2. PLC
Programmable Logic Controller
Designed for industrial processes.
Works under severe conditions.
Real time system.
Handles sensors and actuators (I/O).
PLC- Overview
3. Process control
Collects inputs (digital, analog)
Runs the process control
Basic logic functions
Complex algorithms (PID…)
Safety functions
Produces actions (outputs)
Provides data to the supervision layer
PLC- Functions
4. Reliable. Used for safety systems.
Robust. Resistant to electrical noise, vibration,
impact, dust, heat.
Extensive range of inputs/outputs.
Extensive range of functionalities.
Long term support by suppliers.
Long life, around 30 years.
PLC- Strength
5. Limited memory.
Special programming environment.
Different programming languages from
different manufacturers.
PLC- Weak points
6. PLC- Hardware Overview
ETHERNET TCP/IP
INDUSTRIAL FIELDBUS
REMOTE I/O
PLC
SENSORS/ACTUATORS
DIRECT WIRING
Supervisory Control And Data Acquisition
SCADA
7. Device which converts the signal from one
form to another.
Sensors
Analog: Temperature, pressure, humidity, level,
flow, weight…
Digital: Level, pushbutton (emergency stop),
position switch, photoelectric sensor…
Actuators
Analog: valve, pump, heater, power supply…
Digital: Signaling column, contactor, electro valve,
switch, OnOff pump…
PLC- Sensors / actuators
8. PLC- Hardware Overview
ETHERNET TCP/IP
INDUSTRIAL FIELDBUS
REMOTE I/O
PLC
SENSORS/ACTUATORS
DIRECT WIRING
Supervisory Control And Data Acquisition
SCADA
9. Communication modules.
I/O Modules.
Convert physical value into numeric value
and vice versa.
Function modules.
PLC- Periphery stations
10. Ethernet
Profibus
CAN
Point to Point
Serial RS 232, RS 485
AS-Interface
Modbus…
PLC- Communication modules
11. Analog
16-bit signed from -32768 to 32767.
Inputs: Resistance, Current, Voltage,
thermocouple…
Outputs: Current, voltage.
Digital
1-bit
Inputs: 120v-230v AC, 24v DC
Outputs: Relay, 120v-230v AC, 24v-48v-125v DC.
PLC- Input / Output modules
12. PID control
Flow
Camera controllers
Numerical controllers
Counters
Positioning
Motor VFD or Soft Starter
PLC- Function modules
13. PLC- Hardware Overview
ETHERNET TCP/IP
INDUSTRIAL FIELDBUS
REMOTE I/O
PLC
SENSORS/ACTUATORS
DIRECT WIRING
Supervisory Control And Data Acquisition
SCADA
14. Industrial Network System
Provides the PLC with I/Os
Time deterministic.
PLC- FieldBus. Overview
16. Sensitive to electromagnetic noise
Specific installation rules.
Several different (incompatible) fieldbus
standards.
PLC- FieldBus. Weak points
17. Profibus (Siemens)
Industry leader. 14 million nodes.
WorldFip
Robust (radiation resistant)
CAN. CANOpen. CANBus
Low cost, Easy to implement
Used for ELMB at CERN
ProfinetIO (Siemens)
Ethernet based
EtherNet/IP (Schneider)
Ethernet Based
PLC- FieldBus. Standards
18. PLC- Profibus. Technical data
Standard PROFIBUS EN 50 170
Access Token ring . Master-Slave
Transmission rate 9.6 kbit/s - 12 Mbit/s
Transmission technology electric: Shielded cooper pair twisted cable
optic: fiberoptics (cristal and plastic)
wireless: infrared and radio
Nodes 127 maximun
Network lenght electric: 9.6 km maximun
optic: 150 km maximun
Topology Daisy Chain, tree, star, ring, redundant ring
Used for Process communication, data transfer
20. PLC- Hardware Overview
ETHERNET TCP/IP
INDUSTRIAL FIELDBUS
REMOTE I/O
PLC
SENSORS/ACTUATORS
DIRECT WIRING
Supervisory Control And Data Acquisition
SCADA
22. PLC- Siemens
S7 200 (low range)
Compact
Low cost
Small systems
23. PLC- Siemens
S7 300 (medium range)
Modular
Wide range of IOs
Widely used
Limited memory
Limited range of fieldbuses
24. PLC- Siemens
S7 400 (high range)
Redundant
architecture
Large memory
High performance
25. PLC- Siemens – New CPUs
S7 1200 (low
range)
Compact
Low cost
Small systems
26. PLC- Siemens – New CPUs
S7 1500 (medium/high
range)
Modular
Wide range of IO
Large memory
High performance
27. Small range
(M340)
4 Mb of memory
1024 digital I/O
256 analog I/O
PLC- Schneider
Medium range
(PREMIUM)
7 Mb of memory
2040 Digital I/O max
512 Analog I/O
High range
(QUANTUM)
8 Mb of memory
8 000 Digital I/O
2500 Analog I/O
28. PLC- Schneider – New CPU
High range (M580)
Compact
High performance
Modular
30. PLC- Memory access, IO access
Internal 16 bits IO devices are mapped in
Data area a memory.
%MW120
0
N
word
Real
%MF137
%IW0.2.3
%QW0.2.3
Input
word
Output
word
%I0.6.3.1
%Q0.7.3.6
Input
Boolean
Output
Boolean
Access to
The Module
Channel in
The Module
Bit in the
Channel
%Q0.7.3.6 := TRUE;
%QW0.2.3 := 16#0F00;
%MW100 := 12;
120
137
138
31. Languages defined in IEC 61131-3
Textual languages
Instruction List (IL)
Structure Text (ST)
Graphical Languages
Ladder (LD)
Functional Bloc Diagram (FBD)
Sequence (Stepper)
Sequential Function Chart (SFC)
31
PLC- Programming languages
32. PLC- Programming languages - IL
IL: Instruction List
Fastest possible logic execution.
Low level language
Similar to assembly language
33. PLC- Programming languages - ST
ST: Structured Text
High level language
Equations, table manipulation
Complex algorithms (If/Then)
34. PLC- Programming languages - LD
Traditional ladder logic is an easy-to-use
graphical programming language that
implements relay-equivalent symbol.
Intuitive.
Limited functionalities.
35. PLC- Programming languages - FBD
FBD : Function Block Diagram
Easy way of programming
Easy way of debugging
Limited for complex algorithms
36. PLC- Programming languages - SFC
SFC : Sequential Function Chart –
A graphical method of representing a
sequential control system (stepper).
37. Siemens : Simatic Step7 v5.5 /
TIA Portal V13SP1
Modular
Wide range of functionalities
Diagnostic tools
Network configuration
Schneider : UNITY Pro V11.0
Easy to manage
Visualization facilities
PLC- Programming software tools
38. PLC- Hardware Overview
ETHERNET TCP/IP
INDUSTRIAL FIELDBUS
REMOTE I/O
PLC
SENSORS/ACTUATORS
DIRECT WIRING
Supervisory Control And Data Acquisition
SCADA
39. Ethernet TCP IP.
Big amount of data transfer.
Non deterministic.
Big data transfer rates.
S7 Driver on TCP IP. Siemens.
Modbus Driver on TCP IP. Schneider.
OPC.
PLC- SCADA communication
40. UNICOS – A CERN Approach
UNICOS : UNified Industrial COntrol System
Based on PVSS/PLC systems for Continuous Process Control (CPC)
Cryogenics for LHC, ATLAS, CMS and other non-LHC cryo Experiments
Detector Gas Systems (LHC experiments)
Vacuum, Cooling & Ventilation
Based on PVSS as SCADA with other Front-Ends (Industrial Computers)
Interlock Systems (PIC, WIC, QPS)
Power of the PS (POPS)
Cryogenic instrumentation (CIET)
Alignment of inner triplets (SURVEY)
Based on a hierarchical object approach
Can be applied in Front-End(Schneider & Siemens PLC or FEC with FESA)
Can be applied in SCADA (PVSS)
Easy to use CERN services and link different control systems
UNICOS helps operation teams and developers (standardization)
41. Data point types + Widgets + Faceplates
UNICOS – What he is doing for me?
PLC
C
Object definition (Baseline)
DFB (or FB) + DDT (or UDT)
Data point creation
Object instantiation
FB (or DB)
Data point configuration
affect addresses to signals
Memory mapping
affect addresses to signals
Generic Logic
feedbacks, I/O links, Errors..
Logic structure
sections (or FC)
Complete Logic
-Interlocks
-Object Dependent Logic
Communication configuration
Communication configuration
SCADA
O
Specifications
Generators
- Grafcet definitions
- Transition Logic
Synoptic building
By drag & drop
43. Front-End technologies 43
Summary- BE-ICS Services
CERN-wide support
Field buses, PLC
DIP, OPC, CANbus
What we provide
Architecture and design recommendations
List of recommended tools/cards
Validation of new commercial software versions
Maintenance of custom software
“Hands On” facility for you to practice
“Show Case” facility as a demonstrator
46. Front-End technologies 46
FE Technologies- Technologies
Supervision
Experimental equipment
LAN
PLC
VME
Field Bus
Process
Sensors/devices
Field buses & Nodes
PLC
OPC
SCADA
Unix
systems
DIM
FSM
Custom
Client Server
Profinet Modus Subscriber
CERN
API/Driver
OPC DIM DIP
Servers
DIP
Publisher
DIP
Publisher
Server
Manufacturers
I. Protocols
Other systems
(LHC, Safety, ...)
Scada
Communications
Commercial Custom
DIM/DIP
47. Front-End technologies 47
Summary- BE-ICS Services
First-line support for research sector
Field buses, PLC, DIP, DIM
CERN-wide support
DIP, OPC, CANbus
What we provide
Architecture and design recommendations
List of recommended tools/cards
Validation of new commercial software versions
Maintenance of custom software
“Hands On” facility for you to practice
“Show Case” facility as a demonstrator
