Interpreting PLC

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Interpreting Programmable
Logic Controller System Drawings
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Instrumentations For additional information on this subject, contact

File Reference: PCI11305 R. Hartman
Engineering Encyclopedia Instrumentations
Contents Pages
PURPOSE, TYPES, AND COMPOSITION OF PLC SYSTEM DRAWINGS ..................... 1

Purpose ..................................................................................................................... 1
Types ........................................................................................................................ 1
Composition.............................................................................................................. 1
Civil and Mechanical Engineering Drawings................................................... 2
Electrical Engineering Drawings .................................................................... 2
FUNCTION AND OPERATION OF THE PLC SIMULATOR UNIT.................................. 3
Operational Requirements ......................................................................................... 3
Process Control......................................................................................................... 3
PLC System Drawings............................................................................................... 3
Mimic Panel Controls and Indicators............................................................. 4
Mimic Panel Status Indicators........................................................................ 5
Mimic Panel Alarm Indicators ........................................................................ 6
Operator’s Panel Controls and Indicators ....................................................... 6
Power Supplies.......................................................................................................... 8
LOCATING SPECIFIC PLC MODULES ...........................................................................11
PLC Simulator Chassis .............................................................................................11
Power Supply Modules.............................................................................................13
Module Location Technique .....................................................................................13
LOCATING SPECIFIC PLC COMPONENTS....................................................................14
PLC Simulator Unit Cabinet .....................................................................................14
Mimic Panel..................................................................................................14
Operator’s Panel ...........................................................................................14
Flow Valve Subpanel ....................................................................................14
Fuse and Terminal Blocks .............................................................................15
Saudi Aramco Specifications ....................................................................................15
Component Location Technique ...............................................................................16
TRACING A FROM THE I/O POINT TO A TERMINAL STRIP ......................................17

Flow Valve Controls and Indicators..........................................................................17

Agitator and Pump Controls and Indicators ..............................................................18
Wiring......................................................................................................................19
Wiring Specification......................................................................................19
PLC Wiring Diagrams...................................................................................20
Wiring Trace of a Flow Valve .......................................................................20
Signal Tracing Technique .........................................................................................22
WORK AID 1: PROCEDURAL STEPS TO LOCATE SPECIFIC PLC MODULES...........24
WORK AID 2: PROCEDURAL STEPS TO LOCATE SPECIFIED PLC

COMPONENTS..................................................................................................................25
WORK AID 3: PROCEDURAL STEPS TO TRACE A SIGNAL FROM THE I/O

POINT TO A TERMINAL STRIP ......................................................................................26
GLOSSARY........................................................................................................................27
Table of Figures Pages
Figure 1. Typical Input Circuit.................................................................................. 5

Figure 2. Typical Output Circuit ............................................................................... 6
Figure 3. PLC Module Layout and Racks ................................................................12
Figure 4. Simplified Flow Valve Motor Circuit ........................................................18
Figure 5. Reference Drawings for Listed Items ........................................................19
Figure 6. Wire Tags.................................................................................................22

PURPOSE, TYPES, AND COMPOSITION OF PLC SYSTEM DRAWINGS
The primary objective of system drawings is to show the details of any system design or
installation in diagram format. The format presents a pictorial view of an installation, and it
permits an evaluation of the degree of conformance with the specifications.
The specifications provide complete data in functional, operational, material, size, shape, weight
and power requirements of an installation. Saudi Aramco Materials Supply Specification 34-
SAMSS-830 on Programmable Logic Controllers (PLC) is an example of a set of specifications.
Specifications are normally supplemented with system drawings.
Purpose
System drawings provide the foundation plans for any installation. They can be easily reviewed
and changed if necessary. The impact of any changes on other parts or functions of the system
can be determined because of the pictorial representations.
The final review of system drawings leads to the final drawings, which then become the blueprint
for the installation. The final drawings provide a true record of the installation and will serve as
an aid to operation and maintenance.
Types
System drawings normally contain typical drawings from the three main engineering disciplines:
Civil, Mechanical and Electrical engineering.
Civil engineering drawings provide the material and construction details. Mechanical engineering
drawings provide material, dimension, layout and fabrication details. Electrical engineering
drawings provide equipment details in conjunction with schematics and wiring diagrams.
Composition
The logical approach to a system drawing is to present a true picture of the items in the design or
installation. Items denote any level of hardware assembly such as system, subsystem, equipment,
components, and parts. The subject matter may be construction details of a building, fabrication,
details of machines, or electrical details of control or service facilities.
Saudi Aramco DeskTop Standards 1

It is not difficult to show a true representation of an item in Civil and Mechanical engineering
system drawings. Electrical engineering drawings are not easy to develop. The electrical
schematics and wiring diagrams are not adequate to represent an installation without some
mechanical drawing content. The mechanical system drawings are used to show the housing and
equipment fabrication, layout, mounting details, and configuration details. The mechanical
drawings with the schematics and wiring diagrams present a hybrid package of drawings for an
electrical system installation such as a PLC simulator.
Civil and Mechanical Engineering Drawings
In Civil and Mechanical engineering, the use of different projection views, such as isometric, first
degree, third angle, and cross-sectional, help to convey an accurate description of the subject
item. Any deviation from this practice is supported by legends or key notes. The system
drawings are generally self evident. The interpretation of these drawings does not present
problems to engineers.
Electrical Engineering Drawings
In Electrical engineering drawings, it is not practical to present a true picture on system drawings
of every item in an installation. This approach would clutter the drawings and render them
unreadable. It is for this reason that electrical symbols have been devised to represent electrical
components. Using symbols, the schematic diagram is a true, but symbolic, representation of an
installation. The schematic is usually supplemented by a wiring diagram. The purpose of the
wiring diagram is to show the point to point wiring details.
The electrical symbols represent both electromechanical and electronic systems and are
recommended by statutory bodies and professional organizations such as the Underwriters
Laboratories (UL), and Institution of Electrical & Electronic Engineers (IEEE). The symbols used
in the PLC system drawings are shown in Drawing 422-2 Sheet 01.
It is important to understand the symbols used in schematic diagrams. It is not possible to

interpret the diagram without this skill. It is also important to have an understanding of the
functions the system is designed to perform and the sequence of operation. The engineer must
have an understanding of the operation of the system and the skill to recognize the function
performed by each circuit in the electrical network.

FUNCTION AND OPERATION OF THE PLC SIMULATOR UNIT
The drawings listed on index sheet 422-C-01 of the PLC Simulator Unit will be used to
demonstrate the principles of interpreting PLC system drawings. The PLC Simulator Unit is used
as a training tool to demonstrate the use of PLCs and electronic supervisory functions in the
process control industry.
Operational Requirements
The operational requirements are given in a set of specifications. The specifications present the
criteria for the design function. The mimic panel shown in Drawing 422-CP-05 is a Piping &
Instrumentation Diagram (P&ID) which presents an outline of the operational requirements
pertaining to a process control situation.
Process Control
The mimic panel P&ID shows the mixing of two fluids, products A and B, in a mixing tank. After
the mixing process, the mixed product is discharged into a storage tank. The mixing tank is
cleaned with water that is then discharged into a drain tank.
The operation requires two pumps, one agitator motor and nine flow valves. Each device may be
controlled with the switches located on the operators' panel. Indicators are used to provide a
level indication of the liquid level in tanks TK101 and TK 214.
The logic to control the operational sequence is provided by an application program to the
Central Processing Unit (CPU). Input and Output (I/O) modules provide the means by which the
CPU interacts with the field input and field output devices.
Drawing 422-P&I Sheet 03 allows the engineer to trace the flow of each product from the entry
piping to the storage tank. Also, the engineer can trace the flow of the wash water from the entry
piping to the discharge tank. The P&ID is a type of pictorial drawing that uses a set of symbols
to represent the various mechanical devices.
PLC System Drawings
Once the operational requirements are defined, system Drawings are prepared to present the
design of the PLC Simulator unit.

Mimic Panel Controls and Indicators
The mimic panel Drawing 422-CP Sheet 05 shows the control and indication functions for the
process. The mimic panel is a graphical representation of the process shown on the Piping &
Instrumentation Diagram (P&ID) Drawing 422-P&I Sheet 03 which illustrates the product
blending process.
The main purpose of the mimic panel is to enable the operator to readily identify the status of
control devices. If the red indication for the recycle pump P-107 is ON, the operator knows
immediately that the recycle pump is OFF. This is in accordance with Saudi Aramco Materials
Supply Specification 34-SAMSS-830, Section 9.10, which states that the color of lights is red for
OFF and green for ON.
The operation of the process control is achieved automatically by the control logic of the CPU or
manually by input to the CPU from the operator’s panel. The I/O modules provide the interface
between the CPU and field devices.
The flow valves are:

• Inlet for product A: FV-101.
• Inlet for product B: FV-102.
• Discharge for mixed fluid into storage tank: FV-103, FV-104 and FV-108.
• Outlet to Drain Tank: FV-109.
• Inlet for wash water: FV-110 and FV-111.
A motor drives the agitator AG-101. The product transfer pump P-106 controls the fluid flow
into the storage tank TK 244. The recycle pump P107 permits liquid flow into the drain tank, and
pump P-214 is used for transferring the mixed product to the loading area.
Figure 1 shows a typical input circuit for the I/O modules. Also see Drawing 422-I/O Sheet 02
which illustrates the fuses, input devices, terminal blocks, and input points for the PLC simulator.

+ Input
Module
Fuse Input Device Terminal
Block
Figure 1. Typical Input Circuit
Mimic Panel Status Indicators
The controls provided on the mimic panel are the annunciator pushbuttons, acknowledge
pushbuttons, reset pushbuttons and lamp test pushbuttons. See Drawings 422-CP Sheet 05 and
422-I/O Sheet 02, lines 116, 117 and 135.
The flow valves are listed as FV-101, FV-102, FV-103, FV-104, FV-105, FV-108, FV-109, FV-
110 and FV-111 on the mimic panel Drawing 422-CP Sheet 05. The red indicator means that the
flow valve is closed, and the green indicator means that the flow valve is open.
The indicator lights for flow valves FV-101, FV-102, FV-103, FV-104, FV-105, FV-108, FV-
109 and FV-110 are driven by Output module 1771-OBD, mounted in rack 1, group 5. Flow
valve FV-111 indicator lights are from Output module group 6, 1771-OBD, on the same rack.
Refer to Drawing 422-I/O Sheet 08.
The two indicator lights on the status of the agitator motor are Agitator Running and Agitator
Stop. These are driven by Output module group 6, 1771-OBD mounted on rack 1. Refer to
Drawing 422-I/O Sheet 08.
The indicator lights for the product transfer pump P-106 are ML324 to denote pumping running,
and ML325 for stop. The corresponding indications for the recycle pump P-107 are ML322 and
ML323, and the product loading pump P-214, ML320 and ML321. These indicator lights are
driven by the same output module as the agitator motor given above.
Figure 2 shows a typical output circuit for the I/O modules. Also see Drawing 422-I/O Sheet 06
which illustrates the output points, fuses, terminal blocks, and output devices for the PLC
simulator.

Output
Module _
Fuse Terminal Output
Block Device
CR
Figure 2. Typical Output Circuit
Mimic Panel Alarm Indicators
The CPU scans all inputs and outputs continuously and updates operation from real time data.
The CPU also runs internal diagnostics for errors and provides alarm indications in the event of
failures.
The alarm indicators on the mimic panel are ML258 (LAH-101), ML260 (LAL-101), ML261
(PAH-107), ML263 (PAL-107), ML264 (LAH-214), and ML266 (PLC Fault). These indicators
are driven by output module group 3, 1771-OW, mounted on rack 1. Refer to Drawing 422-I/O
Sheet 07.
Operator’s Panel Controls and Indicators
The operator’s panel provides the human interface to the system. The main purpose of this panel,
in conjunction with the mimic panel, is to enable the satisfactory execution of all control
functions. Drawing 422-CP Sheet 07 shows the operator’s panel with controls and indicators.
Under manual mode, the operator controls each flow valve and motor. In the event of an
emergency, the operator is free to take precautionary measures.
The identification label of a panel device is mounted immediately below the device for ease of
traceability to the system drawings. For example, the emergency stop pushbutton has an
identification label below it that reads HS433. This is shown in Drawing 422-CP Sheet 07,
Reference 3. The schematic diagram 422-I/O Sheet 09, Line 354 shows the same pushbutton, the
electrical connect to the PLC, and the PLC input address. The identification is in accordance with
Section 9.4.2 of Saudi Aramco Materials Supply Specification 34-SAMSS-830.

Operator’s Panel Controls - Drawing 422-CP Sheet 07 shows the control switches and their
associated tag numbers. The switches are used for flow valve and motor controls. The switches
are spring return to the center from both open and close positions. The operation of the switch is
similar to a pushbutton, since a contact is made only momentarily when the switch is turned.
The flow valve controls are as follows:

• FV-101: HS101/Open-Off-Close
The motor controls are as follows:
• Agitator AG-101: HS112/Start-Neutral-Stop
• Production Loading Pump P-204: HS214/Start-Neutral-Stop
• Recycle Pump P107: HS107/Start-Neutral-Stop
• Product Transfer Pump P-106: HS106/Start-Neutral-Stop
Other controls are as follows:
• Emergency Shutdown: HS433
• Emergency Shutdown Reset: HS434
• Auto Mode: HS337/Start-Stop
• Resume Cycle: HS136
• System Mode: HS335/Manual-Auto
• Batch/Wash Cycle: HS153/Batch/Wash 1/Wash 2
All of the above controls use the typical input circuit for the I/O modules as shown in Figure 1.
Operator’s Panel Status Indicators are:

• Emergency Shutdown: PL436 (Red)
• Panel Power On: PL432 (White)

• Auto Mode Enabled: PL336 (Amber)

• Pause Mode: PL335 (Amber)
• Level Indicators: LI-101 for Mix Tank TK-101 LI-214 for Product Storage Tank
TK-214
The Operator’s Mimic Panel Alarm is an audible alarm provided by a sonalert. When an alarm
occurs, an appropriate red pulsing alarm indication lamp is ON to alert the operator of the type
and location area of the fault. The operator presses the Alarm Acknowledge pushbutton to
silence the alarm. The alarm indication remains ON solid (i.e., no longer pulsing). The operator
then depresses the Alarm Reset pushbutton to clear the fault.
All the above outputs use the typical output circuit for the I/O modules as shown in Figure 2.
Power Supplies
The power requirements are calculated from the design load plus a certain percentage to allow for
expansion of the equipment modules. The CPU and I/O logic power is provided by the two slot-
type power modules, 1771-P4S, shown on Drawing 422-I/O Sheet 01. One power module is in
group 0 of rack 0 while the other is in group 0 of rack 1.
The auxiliary power supply voltages are 120 Vac, 24 Vdc, and 12.6 Vdc. The auxiliary power
supplies are used to provide the power for field devices connected to the I/O modules. The
power supply schematic is shown on Drawing 422-EWS Sheet 01 and the wiring diagram on
Drawing 422-WD Sheet 07.
The 120 Vac input power to the PLC cabinet is controlled by a main switch-fuse, with the
exception of the two fluorescent lights and convenience outlet, which are protected by a 7A fuse
FU2.
The modules with 120 Vac input and output are:

• Output module 1771-OAD, group 7, rack 1.
• Input module 1771-IAD, group 0, rack 2.
The 24 Vdc output is protected by a 7A fuse FU4. The 24V dc positive bus terminals are TB1-
12, TB1-13, TB1-14, TB1-16 and TB1-17. The 24 Vdc negative bus terminals are TB1-19 and
TB1-20.
The modules powered by 24 Vdc are:

• Input module 1771-IBD, group 1, rack 0.


• Output module 1771-OB, group 1, rack 1.
• Output module 1771-OB, group 2, rack 1.
• Output module 1771-OW, group 3, rack 1.
• Output module 1771-OBD, group 5, rack 1.
• Output module 1771-OBD, group 6, rack 1.
The 12.6 Vdc output is protected by a 10A fuse FU6. The negative bus terminal is TB1-9. The
12.6 Vdc is used for the motor circuit in the flow valve simulator only. Refer to Drawings 422-
EWS Sheets 02 and 03.
The Grounding of equipment is vital for safe operation. In the event of a ground fault, the fault
current is shunted to ground. Primary and secondary fuses in the PLC circuits offer protection
against significant fault currents.
It is required to provide separate ground buses for ac, dc and shield connections in the PLC
system. Section 9.1.3 of Saudi Aramco Materials Supply Specification 34-SAMSS-830 describes
the details of equipment grounding.
Fuses are necessary to enforce overload and short circuit protection. All input and output points
are required to be fused or employ current limiting circuitry in conformance with Saudi Aramco
Materials Supply Specification 34-SAMSS-830. The input power supply to components are
provided with primary fuse protection. Secondary fuse protection is applied to all inputs and
outputs of the PLC modules. The fuse rating is 1A. All fuses are mounted on blocks TB1, TB2,
TB3 and TB4 shown on Drawing 422-CP Sheet 03. All fuses carry numerical identification labels
as shown in wiring Drawing 422-WD Sheet 03.
Terminals Blocks are used for all internal wiring and interface connections. It is common
practice to make connections between any two components via a terminal block. This practice
permits an ease in maintenance since isolation or replacement of a unit is undertaken with
minimum disturbance to the system.
Field I/O wiring is connected to the I/O rack via terminal block connections. Terminals provide
the flexibility to permit multiple conductor terminations when jumper wires are used. No more
than two wires are permitted on a single terminal, as per Section 9.12.3 of Saudi Aramco
Materials Supply Specification 34-SAMSS-830, so that the use of jumper wires is made to
conform with the specification requirements. Wiring terminations are made with a degree of slack
to allow for future work. A wire slack of 15 cm (6”) is required as per Section 9.7.1 of Saudi
Aramco Materials Supply Specification 34-SAMSS-830.
The terminal blocks TB5, TB6, TB7 and TB8 are shown on Drawing 422-CP Sheet 02. The
location of these blocks presents no problems on the maintenance aspects of any component.

The terminals numerical identification and coding are in compliance with Section 9.9.2 of Saudi
Aramco Materials Supply Specification 34-SAMMS-830. The numbers are assigned sequentially
in ascending order to each terminal in a row and each vertical row in a group. For example, row
TB5 has 40 terminals numbered 1 to 40, and each vertical row in the group is identified as TB5,
TB6, TB7 and TB8. Refer to wiring Drawing 422-WD Sheet 04.

LOCATING SPECIFIC PLC MODULES
An engineer must be able to use the PLC system drawings to locate a specific module for
purposes of troubleshooting, system modification, or general maintenance.
PLC Simulator Chassis
The location of the PLC chassis, 1 and 2, are shown on Drawing 422-CP Sheet 03. The chassis
are mounted on subpanel 2 in the rear of the cabinet. The location of this subpanel is shown on
Drawing 422-CP Sheet 01. The rear door gives full access to the PLC chassis. The two PLC
chassis are identified as chassis 1 and chassis 2. Rack 0 is on chassis 1 and racks 1 and 2 are
located on chassis 2. Chassis 1 is an 8-slot rack because of limited panel space while chassis 2
provides 12 slots. The PLC module assignment for chassis 1 and 2 is shown on Drawing 422-I/O
Sheet 01. Figure 3 shows the PLC racks.

RACK 0
Chassis 1
Module Group
CPU 00 01 02 03 04 05 06 07
1785 1771 1771 1771 1771 1771 1771 1771 SPARE
- - - - - - - - SLOT
L20B P4S IBD IBD IBD IR IFE OFE2
Module Type
RACK 1
Chassis 2
I/O 00 01 02 03 04 05 06 07
Adapter
1771 1771 1771 1771 1771 1771 1771 1771
- - - - - BLANK - - -
ASB P4S OB OB OW OBD OBD OAD
RACK 2
Chassis 2
00 01 02 03
1771
- BLANK BLANK BLANK
IAD
Figure 3. PLC Module Layout and Racks
The location of a specific module may be necessary in the event of a failure in order to either
perform troubleshooting or replacement of that particular module.

Power Supply Modules
The power supply modules are mounted on subpanel 2 in the rear of the cabinet. This panel
includes the main disconnect switch/fuse DS-1 for the system. The layout of the power
equipment is shown on Drawing 422-CP Sheet 03. The power units are located above the PLC
racks to minimize the adverse effects of temperature rise on the PLC modules due to power
dissipation. The placement is in accordance with Section 9.6.2 of Saudi Aramco Materials Supply
Specification 34-SAMSS-830.
Module Location Technique
The location of a specific module is important in the event of a failure. In order to perform
troubleshooting or replacement of a module, the skill to locate a specific module is necessary,
If there is a failure in the operation of flow valve FV-111 to open, the mimic panel indication
M316, as shown in Drawing 422-I/O Sheet 08, Line 316, will fail to go on. It is essential to
understand the operation of a flow valve and a knowledge of the circuit symbols is necessary.
When switch HS111 is turned to the left position, the request to open flow valve FV-111 is made.
This action presents an input voltage to the terminal of an assigned input module. Drawing 422-
I/O Sheet 03, Reference 144, shows contact XOO is closed when switch HS111 is turned to the
open position. This contact is wired to terminal 04 of input module 1771-IBD, group 3 on rack 0
The tag identification of the wire on terminal 04 reads I:003/04. Refer to wiring Drawing 422-
WD Sheet 01. This notation means that wire number 4 is associated with input module, group 3
on rack 0. Drawing #422-I/O-01 shows the input module is located in group 3 on rack 0 is 1771-
IBD. This location is in agreement with the module identification given in the drawing which
shows switch HS111 input circuit.
The next module in the circuit operation is identified in a similar way if a logical sequence is
followed. When terminal 04 of I/P module 1771-IBD, group 3 on rack 0 goes high, the relay
CR330 energizes. This relay is required to operate flow valve FV-111 to the open position, refer
to Drawing 422-EWS Sheet 03, Reference 525-528. By referring to the Drawing 422-I/O Sheet
08, which shows CR330, it is possible to locate the O/P module that is 1771-OBD in group 6 on
rack 1.
A knowledge of circuit symbols and operational sequence is required to locate a specific module.

LOCATING SPECIFIC PLC COMPONENTS
In order to locate specific PLC components, it is necessary to associate the component with a
type or group of equipment. Once the type or group of equipment is known, then the appropriate
drawing can be consulted.
PLC Simulator Unit Cabinet
Three main areas of the Simulator cabinet are identified for the mounting of all components.
These areas are:
• The front door of the Simulator unit cabinet that houses the mimic panel and the
operator’s panel.
• Subpanels 1 and 3 that are mounted on the front section of the cabinet. Subpanel 1
houses the flow valve components and terminal blocks. The lamp test relay CR247
is mounted on subpanel 3.
• A subpanel 2 that is mounted on the rear section of the cabinet that houses the
power modules, PLC racks, and fuse blocks.
The cabinet construction details are given in Sections 9.2, 9.3, and 9.4 of Saudi Aramco Materials
Supply Specification 34-SAMSS-830. The cabinet is an open frame construction avoiding
supports which restrict access to the chassis and components. Removable lifting rings are
provided. The cabinet is convection ventilated and is accessible from either the front or rear.
Drawings 533-CP Sheets 01, 02, 03 and 04 show the cabinet details.
Mimic Panel
The mimic panel is located on the upper segment of the front door. It is located where it can be
viewed by the operator and is within reasonable reach for operation and maintenance. The
location of the mimic panel is shown on Drawing 422-CP Sheet 01. The details of the
components for the mimic panel are shown on Drawings 422-CP Sheets 05 and 06.
Operator’s Panel
The operator’s panel is located under the mimic panel. The operator panel is positioned to permit
easy operation by the operator. The location of the panel is shown on Drawing 422-CP Sheet 01.
The details of controls and indicators is shown on Drawings 422-CP Sheets 07 and 08.
Flow Valve Subpanel
The flow valves are mounted on a half-size subpanel 1 that is located in the front of the PLC
cabinet. The front door provides access to the flow valves. A view of the flow valve mounting
panel is shown on Drawing 422-CP Sheet 01. Details of the flow valves are shown on Drawings
422-CP Sheet 02 and 02A.

The simulator for a flow valve is a geared motor with limit switches and two controlling relays.
One relay drives the motor in one direction to simulate an open valve condition. The other relay
drives the motor in the opposite direction to simulate a closed position.
A total of nine motors and eighteen relays are used to operate the nine flow valve simulators. The
layout of these components are shown on Drawing 422-CP Sheet 02. The schematic is shown on
Drawings 422-EWS Sheets 02 and 03.
Fuse and Terminal Blocks
A total of four fuse blocks and four terminal blocks are provided for the PLC Simulator Unit.
The four fuse blocks are mounted in the lower section of the full size subpanel 2. This panel is
located in the rear of the cabinet. The rear door provides access to the fuse blocks TB1, TB2,
TB3, and TB4. The layout is shown on Drawing 422-CP Sheet 03 and the wiring details of the
fuse blocks are shown on Drawing 422-WD Sheet 03.
The terminal blocks are mounted in the lower section of the half size subpanel 1. This panel is
located in the front of the cabinet. The front door provides access to the terminal blocks TB5,
TB6, TB7, and TB8. The layout of the terminal blocks is shown on Drawing 422-CP Sheet 02
and the wiring details are given on Drawing 422-WD Sheet 04.
The full size subpanel 1 consists of the power modules, PLC rack and fuse blocks TB1, TB2,
TB3 and TB4. Relays CR434, MS344, MS348 and MS350 are also included. The details are
shown in Drawing 422-CP Sheet 03.
Saudi Aramco Specifications
In accordance with Section 9.4.2 of Saudi Aramco Materials Supply Specification 34-SAMSS-
830, all instruments, push/pull buttons, switches, lamps etc., mounted either in the front or rear of
the cabinet are identified by two identical nameplates, one on the front and one on the rear of the
panel. All nameplates are mounted immediately below the corresponding instrument or accessory
unless specified otherwise. Section 9.12.4 specifies that each terminal strip is to be labeled with a
terminal number as per wiring diagrams and terminal layouts. The tagging of internal wiring also
provides information on location of specific PLC components as described in Section 9.9.1.

Component Location Technique
It is useful to associate the component with a type or group of equipment. Once the type or
group is known, then consult the appropriate drawings for the component. For example, a
problem requires the engineer to locate a pushbutton. Pushbuttons are generally associated with
the operator’s panel and it is logical to refer to Drawing 422-CP Sheet 07 which gives details of
the panel. There are also areas identified by dotted demarcation lines which are clearly labeled.
For example, a group of indicators shown on Drawing 422-I/O Sheet 08 is located on the mimic
panel.
A drawing may show the location of a specified component, but details of the component may be
referenced to other drawings. For example, the location of the operator's panel is shown on
Drawing 422-CP Sheet 01 where the details are given on Drawing 422-CP Sheet 07.

TRACING A FROM THE I/O POINT TO A TERMINAL STRIP
The ability to read system drawings and a knowledge of the system’s operational sequence are
essential elements to signal tracing.
Flow Valve Controls and Indicators
In order to follow the system drawings on the flow valve simulation controls, it is necessary to
understand the design approach taken. The following discussion includes the system response
when a device is activated. The discussion also traces the signal from a device to the I/O module
and vice versa.
A three-position switch is used to control the operation of a flow valve. When the switch is
turned to the left, the flow valve opens. A similar action to the right position closes the flow
valve. There are also two control relays. One control relay drives a motor in the forward
direction to simulate the open position the flow valve, and the other relay reverses the motor
drive for the close position. The open or close status of the flow valve is determined by two
separate limit switches actuated by the motor gear train. All pushbuttons and switches present
digital logic inputs to the Central Processor Unit (CPU). The CPU produces the desired outputs
as a result of the application program logic.
Drawing 422-I/O Sheet 02 shows Input Module 1771-IBD in group 1 on rack 0. Assume
pushbutton HS101 is turned to the left position by the operator, that is a request to open flow
valve FV-101. The contact XOO of this switch is closed momentarily which allows I/P 00 to go
high. Refer to Drawing 422-I/O Sheet 02, Reference 102. A voltage is provided through the
application logic on terminal 00 of Output Module 1771-OB in group 1 on rack 1, shown on
Drawing #422-I/O-06, Reference 221. This voltage energizes the control relay CR221 which
closes the circuit for the 12 Vdc motor. The motor simulates the operation of the flow valve.
The schematic circuit for FV-101 motor control is shown on Drawing #422-EWS-02, Reference
2471-474. This drawing also shows the limit switches XSH-101 which represent an open
condition of the flow valve and XSL-101 for the close condition. The limit switch XSH-101
opens and provides a low condition to terminal 02 of the above input module in group 1 on rack
0, Drawing #422-I/O-02, Reference 104. A green indication ML297 is driven by terminal 00 on
output module 1771-OBD in group 5 on rack 1 to denote FV-101 is open. The indication circuit
is shown on Drawing #422-I/O-08, Reference 297.
The above control logic for FV-101 applies to all flow valves. The control relay CR222 when
energized, causes the motor to run in the reverse direction. This activates the XSL-101 limit
switch which indicates that the valve is closed.

The limit switch de-energizes the appropriate control relay through the application logic. The
contacts of the control relay are then opened to disconnect power to the motor. Figure 4 shows a
simplified circuit for the flow valve motor.
CR221
12.6 V+
+
5 9
M
12.6 V- -
8 12
CR222
8 12
5 9
Figure 4. Simplified Flow Valve Motor Circuit
Agitator and Pump Controls and Indicators
The design approach for the simulated controls of the agitator motor and pumps follow the
identical pattern. Under manual control, the operator turns a switch to the appropriate position
that, in turn, energizes a control relay via the CPU control logic. A contact of the control relay
presents a digital logic input to the CPU. The CPU provides the mimic panel indication on the
status of the controlled device.
Assume the operator turns the Agitator switch HS112 to the left position, that is a request to start
the agitator. Drawing #422-I/O-09, Reference 358, shows a closed contact XOO of this switch
presents a high input to terminal 04 of I/P module 1771-IAD in group 0 on rack 2. This energizes
the control relay MS344 via terminal 11 of output module 1771-OAD in group 7 on rack 1, as
shown in Drawing #422-I/O-09, Reference 344. A contact of MS344 relay is input to terminal 15
of the above input module 1771-IAD, Reference 367. A green indication ML318 on the mimic
panel is given to denote agitator running as terminal 02 of the output module 01771-OBD in
group 6 on rack 1 goes high. See Drawing #422-I/O-08, Reference 318.
In effect, there is no motor application to simulate the agitator and pump operation. This
simulation is achieved by indications only. The control circuitry to simulate Agitator Stop
condition is similar to the above explanation, that is the operation of the Agitator switch to the
right position deenergizes the MS344 relay. This action gives the red indication ML319,
displaying agitator stop status.

Figure 5 identifies the drawings for the components of the agitator motor, recycle pump, product
transfer pump and product loading pump.
Item Switches Control Relays Indications

Agitator Motor #422-I/O-09 #422-I/O-09 #422-I/O-08
Recycle Pump #422-I/O-09 #422-I/O-09 #422-I/O-08
Product Transfer Pump #422-I/O-09 #422-I/O-09 #422-I/O-08
Product Loading Pump #422-I/O-09 #422-I/O-09 #422-I/O-08
Figure 5. Reference Drawings for Listed Items
Wiring
The wiring of the Simulator unit can be considered when all the components are installed. The
guidelines for wiring installation are normally in conformance with recommendations from
statutory and professional organizations.
Wiring Specification
Section 9.7 of the Saudi Aramco Materials Supply Specification 34-SAMSS-830 presents the
details of power and signal wiring. Wiring between I/O terminals and PLC modules is run in
dedicated ducts or raceways and neatly harnessed with tie-wraps. A wiring slack of 15 cm (6
inches) is recommended to permit future modifications. The segregation of ac and dc wiring is
recommended. Wiring type, size and color are taken into consideration for each type of circuit
application, such as power or signal.
The identification of all wiring generally follows the Section 9.9.1 of Saudi Aramco Materials
Supply Specification 34-SAMSS-830. Section 9.9.1 specifies that I/O and interconnecting wiring
are to be tagged at each end with two identification tags or one if sufficient separation is allowed
between wire numbers. The first tag which is closest to the end of the wire identifies the terminal
number to which the wire is connected. The second tag identifies the terminal number to which
the opposite end of the wire is connected.
Drawing 422-I/O Sheet 2, Line 102 shows the input circuit to open flow valve FV-101 using
switch HS101. The switch is wired to terminal 00 of input module 1771-IBD located in group 1
on rack 0. The tags of the wire from the input module on terminal 00 to terminal block TB5-9,
will read as I:001/00 TB5-9 at the input module termination, and TB5-9 I:001/00 at the terminal
block. Refer to wiring Drawing 422-WD Sheet 01 for the input module termination and Drawing
422-WD Sheet 04 for the terminal block. The nomenclature I:001/00 indicates that this wire is
associated with an input (I/P) module. The two digits 00 which follow I: represent the rack
number, that is rack 0. The third digit 1 signifies the module group number is 1.

The remaining two digits 00 indicate the terminal number. Therefore, the notation I:001/00
means that the wire is associated with input module group 1 on rack 0, terminal 00. Similarly on
Drawing 422-I/O Sheet 08, Line 297, the wire from terminal 00 of output module 1771-OBD to
fuse FU95, is identified as O:015/00, means this wire is numbered 00 and is associated with
output module group 5 on rack 1. The other end of this wire goes to fuse FU95
PLC Wiring Diagrams
The drawings for the PLC Simulator unit present a hybrid package of mechanical and electrical
system drawings. Drawing 422-CP Sheet 01, for example, is mechanical in presentation since it
addresses the shape, size, and layout of components. The electrical drawings generally fall under
a schematic or wiring category.
The schematic illustrates a circuit using symbols, whereas a wiring diagram shows components
and point to point wiring details. The schematic drawings for the flow valves are 422-EWS Sheet
02 and 422-EWS Sheet 03, and the corresponding wiring drawing is 422-WD Sheet 06. The
loop diagram shown in Drawing 22-LOOP Sheet 01 is a type of schematic diagram showing the
interconnected elements of the flow valve.
It is possible to add wiring details on a schematic if the circuit is a simple one. In practice, when a
system installation is large and complex, separate schematics and wiring diagrams are essential.
Wiring Trace of a Flow Valve
The wiring details of a function are discussed in order to demonstrate the techniques of tracing
the wiring and understanding the significance of the number notations. The wiring details of flow
valve FV-101 are taken into consideration. The subject item is traced by following the actual
wiring of the equipment that comes into operation when a request to open the flow valve is made
by the panel operator.
When switch HS101 is turned to the left position, the contact is closed and a digital input is
presented to the CPU via an assigned input module. In this case, the assigned module is 1771-
IBD, group 1 on rack 0. It is then possible to trace the wiring if it is understood what precise
function is carried out when switch HS101 is turned.
The circuit for the above input module appears on Drawing 422-I/O Sheet 02, Line 102. There
are two wires from the open contact XOO of the switch. One wire goes to fuse FU7 and the
other goes to terminal TB5-9. The tag of this wire, that is terminated on fuse FU7, will read FU7
HS101-R4, as shown in Drawing 422-WD Sheet 03. This means that the tag at the other end of
the same wire terminated on R4 terminal of HS101 switch assembly, will read HS101-R4 FU7;
refer to Drawing 422-WD Sheet 08. The tags of the second wire which goes from the switch to
terminal block TB5-9 will read HS101-R3 TB5-9 at the switch termination as per Drawing 422-
WD Sheet 08 and will read TB5-9 HS101-R3 at the terminal block shown on Drawing 422-WD
Sheet 04.

It is important to have the means to identify all wires since the tracing of wires is normally done in
different locations. The practice is to provide two tags at each end for the same wire or one tag
with sufficient separation between wire numbers. The first tag or tag nearest to the post will
identify the point of termination for the subject end. The second tag will identify the termination
post of the other end of the same wire.
Now it is required to trace the wire from TB5-9 to the input module 1771-IBD, group 1 on rack
0. The tag on this wire at the terminal block will read TB5-9 I:001/00 as shown on Drawing
#422-WD-04. This means the wire is terminated on post 9 of terminal block TB5 and the other
end of the wire is terminated on terminal 00 of the input module, group 1 on rack 0. The other
end of this wire will read I:001/00 TB5-9 as shown on Drawing #422-WD-01.
The above completes tracing of the wiring on the input circuit of switch HS101, XOO contact to
input module 1771-IBD, group 1 on rack 0.
The operational sequence which follows after the above mentioned step of the circuit logic to
open flow valve FV-101 is:
1) The relay CR211 is energized. Refer to Drawing 422-I/O Sheet 06, Line 211.
2) CR211 energized in conjunction with CR22 deenergized completes the operating
circuit to drive flow valve FV-101 simulator motor to the open position. See
Drawing 422-EWS Sheet 02, Line 471-474.
3) The limit switch XSH-101 opens and this contact is presented as an input to the
CPU via the above input module 1771-IBD, group 1, rack 0. Refer to Drawing
422-I/O Sheet 02, Line 104.
4) A green indication ML297 on the mimic panel is driven by the CPU via output
module 1771-OBD, group 5 on rack 1. Refer to Drawing 422-I/O Sheet 08, Line
297.

Figure 6 presents the tags the a wiring trace on CR221 control relay shown on Drawing 422-I/O
Sheet 06, Line 221.
Termination Tag Wiring Drawing # Wire Run

O/P mod. 00 O:011/00 FU71 422-WD-02 O/P module to FU71
FU71 FU71 O:011/00 422-WD-03 FU71 to O/P module
FU71 FU71 TB7-1 422-WD-03 FU71 to TB7-1
TB7-1 TB7-1/ O01100A 422-WD-04 TB7-1 to FU71
TB7-1 TB7-1/O01100A 422-WD-04 TB7-1 to CR221, ter. 14
CR221, ter. 14 CR221-14 TB7-1 422-WD-06 CR221, ter. 14 to TB7-1
CR211, ter. 13 CR221-13 TB6-5 422-WD-06 CR221, ter. 13 to TB6-5
TB6-5 TB6-5 CR221-13 T422-WD-04 TB6-5 to CR221, ter. 13
Output Module -
Rack 1/Group 1
FU71
O:011/00 FU71 O:011/00 FU71
00
* NOTE: Tag numbers may be read left to right or right to left; a device alpha-numeric will
always appear near the device. In the above figure, the FU71 designation appears next to the
fuse while the O:011/00 designation appears next to the Output Module.
Figure 6. Wire Tags
Signal Tracing Technique
Signal tracing for the operation of the recycle motor is used as an example to describe a signal
tracing technique. The operational sequence of the recycle pump must be considered first. When
the operator turns the recycle pump switch to the start position, how is this signal traced? If the
operational sequence is known, the next step is to locate the input module assigned to the start
contact XOO of the recycle pump switch. Drawing 422-I/O Sheet 09, Line 362 shows this
contact in input to terminal 10 of input module 1771-IAD in group 0 on rack 2. A voltage
measurement at this terminal will reveal the presence of 120 Vac only when the switch is turned.
This confirms that the correct circuit is being traced.

The next step is to trace and determine that MS348, the recycle pump start relay is energized.
Drawing 422-I/O Sheet 09, Line 348 shows that the output module 1771-OAD in group 7 on
rack 1 operates the relay via terminal 15. An indication of 120 Vac on this terminal confirms the
circuit.
The MS348 relay contact input to an assigned input module must be located. The contact of
MS348 relay is wired to terminal 17 of input module 1771-IAD in group 0 on rack 2 as per
Reference 369 of the Drawing above (422-I/O Sheet 09). The presence of 120 Vac on terminal
17 verifies the circuit.
The last step is to locate the recycle pump indicator driven from an assigned output module. The
output module 1771-OBD in group 6 on rack 1 shows the indicator ML322 is wired to terminal
06, as shown in Reference 322 in Drawing 422-I/O Sheet 08. A 24 Vdc measurement taken at
terminal 06 concludes the signal trace.
The procedure of signal tracing requires a knowledge of a circuit’s operational sequence and the
function of each component in the circuit.

WORK AID 1: PROCEDURAL STEPS TO LOCATE SPECIFIC PLC MODULES
1. Identify the input module for the specified switch.

2. Identify the output module for the control relay.
3. Identify the input module for the limit switch.
4. Identify the output module for the indication.
5. Locate the specific modules on the module layout diagram.

WORK AID 2: PROCEDURAL STEPS TO LOCATE SPECIFIED PLC

COMPONENTS
1. Identify the specific component by its label and associate it with the type or group
of equipment.
2. Locate the group of equipment on the layout diagram.
3. If the layout diagram shows the details of that particular group of equipment, then
identify the subject component by the appropriate identification label, otherwise
refer to the diagram which shows the necessary details of the equipment group.
4. Verify identification of the component by the wiring tags.

WORK AID 3: PROCEDURAL STEPS TO TRACE A SIGNAL FROM THE I/O

POINT TO A TERMINAL STRIP
1. Identify the Auto Mode switch on the operator’s panel.

2. Locate the wiring details of the Auto Mode switch and identify the interfacing
module by the wiring tag.
3. Locate the interfacing module schematic and verify it is the correct module by the
wiring tags.
4. Trace the signal from the field device to the I/O point of the identified module.
5. Identify the Auto Mode indication on the operator’s panel.
6. Locate the wiring details of the Auto Mode indication and identify the interfacing
module by the wiring tag.
7. Locate the interfacing module schematic and verify it is the correct module by the
wiring tags.
8. Trace the signal from the I/O point to the terminal strip, and from the terminal
strip to the field device.

GLOSSARY
mimic panel A graphic panel that dynamically represents a process.
signal tracing Tracking control signal levels from point to point through
the wiring terminations.

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Chapter : Instrumentations For additional information on this subject, contact

PURPOSE, TYPES, AND COMPOSITION OF PLC SYSTEM DRAWINGS ..................... 1

Saudi Aramco DeskTop Standards

Flow Valve Controls and Indicators..........................................................................17

WORK AID 2: PROCEDURAL STEPS TO LOCATE SPECIFIED PLC

WORK AID 3: PROCEDURAL STEPS TO TRACE A SIGNAL FROM THE I/O

Table of Figures Pages

Figure 1. Typical Input Circuit.................................................................................. 5

Saudi Aramco DeskTop Standards

PURPOSE, TYPES, AND COMPOSITION OF PLC SYSTEM DRAWINGS

Saudi Aramco DeskTop Standards 1

Civil and Mechanical Engineering Drawings

Electrical Engineering Drawings

It is important to understand the symbols used in schematic diagrams. It is not possible to

Saudi Aramco DeskTop Standards 2

FUNCTION AND OPERATION OF THE PLC SIMULATOR UNIT

PLC System Drawings

Saudi Aramco DeskTop Standards 3

Mimic Panel Controls and Indicators

The flow valves are:

Saudi Aramco DeskTop Standards 4

Figure 1. Typical Input Circuit

Mimic Panel Status Indicators

Saudi Aramco DeskTop Standards 5

Figure 2. Typical Output Circuit

Mimic Panel Alarm Indicators

Operator’s Panel Controls and Indicators

Saudi Aramco DeskTop Standards 6

The flow valve controls are as follows:

Operator’s Panel Status Indicators are:

Saudi Aramco DeskTop Standards 7

• Auto Mode Enabled: PL336 (Amber)

The modules with 120 Vac input and output are:

The modules powered by 24 Vdc are:

Saudi Aramco DeskTop Standards 8

• Input module 1771-IBD, group 3, rack 0.

Saudi Aramco DeskTop Standards 9

Saudi Aramco DeskTop Standards 10

LOCATING SPECIFIC PLC MODULES

PLC Simulator Chassis

Saudi Aramco DeskTop Standards 11

1785 1771 1771 1771 1771 1771 1771 1771 SPARE

L20B P4S IBD IBD IBD IR IFE OFE2

1771 1771 1771 1771 1771 1771 1771 1771

ASB P4S OB OB OW OBD OBD OAD

- BLANK BLANK BLANK

Figure 3. PLC Module Layout and Racks

Saudi Aramco DeskTop Standards 12

Power Supply Modules

Module Location Technique

Saudi Aramco DeskTop Standards 13

LOCATING SPECIFIC PLC COMPONENTS

PLC Simulator Unit Cabinet

Flow Valve Subpanel

Saudi Aramco DeskTop Standards 14

Fuse and Terminal Blocks

Saudi Aramco Specifications

Saudi Aramco DeskTop Standards 15

Component Location Technique

Saudi Aramco DeskTop Standards 16