GENERAL INFORMATION

This catalog should give you an overview of the B&R product range which includes PLC systems, visualization devices, industrial networks, communication software and industrial computers.

The products described in this catalog are divided into seven main chapters，which are labeled from A to G. The seven chapters are:

A PLC Systems

B Visualizations

C Industrial Networks & Communication

D Industrial Computers

E Accessories

F Documentation

G Sales and Support

The pages that belong to a chapter are marked with a colored bar. The colored bar can be seen from the edge of the catalog.Most of the chapters are separated into sections. The sections are numbered.

For example, the chapter B "Visualization" contains following sections:

1 System Selection

2 Operator Panel Visualization

3 Semigraphic Visualization

4 Full Graphic Visualization

The table of contents on pages 2 and 3 contain a list of all main chapters and their sections. The main chapter and section description can be found on the top of each page. Additionally, a pictograph can be found on the top outside edge which corresponds to the respective chapter. This should allow you to quickly find the chapter that you need.

Example

Section "Operator Panel Visualization" can be found in chapter B "Visualization".It is the second section (2). The chapter is labeled B2. These labels can be found on all pages of the respective section:

The PLC serves as the foundation of an automation system. All process or machine level information passes through the PLC. The efficiency and the reliability of the entire system depends directly on the efficiency and reliability of the PLC. B&R has used this knowledge to produce a philosophy based on three criteria: ● Functionality ● Reliability ● Operation Security 

FUNCTIONALITY Functionality is the ability of PLC systems to accomplish specific tasks. Such as: - Logic Control - Positioning - Visualization - Communication - Data Acquisition, Storage and Management A PLC system not only needs to be able to solve all current automation tasks, but it also must provide enough reserve efficiency for future expansion. A PLC system with only one processor has two technological limitations to it's efficiency: - Limited application program execution speed - Limited program memory In practice, such a system can usually only accomplish part of the required tasks and will not allow subsequent function extensions. The modular concept of B&R PLC systems guarantees that your resources are never completely used. The efficiency of the entire system can be extended at any time with parallel processors. The network capability of all B&R PLC systems enables the formation of distributed PLC groups.

RELIABILITY The functionality describes only the basic abilities of a PLC system to complete tasks. Reliability is the ability of a PLC system to complete these tasks continually over a long period of time. Reliability is always a limited value because the occurrence of errors can never be completely excluded. One measurement of reliability is the failure rate. 

The following diagram shows the development of the failure rate over a period of time: Early Failure The early failure phase is caused by material and production defects and is distinguished by a comparatively steep decreasing failure rate during the first operating period. This phase can be eliminated before delivery by testing for several days at increasing operating temperatures. Random Failure The random failure phase is marked by a small, relatively constant failure rate. Wear-out Failure The failure rate increases in the wear-out phase and is equivalent to the end of serviceability. This occurs with electronic controls after a very long period of time (decades). Once made aware of these facts, the question of how to put these failure rates into relation often arises, especially with random failures. Procedures have been developed in order to establish the expected durability of electronic devices. 

The "meantime-between-failure" - (MTBF) is basically determined from experience. For a certain observation period, the number of failed units is compared with the sum of the operating times of all delivered units. The observation time must be very long in order to achieve relevant results with this procedure. Different methods for establishing MTBF rates are usually expensive and do not produce reliable results. Therefore, the MTBF indications are theoretical and can only be applied limitedly in reality. 

B&R Systems are Reliable: - All B&R components are developed, manufactured and tested. Utilization of high quality components, precise control of received products, visual check of all manufacturing steps, computer supported rack testing and 48 hour function test at increased operating temperatures in a controlled climate are part of the B&R quality control process. - A new B&R product is only put on the market after it is thoroughly tested. - PLC reliability within a system is usually overemphasized during the overall evaluation of the reliability of a machine/device. Statistics have proven that only about 5 % of all errors in PLC controlled machines or devices are caused by the PLC. 95 % of the errors emerge from signalling devices, drives, wiring positioning devices etc. 

OPERATING SECURITY Errors in operation cannot be 100% excluded despite the measures mentioned above for achieving maximum reliability. A PLC system is "operation secure" if eventual hardware or software errors do not create a machine/device failure, which could possibly cause personal injury or damage. Errors must be recognized immediately and the system must react correspondingly. All B&R PLC systems have extensive security and diagnosis functions which quickly and reliably detect hardware errors as well as software errors and bring the system to a safe operation mode in case of a defect. If an error occurs, all system outputs are set to a secure operating state, i.e. digital outputs are reset (log. 0), analog outputs are reset to 0 V or 0 mA. Diagnostic functions can be grouped as: - Hardware controlled diagnosis functions - Hardware/software controlled diagnosis functions - Software controlled diagnosis functions

Hardware Controlled Security and Diagnosis Functions Hardware controlled security and diagnosis functions are still effective in case of a complete failure of the CPU module. Hardware Watchdog The hardware watchdog is a protection function that brings the system to a secure operating mode in case of complete failure of the PLC processor or other components required for the operation of the PLC. Hardware Reset All outputs of the PLC system are reset if an error occurs. This guarantees that a safe operating mode is achieved in case of a complete CPU breakdown. Ready Relay The ready relay provides a contact that is only closed if the PLC is functioning correctly. Any hardware or software errors cause this relay to be released. The ready relay represents an additional security function when wired correctly. Hardware/Software Controlled Security and Diagnosis Functions For these functions, the fault testing is executed by the software on the appropriate hardware. Bus Monitoring The PLC bus is constantly monitored. Short circuits on the bus caused by defects or conductive pollution are immediately detected. Expansion Test MULTICONTROL systems expansion racks are also constantly tested. A defect in an expansion rack or on a connection to an expansion rack such as a bus error will be detected. 

Software Controlled Security and Diagnosis Functions The sense of software controlled diagnosis functions often comes into question since the proper operation of the CPU and the power supply module must be taken for granted. As described previously in the "Reliability" section, only 5 % of all errors in PLC controlled machines or devices are caused by the PLC itself. A closer look at the statistics of these PLC errors shows that approx. 10 % of the errors occur in the CPU or in the power supply module. The other 90 % occur in the other PLC components. That means the CPU and the power supply modules are some of the most reliable components of a PLC system. Therefore, it makes sense to place security and diagnosis functions in these components. Application Program The checksum of an application program is constantly Checksum monitored for defects in the application program memory. Software Watchdog All B&R PLC systems provide a software watchdog, that (Runtime Monitoring) checks the maximum permissible program scan time. The software watchdog recognizes a runtime error and executes a software reset if a program scan is not completed after a defined period of time (e.g. 100 msec). Endless loops are detected in an application program in this way. Trap Error Detection If the processor encounters an unknown command when the application program is being executed, a trap error occurs. Trap errors are often caused by software errors in indexed jump instructions. Stack Pointer Test The system stack memory is checked at the end of every program scan to find software errors such as a subroutine that is not terminated with RTS or errors caused by using the system stack memory as data memory