1、FORD MANUFACTURING STANDARDS =S=-E-=- - - - -CM_ _=E EL3X PROGRAMMABLE CONTROLLERS - APPLICATIONS EL3X DECEMBER 1992 Page 1 =-E=-=-=-=-=-E=_ -z-= 1. 1.1 GENERAL: The provisions of this Standard shall apply to all electrical/electronic control equipment for machine tools and industrial process equipm
2、ent where programmable controllers (PLCs) are specified. 1.2 This Standard shall supplement requirements in Ford Manufacturing Standards ELX, (electronic systems), EXl, (electrical equipment), and NEMA ICS 3-304, programmable controllers. 1.3 Use of the word “shall“ herein is understood as a require
3、ment; the word “should“ as a recommendation. 1.4 This Standard is not intended to be all-inclusive and any areas where questions of interpretation arise shall be submitted to the specifying activity for resolution. 1.5 Deviations from this Standard shall have the approval of the specifying activity
4、in writing. Any waivers granted shall apply only to the order in question and shall not be considered as permanent. 1.6 Hybrid PLC systems which include special electronic controls not integral to the PLC, and not already listed on the Form 2630 (e.g. for data conversion, communications, etc.) shall
5、 not be supplied without prior written approval from the specifying activity. 1.7 The selection and installation of accessories utilized with PLCs shall comply with the Electrical Equipment Data Form 2630, and any other documents issued by the specifying activity. 1.8 For requirements for PLCs, see
6、Ford Manufacturing Standard EL3. 2. ENVIRONMENT AND ENCLOSURE: 2.1 WINDOWS IN DOORS: *-k* When specified, a sealed window, minimum 0.125 inches thick (Lexan No. 940, or equivalent polycarbonate resin), shall be provided in NEMA 12 enclosure door(s) for observing status indicating lights. Radio frequ
7、ency suppression material (screen or film type) shall be applied to the window to maintain the RF immunity of the panel. gi I y- -w: c NOTE: * Indicates the following item belongs on the attached EL3X p 2 Option Sheet. .a .- . . . . .d“ 2.1.1 POWER SUPPLY REQUIREMENTS: FORD MANUFACTURING STANDARDS =
8、-=-=-_=_II-= 1=D=z= E-s=- EL3X PROGRAMMABLE CONTROLLERS - APPLICATIONS EL3X DECEMBER 1992 Page 2 =- -;x=-= _-_-c-_- i 2.1.1.1 Enclosures containing PLC mainframes, configurable PLC perinpherals or intelligent I/O devices shall have a transformer isolated power source and a transient suppressor appro
9、ved for programmable controller protection. 2.1.1.2 2.1.1.3 2.1.1.4 2.1.1.5 LINE OR LOAD SIDE POWER: * Power supplied to the isolation transformer shall be sourced from the LOAD side of the enclosures main disconnect or, at the specifying activitys WRITTEN OPTION, sourced from an approved lighting t
10、ransformer/disconnect (LTD) connected to the LINE side of the enclosures main disconnect. The LTD (or its Nema 1 switch and fuse portion, for those units with separate transformers sized 2000 VA and larger) shall be mounted behind the same control enclosure door as the main disconnect, typically the
11、 rightmost door. See Appendix A and B for diagrams. CONSTANT-VOLTAGE POWER: * When specified, regulated (or constant- voltage) power shall be used for both PLC power supplies AND their input modules. All PLC power supplies and input modules, including those in remote racks, shall receive power from
12、this same constant-voltage transformer. It may also be used for peripheral equipment, such as gaging, if required. Output modules shall draw power from the same AC source as the I constant-voltage transformer, but NOT from the secondary of i that transformer. (Refer to PLC manufacturers installation
13、 instructions for details). POWER PROVIDED THROUGH CRM CONTACTS: When the line side LTD option is used, all electrical equipment powered from an external source, and controlled by the PLCs outputs shall receive power through CRM contacts, or an electro- mechanical contactor which is de-energized by
14、CRM. Examples include, but are not limited to: a pick main console is typical. FORD MANUFACTURING STANDARDS mBs_- -_-_=_-c=-_-I-_-I -x=m_ _-_ -= EL3X PROGRAMMABLE CONTROLLERS - APPLICATIONS EL3X DECEMBER 1992 Page 4 . =- -=_=-sz=- -a-=-=- -xc-cc=_ -z=m 2.3.1 MESSAGE DISPLAYS: Where programmable mess
15、age displays are mounted in locations which cannot be accessed while the machinery is operating, such as wireways or enclosures above the line, the same programming provisions as required for PLCs on balconies shall apply. Cable length limitations shall be observed. 2.4 2.5 2.6 2.7 2.8 2.9 Minimum e
16、nclosure depth shall allow for at least 6 inches of clearance from the door surface, or door mounted components to the front of the PLC. ACCESSIBILITY OF EQUIPMENT: PLC equipment shall not be mounted behind a door mullion unless there is adequate space for servicing and replacement of the component.
17、 PROGRAMMING SHELF: f* When specified, a fold-down shelf shall be provided on enclosure doors which cover a PLC or remote communications ports to the PLC. The shelf shall safely support a programming device and related equipment and shall pull upward for use, and be equipped with sliding “gravity lo
18、ck“ braces or other means to prevent accidental collapse. Magnets shall NOT be used anywhere on the shelf. Shelves shall be those furnished by approved enclosure manufacturers or designs approved by the specifying activity. i The PLC shall be installed in the same enclosure with other electrical con
19、trol devices necessary for the operation of the machine or equipment, The PLC may be mounted on a common subplate with the electro-mechanical devices, e.g., motor starters, relays, etc., if such layout is approved by the PLC manufacturer and the specifying activity. Mounting of equipment on hinged p
20、anels, doors, etc., is not acceptable. WIRING multiply the ladder logic file size (in kilobytes) by 1.25 and provide excess memory accordingly. MEMORY FOR CIM: * When specified, the PLC shall contain memory to accommodate CIM/Memory Map requirements, in addition to the spare memory required by secti
21、on 2.11.2. 3. SYSTEM REQUIREMENTS: 3.1 PLC NETWORKS: Peer communications interfaces shall be provided on the PLCs for programming devices to communicate with all PLCs on the peer link network, one PLC at a time, from each PLC location. This same network may be used for data interchange and other fun
22、ctions needed to support CIM. 3.2 3.3 3.3.1 3.3.2 POWER SUPPLY INTERLOCKING: When more than one PLC power supply is used for a system, interlocking shall be provided between them to ensure that a failure which turns off one power supply shall also turn off the others. (Al so see section 2.1.1.5 abov
23、e). MOTION INTERLOCKS a: Inputs (8. Sotck List outputs (9. Auxiliary Diagrams, as required Interlocks for DIP switch settings (or soft- Charts (Sequence ware configuration equivalents), and Cycle Time) etc. Spare numbered sheets shall be assigned in each section for power, inputs, and outputs to acc
24、ommodate future expansion as specified by Paragraph 2.11, unless otherwise specified by the specifying activity. Sheet re-numbering (such as ,6A“) shall be avoided. In general, furnish a spare sheet to accommodate unpopulated spare slots in the PLC I/O rack(s), and after any hardwired circuit sheet
25、that is more than 50% filled. - =lllCl=lLblJ 0053532 57b m FORD MANUFACTURING STANDARDS =_=_U_=-_-_=_IL_ -_- =_F_=_=_=-=- - -_- =e=z=e= EL3X PROGRAMMABLE CONTROLLERS - APPLICATIONS EL3X DECEMBER 1992 Page 8 -=wa-m-=L-_- PMLL- -=sze=-E= c 4.1.4 FORD DRAWING NUMBERS: Hardcopy documentation associated
26、with the system shall be identified with the 70Z*-drawing number assigned by the specifying activity. (Where the * represents the Letter associated with a particular Ford division, e.g. “P“ 4.1.5 4.1.6 FILENAMES FOR LOGIC/ANNOTATION: DOS Filenames for PLC logic and annotation shall be derived as fol
27、lows from the 7OZ*- drawing number for the electrical diagrams, unless other naming conventions are established in writing by the specifying activity: Save the logic for machine 7OZ*-10589 on disk as filename Z*10589.xxx (where the xxx represents the file extension created by the software. The use o
28、f only seven characters leaves space for one character to serve as a revision level, if desired). Separate diskettes shall be used for separate machines, unless required otherwise by the specifying activity. PROGRAMMING SOFTWARE: * Unless specified otherwise, the programming and documentation softwa
29、re provided by the PLC manufacturer shall be used. This will avoid incompatibility problems due to differences in filenames and formats, descrip- tive field lengths, “disallowed“ characters in address labels, I etc. as can occur if third party software is used without observing the limitations impos
30、ed by the original PLC manufac- turers software. 4.2 LOGIC DOCUMENTATION: 4.2.1 LOGIC PRINTOUT SHEETS SHALL BE COMPLETE WITH THE FOLLOWING: - All annotation shall be in English. Specifying activities may also require annotation files in other languages as part of the order for the machinery. - TITLE
31、 BLOCK: Printouts shall begin with a Title Block, which includes as a minimum the machine suppliers name, the machine type/process part, and the full 702*-drawing number. - ANNOTATION: Each contact or instruction element shall be annotated with its numeric PLC Address, Device identifica- tion in the
32、 form of an address label or symbol, and a Functional description. - I/O Device identification in the logic program shall be the same as that appearing on the 70Z*-drawings and ID tags on r the machine. Use abbreviations from Ford Manufacturing Standard EXl as appropriate. Examples: 10012PX, 000024S
33、OL, 1:00/14LS, 0:01/24M. (Note: Where the logic program displays FORD MANUFACTURING STANDARDS _-_- - -=I=E=-=- -I - EL3X PROGRAMMABLE CONTROLLERS - APPLICATIONS EL3X DECEMBER 1992 Page 9 -w-e. -,-* _w=- _ -srz.z- - -=-=-=- and prints a contact or instruction elements address automatically, it is not
34、 always necessary to repeat the address in the annotation. Comply with the written direc- tives of the specifying activity on this.) - UNIQUE LABELS OR SYMBOLS: Repetitive words such as LIGHT or SOLENOID or PUSHBUTTON shall not be used for address labels or symbols. (This can lead to confusion, as t
35、he labels are all that appears above contacts or instruction elements when viewing the logic on the programming device screen, without pressing additional keys. It also defeats the ability of the programming software to search for an instruction by its UNIQUE label.) - Avoid using labels or symbols
36、to replace any actual address appearing in an instruction. For example, do not replace T4:8 in a timer or counter with a symbol, such as “PART TIMER.“ - WORDING OF DESCRIPTIONS: Words entered into the lines available for the Functional description shall be broken only at their syllables. Functional
37、descriptions for I/O contacts or coils shall be the same as that on the 702*- drawings and ID tags, to the extent permitted by field lengths. - Each internal contact or instruction element in a rung shall have an adjacent cross reference to the line location of its parent Itcoil.“ - CONSOLIDATED ANN
38、OTATION FOR REGISTERS: Registers or memory locations may be annotated in a listing at the end of the logic program printout. 4.2.2 The following additional information shall be included with the printout (or on the drawings if the software lacks the capability): - The PLC system configuration, consi
39、sting of: - Actual Used and Maximum Available numbers of: coils, inputs, outputs, timers, registers, and logic lines. - PLC memory used, memory remaining, and total system memory. - Data table utilization. - Memory Map listing for all PLCs where memory maps are required by the specifying activity. F
40、ORD MANUFACTURING STANDARDS - =E=5-=- -_-_q=_=_ - EL3X PROGRAMMABLE CONTROLLERS - APPLICATIONS EL3X DECEMBER 1992 Page 10 =-i=-=- p-LL-=- -I-CL-_ - - c 4.2.3 CROSS-REFERENCES: Full cross references shall be shown at each coil or output element and in summary (with descriptions) at the end of the pri
41、ntout. 4.2.4 4.2.4.1 4.2.5 4.2.6 LOGIC DOCUMENTATION MEDIA: 4.2.6.1 The logic file, (PLC program recorded from the controller) and the annotation or mnemonic file(s) shall be duplicated using specifying activity approved media and format. All disables, forces, temporary “jumpers“ and latches shall b
42、e removed at the time of the recording. 4.2.6.2 RUNG COMMENTS: Attach a Line or Rung Comment to each rung containing any logic elements beyond simple contacts and coils, or which is not easily understood. This includes, but is not limited to, rungs containing arithmetic functions, data manipulation
43、such as block transfers or bit shifts, communica- tions with peripherals, etc. Provide enough detail to fully describe the action of the rung. NUMBERING OF LINE MARKERS: For those PLCS where the line comment is attached to the rung by means of an arbitrarily numbered “Line Marker,“ the line marker n
44、umber shall be the same as the address of the output element or coil on that rung. (This maintains a one-to-one correspondence between the line comment and the rung, regardless of later editing and restructuring of the logic program). DATA TRANSFERS FULLY DEFINED: All data transfers and interlocks b
45、etween PLCs, or between PLCs and peripheral devices, shall be fully and clearly defined (timing, 1 sequence, time duration and logic level, etc.). Include this information in both the line or rung comments and on the 702*-drawings. TWO COPIES of the program and annotation files shall be provided on
46、separate diskettes. Only name brand diskettes, formatted to their intended capacities shall be provided. (P unching extra holes or notches in diskettes is strictly prohibited!) 4.2.6.3 * Two hard copy, annotated program listings shall be provided on paper approved by the specifying activity. 4.3 I/O
47、 DOCUMENTATION: 4.3.1 GENERAL: FORD MANUFACTURING STANDARDS =-=-_-EP=-=-=- - - -_ i=- -oz=e-_ - EL3X PROGRAMMABLE CONTROLLERS - APPLICATIONS EL3X DECEMBER 1992 Page 11 =-P-=E=E=s= -=E=-s=E=-=E=- -= 4.3.1.1 I/O drawings shall be drawn in accordance with standard EXl in standard ladder diagram format, drawings shall appear with Ford title block on media specified by specifying activity. 4.3.1.2 4.3.1.3 4.3.1.4 4.3.2 I/O DOCUMENTATION MEDIA: 4.3.2.1 *I/O drawings shall be provided on mylar “D“ size sheets unless otherwise specified by requisitioning au
