AllenBradley PLC5 Control With A Soft IOC Jim

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

Background 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 2

Storage Ring Process Water System 3

Storage Ring Process Water Station 4

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 • 5

Network Topology VME 6

Epics Evolution (2001 -2007) • EPICS 3. 14 * IOC Core Linux • Ethernet/IP Driver for Allen-Bradley Control. Logix PLC • ENET PLC-5 Driver 7

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

Old Network VME 9

New Network 10

Network Switches & Media Converters 11

EPICS Software Db/cxlogix. db record(ai, Sxx: 00_Float. AI) { field(SCAN, "5 second") field(DTYP, "Ether. IP") field(INP, "@clx_plc_$(NUM) PLC 5_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") } 12

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

RSLogix 5 Multihop Messaging 14

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 Control. Logix 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 Control. Logix PLC Starting Address Of Destination File In The Target Processor Channel For Message Communications (PLC-5 = Channel 3 A) • PLC-5 Instruction Set Reference — Rockwell Publication 1785 -6. 1 1998 (Pg. 263 – 267) 15

Present Water Control System 16

Future Water Control System 17

PLC-5 Reference Documents • Enhanced and Ethernet PLC-5 Programmable Controllers – Rockwell Publication 1785 -UM 012 D-EN-P (Pg. 203 -206) • Control. Logix. 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 18

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