PLC for dummies

BE-ICS-FD
Jerónimo ORTOLA
Marc QUILICHINI

[email protected]
PLC
PLC- Overview
 Programmable Logic Controller
 Designed for industrial processes.
 Works under severe conditions.
 Real time system.
 Handles sensors and actuators (I/O).
PLC- Functions
 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- Strength
 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 service life, around 20 years.
PLC- Weak points
 Limited memory.
 Low performance.
 Dedicated programming environment.
 Different programming languages from
different manufacturers.
PLC- Hardware Overview
Supervisory Control And Data Acquisition
SCADA

ETHERNET TCP/IP

PLC

INDUSTRIAL FIELDBUS
DIRECT WIRING

REMOTE I/O

SENSORS/ACTUATORS
PLC- Sensors / actuators
 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- Hardware Overview
Supervisory Control And Data Acquisition
SCADA

ETHERNET TCP/IP

PLC

INDUSTRIAL FIELDBUS
DIRECT WIRING

REMOTE I/O

SENSORS/ACTUATORS
PLC- Periphery stations
 Communication modules.

 I/O Modules.
 Convert physical value into numeric value
and vice versa.

 Function modules.
PLC- Communication modules

 Ethernet
 Profibus
 Profinet
 Modbus
 Ethernet IP
 CAN
 Serial, Point to Point
 AS-Interface
PLC- Input / Output modules
 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- Function modules

 PID control
 Flow
 Camera controllers
 Numerical controllers
 Counters, positioners.
 Motor VFD or Soft Starter
PLC- Hardware Overview
Supervisory Control And Data Acquisition
SCADA

ETHERNET TCP/IP

PLC

INDUSTRIAL FIELDBUS
DIRECT WIRING

REMOTE I/O

SENSORS/ACTUATORS
PLC- FieldBus. Overview
 Industrial Network System
 Provides the PLC with I/Os
 Time deterministic
PLC- FieldBus. Strength
 Controls multiple I/Os
 Saves cabling costs
 Allows distributed layouts and
topologies
 Safety compliant
PLC- FieldBus. Weak points
 Sensitive to electromagnetic noise.
 Installation constraints (specific
installation guidelines).
 Several different (incompatible) fieldbus
standards.
PLC- FieldBus. Standards
 Profibus
 Industry leader (56.1 million nodes)
 WorldFip
 Robust (radiation resistant)
 CAN. CANOpen. CANBus
 Low cost, Easy to implement
 Used for ELMB at CERN
 Over Industrial Erthernet:
 Profinet (16.4 million nodes)
 EtherNet/IP
 Powerlink
 EtherCAT
PLC- FieldBus. Market share
 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
PLC- Profibus

Active nodes. Master

PC
PLC PLC

PROFIBUS

Passive nodes. Slaves.

PLC- Hardware Overview
Supervisory Control And Data Acquisition
SCADA

ETHERNET TCP/IP

PLC

INDUSTRIAL FIELDBUS
DIRECT WIRING

REMOTE I/O

SENSORS/ACTUATORS
PLC- Supported at CERN

Siemens Schneider
CERN-SIEMENS B1130A/GEN 31-12-1999 CERN-SCHNEIDER. B1129/GEN 12-11-1999
PLC- Siemens
 S7 200 (low range)
 Compact
 Low cost
 Small systems
PLC- Siemens
 S7 300 (medium range)
 Modular
 Wide range of IOs
 Widely used
 Limited memory
 Limited range of fieldbuses
PLC- Siemens
 S7 400 (high range)
 Redundant
architecture
 Large memory
 High performance
PLC- Siemens – New CPUs
 S7 1500 (medium/high
range)
 Modular
 Wide range of IO
 Large memory
 High performance
PLC- Schneider
 Small range  Medium range  High range
(M340) (PREMIUM) (QUANTUM)

 4 Mb of memory  7 Mb of memory  8 Mb of memory

 1024 digital I/O  2040 Digital I/O max  8 000 Digital I/O
 256 analog I/O  512 Analog I/O  2500 Analog I/O
PLC- Schneider – New CPU
 High range (M580)

 Compact
 High performance
 Modular
PLC- Processor

Executes
user Writes Outputs
program

Scan cycle
5-500 ms

OS functions
Reads Inputs Comm
Diagnostics
PLC- Memory access, IO access
Internal 16 bits IO devices are mapped in
Data area a memory.
0
Input Input
120 %MW120 word word %IW0.2.3 Boolean %I0.6.3.1

Access to Channel in Bit in the

137 %MF137 The Module The Module Channel
Real
138

Output %QW0.2.3 Output %Q0.7.3.6

word Boolean
N
%MW100 := 12; %QW0.2.3 := 16#0F00; %Q0.7.3.6 := TRUE;
PLC- Programming languages
 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 - IL
 IL: Instruction List
 Fastest possible logic execution.
 Low level language
PLC- Programming languages - ST
 ST: Structured Text
 High level language
 Equations, table manipulation
 Complex statements and nested instructions
 Iteration loops (REPEAT-UNTIL; WHILE-DO)
 Conditional execution (IF-THEN-ELSE; CASE)
 Functions (SQRT(), SIN())
PLC- Programming languages - LD
 Traditional ladder logic is an easy-to-use
graphical programming language that
implements relay-equivalent symbol.

 Intuitive.

 Limited functionalities.
PLC- Programming languages - FBD
 FBD : Function Block Diagram
 Easy way of programming (intuitive)
 Easy way of debugging
 Limited for complex algorithms
PLC- Programming languages - SFC
 SFC : Sequential Function Chart
 A graphical method of representing a
sequential control system (stepper).
PLC- Programming software tools
 Siemens : Simatic Step7
 Modular
 Wide range of functionalities
 Diagnostic tools
 Network configuration

 Schneider : UNITY Pro V11.0

 Easy to manage
 Visualization facilities
PLC- Hardware Overview
Supervisory Control And Data Acquisition
SCADA

ETHERNET TCP/IP

PLC

INDUSTRIAL FIELDBUS
DIRECT WIRING

REMOTE I/O

SENSORS/ACTUATORS
PLC- SCADA communication
 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.