JCOP FW Training Course

30 June – 4 July 2014

EN-ICE

Front-End technologies 2

Location and Time Schedule

ScheduleTuesday–Friday: 09:00-12:30

14:00-17:30

Monday: 14:00-17:30

Location

Building:Training Center 593-572Room #25

Front-End technologies 3

Course Outline Overview

� Front-end technologies� DCS Architecture� DIP basics� OPC basics� PLC overview� Summary

� PVSS JCOP FW� PVSS basics

� Use of JCOP FW

Tuesday-Friday

Today

Front-End technologies 4

FE Technologies

DCS Architecture

EN/ICE-SIC

Ben Farnham / Ivan Prieto Barreirohttp://cern.ch/EN-ICE

Front-End technologies 5

FE Technologies- DCS

� Expectations

� Architecture

� Layers and responsibilities (High and low level data)

� Technologies

� Follow -up

Front-End technologies 6

� Operational point of view:

� Continuous control and monitoring of field elements and processes.

� Deals with the dynamic aspects of the System.

� Manages low and high -level data.

FE Technologies- Expectations (1/2)

Front-End technologies 7

� Architectural point of view:

� Reliability

� Availability

� Operability

� Flexibility / Extensibility / Maintainability

� Security

FE Technologies- Expectations (2/2)

Front-End technologies 8

FE Technologies- Architecture

Supervision

ProcessManagement

FieldManagement

Experimental equipment

LAN

WAN

Storage

Oth

er

sys

tem

s

(LH

C,

Safe

ty,

...)

Configuration DB,

Archives,

Log files, etc.

Controller/

PLC VME

Field Bus

LAN

Node Node

Front-End technologies 9

FE Technologies- Follow -up

Supervision

Experimental equipment

LAN

WAN

Storage

Oth

er

sys

tem

s

(LH

C,

Safe

ty,

...)

Controller/

PLC VME

Field Bus

LAN

Node Node

ProcessManagement

FieldManagement

Sensors/devices

Field buses & Nodes

PLC/UNICOS

OPC

Communication Protocols

SCADA

VME

FSM

Commercial Custom

DIPConfiguration DB,

Archives,

Log files, etc.

DIM

Front-End technologies 10

FE Technologies

DIP Overview

EN/ICE-SIC

Ben Farnham / Ivan Prieto Barreiro

http://cern.ch/EN-ICE/DIP+and+DIM

Front-End technologies 11

FE Technologies- DIP middleware

� Integration and role in DCS Architecture

� DIP Principles (Development bricks and dynamic aspects)

� Pros and Cons

� DIP Browser demo

Front-End technologies 12

DIP- Integration and role in DCS

Supervision

LAN

WAN

Experimental equipment

Oth

er

sys

tem

s

(LH

C,

Safe

ty,

...)

Controller/

PLC VME

Field Bus

LAN

Node Node

ProcessManagement

FieldManagement Experimental equipment

E.g. DCS E.g. Access control

LAN

DIP

Front-End technologies 13

DIP- Introduction

� Lightweight and simple data orientedpublish/subscribe communication protocol.

� Meant for high-level (real-time) data.

� “Soft” Data contract between publishers and subscribers.

� Data carried consists of primitive types (including arrays and structures of.), quality and timestamp.

� Portable C++ and Java API, provided for Linux (SLC6) and Windows platforms.

Front-End technologies 14

DIP- Principles : Development bricks

� DIP Runtime, to be used by custom logic to publish and subscribe to DIP data.

� DIP Name Server (DNS), to maintain the mapping between the data being published and the publishers.

� That's all, any DIP “application” rely only on these 2 components.

Front-End technologies 15

DIP- Principles : Dynamic aspects

NET

DIP Name

Server (DNS)

DIP API

Manager

(PVSS)

DIP Runtime

PS BDIP Runtime

PlantManager

PS B

Browser logic

DIP Runtime

PS B

Subscribe to

“PlantStatus” dataPublish “PlantStatus”

data

“PlantStatus” published

by “PlantManager”

Server

Front-End technologies 16

DIP- Pros and Cons

� Pros:

� A very easy to use data distribution mechanism.

� Enforces decoupling between interconnected systems.

� Support for multiple platforms. And tooling available ( PVSS API Manager, DIP Browser…)

� Cons:

� No high level services (built –in fault tolerance, security, transaction, …).

� A non industry -standard middleware.

Front-End technologies 17

DIP- Browser Demo

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FE Technologies

OPC Overview

EN/ICE-SIC

Ben Farnham / Ivan Prieto Barreiro

http://cern.ch/EN-ICE/OPC+Support

Front-End technologies 19

OPC- outline

� Integration and role in DCS Architecture

� OPC Data Access

� Principles

� Pros and Cons

� Demo with real hardware

Front-End technologies 20

OPC- integration and role in DCS

Supervision

Experimental equipment

LAN

WAN

Storage

Oth

er

sys

tem

s

(LH

C,

Safe

ty,

...)

Controller/

PLC VME

Field Bus

LAN

Node Node

ProcessManagement

FieldManagement

Configuration DB,

Archives,

Log files, etc.

OPC

Front-End technologies 21

Dev. Type

2

Client 1 Client 2 Client 3 Client 4

OPC- Why do we need OPC?

Dev. Type

1

modbus CANbus

Front-End technologies 22

Dev. Type

1

Client 1 Client 2 Client 3 Client 4

OPC

Dev. Type

2

OPC

OPC- Solution: Middleware

modbus canbus

Front-End technologies 23

OPC- Concepts and Terminology

� Overview

� Component model

� Overview

� Client/Server Communication

� Address space and data Model

Front-End technologies 24

OPC- Client/Server relation

OPC Client

Process data

OPC Server

OPC Client

Process data

OPC Server

Front-End technologies 25

OPC- Data Model

Process data

OPC Server

OPC Client

OPC Group

OPC itemOPC itemOPC item

OPC Group OPC Group

OPC Client

OPC itemOPC item OPC item

Front-End technologies 26

OPC- Data Model

Process data

OPC Server

OPC Client

OPC Group

OPC itemOPC itemOPC item

OPC Group OPC Group

OPC Client

OPC itemOPC itemOPC item

OPC item

An OPC group influences on:• When a device is accessed

• How data is packaged and sent to a client• How frequently a client is informed of data changes

OPC Item propertiesName: OnType: BoolValue: TrueQuality: GoodTimestamp: 22/1/09 09.04.49Etc.

OPC item OPC item

Front-End technologies 27

OPC- Data Discovery (Browsing)

Pressure

Temperature

Power

Dev1

Dev2

PLC1

Dev1

Rack

Front-End technologies 28

� 3 types of access

� Read/Write on request: any number of items from a same OPC group on one request.

� Synchronous/Asynchronous� Device/Cache (reading only)

� Subscription reads: values sent by the server on change.� Update rate� Dead band

� Refresh

� Flags� Time stamp and quality

OPC- Data access mechanisms

Front-End technologies 29

OPC- Specifications

� OPC-DA (Data Access)� Provides access to real-time data.

� OPC-HDA (Historical Data Access) � Used to retrieve historical process data for analysis.

� OPC-AE (Alarms & Events) � OPC AE servers are used to exchange and acknowledge process alarms and

events.

� OPC-XML (XML Data Access) � Defines schema and data representation format based upon XML standard.

� OPC Unified Architecture (Under adoption in the industry)� Cross -platform, new functionality and new security strategy, not

compatible with current DA OPC servers and clients.

Front-End technologies 30

OPC- Tools

� COTS OPC DA servers� PLCs (Siemens, Schneider, Wago)� Devices (CAEN, ISEG, Wiener)

� Custom OPC DA servers� Standard ELMB

� OPC toolkits and tools� Softing (commercial)� Matrikon (commercial)� Matrikon client/server (free)� Iconics free OPC client

Front-End technologies 31

OPC- Pros and Cons� Pros

� Strong industry support

� Flexibility (dead band, groups, etc..)

� Extensibility of system

� Standard interface.

� Many tools available for free

� Cons� Windows platform

� DCOM settings

� Dev effort required for custom OPC server

� Licenses/Cost

Front-End technologies 32

OPC Client

PVSS II

CAEN OPC server

SIEMENS OPC server

WIENER OPC server

Physical devices

CAENWiener

Ethernet

Remote PC

Local PC

PLC SM 300VME crate UEP 6021

PS SY1527

OPC- architecture examples

SIEMENS

Front-End technologies 33

Physical devices

CAEN

Local PC

PS SY2527

OPC- Demo with real hardware

OPC server“caen”

OPC Client“Matrikon”

Front-End technologies 34

Break !

FE Technologies

PLC basis…EN-ICE-PLC

Jacques ROCHEZ

Jerónimo ORTOLA

plc.support@cern.ch

PLC

� Programmable Logic Controller

� Designed for industrial processes.

� Works under severe conditions.

� Real time system.

� Handles sensors and actuators (I/O).

PLC- Overview

� 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

PLC- Functions

� 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.

PLC- Strength

� Limited memory.

� Complex programming environment.

� Different programming languages from different manufacturers.

PLC- Weak points

PLC- Hardware Overview

ETHERNET TCP/IP

INDUSTRIAL FIELDBUS

REMOTE I/O

PLC

SENSORS/ACTUATORS

DIRECT WIRING

Supervisory Control And Data AcquisitionSCADA

� 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…

PLC- Sensors / actuators

PLC- Hardware Overview

ETHERNET TCP/IP

INDUSTRIAL FIELDBUS

REMOTE I/O

PLC

SENSORS/ACTUATORS

DIRECT WIRING

Supervisory Control And Data AcquisitionSCADA

� Communication modules

� I/O Modules.

� Convert physical value into numeric value and vice versa.

� Function modules.

PLC- Periphery stations

� Analog

� 16-bit signed from -32768 to 32767.

� 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.

PLC- Input / Output modules

� PID control

� Flow

� Camera controllers

� Numerical controllers

� Counters

� Positioning

PLC- Function modules

� Ethernet

� Profibus

� CAN

� Point to Point

� Serial RS 232, RS 485

� AS-Interface

� Modbus…

PLC- Communication modules

PLC- Hardware Overview

ETHERNET TCP/IP

INDUSTRIAL FIELDBUS

REMOTE I/O

PLC

SENSORS/ACTUATORS

DIRECT WIRING

Supervisory Control And Data AcquisitionSCADA

� Industrial Network System

� Provides the PLC with I/Os

� Time deterministic.

PLC- FieldBus. Overview

� Controls multiple I/Os

� Saves cabling costs

� Safety compliant

PLC- FieldBus. Strength

� Sensitive to electromagnetic noise.

� Specific installation rules.

� Several different (incompatible) fieldbus standards.

PLC- FieldBus. Weak points

� Profibus� Industry leader. 14 million nodes.

� WorldFip� Robust (radiation resistant)

� CAN. CANOpen. CANBus� Low cost� Easy to implement� Used for ELMB at CERN

� ProfinetIO� Interbus integrated (Phoenix Contact).� Ethernet based fieldbus

PLC- FieldBus. Standards

PLC- Profibus. Technical data

� Standard PROFIBUS EN 50 170

� 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

PLC- Profibus

PROFIBUS

Active nodes. Master

Passive nodes. Slaves.

PLCPLCPC

PLC- Hardware Overview

ETHERNET TCP/IP

INDUSTRIAL FIELDBUS

REMOTE I/O

PLC

SENSORS/ACTUATORS

DIRECT WIRING

Supervisory Control And Data AcquisitionSCADA

PLC- Supported at CERN

Siemens

CERN-SIEMENS B1130A/GEN 31-12-1999

Schneider

CERN-SCHNEIDER. B1129/GEN 12-11-1999

PLC- Siemens

� S7 200 (low range)

� Compact

� Low cost

� Small systems

PLC- Siemens

� S7 300 (medium range)� Modular� Wide range of IOs� Widely used� Limited memory� Limited range of fieldbuses

PLC- Siemens

� S7 400 (high range)� Redundant architecture

� Large memory

� High performance

PLC- Schneider

� Medium range (PREMIUM)

� Around 1 Mbyte

� Open to fieldbus

� Large choice of IO

� High range (QUANTUM)

� Few Mbytes.

� Bigger library of functions

WriteOutputs

Read InputsOS

communicationtasks

USERAPPLICATION

(timeconsuming)

Cycle time

5-500 msec

Process Cycle

PLC- Processor

PLC- Memory access, IO access

Internal 16 bits IO devices are mapped in Data area a memory.

%MW120

0

N

word

Real%MF137

%IW0.2.3

%QW0.2.3

Input word

Output word

%I0.6.3.1

%Q0.7.3.6

Input Boolean

Output Boolean

Access to The Module

Channel in The Module

Bit in the Channel

%Q0.7.3.6 := TRUE;%QW0.2.3 := 16#0F00;%MW100 := 12;

120

137138

PLC- Programming languages

� Traditional ladder logic is an easy-to-use graphical programming language that implements relay-equivalent symbol. Intuitive. Limited functionalities.

PLC- Programming languages

� STL: Statement List / Instruction List -Fastest possible logic execution. Low level language (similar to assembly language)

PLC- Programming languages

� FBD : Function Block Diagram

PLC- Programming languages

� ST: Structured Text - Equations, table manipulation, complex algorithms (If/Then)

PLC- Programming languages

� SFC : Sequential Function Chart -A graphical method of representing a sequential control system (stepper).

� Siemens : Simatic Step7 v5.4� Modular

� Wide range of functionalities

� Diagnostic tools

� Network configuration

� Schneider : UNITY Pro v4.0� Easy to manage

� Visualization facilities

PLC- Programming software tools

PLC- Hardware Overview

ETHERNET TCP/IP

INDUSTRIAL FIELDBUS

REMOTE I/O

PLC

SENSORS/ACTUATORS

DIRECT WIRING

Supervisory Control And Data AcquisitionSCADA

� Ehternet 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.

PLC- SCADA communication

� Framework to build control systems� UNified Industrial COntrol System� Started for LHC cryogenics industrial controls

Offers General-purpose features:� Standard way to modelize object – oriented applications.� Provides library of objects for PVSS and PLC.� Each object has its functionality defined in PLC and represented

in PVSS.� Communication between PVSS and Front-End is also provided.� In PVSS, Synoptics, Navigation,Trending, Archiving, Alarm and

Event lists are provided.� Easy development/evolution by operators/users.� Less work as possible for the application developer.� Used successfully in non-cryogenics control applications

� With PLCs Schneider/SIEMENS (LHC Gas Control System)� and LynxOS/Linux FESA front-ends

UNICOS - A CERN approach

UNICOS - Application Basic components

PLC

UNICOS FW

UNICOS objectlibrary

UNICOS SCADA Middleware

Supervision

UNICOS PLC Middleware

- Graphical components (Widgets / Faceplates)- Navigation tools- Objects explorer- Trends and alarms handling- Access control

PLC- UNICOS. Generic device appearance.

Mode

AlarmData quality

Body

Selection

Device selected

Mouse over

Device selected

mouse over

Device selected

by another Console:

No action possible

Right Click

PLC- UNICOS. PVSS screen layout

Contextual area Last received messages (Last) Device selectedRemaining

Select time

Configuration/

Management

menus Current user,

date & timeAlert row

Panel, trend horizontal navigation

(as Web Browsing)

UNICOS utilities:

WindowTree, TrendTree

AlarmList, EventList, etc.

Front-End technologies 74

Summary- EN-ICE 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

Front-End technologies 75

Thank You

FE-Technologies- End

plc.support@cern.ch

Front-End technologies 76

FE-Technologies- Summary

� Technologies seen

� EN-ICE Support

� What comes next..

Front-End technologies 77

FE Technologies- TechnologiesSupervision

Experimental equipment

LAN

PLC

VME

Field Bus

Process

Sensors/devices

Field buses & Nodes

PLC

OPC

SCADA

Unix systems

DIM

FSM

Custom

Client ServerProfinet Modus Subscriber

CERN

API/DriverOPC DIM DIP

Servers

DIP Publisher

DIP Publisher

Server

Manufacturers

I. ProtocolsOther systems

(LHC, Safety, ...)

Scada

Communications

Commercial Custom

DIM/DIP

Front-End technologies 78

Summary- EN-ICE 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

Front-End technologies 79

Thank You

FE-Technologies- End

icecontrols.support@cern.ch

http://cern.ch/en-ice

Front-End technologies 80

Location and Time Schedule

ScheduleTuesday–Friday: 09:00-12:30

14:00-17:30

Monday: 14:00-17:30

Location

Building:Training Center 593-572Room #25