FE Technologies PLC basis BEICSPLC Jernimo ORTOLA Benjamin

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

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

PLC- Functions n Process control n n Collects inputs (digital, analog) Runs the process control n n n Basic logic functions Complex algorithms (PID…) Safety functions Produces actions (outputs) Provides data to the supervision layer

PLC- Strength n n Reliable. Used for safety systems. Robust. Resistant to electrical noise, vibration, impact, dust, heat. n Extensive range of inputs/outputs. n Extensive range of functionalities. n Long term support by suppliers. n Long life, around 30 years.

PLC- Weak points n Limited memory. n Special programming environment. n 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 n Device which converts the signal from one form to another. n Sensors n n n Analog: Temperature, pressure, humidity, level, flow, weight… Digital: Level, pushbutton (emergency stop), position switch, photoelectric sensor… Actuators n n Analog: valve, pump, heater, power supply… Digital: Signaling column, contactor, electro valve, switch, On. Off 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 n Communication modules. n I/O Modules. n n Convert physical value into numeric value and vice versa. Function modules.

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

PLC- Input / Output modules n Analog n n 16 -bit signed from -32768 to 32767. Inputs: Resistance, Current, Voltage, thermocouple… Outputs: Current, voltage. Digital n n n 1 -bit Inputs: 120 v-230 v AC, 24 v DC Outputs: Relay, 120 v-230 v AC, 24 v-48 v-125 v DC.

PLC- Function modules n n n n 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- Field. Bus. Overview n Industrial Network System n Provides the PLC with I/Os n Time deterministic.

PLC- Field. Bus. Strength n Controls multiple I/Os n Saves cabling costs n Safety compliant

PLC- Field. Bus. Weak points n Sensitive to electromagnetic noise n Specific installation rules. n Several different (incompatible) fieldbus standards.

PLC- Field. Bus. Standards n Profibus (Siemens) n n World. Fip n n n Low cost, Easy to implement Used for ELMB at CERN Profinet. IO (Siemens) n n Robust (radiation resistant) CANOpen. CANBus n n Industry leader. 14 million nodes. Ethernet based Ether. Net/IP (Schneider) n Ethernet Based

PLC- Profibus. Technical data n Standard PROFIBUS EN 50 170 n Access Token ring. Master-Slave n Transmission rate 9. 6 kbit/s - 12 Mbit/s n Transmission technology electric: optic: wireless: n Nodes 127 maximun n Network lenght electric: optic: n Topology Daisy Chain, tree, star, ring, redundant ring n Used for Process communication, data transfer Shielded cooper pair twisted cable fiberoptics (cristal and plastic) infrared and radio 9. 6 km maximun 150 km maximun

PLC- Profibus Active nodes. Master PLC PC PROFIBUS Passive nodes. Slaves. PLC

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 B 1130 A/GEN 31 -12 -1999 CERN-SCHNEIDER. B 1129/GEN 12 -11 -1999

PLC- Siemens n S 7 200 (low range) n n n Compact Low cost Small systems

PLC- Siemens n S 7 300 (medium range) n n n Modular Wide range of IOs Widely used Limited memory Limited range of fieldbuses

PLC- Siemens n S 7 400 (high range) n n n Redundant architecture Large memory High performance

PLC- Siemens – New CPUs n S 7 1200 (low range) n n n Compact Low cost Small systems

PLC- Siemens – New CPUs n S 7 1500 (medium/high range) n n Modular Wide range of IO Large memory High performance

PLC- Schneider Small range (M 340) n n 4 Mb of memory 1024 digital I/O 256 analog I/O n n Medium range (PREMIUM) 7 Mb of memory 2040 Digital I/O max 512 Analog I/O n n High range (QUANTUM) 8 Mb of memory 8 000 Digital I/O 2500 Analog I/O

PLC- Schneider – New CPU n n High range (M 580) Compact High performance Modular

PLC- Processor USER APPLICATION (time consuming) Write. Outputs Process Cycle time 5 -500 msec Read Inputs OS communication tasks

PLC- Memory access, IO access Internal 16 bits Data area 0 120 137 138 %MW 120 word %MF 137 Real IO devices are mapped in a memory. Input word %IW 0. 2. 3 Access to The Module Channel in The Module Input Boolean %I 0. 6. 3. 1 Bit in the Channel Output %QW 0. 2. 3 word Output %Q 0. 7. 3. 6 Boolean %QW 0. 2. 3 : = 16#0 F 00; %Q 0. 7. 3. 6 : = TRUE; N %MW 100 : = 12;

PLC- Programming languages n Languages defined in IEC 61131 -3 n Textual languages n n n Graphical Languages n n n Instruction List (IL) Structure Text (ST) Ladder (LD) Functional Bloc Diagram (FBD) Sequence (Stepper) n Sequential Function Chart (SFC) 31

PLC- Programming languages - IL n IL: Instruction List n Fastest possible logic execution. n Low level language n Similar to assembly language

PLC- Programming languages - ST n ST: Structured Text n High level language n Equations, table manipulation n Complex algorithms (If/Then)

PLC- Programming languages - LD n Traditional ladder logic is an easy-to-use graphical programming language that implements relay-equivalent symbol. n Intuitive. n Limited functionalities.

PLC- Programming languages - FBD n FBD : Function Block Diagram n Easy way of programming n Easy way of debugging n Limited for complex algorithms

PLC- Programming languages - SFC n n SFC : Sequential Function Chart – A graphical method of representing a sequential control system (stepper).

PLC- Programming software tools n Siemens : Simatic Step 7 v 5. 5 / TIA Portal V 13 SP 1 n n n Modular Wide range of functionalities Diagnostic tools Network configuration Schneider : UNITY Pro V 11. 0 n n 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 n n n Ethernet TCP IP. Big amount of data transfer. Non deterministic. Big data transfer rates. S 7 Driver on TCP IP. Siemens. Modbus Driver on TCP IP. Schneider. OPC.

UNICOS – A CERN Approach n UNICOS : UNified Industrial COntrol System n n Based on PVSS/PLC systems for Continuous Process Control (CPC) n Cryogenics for LHC, ATLAS, CMS and other non-LHC cryo Experiments n Detector Gas Systems (LHC experiments) n Vacuum, Cooling & Ventilation Based on PVSS as SCADA with other Front-Ends (Industrial Computers) n n n n Interlock Systems (PIC, WIC, QPS) Power of the PS (POPS) Cryogenic instrumentation (CIET) Alignment of inner triplets (SURVEY) Based on a hierarchical object approach n Can be applied in Front-End(Schneider & Siemens PLC or FEC with FESA ) n 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 Synoptic building By drag & drop Generators Complete Logic -Interlocks -Object Dependent Logic - Grafcet definitions - Transition Logic Generic Logic feedbacks, I/O links, Errors. . Logic structure sections (or FC) Communication configuration Data point configuration affect addresses to signals Memory mapping affect addresses to signals Object instantiation FB (or DB) Object definition (Baseline) DFB (or FB) + DDT (or UDT) Data point creation Data point types + Widgets + Faceplates SCADA PLC

UNICOS – PVSS screen layout

Summary- BE-ICS Services n CERN-wide support n n n Field buses, PLC DIP, OPC, CANbus What we provide n n n 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 Front-End technologies 43

FE-Technologies- End Thank You plc. support@cern. ch Front-End technologies 44

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

FE Technologies- Technologies Supervision Manufacturers API/Driver Profinet Modus OPC Client Server Commercial Custom CERN DIM DIP Server Subscriber FSM Servers SCADA Scada LAN DIM/DIP Publisher Communications OPC Other systems PLC DIM I. Protocols (LHC, Safety, . . . ) VME Custom Field Bus PLC Process Unix systems Field buses & Nodes Experimental equipment Front-End technologies Sensors/devices 46

Summary- BE-ICS Services n First-line support for research sector n n CERN-wide support n n Field buses, PLC, DIP, DIM DIP, OPC, CANbus What we provide n n n 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 Front-End technologies 47

FE-Technologies- End Thank You icecontrols. support@cern. ch http: //cern. ch/en-ice Front-End technologies 48

Location and Time Schedule Building: Training Center 593 -572 Room #25 Location Monday: 14: 00 -17: 30 Schedule Tuesday–Friday: 09: 00 -12: 30 14: 00 -17: 30 Front-End technologies 49