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

2. PLC- Overview PLC Programmable Logic Controller
Designed for industrial processes.
Works under severe conditions.
Real time system.
Handles sensors and actuators (I/O).

3. 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

4. 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.

5. PLC- Weak points Limited memory. Special programming environment.
Different programming languages from different manufacturers.

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

7. 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…

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

9. PLC- Periphery stations
Communication modules.
I/O Modules.
Convert physical value into numeric value and vice versa.
Function modules.

10. PLC- Communication modules
Ethernet
Profibus
CAN
Point to Point
Serial RS 232, RS 485
AS-Interface
Modbus…

11. PLC- Input / Output modules
Analog
16-bit signed from to
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.

12. PLC- Function modules PID control Flow Camera controllers
Numerical controllers
Counters
Positioning
Motor VFD or Soft Starter

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

14. PLC- FieldBus. Overview
Industrial Network System
Provides the PLC with I/Os
Time deterministic.

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

16. PLC- FieldBus. Weak points
Sensitive to electromagnetic noise
Specific installation rules.
Several different (incompatible) fieldbus standards.

17. 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

18. PLC- Profibus. Technical data
Standard PROFIBUS EN
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 Token ring PC PLC PLC Active nodes. Master
Passive nodes. Slaves.

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

21. PLC- Supported at CERN Siemens Schneider
CERN-SIEMENS B1130A/GEN
Schneider
CERN-SCHNEIDER. B1129/GEN

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. 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

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

29. 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

30. 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 %I
Access to
The Module
Channel in
The Module
Bit in the
Channel
137
138
%MF137
Real
Output
word
Output
Boolean
%QW0.2.3 %Q N
%MW100 := 12;
%QW0.2.3 := 16#0F00;
%Q := TRUE;

31. PLC- Programming languages
Languages defined in IEC
Textual languages
Instruction List (IL)
Structure Text (ST)
Graphical Languages
Ladder (LD)
Functional Bloc Diagram (FBD)
Sequence (Stepper)
Sequential Function Chart (SFC)

32. 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.

33. 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.

34. 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.

35. 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.

36. 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.

37. 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

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

39. 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.

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. 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

42. UNICOS – PVSS screen layout

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
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

44. 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
Front-End technologies 44 44

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

46. 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

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
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

48. 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
Front-End technologies

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