1. Allen-Bradley PLC-5 Control With A ‘Soft’ IOC 1 Jim Stevens APS Controls Group Epics Collaboration Meeting May 20, 2015 Rick Putnam APS MOM Group

2. Background 2 Introduction: APS Started User Operations in 1996 Twenty Storage Ring Process Water Control Stations Two Discrete Subsystems: “Copper” & “Aluminum” * Copper = Magnets, Power Supplies, Absorbers, etc. * Aluminum = Deionized Water For Aluminum Vacuum Chambers Johnson Controls “Local Control Panel” Controller Allen-Bradley PLC-5 * Gain Precise Control Over Circulating Water Temperature

3. 3 Storage Ring Process Water System

4. Storage Ring Process Water Station 4

5. 5 Original Hardware Setup IOC = VME, Motorola MVME-167, (2) Allen-Bradley VME 6008 Scanner Blue Hose Data Transfer Rate 57.6 kbps Blue Hose / Fiber Conversion * 1771-AF Fiber Optic Module Allen-Bradley VME 6008 Scanner Obsolete

6. 6 Network Topology VME

7. 7 Epics Evolution (2001-2007) EPICS 3.14 * IOC Core Linux Ethernet/IP Driver for Allen-Bradley ControlLogix PLC ENET PLC-5 Driver

8. PLC-5 ---> ControlLogix ---> Linux Soft IOC 8 PLC Upgrade Scheme 1. 1785-ENET Network Interface Sidecar Module 2. ControlLogix PLC / 1756-ENBT Network Module 3. Linux Box

9. 9 Old Network VME

10. New Network 10

11. 11 Network Switches & Media Converters

12. 12 EPICS Software Db/cxlogix.db record(ai, Sxx:00_FloatAI) { field(SCAN, "5 second") field(DTYP, "EtherIP") field(INP, "@clx_plc_$(NUM) PLC5_to_EPICS_FP_DATA[0]") field(PREC, "2") field(LINR, "NO CONVERSION") field(HOPR, "100.0") field(LOPR, "0.0") field(EGU, "GPM") field(EGUF, "100.0") field(EGUL, "0.0") }

13. 13 RSLogix 5000 Ladder Logic (CLX) RSLogix 5 Ladder Logic (PLC-5)

14. 14 RSLogix 5 Multihop Messaging

15. 15 RSLogix 5 MSG Instruction Detail Allows PLC-5 Processors To Transfer Data Over Ethernet –1785-ENET Module + Static IP Address MSG “Multihop” Instruction –Send File To ControlLogix PLC MSG Instruction Parameters —Control Block Address (Status & Instruction Parameters) —Number Of Elements (Binary = One 16 Bit Word, Float = Two 16 Bit Words) —Destination = Full Internet Address Of ControlLogix PLC —Starting Address Of Destination File In The Target Processor —Channel For Message Communications (PLC-5 = Channel 3A) PLC-5 Instruction Set Reference —Rockwell Publication 1785-6.1 1998 (Pg. 263 – 267)

16. Present Water Control System 16

17. Future Water Control System 17

18. 18 Enhanced and Ethernet PLC-5 Programmable Controllers –Rockwell Publication 1785-UM012D-EN-P (Pg. 203-206) ControlLogix.pdf –CLX_COM.ACD PLC-5 Logix.pdf –COM_TEST.RSP PLC-5 Instruction Set Reference Rockwell Publication 1785-6.1 1998 (Pg. 263 – 267) CLX EPICS DEMO DATABASE –clx.tar.gz PLC-5 Reference Documents

19. 19 Rick Putnam Van Nguyen Richard Farnsworth Epics Community Credits