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

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. 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 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 Saves cabling costs Safety compliant

PLC- FieldBus. Weak points Sensitive to electromagnetic noise Specific installation rules. Several different (incompatible) fieldbus 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 PROFIBUS Token ring PC PLC PLC Active nodes. Master 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 Schneider 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 (M340) 4 Mb of memory 1024 digital I/O 256 analog I/O 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

PLC- Schneider – New CPU High range (M580) Compact High performance Modular

PLC- Processor Internal mechanism of a PLC simple. (more or less like a single task processor) Not very fast from 4 to few 100 msec NO DATA acquisition from PLC No protection in the memory management the OS will not decide for you. The designer has to analyze all cases like div by zero, funny values

PLC- Memory access, IO access Internal 16 bits IO devices are mapped in Data area a memory. Input word Input Boolean 120 word %MW120 %IW0.2.3 %I0.6.3.1 Access to The Module Channel in The Module Bit in the Channel 137 138 %MF137 Real Output word Output Boolean %QW0.2.3 %Q0.7.3.6 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)

PLC- Programming languages - IL IL: Instruction List Fastest possible logic execution. Low level language Similar to assembly language Language close to old cabling used by electrician.

PLC- Programming languages - ST ST: Structured Text High level language Equations, table manipulation Complex algorithms (If/Then) Language close to old cabling used by electrician.

PLC- Programming languages - LD Traditional ladder logic is an easy-to-use graphical programming language that implements relay-equivalent symbol.  Intuitive. Limited functionalities. Language close to old cabling used by electrician.

PLC- Programming languages - FBD FBD : Function Block Diagram Easy way of programming Easy way of debugging Limited for complex algorithms Language close to old cabling used by electrician.

PLC- Programming languages - SFC SFC : Sequential Function Chart – A graphical method of representing a sequential control system (stepper). Language close to old cabling used by electrician.

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 O Complete Logic -Interlocks -Object Dependent Logic Synoptic building By drag & drop Generators - Grafcet definitions - Transition Logic Generic Logic feedbacks, I/O links, Errors.. Logic structure sections (or FC) Communication configuration Communication configuration Data point configuration affect addresses to signals Memory mapping affect addresses to signals Data point creation Object instantiation FB (or DB) Data point types + Widgets + Faceplates Object definition (Baseline) DFB (or FB) + DDT (or UDT) UNICOS SCADA PLC

UNICOS – PVSS screen layout

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 The EN-ICE-SIC section has selected tools in the three categories listed above, in particular OPC servers for simulation, recommended PLC and fieldbuses as well as for hardware currently used in CERN Hands-ON: Set of exercises to provide users with practical experience with the recommended tools and technologies. Show Case: Demonstration of FE technologies in the EN-ICE-SIC laboratory Front-End technologies 43 43

Front-End technologies FE-Technologies- End Thank You The EN-ICE-SIC section has selected tools in the three categories listed above, in particular OPC servers for simulation, recommended PLC and fieldbuses as well as for hardware currently used in CERN plc.support@cern.ch Front-End technologies 44 44

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

FE Technologies- Technologies Supervision Commercial Custom Manufacturers CERN Server OPC API/Driver DIM DIP Client Profinet Modus Server Subscriber FSM Servers Scada SCADA LAN Communications DIM/DIP DIP Publisher DIP Publisher OPC DIM Other systems (LHC, Safety, ...) PLC I. Protocols Unix systems Responsibilities for each layer: Field management: Closest layer to the field, it manages data acquisition, low level data management using low level, but high speed and robust communication protocols. Handled by low/medium intelligence level devices. Process management: This layer is in charge of the dynamic aspects of the management of equipments, the business process. (Algorithms, emergency procedures and alarms generation…). It provides high reliability and quick reaction time, and often processes the low level data to extract the relevant high level information to provide the Supervision layer with.) Supervision: The supervision layer receive the high level information processed by the Process Management layer, and often lower level data untouched by the Process Management layer for in depth analysis of plant status. Supervision is the decision layer. At this level, the Operator receives combined and summarized information to support him in the decision making process. Notice that physically, it is often the case that Process Management and Supervision are located on the same machines (Linux or Windows PCs). VME Custom PLC Process Field Bus Field buses & Nodes Sensors/devices Experimental equipment Front-End technologies

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 The IT-CO-FE section has selected tools in the three categories listed above, in particular OPC servers for simulation, recommended PLC and fieldbuses as well as for hardware currently used in CERN Hands-ON: Set of exercises to provide users with practical experience with the recommended tools and technologies. Show Case: Demonstration of FE technologies in the IT-CO-FE laboratory Front-End technologies

Front-End technologies FE-Technologies- End Thank You The IT-CO-FE section has selected tools in the three categories listed above, in particular OPC servers for simulation, recommended PLC and fieldbuses as well as for hardware currently used in CERN icecontrols.support@cern.ch http://cern.ch/en-ice Front-End technologies

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