Main PLC upgradation Project of PHS PRESENTED BY

Main PLC up-gradation Project of PH&S PRESENTED BY RAHMANULLAH KHAN

A State-of-the-Art Siemens PLC SIMATIC S 7 -400 H SIMATIC S 5 -155 H SIMATIC S 7 -400 H To

Overview S 7 -400 H Highlights Design SIMATIC S 7 -400 Modules CPUs

SIMATIC S 7 -400 Overview Highlights CPUs Modules Design flexibility SIMATIC S 7 -400 H System Family aa aa aa

SIMATIC S 7 -400 SIMATIC S 7 Overview SIMATIC Highlights S 7 - 400 H CPUs Modules Hot Standby (Redundant) Design flexibility STEP 7 (Programming Software) SIMATIC S 7 -400 H SIM AT I Siemens Automation C Industrial Components (Siemens’ Industrial Automation Components) CPU Series (412, 414, 416, 417)

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SIMATIC S 7 -400 Overview Highlights CPUs Modules Design flexibility SIMATIC S 7 -400 H OLD vs NEW SIMATIC S 5 SIMATIC S 7 Programming Software STEP 5 - DOS based STEP 7 - Windows based HMI Software Wonderwares SIMATIC-Win. CC Redundancy Dual Redundant I/O cards’ Address Area 16 -bit 32 -bit Performance Comparison SIMATIC S 5 Windows SIMATIC S 7 Scan Time 500 -ms 30 -ms Memory 256 -k. B 20 -MB Instr. Processing Time 0. 5 -ms 30 -ns Instruction Processing Time is 16 -times faster Digital I/O’s 4096/4096 131072/131072 Analogue I/O’s 256/256 8192/8192 16 -times reduced Scan time Memory capacity increased by 80 -times 32 -times more digital I/O’s Handling Capacity 32 -times more Analogue I/O’s Handling Capacity C C Control Center

SIMATIC S 7 -400 Overview Highlights CPUs Modules What is new in S 7? v Control stations expansion: Two control stations; 1) Operator’s control station (OCS) & 2) Engineering control station (ECS) Design flexibility v Dual Monitor Win. CC HMI SIMATIC S 7 -400 H v SITOP Module: Modular Power Supply v Redundancy Module: Redundant Power Supply Module v Wiring adapters: Plug and Play v The S 7 slot assignment is more flexible than for S 5. v The new modules do not require cooling fans.

SIMATIC S 7 -400 Overview PRINCIPLE OF OPERATION CYCLIC PROGRAM IN FIVE STEPS IS SCAN CYCLE Highlights CPUs Modules Design flexibility SIMATIC S 7 -400 H § EXTENSIVE SELF TESTS § TESTS OF I/O MODULES DURING Reading input OPERATION Writing output § DATA TRANSMISSION AND COMPARISON Storing output to memory Scan cycle Storing input to memory Processing the logic

Cyclic PLC program execution SIMATIC S 7 -400 Watch-dog Timer Overview Reading Inputs Highlights CPUs Storing Inputs Modules Logic Processing Design flexibility SIMATIC S 7 -400 H Storing Outputs Writing outputs

SIMATIC S 7 -400 overview Overview Highlights CPUs Modules Design flexibility SIMATIC S 7 -400 H system S 7 -400 FH system

SIMATIC S 7 -400 Overview Highlights CPUs Modules Design flexibility SIMATIC S 7 -400 H Windows Control Centre (Win. CC) HMI

SIMATIC S 7 -400 Overview Highlights Engineering Design CPUs Modules Performance IEC 61131 -3 Ci. R High processing speed Availability Hot Swapping Scalable Performance Graphic Programming Decentral Peripherie (DP) Communication Design flexibility SIMATIC S 7 -400 H

SIMATIC S 7 -400 Overview Highlights CPUs Modules Design flexibility SIMATIC S 7 -400 H CPU Design

SIMATIC S 7 -400 Graduated Performance Spectrum Overview Highlights CPUs Modules Type 412 -1 Design flexibility SIMATIC S 7 -400 H PLC 412 -2 PLC 414 -2 414 -3 PLC 416 -2 416 -3 PLC 417 -4 Memory is increased with CPU advancement Memory Instr. processing Communication interfaces Counters/timers 144 KB 256 KB from 100 ns 512 KB 1. 4 MB 2. 8 MB 5. 6 MB Inst. Processing time is reduced with CPU advancement from 60 ns from 40 ns 20 MB from 30 ns MPI/DP PROFIBUS-DP 2048 / 2048

SIMATIC S 7 -400 Overview Highlights CPUs Modules Design flexibility SIMATIC S 7 -400 H S 7 -400: Modules ss ss ss

SIMATIC S 7 -400 Expansion facilities with the S 7 -400 Overview An S 7 -400 programmable controller consists of a Highlights 1) Central rack (CR) 2) One or more expansion racks (ERs) CPUs Modules v Central rack (CR) v Expansion racks (ERs) Design flexibility v When using ERs, you need interface modules (IMs): SIMATIC S 7 -400 H v Need for expansion racks Central Rack (CR) Send Interface Module (IM) v up to 21 ERs Profibus DP Expansion Rack (ER) Receive Interface Module (IM)

High-available SIMATIC S 7 -400 H ET 200 M PROFINET CPU 41 x-5 H

SIMATIC S 7 -400 H Fault Tolerant Automation System Overview Redundany Features Configuration Pros & Cons PH&S Architecture Motivation for the use of H-PLC Systems Ø Expensive downtimes Ø Production Loss Ø High restart costs after control failure Ø High availability

SIMATIC S 7 -400 H Overview High Availability Overview Failure of an IO device (ET 200 M) is limited to the damaged ring node ET 200 M Redundany Features Configuration Cable break between two devices does not affect functionality of the system Master Slave Pros & Cons PH&S Architecture Failure of a CPU does not affect functionality of the redundant system Sync wiring Data synchronization CPU 41 x-5 H Automatic synchronization after replacement of faulty component CPU 41 x-5 H Switch PROFINET Switch ET 200 M Switch E 200 M

SIMATIC S 7 -400 H Synchronisation Principle Event- Synchronisation Overview Without Synchronisation Cycle. Synchronisation Time. Synchronisation Clock. Synchronisation Redundany Features Configuration Pros & Cons CPU B CPU A PH&S Architecture

SIMATIC S 7 -400 H Online Repair v S 7 -400 Components Overview Ø I/O modules Redundany Features Configuration Ø Communication Processor Pros & Cons Ø Interfacing Module and CPU PH&S Architecture Ø Power Supply v DP Components Ø IM 153 -2 Ø I/O modules

SIMATIC S 7 -400 H Overview Redundany Features Configuration Pros & Cons Benefits Achieved by Upgrading to SIMATIC S 7 Log Protocols Compressors & Dryers Monitoring Siemens Technical Support Trends MMC for CPU Spares Control Stations Expansion Compact Design MOS Flexible Monitoring Printing Facility Cost Saving PH&S Architecture

SIMATIC S 7 -400 H Overview Redundany Features PH&S Architecture Ø Total Racks installed: 12 Central Racks: 2, Expansion Racks: 10, 22 IMs Configuration Pros & Cons PH&S Architecture Ø Total Digital I/O Cards: 70 Digital Input Cards: 48 Digital Output Cards: 22 Ø Total Analogue I/O Cards: 6 Analogue Input Cards: 4 Analogue Output Cards: 2 A 0 and A 4

Operator’s Station Central Rack 2 Central Rack 1 FO Cable for H-system To All IMs 24 -V DC Power Supply 1 SITOP 1 Power Supply 2 SITOP 2 Redundancy Module PSE 202 U Expansion Racks Engineering Station SCALANCE 24 -V DC Expansion Racks