The document provides an overview of programmable logic controllers (PLCs). It describes that PLCs are designed for industrial processes and can handle sensors and actuators in real time under severe conditions. The document outlines the main functions of PLCs, including collecting inputs, running control processes through logic and algorithms, producing outputs, and providing data to supervisory systems. It also discusses the strengths and weaknesses of PLCs, as well as their hardware components like communication modules, I/O modules, and function modules that connect to sensors, actuators, and fieldbus networks. Common PLC manufacturers like Siemens and Schneider are also mentioned.
The document provides an overview of programmable logic controllers (PLCs). It describes that PLCs are designed for industrial processes and can handle sensors and actuators in real time under severe conditions. The document outlines the main functions of PLCs, including collecting inputs, running control processes through logic and algorithms, producing outputs, and providing data to supervisory systems. It also discusses the strengths and weaknesses of PLCs, as well as their hardware components like communication modules, I/O modules, and function modules that connect to sensors, actuators, and fieldbus networks. Common PLC manufacturers like Siemens and Schneider are also mentioned.
The document provides an overview of programmable logic controllers (PLCs). It describes that PLCs are designed for industrial processes and can handle sensors and actuators in real time under severe conditions. The document outlines the main functions of PLCs, including collecting inputs, running control processes through logic and algorithms, producing outputs, and providing data to supervisory systems. It also discusses the strengths and weaknesses of PLCs, as well as their hardware components like communication modules, I/O modules, and function modules that connect to sensors, actuators, and fieldbus networks. Common PLC manufacturers like Siemens and Schneider are also mentioned.
The document provides an overview of programmable logic controllers (PLCs). It describes that PLCs are designed for industrial processes and can handle sensors and actuators in real time under severe conditions. The document outlines the main functions of PLCs, including collecting inputs, running control processes through logic and algorithms, producing outputs, and providing data to supervisory systems. It also discusses the strengths and weaknesses of PLCs, as well as their hardware components like communication modules, I/O modules, and function modules that connect to sensors, actuators, and fieldbus networks. Common PLC manufacturers like Siemens and Schneider are also mentioned.
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FE Technologies
PLC basis… BE-ICS-PLC Jerónimo ORTOLA Benjamin BRADU Marc QUILICHINI Will BOOTH
[email protected] PLC- Overview PLC 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 life, around 30 years.
PLC- Weak points Limited memory.
Special 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.
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 CAN Point to Point Serial RS 232, RS 485 AS-Interface Modbus… 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 Positioning 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
standards. PLC- FieldBus. Standards 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- 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 1200 (low range) Compact Low cost Small systems 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
USER APPLICATION WriteOutputs (time consuming)
Process Cycle Cycle time 5-500 msec
OS Read Inputs communication tasks 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)
Sequence (Stepper) Sequential Function Chart (SFC) 31 PLC- Programming languages - IL IL: Instruction List
Fastest possible logic execution.
Low level language
Similar to assembly language
PLC- Programming languages - ST ST: Structured Text
High level language
Equations, table manipulation
Complex algorithms (If/Then)
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
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 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- 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. 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) UNICOS – What he is doing for me? Specifications C
Synoptic building Complete Logic
-Interlocks By drag & drop Generators -Object Dependent Logic
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
Technologies seen BE-ICS Support What comes next..
Front-End technologies 45 FE Technologies- Technologies Supervision Commercial Custom Manufacturers CERN OPC API/Driver DIM DIP Server Client Profinet Modus Server Subscriber FSM
Servers SCADA Scada
LAN
Communications DIM/DIP DIP DIP Publisher Publisher OPC DIM Other systems PLC (LHC, Safety, ...) I. Protocols
VME Unix Custom PLC Process systems Field Bus
Field buses & Nodes
Experimental equipment Sensors/devices
Front-End technologies 46 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
