Industrial Controls Saffety Systems Beams Department UNICOS UNIFIED
Industrial Controls & Saffety Systems Beams Department UNICOS: UNIFIED INDUSTRIAL CONTROL SYSTEM CPC (CONTINUOUS PROCESS CONTROL) BASIC COURSE SESSION 3: PLC BASICS UCPC 6 UNICOS-Continuous Process Control CERN EN/ICE group
OVERVIEW Industrial Controls & Safety Systems Beams Department 2
OVERVIEW Industrial Controls & Safety Systems Beams Department Programmable Logic Controller � Designed for industrial processes. � Works under severe conditions. � Real time system. � Handles sensors and actuators (I/O). 3
FUNCTIONS Industrial Controls & Safety Systems Beams Department 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
FEATURES Industrial Controls & Safety Systems Beams Department 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. Long life, around 30 years. 5
Industrial Controls & Safety Systems Beams Department HARDWARE OVERVIEW Supervisory Control And Data Acquisition SCADA ETHERNET TCP/IP PLC INDUSTRIAL FIELDBUS DIRECT WIRING REMOTE I/O SENSORS/ACTUATORS 6
SENSORS - ACTUATORS Industrial Controls & Safety Systems Beams Department 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, On. Off pump… 7
Industrial Controls & Safety Systems Beams Department HARDWARE OVERVIEW Supervisory Control And Data Acquisition SCADA ETHERNET TCP/IP PLC INDUSTRIAL FIELDBUS DIRECT WIRING REMOTE I/O SENSORS/ACTUATORS 8
PERIPHERY STATIONS Industrial Controls & Safety Systems Beams Department Communication modules I/O Modules. � Convert physical value into numeric value and vice versa. Function modules. 9
I/O MODULES Industrial Controls & Safety Systems Beams Department Analog � 16 -bit signed from -32768 to 32767. � Inputs: Resistance, Current, Voltage, thermocouple… � Outputs: Current, voltage. Digital � 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. 10
FUNCTION MODULES Industrial Controls & Safety Systems Beams Department PID control Flow Camera controllers Numerical controllers Counters Positioning 11
COMMUNICATION MODULES Industrial Controls & Safety Systems Beams Department Ethernet Profibus CAN Point to Point Serial RS 232, RS 485 AS-Interface Modbus… 12
Industrial Controls & Safety Systems Beams Department HARDWARE OVERVIEW Supervisory Control And Data Acquisition SCADA ETHERNET TCP/IP PLC INDUSTRIAL FIELDBUS DIRECT WIRING REMOTE I/O SENSORS/ACTUATORS 13
FIELDBUS- OVERVIEW Industrial Controls & Safety Systems Beams Department Industrial Network System Provides the PLC with I/Os Time deterministic. Saves cabling costs Sensitive to electromagnetic noise. Specific installation rules. Several different (incompatible) fieldbus standards. 14
FIELBUS STANDARDS Industrial Controls & Safety Systems Beams Department Profibus � Industry leader. 14 million nodes. World. Fip � Robust (radiation resistant) CANOpen. CANBus � Low cost � Easy to implement � Used for ELMB at CERN Profinet. IO � Interbus integrated (Phoenix Contact). � Ethernet based fieldbus 15 15
Industrial Controls & Safety Systems Beams Department PROFIBUS Active nodes. Master PLC PC PLC PROFIBUS Passive nodes. Slaves. 16 16
Industrial Controls & Safety Systems Beams Department HARDWARE OVERVIEW Supervisory Control And Data Acquisition SCADA ETHERNET TCP/IP PLC INDUSTRIAL FIELDBUS DIRECT WIRING REMOTE I/O SENSORS/ACTUATORS 17
Industrial Controls & Safety Systems Beams Department SIEMENS S 7 -200 S 7 200 (low range) � Compact � Low cost � Small systems 18
Industrial Controls & Safety Systems Beams Department SIEMENS S 7 -300 S 7 300 (medium range) � � � Modular Wide range of IOs Widely used Limited memory Limited range of fieldbuses 19
Industrial Controls & Safety Systems Beams Department SIEMENS S 7 -400 S 7 400 (high range) � Redundant architecture � Large memory � High performance 20
Industrial Controls & Safety Systems Beams Department OVERVIEW S 7 1200 (high range) � S 7200 replacement � New architecture � TIA Portal S 7 1500 (high range) � New architecture � Not redundant architecture (yet) � Larger memory � Higher performance � TIA Portal 21
Industrial Controls & Safety Systems Beams Department PROCESS CYCLE Read inputs Copy inputs to Input Process Image Comm tasks Process Cycle time 5 -500 ms Execute user program Write outputs Copy Output process Image to outputs 22 22
PROGRAMMING LANGUAGES n Industrial Controls & Safety Systems Beams Department Traditional ladder logic is an easy-to-use graphical programming language that implements relay-equivalent symbol. Intuitive. Limited functionalities. 23 23
PROGRAMMING LANGUAGES n Industrial Controls & Safety Systems Beams Department STL: Statement List / Instruction List Fastest possible logic execution. Low level language (similar to assembly language) 24 24
PROGRAMMING LANGUAGES n Industrial Controls & Safety Systems Beams Department FBD : Function Block Diagram 25
PROGRAMMING LANGUAGES n Industrial Controls & Safety Systems Beams Department ST: Structured Text - Equations, table manipulation, complex algorithms (If/Then) 26
PROGRAMMING LANGUAGES n Industrial Controls & Safety Systems Beams Department SFC : Sequential Function Chart -A graphical method of representing a sequential control system (stepper). 27
Industrial Controls & Safety Systems Beams Department HARDWARE OVERVIEW Supervisory Control And Data Acquisition SCADA ETHERNET TCP/IP PLC INDUSTRIAL FIELDBUS DIRECT WIRING REMOTE I/O SENSORS/ACTUATORS 28
SCADA COMMUNICATION Industrial Controls & Safety Systems Beams Department Ehternet TCP IP. Big amount of data transfer. Non deterministic. Big data transfer rates. S 7 Driver on TCP IP. Siemens. OPC. 29
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