The document provides an overview of programmable logic controllers (PLCs), including their functions, hardware components, programming languages, communication protocols, and the support services provided by CERN's BE-ICS group for PLC systems. PLCs are industrial control systems that can handle input and output signals to control machinery and processes, and are commonly used in applications that require reliability under harsh conditions. The document also discusses the UNICOS control system approach used at CERN which standardizes PLC and SCADA systems across different experimental areas.

1. FE Technologies
PLC basis…
BE-ICS-PLC
Jerónimo ORTOLA
Benjamin BRADU
Marc QUILICHINI
Will BOOTH
plc.support@cern.ch

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

15.  Controls multiple I/Os
 Saves cabling costs
 Safety compliant
PLC- FieldBus. Strength

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

19. PLC- Profibus
PROFIBUS
Active nodes. Master
Passive nodes. Slaves.
PLC
PLC
PC

20. PLC- Hardware Overview
ETHERNET TCP/IP
INDUSTRIAL FIELDBUS
REMOTE I/O
PLC
SENSORS/ACTUATORS
DIRECT WIRING
Supervisory Control And Data Acquisition
SCADA

21. PLC- Supported at CERN
Siemens
CERN-SIEMENS B1130A/GEN 31-12-1999
Schneider
CERN-SCHNEIDER. B1129/GEN 12-11-1999

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

29. WriteOutputs
Read Inputs
OS
communication
tasks
USER
APPLICATION
(time
consuming)
Cycle time
5-500 msec
Process Cycle
PLC- Processor

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

42. UNICOS – PVSS screen layout

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

44. Front-End technologies 44
Thank You
FE-Technologies- End
plc.support@cern.ch

45. Front-End technologies 45
FE-Technologies- Summary
 Technologies seen
 BE-ICS Support
 What comes next..

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

48. Front-End technologies 48
Thank You
FE-Technologies- End
icecontrols.support@cern.ch
http://cern.ch/en-ice

49. Front-End technologies 49
Location and Time Schedule
Schedule
Tuesday–Friday: 09:00-12:30
14:00-17:30
Monday: 14:00-17:30
Location
Building: Training Center 593-572
Room #25