610351 610345 610365 4 20 mA The Analog Rail can plug into the 1 0 port of an A20 A30 A40 LIOP 45C200B and Re mote Head 45C37 45638 or 570330 When plugged into a processor direct port a lo cal head can also be used where the analog value is multiplexed through one 1 0 register 4 Channel 4 Channel Analog Analog Input Output Range Thumbwheel Switch Interface 45C630 The TWS Interface Module is configured as a rail in the AutoMate 15E 20 20E 30 and 40 processor or can be treated as numerical 1 0 when used with the AutoMate 30 or 40 processor The data read from the TWS is binary coded decimal and displayed in 4 data input digits aa zip ele cr ELECTRIC E LED Interface Module 456631 Reliance Electric s Model 45C631 LED Interface displays numerical data from the AutoMate family of programmable controllers except AutoMate 15 These devices convert BCD information from the AutoMate programmable controller into a seven segment digital display Digits on the LED Display are 0 43 inches high and are covered with a transparent red lens Features e 7 Segment LED Display Easy to read 0 43 inch high characters Decimal point is switch selectable Easy to mount no wiring Local Head 61022 The Local 1 0 heads used with the AutoMate 20 20E 1 0 system are built around a custom LSI chip to insure reliability and increase speed They are communicatio2. 456601 5 CHANNEL COUNTER 1 456610 64K DATA MEMORY 1 450630 TWS INPUT MODULE 1 456631 LED OUTPUT MODULE 1 45C70 COAX BNC TEE CONECTOR 2 PER PACKAGE 1 45C71 COAX BNC 75 OHM TERMINATING LOAD 2 PER PACKAGE 1 45C72 COAX BNC MALE CONNECTOR 5 PER PACKAGE 1 45C8 LOCAL HEAD INTERCONNECT CABLE 1 45694 MINI PROGRAMMER 1 45095 MONITOR LOADER PANEL 1 45697 AUTORAIL INTERFACE 1 45098 ENHANCED MEMORY MODULE 1 45699 TOLEDO SCALE EMM 1 61622 LOCAL HEAD 115 1 61023 LOCAL HEAD VDC 1 616326 1 0 SAVER RAIL 1 0 PLC INTERFACE 1 610345 4 20 MADC ANALOG RAIL 4 INPUT CHANNELS 1 610346 0 10 VDC ANALOG RAIL 4 INPUT CHANNELS 1 610350 0 10 VDC ANALOG RAIL 2 IN 2 OUT CHANNELS 1 61 351 4 20 ANALOG RAIL 2 IN 2 OUT CHANNELS 1 610365 4 20 MADC ANALOG RAIL 4 OUTPUT CHANNELS 1 61 366 0 10 VDC ANALOG RAIL 4 OUTPUT CHANNELS 1 610540 4 20 ANALOG INPUT MODULE 16 CHANNEL REQUIRES 6106549 OR 61 550 1 610542 10 VDC ANALOG INPUT MODULE 16 CHANNEL REQUIRES 616547 OR 610548 1 610544 RTD ANALOG INPUT MODULE 16 CHANNEL REQUIRES 2 EACH 610545 OR 61C546 1 610545 RTD CONNECTOR TERMINAL 8 CHANNEL PANEL MOUNTED WITH 60 CABLE 1 610546 RTD CONNECTOR TERMINAL 8 CHANNEL DIN RAIL MOUNTED WITH 60 CABLE 1 610547 10 VDC CONNECTOR TERMINAL 16 CHANNEL PANEL MOUNTED WITH 60 CABLE 1 610548 10 VDC CONNECTOR TERMINAL 16 CHANNEL DIN RAIL MOUNTED W 60 CABLE 1 610549 4 20 MADC CONNECTOR TER
3. and saving money Up to 12 remote subsystems can be connected to an AutoMate 30 controller and up to four groups of 32 remote subsystems with a maximum of 80 total digital 1 0 drops be connected to an AutoMate 40 controller in a master slave multi drop configuration Communication takes place at 800K baud standard coaxial cable The maximum distance up to 6000 ft allowed is determined by the type of cable used Remote 1 0 Processor 456201 The Remote 1 0 Processor provides the means for communicating to remotely mounted 1 0 When placed in the AutoMate card rack the Remote 1 0 Processor serves as the master in the remote 1 0 communication scheme The card receives data from devices on MultiBus transmits it to the proper remote subsystems receives the response data and makes that data available to devices on module All communications protocol and error checking are handled by the card so that the AutoMate 30 40 processor is not burdened with remote 1 0 update zip ele cr ELECTRIC E The Remote 1 0 Processor can also serve as a slave when placed in a rack that does not contain an Automate 30 40 processor This rack then serves as a remote 1 0 subsystem The various numerical 1 0 cards previously described can be placed in the remote rack to achieve remote numerical 1 0 A local 1 0 Processor can be used along with rails and modules for remote digital 1 0 In this mode the card receives data from the master updates the
4. non volatile random access memory is a truly non volatile read write memory It serves two purposes in the AutoMate memory system First it saves the status of the retentive variables both 1 0 points and registers so the contents of these variables are not lost Second it is used to temporarily save program changes during transfer from R W to EEPROM When a change is made in the R W the change is also stored in the NVRAM The contents of the R W are then transferred to the EEPROM Due to the slow write times of EEPROM the process takes some time and it is possible for a power failure to occur during the transfers If this were to happen the program would be lost With the incremental change stored in NVRAM however the program can be reconstructed on power up regardless of when power failed thus providing a totally non volatile read write memory The processor unit is the main component of the AutoMate 15 system It integrates the power supply the CPU with memory and the R NET communication interface on those processors with R NET capability The processor unit is available in four versions 120 240 VAC power supply 24VDC 120 240 VAC with R NET and 24VDC with R NET The Power supply provides all voltages necessary to power the other sections of the processor unit the 1 0 modules and the Mini Programmer when connected The processor contains the Intel 801 microprocessor that executes the user program and communicates with t
5. the system shut down Maximum flexibility in system configuration is accommodated via the The diagnostics included in the AutoMate 30 and 40 controllers are availability of seven card rack sizes as shown below listed below Model Number Description 456310 6 Card Slots Memory Checks 456311 8 Card Slots 456312 10 Card Slots On Line Parity 450313 13 Card Slots Panel Mounted ae rou e Roue 450314 13 Card Slots Rack Mounted On Line Background Pattern Test 45C315 16 Card Slots Power Up Checksums 45C316 19 Card Slots Power Up Diagnostic These racks will accept N minus 2 cards if a 2 slot power supply is Off Line User Initiated Diagnostics used or N minus 3 cards if a 3 slot power supply is used These racks will accept N minus 3 cards if a 2 or 3 slot power supply is used Bus Checks aa N Total number of available card rack slots On Line Checkerboard Patterns Test all Bus Lines Processor Checks Watchdog Timer On Line Logic Check Program Communications Checks 6 Bit CRC Checksums on R NET and Remote 1 0 Parity on Local 1 0 The unique bus checking technique detects and traps any address or data bus line failures data incorrectly written to more than one card improper addressing or most other difficult to detect bus failures AutoMate System Components The AutoMate 30 40 system consists of the following basic components Card Rack Power Supply Processo
6. inputs are multiplexed to an instrumentation amplifier which drives a fourteen bit A D converter This configuration measures the voltage drop across the selected RTD element The RTD may be used in either local or remote racks No external power supply is required for the RTDs The Card Features 16 Channels of 100 Ohm platinum RTD input Converts to degrees Fahrenheit or Celsius 2 3 4 wire RTDs Broken wire detection Automatic calibration Local or remote racks No external power supply required Running average 1 60 samples 4 alarm setpoints per channel 12 bit resolution plus sign DESEE ELECTRIC E Analog Thermocouple Input Module 610613 The analog input module features 16 individually isolated analog inputs capable of multiplexing signals from any combination of thermocouples and low or high level voltages It must be used in conjunction with the 610614 Thermocouple Voltage Termination Panel The module provides automatic linearization and cold junction compensation for type B E J K R and T thermocouples Thermocouples may be read in either degrees Centigrade or Fahrenheit Thermocouple inputs can be read as often as once every 110 msec Thermocouple inputs require the use of the 610614 Thermocouple Voltage Termination Panel Each analog input channel has 200 volt channel to channel isolation and 1000 volt isolation to logic common Each channel may be independently configured to accept voltage ranges from 1
7. output cards in the rack and send the data from the input cards back to the master Remote 1 0 Interface 45037 The Remote 1 0 Interface or remote 1 0 head is used in conjunction with 1 0 rails and digital 1 0 modules to create a digital 1 0 subsystem A maximum of four 1 0 rails can be connected to a remote head for up to 64 digital 1 0 or a maximum of four local heads can be connected if up to 256 digital 1 0 are required The remote head receives data from the remote 1 0 processor in the master rack updates the modules in the 1 0 rails and then transmits the data back to the master The remote head also includes a power supply capable of supplying power to four full ports of digital 1 0 modules Two versions of the head are available based on the input power supplied 45C37 for 120 240 VAC operation 45038 for 24 VDC operation gt E a AutoMate Programmable Logic Controllers 7 Model Number Description List Price E 4561 0 RAIL 1 9 456124 R NET PC LINK 1 456130 AUTOMATE PROGRAMMING EXECUTIVE VERSION 4 0 1 456134 AUTOMATE PROGRAMMING SYSTEM APS 1 456140 AUTOMATE PROGRAMMING EXECUTIVE VERSION 4 0 UPGRADE 1 45615 AUTOMATE 15 120 240 VAC 1 45C16 AUTOMATE 24 48 VDC 1 450166 DUAL CONTACT OUTPUT MODULE 0 1 45C17 AUTOMATE 15 WITH R NET 120 240 VAC 1 450175 8 TERMINAL CONNECTOR 1 45C176 20 TERMINAL CONNECTOR 1 4502 1 0 RAIL MOTHERBOARD 1 45620
8. the system to be closely tailored to the actual requirements 2 Mounting Flexibility The 1 0 rails and processor may be mounted in a vertical column to fully emulate a terminal strip or they may be mounted side by side or in other arrangements to suit the available space 3 Standard Screw Terminals The terminal strip uses standard self lifting pressure plate wire terminals that allow two 12 gauge stranded wires to be fastened to each terminal 4 Two Screw Terminals Per Channel Each 1 0 channel or point is provided with two screw terminals thus allowing separate electrical commons If the application requires the commons to be tied together an optional jumper strip is available DESEE ELECTRIC E Digital 1 0 Modules The design and construction of the AutoMate 1 0 Modules is a direct response to PLC users who have found that many currently available 1 0 systems and components do not stand up to industrial service Industrial applications hold many hazards for electronic devices such as high temperatures high humidity high current loading output circuits electrical noise and vibration Outputs Rated 2 Amps 60 C Voltage levels include M N Description 45C60 115 VAC 45C62 230 VAC 45C63 24 VDC 45C65 24 VAC 45C66 Hi Pwr Contact 0 45C166 Hi Pwr Contact N C 45C67 24 VAC 45C68 250 VDC 0 5 amps 45C69 Low Power Contact Each output circuit is electrically isolated and each outp
9. up to its maximum 1 0 capacity of 64 channels The AutoMate 15E controller adds the capability of interfacing to analog signals as well as handling four function math to the AutoMate 15 controller It can handle up to 64 digital or 16 analog 1 0 or some combination The AutoMate 20 controller through the use of Local 1 0 Heads expanded memory can address up to 256 digital or 64 analog 1 0 or some combination It offers four function math logic data conversion table handling flow of control instructions and drum controller functions as well as relay replacement The AutoMate 20E controller has the memory and capability to perform PID control a feature that previously was only available within the framework of large PLCs It is ideally suited for distributed process control applications which require analog signal interface sequence control and the communication ability provided by the R Net industrial network AutoMate 15 64 Digital 1 0 64 Internal Coils 56 Registers 1K x 16 Non volatile Memory no battery required 4 milliseconds K Ladder Element Execution Speed Host Computer Interface Capability Ladder Diagram Language Programmed via an IBM compatible personal computer or hand held Mini Programmer User friendly Programming Tools include Off and On line Programming Extensive Diagnostics Rugged Industrial Packaging Communications via the R NET Industrial Network available DESEE ELECTRIC E Au
10. 2 5 mVolts through 10 0 Volts Sixteen input channels Thermocouple low level analog or combination Automatic linearization and cold junction compensation Offset and span compensation for each channel 12 bit or 14 bit resolution software selectable Dual slope integrating A D converter 200 Volt channel to channel isolation Thermocouple Analog Termination Panel 610614 The 616614 Termination Panel contains the cold junction compensation circuits used for thermocouple readings into the 610613 Analog input module The panel offers a convenient terminal strip for direct thermocouple terminations as well as for analog signals The 19 panel includes two 6 foot ribbon cables for connection to the analog input card 64K Data Memory 456610 The 456610 memory card allows the user storage of data register information The card also features a real time clock and status indicators 5 Channel Counter 456601 The 456601 is a five channel high speed counter with up to 100 KHz frequency input Applications include event counting frequency counting and period measurement A debounce circuit is provided on the inputs for contact closure inputs Each channel is optically isolated AutoMate Programmable Logic Controllers Remote 1 0 The AutoMate 30 40 system includes the capability of remotely mounting digital or numerical 1 0 This allows the 1 0 to be mounted wherever needed on the machine or process thus eliminating wiring
11. 41 8 CHANNEL ANALOG INPUT 0 5 VDC 1 450342 8 CHANNEL ANALOG INPUT 0 10 VDC 1 450344 8 CHANNEL ANALOG INPUT 10 VDC 1 45035 AUTOBUS INTERFACE HEAD 120 240 VAC 1 450360 4 20 MA ANALOG OUTPUT 8 CHANNEL 1 456361 0 5 VDC ANALOG OUTPUT 8 CHANNEL 1 450362 0 10 VDC ANALOG OUTPUT 8 CHANNEL 1 450363 5 VDC ANALOG OUTPUT 8 CHANNEL 1 1 Refer to Numeric Section 1 for Pricing iom RELIANCE m Lee ELECTHICN AutoMate Programmable Logic Controllers Model Number Description List Price 450364 10 VDC ANALOG OUTPUT 8 CHANNEL 1 e 45637 REMOTE 1 0 HEAD 120 240 VAC 1 450380 REGISTER INPUT CARD 16 BIT 1 456381 REGISTER OUTPUT CARD 16 BIT 1 45C4 1 0 RAIL CABLING CHANNEL KIT 1 45C40 DUAL 115 VAC DC INPUT MODULE 1 45642 DUAL ELECTRONIC INPUT MODULE 1 45C43 DUAL 230 VAC DC INPUT MODULE 1 45C44 DUAL 24 VAC DC INPUT MODULE 1 45 46 VOLTAGE COMPARATOR INPUT MODULE 1 450400 LOGIC PROCESSOR 1 450409 40 CONTROL PROCESSOR 1 456410 A40 CONTROL PROCESSOR 1 45C411 ENHANCED CONTROL PROCESSOR 1 45C5 1 0 RAIL INTERCONNECT CABLE 1 45C60 DUAL 115 VAC 2A OUTPUT MODULE 1 45C62 DUAL 230 VAC 2A OUTPUT MODULE 1 45C63 DUAL 24 VDC 2A OUTPUT MODULE 1 45C65 DUAL 115 VDC 2A OUTPUT MODULE 1 45C66 DUAL CONTACT OUTPUT MODULE N O 1 45C67 DUAL 24 VAC 2A OUTPUT MODULE 1 45C68 DUAL 250 VAD 0 5A OUTPUT MODULE 1 45C69 DUAL DRY CONTACT OUTPUT MODULE N O 1
12. 56272 32K Memory Expansion 456273 48K Memory Expansion One or two memory expansion cards of any mix can be used per AutoMate 40 Processor set to increase non volatile application memory to a maximum of 104K x 16 32K x 16 max with the 40X Local Rail 1 0 System The AutoMate digital and analog rail 1 0 can be locally mounted at the processor rack or remotely mounted where needed on the machine or process The AutoMate 30 40 controller utilize the field proven rail 1 0 hardware introduced with an AutoMate 15 controller and include the features that have made this 1 0 system the standard in the industry for cost effective industrially rugged highly reliable performance Local 1 0 Processor 45C200 The local 1 0 Processor also utilizing a custom LSI chip allows up to 256 additional digital 1 0 to be connected to AutoMate 30 40 master rack or remote 1 0 rack The Local 1 0 Processor can communicate directly to four 1 0 rails for up to 64 digital or 16 analog 1 0 or to a maximum of four Local Heads for up to 256 digital 1 0 or to any mix of 1 0 rails and Local Heads Communication takes place at 250K baud and data integrity is insured using parity The Local 1 0 Processor handles all the communications protocol and error checking then makes the data available on MultiBus Therefore these tasks are unloaded from the AutoMate 30 40 Processor another example of multiprocessing AutoMate Programmable Logic Controllers An
13. AUTOMATE 20 120 240 VAC 1 456200 LOCAL 1 0 PROCESSR 1 456201 1 0 PROCESSOR 1 456202 R NET PROCESSOR 1 456203 SERIAL COMMUNICATIONS PROCESSOR 1 450204 REDUNDANCY PROCESSOR 1 450207 TOLEDO SCALE COMMUNICATION CARD 1 456220 AUTOMATE 20 WITH R NET 120 240 VAC 1 456224 AUTOMATE 20E 120 240 VAC 1 456225 AUTOMATE 20E WITH R NET 120 240 VAC 1 456233 AUTOMATE 15E WITH R NET 24 48 VDC 1 45627 R NET GATEWAY INTERFACE 120 240 VAC 1 45C270 8K MEMORY EXPANSION 1 45C271 16K MEMORY EXPANSION 1 456272 32K MEMORY EXPANSION 1 45C273 48K MEMORY EXPANSION 1 45029 PROCESS CONTROL GATEWAY HEAD 120 240 VAC 1 45C3 1 0 RAIL JUMPER BAR KIT 1 456301 STANDARD PROCESSOR 4K MEMORY 1 450305 ENHANCED PROCESSOR 4K MEMORY 1 456307 ENHANCED PROCESSOR 8K MEMORY 1 456310 6 SLOT AUTOMATE RACK 1 45C311 8 SLOT AUTOMATE RACK 1 456312 10 SLOT AUTOMATE RACK 1 456313 13 SLOT AUTOMATE RACK 1 456314 13 SLOT AUTOMATE RACK CABINET MOUNT 1 450315 16 SLOT AUTOMATE 1 450316 19 SLOT AUTOMATE RACK 1 450321 20 AMP AUTOMATE POWER SUPPLY 1 450322 50 AMP AUTOMATE POWER SUPPLY 1 45033 DCS REMOTE HEAD 1 450330 FAN KIT 6 SLOT RACK 1 456331 FAN KIT 8 SLOT RACK 1 450332 FAN KIT 10 SLOT RACK 1 450333 FAN KIT 13 SLOT RACK 1 450334 FAN KIT 13 SLOT RACK CABINET MOUNT 1 450335 FAN 16 SLOT RACK 1 450336 FAN KIT 19 SLOT RACK 1 450340 8 CHANNEL ANALOG INPUT 4 20 MA 1 4563
14. AutoMate Programmable Logic Controllers The AutoMate Family The AutoMate family is a complete line of programmable logic controllers PLCs capable of a wide range of control applications Each individual AutoMate processor supports certain common features which are used throughout the entire product line The AutoMate processors are identified by model numbers ranging from 15 to 40 with the AutoMate 40 series being the most capable machine All of the lower model processors share a subset of a common software language found in the AutoMate 40E The E designation is used to denote an enhanced version of the basic model Each processor in the AutoMate family comes as a base or as an enhanced version A Common 1 0 Structure All AutoMates share a common 1 0 structure The structure is unique in that all digital 1 0 modules contain two 1 0 points for greater flexibility lower cost and robust features Up to eight cards or 16 electronically isolated points can be mounted on a rail which allows for wire terminations and a heatsink for head dissipation The rail 1 0 structure is unique in the PLC industry and offers the greatest number of features found in any system available today A Common Instruction Set A common software language is used in all of the AutoMate controllers The AutoMate Programming System software is used to program any AutoMate controller Each controller model utilizes a subset of the instructions found in
15. INDICATORS AC POWER ON Incoming power is supplied to the power supply within specified ranges POWER SUPPLY READY The power supply is producing all required voltages within specified ranges SYSTEM READY No faults have been detected on any card within the system Works in conjunction with Ready Relay THREE POSITION KEYSWITCH RUN The program or status cannot be modified PROGRAM The program and status can be changed Variable data can be modified SETUP The program or status cannot be changed Variable data can be modified TERMINAL STRIP Ready Relay Contacts N O and Drop out whenever a system error is detected 120 240 Selection Jumper L1 L2 120 240 VAC Input Power Fuse Type AGC RELIANCE tote AutoMate Programmable Logic Controllers AutoMate 30 Processor Card STATUS INDICATORS The processor card is the key to the power speed and flexibility of RUN Application program is being executed 9 the AutoMate 30 controller When it is plugged into a rack with power FORCING Status of an input or coil is being overridden by the 8 supply and 1 0 a stand alone controller is created forcing function READY Processor is working properly within the limits of internal Three processor card variations are available allowing the user to select diagnostics the power and features required for the specific application RAIL FAULT Comm
16. MINAL 16 CHANNEL PANEL MOUNT WITH 60 CABLE 1 610550 4 20 MADC CONNECTOR TERMINAL 16 CHANNEL DIN RAIL MOUNT W 60 CABLE 1 616605 THERMOCOUPLE INPUT MODULE 8 CHANNEL 1 610613 16 CHANNEL LOW LEVEL ANALOG INPUT MODULE REQUIRES 610614 1 61C614 THERMOCOUPLE LOW LEVEL VOLTAGE TERMINATION PANEL 16 CHANNEL 1 1 Refer to Numeric Section 1 for Pricing RELIANCE ELECTHICES
17. ail for updating the outputs and then read back for updating the inputs Two error detection bits are added to the normal 1 0 data and these bits are used to determine if communications is taking place properly If a fault is detected the RAIL FAULT LED on the face of the processor is illuminated and the fail fault coil is energized Also the function of the COM DATA LED and the FORCING LED change to indicate on which rail the fault was detected The rail fault coil can be used to take whatever action is desired such as using it in conjunction with the programmable fault coil to drop out the READY contacts zip ele cr ELECTRIC E Non volatile R W memory without battery backup The AutoMate 15 and the AutoMate 20 processors combine three memory technologies to provide true non volatile memory without batteries and their inherent problems The AutoMate family memory system uses a CMOS read write R W memory to store application programs The program is executed and any changes are made from the R W As changes occur program execution is affected immediately The EEPROM stores a copy of the R W application program Each time a change is made to the R W the same change is also made in the EEPROM If there is a power failure the program is lost in the R W but is still available in EEPROM On power up the contents of EEPROM are transferred to the R W and the program is run The EEPROM serves as an off line backup memory NVRAM
18. alog Input Modules Current 61540 Voltage 61542 Analog inputs are wired to a separate termination panel DIN rail or flat panel mounted The termination panel communicates over a five foot cable to the Multibus input module Cables are supplied with termination panels All 16 channels of analog input can be accommodated on a single termination panel These modules can be mounted in either local or remote racks An external power supply is required to supply the 4 20 mA transmitters on the current input card The cards feature 16 channels of either voltage or current input Broken wire detection Running average 1 60 samples Square root extraction Scale or unscaled 4 alarm set points per channel low low low high high high 13 bit resolution plus sign Automatic calibration and can be used in local or remote racks Analog Output Cards Analog cards are available to interface to a wide variety of signals 456360 4 20 mA 456361 0 to 5 VDC 456362 0 to 10 VDC 450363 5 VDC 450364 10 VDC All cards feature Eight Channels Electrical Isolation Analog to Logic 12 Bit resolution On board Power Supply Analog power can be supplied internally or externally 20 Terminal Removable Connector Internal Span amp Zero Adjustment for each Channel Protective Housings Register input output cards The register input and output cards available for interfacing to LED outputs thumbwheel switch inpu
19. anded to a maximum of 104K x 16 non volatile application memory with the addition of up to two memory expansion cards All of the AutoMate 40 Processor sets have identical software programming features These features include all software functions of the Enhanced AutoMate 30 controller plus additional instruction blocks for improved ASCII communications and string handling capabilities The AutoMate 40 controller is capable of interrupt servicing This permits the processors to leave the main application program scan to respond to real time inputs Logic Processor The 45C400 Logic Processor uses dedicated logic to solve ladder functions at extremely high speed This processor has 4 1 0 ports to communicate directly to four rails for up to 64 digital or 16 analog 1 0 or to four local heads for up to 256 digital or 64 analog 1 0 or to any mix of 1 0 rails and local heads Communications take place at 250K baud and data integrity is insured using parity LED s are used for status indication Control Processors The 450409 456410 and the 456411 Control Processors all use the Motorola 68000 microprocessors to perform the advanced software functions such as mathematics data conversion program flow control ASCII communications and more All Control Processors have an RS 232 communications port and LED status lights ELECTRIC E Model Number 456270 8 456271 16K Memory Expansion 4
20. d Binary patter of FORCE and COM DATA LED s indicates which of the four rails is involved COMMUNICATIONS PORT For programmer connection USER REPLACEABLE FUSE 1 0 RAIL CONNECTIONS INPUT POWER CONNECTIONS 120 VAC 50 60 Hz 240 VAG 50 60 Hz 24 VDC available on some models To READY CONTACT Opens if internal diagnostic test fails Can be used for emergency shutdown RELIANCE m ELECTRICE AutoMate Programmable Logic Controllers Processor Unit Executive Software The AutoMate 15 20 processor contain an executive software program which is a subset of the Enhanced Ladder Diagram language used in the larger AutoMate 30 and AutoMate 40 processor As you progress up the AutoMate line of PLCs from the AutoMate 15 through the AutoMate 40E each model adds additional software features This makes it easy to select the AutoMate controller which is ideally suited to your application Because all AutoMates use subsets of the same programming language it is very easy for the programmer to move between AutoMate models Once the Enhanced Ladder Diagram Language is learned you know how to program the full AutoMate family All AutoMates share a common ReSource Programming Executive software package which runs on an IBM compatible personal computer Details of this programming system are contained in section IV of this product summary Table of Software Functions Master Control R
21. drop configuration The R NET network connects devices up to 6000 feet apart easily accommodating typical industrial control applications Utilizing a token passing scheme each network node controls the network node controls the network in turn and transmits for a certain maximum time When the transaction is complete the token is passed to the next node in sequence specified by card front switches zip ele cr ELECTRIC E Because of the deterministic nature of the token passing scheme and a data rate of 800K baud the R NET network has the speed that is required to handle real time control applications An IBM compatible personal computer can be connected anywhere along the network to program monitor any AutoMate PLC on the R NET network using the R NET link card Interfacing the AutoMate 30 40 to the R NET network is as simple as plugging an R NET network processor 456202 card into the rack and connecting the network cable to it The R NET processor handles all network communications thus freeing the AutoMate processor to perform other tasks Data transfer between the processors occurs directly over Multibus module not serially The R NET system is therefore superior to networks utilizing programming ports for serial communication between PLCs and network processors Interfacing other devices minicomputers color graphics terminals etc to R NET is accomplished using available Reliance gateways The R NET gateway inter
22. e as few as 20 relays or as many as 40 analog PID loop controllers The AutoMate 40 provides additional 1 0 memory and processing power for even the most demanding situations Typical AutoMate PC applications include material handling machine tools and robotics automated packaging and assembly machines wood and paper processing injection molding welding machines and chemical petrochemical processing Flexibility for tomorrow With the Automate 30 and AutoMate 40 controllers you don t have to worry about running out of capacity to handle your control needs The AutoMate 30 and 40 are members of the AutoMate Family of controllers all of which share a common architecture and which are built from a common set of control building blocks And all of which communicate together over the R NET Industrial Network So if your control needs grow so can your AutoMate PLC You can plug in more processors to utilize multi processing You can network several AutoMate PLCs together to utilize distributed control Or you can simply replace an AutoMate 30 processor with the larger AutoMate 40 processor Ease of expansion and control flexibility without fear of obsolescence ELECTRIC E State of the art technology delivers state of the art performance The AutoMate 30 and AutoMate 40 controllers incorporate state of the art technology to achieve a price performance ratio and a standard of reliability far better than those of a
23. elay Coils X N C and 0 Contacts X Internal Coils X Timer Coils X Counter Coils X Shift Register Coils X Retentive Memory Coils X System Coils X Global Coils X X Transitional Contacts 4 Function Math Logical Functions Data Tables Data conversion Flow of Control Drum Controllers Network Functions Analog In Out PID Scaling Functions Square Root Timed Loops gt lt gt lt gt lt lt X X lt lt gt lt gt lt gt lt gt lt lt lt gt lt gt lt gt lt lt lt lt lt lt lt X lt 0X lt 0X 0X 0X lt lt Programming Software Model Number Description APX 4 0 Programming Executive APS Programming Executive APX 4 0 Programming Executive Upgrade 456130 456134 450140 zip ele cr ELECTRIC E Rail Input Output System The 1 0 system of the AutoMate 15 15E 20 and 20E controller has been designed to withstand typical conditions within the industrial environment meet specific application requirements and provide maximum industrial control flexibility AutoMate programmable controllers can be matched with a Digital Rail 1 0 system or the new Analog Rail 1 0 not available with the AutoMate 15 controller which is ideally suited for process and sequence control applications For situations that require a cost effective method of displaying and entering data a number of optional special pur
24. face head 45C27 is a stand alone communications processor that connects to foreign devices via RS 232 RS 422 or 20mA current loop Messages to or from the foreign device are buffered and translated to R NET protocol by the gateway The Process Control Gateway 45629 is a communication processor that uses MODBUS protocol and provides a standard RS 232 interface The R NET PC Link card 45C124 plugs into any IBM AT compatible computer and allows many operator interface or programming terminal functions to be executed at network speed without RS232 bottlenecks The AutoMate Cable Redundancy Module 45C31 allows either the R NET network or Remote 1 0 coax cables to be split into two separate paths to allow for possible cable breakage with no loss of communication gt J E 2 n a lt AutoMate Programmable Logic Controllers The AutoMate 30 A mid size programmable controller with the power flexibility technology and architecture of much larger and more expensive controllers The AutoMate 40 AutoMate 40 is the large programmable controller with extra power to handle any control needs Power for Today The AutoMate 30 controller is designed for use in applications ranging from simple relay replacement to complex control functions including closed loop control ASCII message handling and sophisticated data manipulation The AutoMate 30 controller can be used to replac
25. from a common set of control building blocks The Rail mounted digital 1 0 hardware used for the AutoMate 15 and AutoMate 20 is the same digital 1 0 used by the larger AutoMate 30 and AutoMate 40 controllers All Reliance Electric AutoMate PLCs have the capability to communicate over the R NET Industrial Network So if your control needs to grow so can your AutoMate PLC System You can network several AutoMate 15 or AutoMate 20 PLCs together to implement distributed control Or you can upgrade to a larger AutoMate controller without disturbing the field wiring and digital 1 0 already in place You get ease of expansion and control flexibility without fear of obsolescence Built in diagnostics The AutoMate 15 and AutoMate 20 controllers include built in diagnostics and LED indicators to signal controller status A CPU diagnostic is made up of a scan loss detector circuit and the software that drives it The CPU must service the scan loss detector every 100 milliseconds or the detector will time out the CPU READY relay will drop out and its contacts will open and the CPU READY LED on the face of the processor will be extinguished The normally open CPU READY contacts can also be programmed by the user to indicate other abnormal conditions The AutoMate 15 and AutoMate 20 Controllers also include an on line diagnostic that checks communication between the AutoMate processor and the 1 0 Rails During each 1 0 update data is sent to the r
26. he 1 0 system and programming devices The processor also contains the application memory and the AutoMate 15 executive The executive program is stored in memory and the user program is stored in the non volatile application memory described in the Introduction Section gt Ef E 2 AutoMate Programmable Logic Controllers WE Communication with the programming devices or host computer is The optional R NET industrial network communication interface with facilitated via an optically isolated serial RS 232 communications standard coaxial connector allows the AutoMate PLC to communicate channel This port defaults to 9600 but can be set to 1200 baud from with other AutoMate controllers and other micro processor based software AutoMate 15E 20 20E only for remote communications devices R NET is available as an option on all models of AutoMate applications A standard DB25 connector is provided on the face of the processor unit for this purpose R NET Connector optional STATUS INDICATORS RUN Application program is being executed POWEER Logic voltages are within the specified range CPU READY Processor is working properly within limits of internal error detector COM DATA Data is being sent or received FORCING Status of an input or coil is being overridden by forcing function RAIL FAULT Communication between the processor and rail has been disrupte
27. llers can send or receive ASCII messages under control of the user s application program The Card features 3 Serial Communication Channels RS 232 or 20mA Signals Software Selectable Communication Parameters Baud Rate Parity Etc DB25 Connectors On Board Power Supply Electrical Isolation Signals to Logic e D a lt AutoMate Programmable Logic Controllers Toledo Scale Communications 456207 The Toledo Scale Communications module is a microprocessor controlled 3 channel serial communications device that allows the AutoMate 30 or 40 Programmable Controllers to access weight data from a Toledo Scale digital indicator The 45C207 is compatible with the following Toledo Scale digital indicators Model 8132 Model 8140 Model 8142 Model 8530 In addition to being used for Toledo Scale communications the module can be used as a general purpose serial interface as well Thermocouple Input Card 610605 The Thermocouple Input Card is an 8 channel analog A D board for measuring temperatures The board provides isolation linearization and cold junction compensation to up to 8 analog input signals The features of the board include programmable registers for A D converter jumper selectable cold junction compensation circuit and self test capability with error messages Input Signal Thermocouple Type J K T S B E R RTD Input Module 610544 The sixteen pairs of measurement
28. ng into an AutoMate PLC A separate power supply Model 45693 is required when operating the Enhanced Memory Module with the computer AutoMate Programmable Logic Controllers AutoMate Programming Peripherals Model Number Description Enhanced Memory Module Mini Programmer Power Supply Mini Programmer 45098 45C93 45094 For use with AutoMate 15 20 and 30 only The 45C94 Mini Programmer is supplied with one 45C101 Programmer Interconnect Cable The Mini Programmer cannot be used to program the Enhanced AutoMate 30 45C305A or 45 307 or the AutoMate 40 but does not permit point and register monitoring loading and supervisory functions RUN STOP etc The 45693 Power Supply is required only when using the Mini Programmer or AutoMate Programming Executive and Enhanced Memory Module together as an off line program ming system R NET Industrial Network As programmable controllers have become more cost effective and more powerful a strong need has arisen for a simple cost effective means of communication between programmable controllers R NET Reliance Electric s Industrial Network meets this need The R NET network provides a real time communications scheme for distributed control and centralized data gathering applications The R NET network allows 32 AutoMate PLCs and or other special purpose devices to communicate with each other The R NET system is a baseband coaxial cable arranged in a multi
29. ns multiplexers that allow four 1 0 to communicate to 1 0 communication ports on the AutoMate 20 20E processor unit Local Head also includes a power supply capable of supplying capable of supplying power to four full rails 64 points of digital 1 0 modules Communication takes place between the processor and Local Heads at 250K baud over the 10 foor cable supplied Parity is used to insure data integrity LED STATUS INDICATORS POWER Incoming power is supplied to the power supply within specified ranges COM Communication is taking place between the processor and local head RAIL FAULT 0 Communication between the local head and Rail 0 has been disrupted RAIL FAULT 1 2 3 INPUT COMMUNICATIONS PORT Communicates to processor 1 0 COMMUNICATIONS PORTS Communicate to up to four 1 0 rails gt J E 2 e a lt AutoMate Programmable Logic Controllers AutoMate 20 20E Remotely Mounted 1 0 In some applications it is necessary or desirable to mount the AutoMate Processor Unit at some distance from the field devices it controls With the AutoMate 20 20E it is possible to mount the digital 1 0 rails close to the field devices to minimize field wiring yet be able to communicate with the processor unit mounted up to 1000 feet away This is facilitated through the use of the AutoBus Interface Head and the AutoRail Interface The AutoBus Interface Head is used in place of a L
30. ny PLC available in today s market Our unique multiprocessing architecture based on the Intel Multibus standard provides power and flexibility never before achieved in a programmable controller Four custom LSI integrated circuits have been designed specifically for use in the AutoMate PLC to increase performance and reliability The Motorola 68000 family of microprocessors has been used in time critical areas to maximize system speed The latest E2ROM and non volatile RAM memory technologies have been incorporated to provide ease of use and insure reliable operation State of the art power semiconductor technology has been used in the 1 0 to achieve unmatched specifications AutoMate Programmable Logic Controllers Diagnostics Card Rack gt The AutoMate 30 and 40 controllers have been designed around the The card rack is the basic unit always required in any AutoMate 30 40 E philosophy of single point failure analysis and therefore include the system configuration Populated with the correct cards the assembly B most complete set of internal self diagnostics available today This can stand alone as a controller be located at a remote location and philosophy states that Any single point failure will not affect the serve as a remote 1 0 subsystem or become part of a network and operation of more than one output or the failure will be detected and communicate via the R NET industrial network to other AutoMate PCs
31. ocal Head and will support up to four digital 1 0 rails 64 1 0 connected directly to the four 1 0 COM ports on its face Two twisted pair wires up to 1000 ft long connect the AutoBus Head to an AutoRail Interface The AutoRail Interface in turn is connected via the 42 inch 1 0 rail interconnect cable to one of the four communications ports on the AutoMate 20 20E Processor Unit Enhanced Memory Module 45098 The Enhanced Memory Module is a portable memory retention device that can be used with the Reliance Electric AutoMate programmable controllers and programming devices It allows the user to copy and store programs from the AutoMate PLCs and the programming devices It retains the program as written without battery backup It permits downloading of the program to an AutoMate for execution or to a programming device for editing storage or documentation The compact size and simple operation of the Enhanced Memory Module make the program transfer as easy as pushing a button There are no cables to connect no special equipment to carry A 25 pin D shell connector on the unit connects to the serial communications port of AutoMate PLCs or the related programming devices The EEROM non volatile memory is large enough to copy an AutoMate application program Program integrity is preserved indefinitely when a program is stored in the Enhanced Memory Module DESEE ELECTRIC E To use an Enhanced Memory Module with an Au
32. pose 1 0 methods are also available gt J E AutoMate 15 15E Each AutoMate digital 1 0 rail can support eight two point 1 0 modules and can connect directly to an AutoMate 15 Processor unit 1 0 port via an 1 0 rail interconnect cable The AutoMate 15 CPU can address up to 64 digital 1 0 and includes four 1 0 ports on the face plate to accommodate four 16 channel rails Rails may be mounted in any arrangement to suit application requirements within the limits of 42 inch interconnect cables Input and output modules may be used in any combination to eliminate wasted 1 0 The AutoMate 15E has the added flexibility of interfacing to analog 1 0 modules as well as the digital rail 1 0 used on the AutoMate 15 controller It can address up to 64 digital 16 analog or some combination through its four faceplate mounted rail ports e D a lt AutoMate Programmable Logic Controllers Digital 1 0 Rail 45C1 Typical industrial PLC Input Output systems are mounted on a panel or to a cabinet and wired to an intermediate terminal strip The Reliance Electric 1 0 system eliminates the need for this costly wiring method By incorporating an industrial quality terminal strip with all the standard terminal strip features into the 1 0 rail itself the intermediate wiring and the cost of the added labor are eliminated 1 Modular Design The modular design of the AutoMate 1 0 allows
33. r Local Digital 1 0 Local Numerical 1 0 Remote 1 0 Special Purpose 1 0 tote RELIANCE ELECTHICES AutoMate Programmable Logic Controllers ma Power Supply AutoMate Manuals The power supply is a single plug in circuit board enclosed in a Model Number Description plated steel and black anodized aluminum heatsink housing This J 3016 AutoMate 15 User s Manual unit provides all of the voltages necessary to power the logic circuitry J 3693 AutoMate 15E User s Manual contained on the cards that may be inserted into the card rack In J 3120 AutoMate 20 User s Manual addition voltages are provided to power the module logic circuitry in 153150 AutoMate 30 40 Programming Reference Manual any directly connected rails A terminal strip is included on the card J 3110 AutoMate Hardware Reference Manual faceplate for ease of input power wiring J 3063 AutoMate Programming Executive APX 4 J 3674 AutoMate Documentation Executive Power supplies are available to accommodate various current J2 3006 Rail I O Manual requirements as shown below J2 3007 MultiBus 1 0 Hardware AutoMax AutoMate Model Number Description J2 3041 AutoMate Programming System 450321 20 amps 120 240V 50 60 Hz 2 card slots 450322 50 amps 120 240V 50 60 Hz 3 card slots Power Supply Features Overvoltage Protection Overcurrent Protection Power Up Down Sequencing Logic to ensure proper controller operation LED STATUS
34. s of the processor card include the following features Capability to Address 512 Digital 1 0 or 128 analog or combinations 512 Internal Coils 1024 Registers 128 Numerical 1 0 4K or 8K Non volatile R W Application Memory as described earlier Truly Non volatile R W Memory for Variable Storage 2 0 microseconds per ladder Instruction Execution Speed Extensive On Line Diagnostics as described earlier Motorola MC 68008 Microprocessor solves advanced functions Custom LSI Boolean Processor solves ladder diagrams at high speed Intel Multibus Compatible tote RELIANCE ELECTHICES n e a lt AutoMate Programmable Logic Controllers Memory Expansion Cards Four sizes of memory expansion cards are available Description AutoMate 40 Processor Card The added power of the AutoMate 40 controller requires two processor cards The Standard AutoMate 40 controller consists of the 450400 Logic Processor and the 450410 Control Processor and will support up to 2048 digital 1 0 The Enhanced AutoMate 40 controller 40E is made up of the 450400 Logic Processor and the 450411 Enhanced Control Processor and will address up to 8192 digital 1 0 For smaller complex applications the AutoMate 40X consists of the 456400 Logic Processor and the 456409 Control Processor and will address up to 1024 digital 1 0 All processor sets have 8K x 16 non volatile application memory Each processor set can be exp
35. the AutoMate 40 zip ele cr ELECTRIC E gt J Ef 5 2 Common Network All AutoMate processors are capable of communicating over R Net the peer to peer industrial network capable of tying up to 32 stations or nodes together a single coaxial cable The R Net is also used to allow computers or other devices to communicate to AutoMate controllers through serial gateways and computer bus cards that allow full speed data transfer at 800KBaud The following pages will provide you detailed information on the AutoMate processors 1 0 networks and peripheral operator interface products available through Custom Classics The AutoMate 15 15E The AutoMate 15 is a small programmable controller with exceptional speed functionality and reliability Competitively priced it includes standard features found on much larger more expensive PLCs The AutoMate 20 20E The AutoMate 20 is an expanded small controller based on the proven AutoMate 15 controller design In addition to larger 1 0 and memory capacity it features powerful enhanced functions readily programmable without computer expertise n a lt AutoMate Programmable Logic Controllers Power for Today The AutoMate 15 15E and the AutoMate 20 20E controllers are primarily intended as relay replacers in smaller electromechanical control systems The AutoMate 15 controller may be economically installed to replace as few as eight relays
36. toMate 15E Same features as the AutoMate 15 controller except as noted e 2K x 16 Non volatile memory no battery required 64 Digital 16 analog or a combination Enhanced Ladder Diagram Language with powerful Instruction Blocks 736 Internal Coils 512 Registers AutoMate 20 256 Digital 64 Analog combination 736 Internal Coils 512 Registers 2k x 16 Non volatile memory no battery required 10 Milliseconds K Ladder Element Execution Speed Host Computer Interface Capability 1200 9600 Baud Enhanced Ladder Diagram Language with powerful Instruction Blocks Programmed via compatible personal computer or hand held Mini Programmer User friendly Programming Tools include Off and On line Programming Extensive Diagnostics Rugged Industrial Packaging Remote 1 0 Mounting Capability Communications via the R NET Industrial Network available AutoMate 20E Same features as the AutoMate 20 controller except as noted 4kx 16 Non volatile Memory no battery required Capacity to handle up to 20 PID loops AutoMate Programmable Logic Controllers Flexibility for Tomorrow While the AutoMate 15 and AutoMate 20 controllers are designed for smaller applications this doesn t mean that they must be replaced if your system grows The AutoMate 15 and AutoMate 20 are members of Reliance Electric s AutoMate family of controllers all of which share a common architecture and all of which are built
37. toMate programmable controller connect the EMM to the PLC s serial communications port To enter a program from the EMM into the AutoMate PLC press the Load button on the EMM Pressing the Load button a second time transfers communications parameters and places the AutoMate controller into RUN mode To save a program from an AutoMate PLC press the Save button on the EMM Program transfer operations are indicated by the illumination of the COM DATA indicator on the AutoMate front panel Program transfer takes approximately 10 seconds The COM DATA light will go out when transfer is complete To transfer a saved program from the EMM into a programmer connect the EMM to the serial programming port and enter the standard Save from AutoMate command The program is now available in the programmer memory for editing documentation or storage on a disk The program is also retained in the EMM To load a program into the EMM that has been created or edited in the programmer the standard Load AutoMate command of the programmer is used The Enhanced Memory Module connected to IBM PC creates an off line programming system The programming operation in this mode is exactly as if the computer were connected to an AutoMate PLC Sequences can be created inserted deleted and modified in the EMM The search force memory usage clear memory and set R NET address functions are also available Once programmed the EMM is ready for storage or loadi
38. ts or other parallel binary BCD logic signals The cards can also be used where large numbers of low level digital 1 0 signals are required PERAN EI ELECTRIC The card Model Numbers are 456380 Register Input 456381 Register Output gt J Ef 5 2 All cards feature the following Single channel direct or six channel multiplexed 6 strobe signals 16 Bit Data On Board Power Supply Electrical Isolation Signal to Logic 24 Terminal Removable Connector Protective Housing TTL to 24 VDC logic levels Input interrupt available Special Purpose 1 0 Microprocessor based 1 0 cards are another example of multiprocessing in the AutoMate 30 40 system These special purpose cards solve dedicated control problems independently of the AutoMate processor By removing the control tasks from the main processor and solving them in parallel system scan time is reduced significantly Serial Communication Processor 456203 The Serial Communication Processor allows the AutoMate 30 40 controllers to interface to various peripheral devices such as CRTs printers host computers or other serial RS 232 or 20 mA asynchronous devices There are two modes of operation for the Serial Communications Processor In the host computer mode a terminal device can communicate to the AutoMate 30 40 processors and read or write 1 0 points registers memory or controller status In the program control mode the AutoMate 30 40 contro
39. unication between the processor card and an Model Number Description 1 0 Rail or local head has been disrupted 450301 4K X 16 Application Memory Standard Software COMM DATA Data is being sent or received through the RS 232 456305 4K X 16 Application Memory Enhanced Software communication port 456307 8K X 16 Application Memory Enhanced Software e RS 232 COMMUNICATION PORT The standard software executive provides for ladder diagram functions Programmer or host computer interconnection as well as the additional capabilities of five function math logical 9600 baud 8 data bits no parity instructions data manipulation numerical 1 0 subroutines and table Isolated from logic handling for advanced control tasks On Board power supply The enhanced software executive includes additional special purpose DB25 Connector instructions for more sophisticated tasks such as file handling ASCII 1 0 COMMUNICATION PORTS communication interprocessor communication remote numerical 1 0 Connect up to 64 Digital or 16 analog 1 0 using 1 0 rails and PID control Connect up to 256 digital or 64 analog 1 0 using local heads The AutoMate 30 Processor can communicate directly to four 1 0 ports for up to 64 digital or 16 analog 1 0 or to four local heads for up to 256 digital or 64 analog 1 0 or to any mix of 1 0 rails and local heads Communications take place at 250K baud and the data integrity is insured using parity All version
40. ut module is built to endure an inrush of 20 amps for 0 1 second Optically Isolated Inputs All input logic level circuits are optically isolated from field signals These high threshold circuits will not energize until a pre determined voltage is reached to prevent triggering by false signals from external interference Input module voltage ratings include Description 115 VAC DC Dual Electronic Input 230 VAC DC 24 VAC DC Voltage Comparator 45C40 45C42 1 45643 45644 45646 Voltage Comparator Module This module compares two analog voltage signals and sends the logical results to the processor It can also compare an external voltage to a preset reference voltage determined by the user Both greater than and less than comparisons are made AutoMate Programmable Logic Controllers Analog Rail 1 0 The Analog Rail modules plug into the 1 0 connections on the face of the AutoMate 15E 20 20E controllers or on the local head Analog rail modules may be intermixed in the system with digital and special purpose 1 0 to give a great degree of flexibility in a small PLC system Features 12 bit resolution for precision measurement and control 4 channels per module Available in 0 10V 4 20 mA versions Faceplate accessible fuse Operates on 115 VAC or 24VDC Panel mounted Easy connection to the controller with rail cable Pull apart terminal boards May be addressed as a local head or as a rail 2 Channel In
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