PAC Systems RX3i Ethernet NIU

The Ethernet NIU makes it possible to use Series 90-30 I/O and PAC Systems RX3i remotely on an Ethernet network. Data exchange is completely automatic once set up by configuration. System control can be provided by any GE Fanuc master device capable of exchanging Ethernet Global Data. The Ethernet NIU provides automatically the controller with status information in each exchange. The program logic of application in the controller can monitor this status data, and issue appropriate commands to the Ethernet NIU.

An RX3i Ethernet NIU station contains of:
• An RX3i Universal Backplane.
• One RX3i Ethernet module or more.
• An RX3i power supply.
• Proprietary of software application.
• The RX3i Ethernet NIU.
• Series 90-30 expansions backplanes optional.
• Series 90-30 modules and/or PAC Systems RX3i as appropriate for the application.

The Ethernet NIU is compatible with the same types of backplanes, modules, and other equipment as a PAC Systems RX3i CPU. See the PAC Systems RX3i hardware and installation manual, GFK-2314 for a list of compatible products. This module requires Machine Edition Logic Developer software version 5.51 or up.

Ethernet NIU features:
• Optional local logic 20Kbytes. Supports all languages except C programming.
• Battery backed 10 Mbytes of CMOS RAM memory for local data storage.
• Built in flash memory of 10 Mbytes for local user data storage.
• Backed batter calendar clock.
• Upgradeable firmware.
• An RS-232 serial port and RS-485 serial port.
• Supports Ethernet communications via the backplane based Ethernet Interface module.
• Using data exchange EGD (Ethernet Global Data).
• Using SRTP for TCP/IP communication services.
• Diagnostic tools and comprehensive station management.
• Supports operation with redundant controllers.
• PAC Systems RX3i and RX7i controllers can send selected COMMREQ to the RX3i ENIU via Ethernet.
• RX3i Ethernet interfaces are identified by their backplane/slot location during EGD configuration.

Ethernet PLC/WinPLC Data Collection

The DataWorx Software package easily connects your Ethernet enabled DirectLogic PLCs, or Think & Do Studio or Think & Do Live! Win PLCs, to stand alone PCs or network servers for simple data logging. This means that any PC or server on the network can receive valuable PLC/WinPLC data without the need for special PC programming or any 3rd party HMI, SCADA, or DAQ software application. DataWorx is easy to set up and us. Without a doubt, DataWorx will save you both time and money.

Simply install the DataWorx software on a PC or file server on the same targeted Ethernet PLC network. Next, the PLC logic to write data to your choice of delimited text file or CSV files onto the networked PCs or file server.

Benefits of DataWorx are:
• Easy set up
• No SCADA software required
• Stores unlimited amounts of data
• Can receive data from an unlimited number of Direct PLCs, or Think & Do Studio or Think & Do Live! Win PLCs,
• Direct Logic PLC, or Think & Do Studio or Think & Do Live! Win PLCs, have completed of storing the data.

Application:
• Log valuable production data to networked PCs or file servers for Statistical process Control decision making.
• Archive test data in a secure server file location with built-in date/time stamping features to satisfy quality assurance or audit trailing procedures.
• Use in data acquisition applications as source content for historical trending to be used by higher-level business system applications.

Enriching the PLC Control Network

What would be advantage of expanding your CompactLogix and ControlLogix PLC system with intelligent remote I/O? The distributed intelligence would not only reduce the additional load on the PLC but also accommodate new special applications and functional requirements, allowing the system to grow while still under the same PLC’s overall control. You could enrich you’re a-B system by expanding its functional and size capabilities, and still be standardized on Logix PLC systems.

For instance, be standardized on Microsoft software and Dell computers but chooses other peripheral from other vendors for specific purposes, you can continue to use Allen-Bradley PLCs, software, and training and maintenance contracts while choosing another vendor for specific I/O needs. Your PLC system supplements with intelligent remote I/O gives you options that may work well in your application. Using intelligent remote I/O may cost less.

Opto 22, a company for manufacturing reliable, industrially hardened I/O, offers an intelligent remote I/O system called SNAP I/O that supports fully Ethernet/IP, the protocol used by Logix PLCs.

Because SNAP I/O supports Ethernet/IP natively, currently engineers using Allen-Bradley PLCs can supplement their expand capabilities and control networks without concerns about compatibility and communication, without extra programming and with little effect on PLC performance.

PLCs usually scan remote I/O directly through a bus-coupler which simply provides communication, not local intelligence. Adding more I/O normally requires resources of PLC both for scanning and myriad functions such as latching, counting, thermocouple linearization, PID loop control, ramping and so on. The additional one or more PID loops can impact significantly system performance.

With Opto 22’s SNAP I/O, all these functions and many more are distributed to the local I/O processor which runs them independently. This I/O intelligent processor is called a brain. The brain is much more than a bus-coupler sitting on the I/O rack, offering not just communication but extensive local functions as well, including functions such as PIC loop control that are more handled easily on the brain than on the PLC, because of different design.

The Advantages of a PLC Network

Programmable Logic Controllers are used in industrial automation and control systems. In these applications, many of the controllers implemented are not like brands and types of PLCs. It is due to many uncontrollable decisions such as:
• Frequent revisions of factory operations.
• Facility expansions.
• Contractors favoring alternate hardware.
• Fluctuating hardware process.
• Discontinuation of hardware/software.
• New management or engineering specs.

This gives the common scenario of multiple segregated control systems being used in the same plant to control various systems. These unique control systems can cause integration difficulties. The task of retrieving data from the PLC control system is sometimes impractical due to added expenses. The problem is that without buying all new control systems or very expensive software, the PLC data registry in these systems can not be monitored at the same time. The advantages of a PLC network with one common data monitoring system can be:
• Increase efficiency.
• Increase productivity.
• Better quality
• More agile system
• Maximum profitability.

The next problem entails the business side being networked with the factory side of a company. A medium needs to be created to transform data from a machine, to more useful data. This real time data will need to be available to both business owners and maintenance employees in remote locations. Depending on who accesses the data, only pertinent information to a specific area of the company needs to be given.

Requirements and Specifications of PLC Network

Wonderware by Invensys is currently one of the most popular and implemented PLC network software packages. Recent advances in National Instrument’s Lab View have also provided a way for human machine interfacing with various PLC’s. The market is calling for other mediums of networking, beyond the high price tag of Wonderware and Lab View.

The current market in automation includes a variety of OPC (open connectivity) protocol converters and software. It feels that by offering a solution to provide data logging without expensive software, the solution will become a new niche in the market.

Requirements:
• Stream multiple unique PLCs dynamic data into excel
1. Control system 1: Micrologix 1100 controller
2. Control system 2: Automation Direct Koyo 105 controller.
• Display real-time data onto a PC.
• Save data to a database.
• Display meaningful data onto a web browser.

Hardware:
• Allen Bradley: 1763 Micrologix 1100
• Automation Direct: Direct Logic 05 DO-05AA
• Automation Direct Communication Card: H0-ECOM100
• {C’s for web server, data base and factory floor
• Ethernet hubs: BELKIN F5U700 Hi-Speed USB 2.0 7-port
• Ethernet cables

Software
• Allen Bradley: RS Linx
• Automation Direct: PC-KEPEBC-3
• Microsoft Windows XP
• Microsoft Office XP (Excel)
• Microsoft Visual Studio Standard 2008 (Visual Basic.Net).

Galil Programming Language

The following application note goes over the process for connecting an Automation Direct Logic 205 PLC to a DMC-40x0 via Ethernet. It will cover multiple steps from basic connectivity to reading and writing both digital and analog I/O. it assumed that the user has knowledge of the Galil programming language, and specifically the SB., CB, MB, and IH commands.

This note will talk about this hardware setup specifically, but in generally any Galil controller can be used as substitute for the DMC-40x0, such as the DMC-21x3, DMC -22x0, DMC-14x5. In addition, almost any PLC which can communicate over the Modbus protocol, or send ASCII strings, can be used instead of the Automation Direct part.

The easiest way to connect the Galil controller and the Automation Direct PLC is over an Ethernet connection. Example, we have DMC-4040, an Automation Direct PLC, and a Windows based host PC all connected to a hub. It is important to note that when a Galil motion controller is communicating to a PLC using the Modbus protocol the Galil controller is the Modbus master and the PLC is the Modbus slave.

The first is to establish connection between the host PC and the controller. Once this connection is established, the next step is to have the controller communicate with the PLC. At this point you will need to know the IP address of the PLC.

Galil Digital Outputs SB and CB Commands

There two different sets of commands that can be used for controlling digital I/O. the lowest level of control involves the user sending Modbus commands directly, using the Galil command MB. The alternative is to use the standard Galil commands for setting I/O on the controller, there are two digital output commands, and they are SB and CB command.

These commands are the common Galil commands to control I/O, but when connected on port 502, the controller then convert them to Modbus before they are sent out. With these commands there is one more catch to the addressing, the controller needs to know which handle the PLC is connected to, and that is done with the following equation:

Address= (Handling Number)*1000 + Bit number

Handle Number: this is the number that corresponds to the letter used when opening connection. For example, if a connection is opened with IHB=…, the handle number would be 2 because B is the second letter of the alphabet.

Bit Number: the bit number is determined with the rules from the section entitled “Addressing I/O”. Once the full address is determined, controlling the output is easy. The SB command turns the output on, and CB command clears the output.

Digital Output MB Command and Digital Input

Beside the SC and CB commands, the I/O can also be controlled with direct Modbus command using the Galil command MB. To do this, Modbus function code 5 is used. If your PLC connected to handle B, and you want to set bit 6, the command would look like this

When using the Modbus commands setting MW1 will insert a small delay between subsequent Modbus commands to allow devices time to process the commands.

The bit number used is simply 6, and does not involve the equation needed for addressing with the SB and CB command. This is because the controller knows which handle to send it to by the letter after the MB.

Digital Inputs
Reading the status of the digital inputs also relies heavily on determining the address of the bit you are trying to read. Once you have to determine the address the address of the bit you are trying to read using the instruction in “Addressing I/O”, you can then issue commands in two ways. The simplest way is by using MG@IN[address]. This is similar to the SB/CB in that is converts the command into the Modbus command that is sent to the PLC. Modbus function 2 is used for reading digital inputs.

Program and Store Messages Using Remote Control ALPHA

A hand held Remote Control is used to program the ALPHA sign to store messages for later use by the PLC. For example, let’s say we want to display any of three different messages that are stored in files A, B and C on an ALPHA sign. The message displayed is based on a “closed switch” input to the PLC. When a switch is closed, the associated message is displayed and remains until a different switch is closed. You can see the ALPHA Remote Control programming.

Using hand held Remote Control, program and store the messages above in the ALPHA sign, following these steps:
Massage A
1. Press the program button.
2. Press the ADV button
3. Type: Parts bin filled. Empty now!
4. Press RUN twice

Message B
5. Press the program button.
6. Press the SELECT button.
7. Press B.
8. Press the CURSOR button until the sign’s cursor is on the bottom line.
9. Type: Safety gate open.
10. Press RUN twice.

Message C
11. Press the program button.
12. Press the SELECT button.
13. Press C
14. Press the CURSOR button until the sign’s cursor is on the bottom line.
15. Type: #8 trays empty.
16. Press RUN twice.

Baldor CST Better Drive Solutions

The Baldor CST (Controlled Start Transmission) is patented 2 in 1 drive that combines a planetary gear reducer and a hydro viscous clutch specifically engineered to deliver and synchronize power from multiple drives, and to control acceleration of high inertia loads such as long haul conveyors.

CST technology has proven to be a very reliable and robust. They are very maintenance friendly. Generally all that is required is periodic oil sampling checks, an oil and filter changes when required, and that just translates into more availability production time.

The efficient incorporation of helical and planetary reduction gears and the hydro-viscous clutch results in a low overall height and a compact footprint, provides very high torque density, and allows efficient and easily controlled synchronizing and load sharing of all drives. These are highly desirable features, particularly underground applications where height and space are always minimal.

A PLC controller (which can synchronize up to four drives) provides an appropriate S-curve start-up ramp via managed hydraulic pressure to the clutch pack. Mine wide connectivity is delivered via DH+ data highway, Ethernet or other popular proprietary links. The CST clutch technology has proven easier to balance than alternatives and is very forgiving on shock loads and surges, which are a major concern for conveyor failure.

Baldor Using Computer Modeling for Structural Designs

Baldor used extensive computer modeling to create, analyze, modify and approve designs. The most complex regions for design included structure for the crusher and apron feeder, a custom engineered curve delivery chute, the take-up carriage and belt tensioning winch, as well as the head drive configuration with elevated delivery structure.

Computer animated particle flow analysis was used to develop the best possible shape and dimensions for the curved delivery chute which was to be located below the crusher at the tail end of the conveyor. The purpose of the chute was to ensure consistent feed and to match feed rates to belt speed. This ensures minimal impact damage to the belting, and eliminates spillage and blockages.

Baldor also designed and commissioned the belt tensioning tail pulley carriage and winch. The optimum design included an Eddy current coupling, a 55kW-3Ph/380V/50Hz/1500 rpm AC motor, multi-disc wet brake, planetary gear reducer. As part of the Baldor control system, load information is sent to a dedicated PLC unit which in-turn provides the necessary signal to the winch to control the starting and running tension of the conveyor.

As part of the design process for each conveyor, Baldor also carries out extensive static and dynamic analysis of the conveyor to ensure safe operation under all foreseeable start up, shut down, full and partially-loaded conditions and power outage situations.

Conveyor Control Network from Baldor

No installation is complete without a comprehensive control system and communication network. Baldor developed and commissioned a multi layered system that delivers total control of all processes to the desk-top.

Primary control of the conveyor system is delivered to the crusher control room located at the tail-end of the conveyor. Two workstations operate RSView32 graphics software which displays all the plant control process parameters, alarms, and start/stop control of the crusher equipment and conveyor drives. Control and feedback information is delivered to six SLC504 PLC controllers over DH+ data highway.

The PLCs are located at strategic point throughput the process. PLC-1 interfaces with the CST controls for the 3 head drives, monitors stock-pile level and all the auxiliary equipment in that area including disc brake, cooling skids, speed sensors and safety interlocks.

PLCs 2, 3, & 4 are located inside the tunnel. These monitor the conveyor belt safety interlocks such as belt-sway and pull cord switches and emergency stops.

PLC-5 is located at the tail end to monitor and control the Eddy-current winch, safety interlocks in that area and belt-weighing system data.

PLC-6 is located with crusher motor control center (MCC), and controls the gyration crusher, apron feeder, dust collectors, air pumps and associated services.

The Real Time Automation Language of Mint

With nearly two decades of history, Mint was designed from the outset around the BASIC programming language. It was understood then, and it is still true today, that BASIC is the de-facto programming language around the world.

Mint fully embraces all the modern BASIC programming functionality including features such as multitasking, function and procedures, data types and local data. Mint’s new Code library makes code re-use even simpler by allowing snippets of code to be stored and used for other projects.

The advantages of Mint-Automation language are:
1. High speed compiled BASIC Programming language for motion and machine control.
2. Multitasking capability for motion, I/O, Human Machine Interface (HMI) and communication tasks. Allows complex applications to be broken down into simpler, more manageable tasks.
3. Modular programming capability, including functions and subroutines, allows for code re-use and ease of debugging.
4. Common programming interface for both Baldor’s NextMove and intelligent drives reduce the learning curve.
5. Comprehensive library of motion types including interpolated moves, CAM profiling, flying shears, gearing and more.
6. Comprehensive Windows tools including color keyword highlighting in the editor, software oscilloscope, online help, drive configuration wizard and auto tuning.
7. ActiveX components, supplied free of charge, aid in the development of Windows front end applications.

Modbus Master RTU of GP-Pro

Using GP-Pro with a GP70 series or GP77R series as a Modbus master (RTU) connected to multiple Automation Direct DL06 slaves. No communication instructions in ladder are needed. This application note is not intended for GP2000 series units. Caution: this solution uses a driver that is no an official release and has not been fully tested.

The solution is to install additional driver files in the GP-Pro Software for Modbus master. Testing was done using GP-Pro V6 with the following limited support driver.
Driver: Modbus Master RTU 1:32 OR (v3.50e).
PLC 32 Modbus RTU Slaves (Holding register).
Software requirements: GP-Pro v3.0 or newer.

Driver updates instruction:
• Copy the Modicon.apn, Modicon.epn and Modicon.hpn files into the [ProPBWin] “\Protocol” directory.
• Copy the Modicon.tbl file into the [ProPBWin] “\PlcTbl” directory.

The GP-Pro Modbus driver will only address complete words. The driver does not have the ability to read and write bits. To translate the address from the DL06 PLC to GP-Pro Modbus Master Driver refer to following table:

The PLC Program Address is the address as it appears in the PLC program.
The PLC Memory map Address is derived from the table gives PLC system V memory equivalents of other types of registers.

Koyo DL06 Communications Using Modbus/TCP

When creating Modbus/TCP client/server connection between a Koyo PLC (client) and EtherMeter features an “always on” Modbus/TCP server on TCP Logical Port 502, and it is configured to auto-detect and service incoming client requests from Modbus-compatible PLC’s. To simplify integration into a Modbus/TP network, the EtherMeter implements Modbus according to the published Modicon standard without proprietary extensions.

In the sample application, the Koyo PLC used was a model DL06, equipped with an Ethernet/Modbus communication module, and LCD Display Module.

The PLC programming software used for this project was DirectSoft5 and the ECOM100 Ethernet Module setup software was NetEdit3.
1. Wiring configuration
The Ethernet ports of the DL06 and EtherMeter are wired directly to each other, without an Ethernet switch, using a single Ethernet crossover cable. Alternatively, the Ethernet ports of both DL06 and EtherMeter could be connected to a common Ethernet switch if expanded network connectivity is desired.
2. EthernetMeter configuration
The EtherMeter was configured with the following setup commands:
SET EXP1 -1
SET EXP2 -1
3. Meter Registers
The connected meters are Senses “ICE” encoder-type registers. Both were pre-programmed to transmit eight totalization digits.

The DL06 and EtherMeter are both powered by a single AC/DC converter (24VDC output).
The DL06 is equipped with an LCD Display module (D0-06LCD).
The DL06 is equipped with an Ethernet/Modbus TCP Module.

The History of Founded PLCopen

PLCopen is an independent organization providing efficiency in industrial automation based on the needs of users. Its members, representing various industries, focus on harmonization of control programming, and application and interfacing engineering. Founded in 1992, PLCopen members have concentrated on technical specifications around IEC 61131-3, creating specifications and implementations in order to reduce cost in industrial engineering. The outcome for example is standardized libraries for different application fields, harmonized language conformity levels and engineering interfaces for exchange. Experts of the PLCopen members are organized in technical committees and together with end users define such open standards.

PLCopen was founded in 1992 just after the programming standard IEC 61131-3 was published. The controls market at that time was a very heterogeneous market with different types of programming methods for many different PLCs. The IEC 61131-3 is a standard defining the programming languages for PLCs, embedded controls, and industrial PCs, harmonizing applications independent from specific dialects, but still based on known methods such as the textual programming languages Function Block Diagram and Ladder Diagram, and the structuring tool Sequential Function Chart.

IEC 61131-3 is a highly accepted programming standard and many-industrial software and hardware companies offer products based on this standard, which in the end are used in many different machinery and other application fields.

Parking Information using PLC Keyence

PLC Type KV-10(16) Keyence , Name Input / Output PLC :

INPUT PLC :
0000 ; Ultrasonic sensor for IN detection.
0001 ; Ultrasonic sensor for OUT detection.

OUTPUT PLC :
0500 ; Output for "FULL" display.
0501 ; Output for "EMPTY" display.

PLC Programming for Parking Information using PLC Keyence

Reading Ladder PLC Programming for Parking Information using PLC Keyence :

Step 1 :
Setting Data equal capacity of parking areas
a.If 1100 = OFF Then DM0001 = 15.
Remarks :
a.1. If capacity of parking areas = 0 Then DM0001 = 10.
a.2. If capacity of parking areas = 5 Then DM0001 = 10 + 5 = 15.
a.3. If capacity of parking areas = 1000 Then DM0001 = 10 + 1000 = 1010.

Step 2 :
"FULL" display => ON
a.If 0000 = ON Then Increments the DM0000 by 1(one).
b.If DM0000 equal or more than 15 ( capacity of parking areas = 5 ) Then 1000 = ON.
c.If 1000 = ON Then 0500 = ON.

Step 3 :
"EMPTY" display => ON
a.If 0001 = ON Then Decrements the DM0000 by 1(one).
b.If DM0000 less than 15 ( capacity of parking areas = 5 ) Then 1001 = ON.
c.If 1001 = ON Then 0501 = ON.

Step 4 :
Minimum and Maximum Limits
Minimum Limits :
a.If DM0000 less than 10 ( LDB 1100 => LDA DM0000 => CMP #00010 => LD 2009 ) Then DM0000=10 ( DW #00010 DM0000 ).
Maximum Limits :
b.If DM0000 more than DM0001/capacity of parking areas ( LDB 1100 => LDA DM0000 => CMP DM0001 => LD 2011 ) Then DM0001=DM0000 ( LDA DM0001 => STA DM0000 ).

Please Download Programming for KV Builder :
Parking Information using PLC Keyence

See : Parking Information

Common Elements of Language Programming IEC 61131-3 Standard

There are many ways to view the IEC 61131-3 standard programming language. One is the common element. In general elements, data types defined. Data typing prevents errors in the initial stages. It is used to determine the types of any parameters used. This is to avoid dividing by an integer such date. Common data types Boolean, Integer, Real and Byte and Word, but also the date, Time_of_Day and String. Based on this, one can define their own types of personal data, known as derived data types. In this way, one can define the analog input channel as data type, and re-use it through again.

Variable is only assigned to explicit hardware addresses (e.g. inputs and outputs) in configurations, resources or programs. In this way created a high level of hardware independence, supporting reusability of software.

Scope of variables is usually limited to the organizational unit in which they state, local example. This means that their names can be reused in other parts without any conflict, eliminating another source of error, such as the scratch pad. If the variables should have global scope, they must be declared as such (VAR_GLOBAL). Parameters can be given an initial cold start up and restart, to get the correct settings.

Configuration, Resources and Tasks of IEC 61131-3 Standard

At the highest level, all the software needed to solve a particular control problem can be formulated as a Configuration. A special configuration for a particular type of control systems, including hardware setup, namely the processing resources, memory addresses for I / O channels and system capabilities.

In one configuration can specify one or more resources. One can view the resource as a processing facility that can be used to execute IEC programs. In resources, one or more tasks can be defined. Control task execution of a program to set and / or function blocks. This can be done periodically or upon the occurrence of certain triggers, such as a change of variables.

The program is built from a number of different software elements written in one language that defined the IEC. Typically, the program consists of a network of Functions and Function Blocks, capable of exchanging data. Functions and Function Blocks are the basic building block, which contains data structures and algorithms.

Let us compare this to the conventional PLC: This contains about resources, running one task, controlling one program, walking is a closed loop. IEC 61131-3 adds much to this, so open for the future. Future that includes a multi-processing and event-driven program

Application Flexibility of HMITechnical Implication of IEC 61131-3

Many current IEC programming environments offer everything you would expect from a modern environment: mouse operation, pull-down menus, screen graphics programming, and support for multiple windows, built on hypertext functionality, verification during design.

Technical implications of the IEC 61131-3 standard height, leaving ample space for growth and differentiation. This makes it suitable for developing standards to the next century.

IEC 61131-3 will have a major impact on all industrial control industries. This is clearly not going to limit ourselves to the conventional PLC market. Today, people see it adopted the motion control market, distributed systems and softlogic / PC based control systems, including SCADA packages. And regions are still growing.

Having a standard over such a broad application area, bringing many benefits to the user / programmer. Benefits to adopt these standards vary, depending on area of application. Just to name a few thoughts for the settings:
• Reducing waste of human resources, in training, debugging, maintenance and consulting.
• Create focus on solving problems through high levels of software reusability.
• Reduce misunderstandings and errors.
• Programming techniques that can be used in a broad environment: general industrial control.
• Combining different components from different programs, projects, locations, companies and / or state.

Relationship between IEC 61850 and IEC 61499

The term automation function is used to differentiate the functions and communication for controlling (involving automatic functions like tripping a circuit breaker, preventing an operation due to a specific interlock condition, or restoring supply to blacked out customers) and those for monitoring from a supervisory point of view (e.g. a SCADA system keeping track of sequence of events). The use of IEC 61850 models and its relationship with IEC 61499 for control functions is illustrated as below.

From the illustration above shows a single device that performs its function controls unit switchgear (circuit breakers, load break switch, disconnected, etc.). Control functions are represented in the IEC 61 850 as a logical node with the name CSWI. The CSWI have a data object attributes post with ctlVal (control values) that can be handled by the computer terminal. Substation control computer sends a message to the device with CSWI Logical node - it addresses CSWI.ctlVal attribute and set it to Open or Close.

The operation was to close the circuit breaker will not be allowed if the condition is configured to block the opening or closing are met. For example, if an adjacent earthen switch is in the closed position, closing the circuit breaker will cause a short circuit and may damage the main equipment.

Fault Location, Isolation and Supply Restoration (FLISR)

Computer based remote control of power system equipment simplifies such processes as restoring power to customers blacked out by a fault. For example, control of sectionalizing switches can be done by remote manual control using a SCADA system. SCADA has been a feature of zone substations for at least three decades. With improvements in technology, SCADA has become cost effective for distribution system equipment as well.

Recently, automated FLISR (Fault Location, Isolation and Supply Restoration) products have begun to appear on the market. These products use the SCADA system as “eyes and arms” to gather information about faults and effect the necessary control actions (opening and closing of switches). In the most common architecture, FLISR is a subsystem of a centralized DMS (Distribution Management System). This architecture leverages the existing role of the DMS as a repository for network related data such as connectivity, equipment ratings and historical load records.

Both FLISR architectures rely heavily on SCADA data communications. The centralized architecture is more compatible with existing SCADA communications network architectures, which have traditionally been designed to support centralized monitoring and control. The decentralized architecture works best with peer to peer communications. In either case, cost effective communications with distribution equipment, widely dispersed on poles and in metal cubicles, has been and continues to be difficult to achieve.

HMI Connectivity Drives Costs Down

Connectivity can be divided into the connectivity hardware and software connectivity. Hardware connectivity brings value in higher performance, reliability and tighter control of the machine or process. Data connectivity software to significantly reduce per-unit license fees that share many factories to pay today.

Hardware extensive connectivity through the HMI value is realized by reducing the burden of PLC communication. Not everyone needs to run through the PLC. Non-essential elements such as Motion control drive and barcode scanners can be easily managed by the HMI. This allows the PLC to be optimized for critical control, using a special bit I / O cards, and less practical development of the code logic. The result can be seen in improving the performance of the best in class choice plus peripheral components that are not limited to the driver that is offered by the PLC.

Connectivity software data connectivity truly and literally be able to put thousands of dollars in SCADA reduce licensing costs per unit of HMI to share data from the device connected to the plant's existing ERP, MES or SCADA system. There needs to spend even a thousand dollars a license restricted to SCADA for each would save $ 50K in the license without the impact of operating costs. These savings go right to the company's bottom line.

Application Flexibility of HMI

Applications change over time. This means your HMI application needs to be updated to match the growing needs of applications. HMI software is more flexible. The problem comes after the HMI is installed or sent to a place from a distance. How will you upgrade the remote sites? You do not want to bring your PC to the site, or if you want to give people the full source files HMI development. Not all suppliers of HMI provide field upgrades easy. But there are some suppliers that offer some good method to update the HMI in the field.

A method of upgrading a few people should look for are:
1. Compact flash cards: Upload new applications into the HMI.
2. USB memory cards: Similar to the method of compact flash.
3. Ethernet: remote connect and download the application in the facility.
4. Internet: HMI Update uses the Internet to eliminate the website of the ministry.
5. Transfer utility: A software utility that does not require full HMI software to update the HMI application.

Upgrade capabilities in this area is not easily found in the datasheet hardware. There are many costs involved in upgrading the field related to the provision and maintenance of equipment once installed. It is important to consider before selecting a vendor or product. , More can be done remotely using the upgrade tool more travel time and money would be saved.

IOVU Open Human Machine Interface (HMI)

The Input and Output Viewer (IOVU) open Human Machine Interface (HMI) facilitates simplified interaction between manual operators and computer-controlled applications through images that represents both data input and output. These images enable operators to quickly identify, evaluate and respond to potential problems.

The IEI IOVU HMI models are designed for automation applications in a diverse range of industries including manufacturing, construction, intelligent transportation, retailing, logistics management, logistics and internet.

Each IOVU is drive by an XScale PXA270 RISC-based CPU, has an IP 65 compliant touch screen THT LCD display and comes with a series of integrated external peripheral connectors including Ethernet ports, serial ports, USB ports, Compact flash slot and audio connectors. A Windows CE 5.0 Embedded OS provides Windows based functions and application software development support.

The IOVU has open software and hardware architectures enabling the easy integration of third party OEM application software such as SCADA/HMI software, database applications, networking stacks and communication applications.

Free or optional software to enable IOVU system integration and application development is available. Available software includes IEI HMI designer, OPC server for PLCs, Thin client technology, IEI Remote management tool, Software Development kit (SDK) for eMbedded Visual C++, Visual basic.NET, and Modbus client SDK.

SIMATIC WinCC SCADA System for Process Visualization

SIMATIC WinCC is the SCADA system for scalable process visualization to suit any requirement – from the single user through to redundant multi user system, as well as for plant operation and monitoring over the internet. WinCC is also the ideal information hub for IT and business integration, e.g. for the integration of MES and ERP systems. The SIMATIC IT MES system is recommended for scheduling and optimizing complex production processes.

SIMATIC WinCC flexible is consistent further development of the SIMATIC HMI software products. WinCC flexible offers a significant boost in configuring efficiency and new innovative automation concepts for machine level applications.

WinCC stands out for its diversity of applications. The basic system is designed to be independent of any specific technology or industrial sector, to be modular and flexible expandable, and to permit not only single user application in mechanical equipment manufacture, but also complex multi user solutions, or even distributed systems with several servers and clients in plant engineering.

WinCC applications that are precisely tailored to the requirements of the industrial plant have thus been created for every sector. These applications are further developed into turnkey add-on products by partners both inside and outside Siemens. If these add-ons meet the general conditions of the Premium Add-on Program for WinCC.

Device Assessments of SCADA Network

From an initial review of the network architectures, security assessment instruments and procedures are selected. The intent is to use procedures and software tools that have a low probability of causing disruption to process operations.

To conduct a device assessment, investigating the networked devices in the process areas including:
• Servers
• Human Machine Interfaces (HMI)
• Modems
• Routers/Switches
• Firewalls
• Programmable Logic Controller (PLC)
• Distributed Control Systems (DCS)
• DCS and PLC Gateways
• Intelligent Electronic Devices (IED)

The information collected (as applicable) includes:
• Operating System Version/Patches/Service Pack
• Operating Processes and Services
• Applications (Approved and Non-Approved)
• Protection Software (Antivirus, Firewall)
• Connectivity hardware (e.g. Ethernet, Serial, WLAN, Fieldbus, etc)
• Connectivity software (e.g. Remote control, Web Access, Email, FTP, etc)
• NetBIOS and NFS Shares
• Open IP Ports
• User and password security policy
• User Lists
• Other configuration
• Physical security

The device assessment is carried out by physically visiting each device and applying the appropriate tool and assessment sheet. The assessment sheets identify basic device information such as the time of assessment, assessor, plant area, location, function, application, custodian, manufacturer, model, operating system and IP address. The device is then assessed for security risk in five areas (physical access, software access, external connectivity, Device specific issues, and comments and observations).

Networking Basics of SCADA

Many automation and modernization program is now using intranet technology, Internet / in industrial control strategy. Ensure the system is a mixture of state-of-the art-and the installation of the legacy and create challenges in the implementation and enforcement of security. Intrusion control system can cause environmental damage, safety risks, poor quality and lost production.

Power engineers deal daily with PLCs, wireless LANs, IEDs, power meters, protection relays and digitally controlled MCCs. These devices rely on networks to convey information and exchange commands.

Networking these devices together was traditionally accomplished through proprietary technologies. This made it difficult to connect to the network and created a natural impediment to electronic intrusion. However, today the connection of devices using Ethernet technology is increasingly being adopted. Consequently, interfacing of industrial equipment is much easier, but there is now significantly less isolation and natural security protection.

In order to understand the threats inherent in networking these computer systems, an awareness of networking basics is required. Communications over Ethernet use TCP/IP to identify nodes and ports to identify processes running on those nodes. Company networks, or intranets, are strung together using hubs, switches and routers. User rights of these networked devices are either defined at the local computer or established in the “Domain”. Furthermore, intranets can be expanded by connecting to other intranets over the internet using Virtual Private Networks (VPN). In this way, the network grows.

The Possibility SCADA Links Use over Cellular and Internet

SCADA systems, whether the new design or system which has been operating for years, can usually migrate to high-speed networks and non-proprietary open protocol with a little planning and study options available. System designers should be familiar with the matter of functionality, delay in transmission, voting cycle, data processing requirements and the available technology. In addition, proprietary and vendor-specific protocols and programs should be avoided at all costs instead of open standards and easily interchangeable software and hardware from other vendors.

Final question for the experts on SCADA, SCADA Does working more than a mobile phone or internet links public? Possible but caution is needed. Cellular telephone networks are designed for short-term conversation, have a low level data, and vulnerable to the current call termination. Except for SCADA systems are designed for dial-up calls short term, is unlikely to be a satisfactory alternative. Internet would have a package similar to the long delay in switching the X-25 Networks example, for credit card processing) and may also suffer from packet loss that can be as high as 10% or more over a period of severe congestion. Internet might be acceptable for some monitoring and data collection, but not for real-time data collection and control requirements.

SCADAServer Address Space

The SCADAServer address space consists of all Modbus registers in all controllers that can be accessed by the server, on all communication connections. An Item ID and optional Access Path specify the registers associated with each item in a group.

The Item ID is the unique identifier of each variable in the server address space. ID specifies the controller station number, the register address and the register format. Strings in the following form describe the Item ID. Note that the format and access path parameters are optional.

station : register : [format] [@accessPath]

The server supports standard an extended Modbus addressing. If standard addressing is configured the server allows station numbers from 1 to 255. If extended addressing is configured the server allows station numbers from 1 to 65534.

Each station can have the following register addresses.

The optional format parameter defines how input and holding registers are read. Each analog register in the controller address space is a 16-bit register. The server allows two consecutive registers to be read as a single 32-bit value. This provides maximum flexibility for OPC clients.

The optional Access Path parameter is used with OPC Clients that don’t support access paths. In most cases it is not required. If the parameter is used, add the character @ followed by the Access Path to the end of the Item ID.

Combination IDP an UAC to Secure PLC Devices

The most likely vector of disturbances in the network control system is not intentional though inappropriate use. An employee or contractor can plug in his laptop to perform routine tasks without being aware that they have taken a worm or spy ware. Worms can then begin scanning the network control system, and cause interference with devices such as PLC because of unexpected traffic. This scenario is more likely with the proliferation of wireless access points. Control over the access point even though each user and device authentication is essential to guarantee security in the round.

One major concern in terms of adding a network control system is to ensure there is minimal inline device that can reduce the availability of the network. The combination of Intrusion Detection and Prevention (IDP) Series in glass mode and Unified Access Control (UAC) enables the creation of policies that restrict access to the application level, while satisfying the need to become completely passive.

For example, if the contractors send a Modbus write command to change the set point PLC, Series IDP can notify the UAC about this event. UAC minimize the need for administrators to create a variety of Access Control Lists (ACL) across the entire network control system for the provision of adequate access for each user.

Legacy Network of SCADA Protocols

The existing SCADA protocols share certain characteristics that make them highly reliable in what might be described as "a strong heritage but older" network.

These networks are often used at very low speed i.e. 300 - 1200 bits per second. The data is usually asynchronous (there is no time synchronization) and remote terminal unit through the poll of single multi-point circuits. All of these polls and responses must occur within a short time is often measured in fractions of minutes.

Currently, to meet the higher demand for data, SCADA equipment manufacturers, system designers and users start looking for higher speed devices. There are very large infrastructure telephone lines, private cable and microwave operating on sound frequency classes, where there are approximately 3000 hertz bandwidths. This is enough to pass for example 9600 bps modem quick poll. Fast poll modems in 1200 to work as a modem to the extent that they pass the data through grade voice lines, telephone lines using four-wire and works in multi-drop fashion.

In addition, a new faster network, and protocol they interact with existing SCADA protocols and present some interesting challenges. Network protocols such as frame relay, Ethernet, and IP, each has a sensitive characteristic time delay will result, causing a short gap in the data, or not to send multiple Data Carrier Detect (DCD) signal transitions. This delay can lead to SCADA protocols to consider error in the link. In this case can be resolved, then there are many new and faster communications networks are available.

Frame Relay and Ethernet of SCADA

Frame relay is a packet switch network. Data packets in frame relay network may not have direct correspondence with the size of the polling SCADA / response packet. Therefore, a SCADA package will often be broken into multiple packets by the frame relay network, with a delay between the frame relay data packets.

Typically the communication system vendors such as Sprint, MCI and AT & T type of packet switching using when the large data transport via large geographical distances. So they carry data encapsulated by the transport protocol for frames relay them through their routers available on all multi lane together long haul networks. Thus the frame is a data communication services provided by telecom operators across the network with one or more points. Cost is based on three elements of the commitment level of information, access circuit and port speed.

Ethernet is one of the Local Area Network was introduced by Xerox in the early 70s. Network type highlights a radical change in how computing done. Instead of using a terminal to access a shared mainframe or mini-computers, users now work directly on a single computer user. A computer in turn connected to a local network provides the users to share access to information stored and general peripheral equipment such as printers and fax machines.

Ethernet is a packet-oriented protocol. Ethernet packets generated regardless of the protocol of data entry. Ethernet devices must comply with the rules of the protocol, related to the need for Ethernet, allowing a variety of devices that may be connected to an Ethernet network that is similar to frame relay.

Virtual SCADA Networks

IP address based on the concept of hosts and networks. Basically any host on the network capable of receiving and transmitting IP packets on the network, such as a workstation / SCADA RTU or SCADA smart field devices such as smart control valves. It is not confused with the server: Server and client workstations all IP hosts.

The Internet has evolved so during the last 15 years. Increasing the availability of Internet and wireless technologies, SCADA vendors to find a remote access solution, which allows almost any telemetry and monitor devices that will connect to the Internet and thus the terminal of your choice. This allows you to connect to a network or device, without limited to the office.

Wireless networks come in many flavors and styles. These include:
• Satellite networks
• Permission VHF and UHF point to point and multi-point radio.
• Distribution of license free spectrum (900 MHz, 2.4 GHz, 5.8 GHz and 24 GHz).
• Point to Point Microwave.

With a narrow range within a building or campus, wireless data can be moved from node to node with a private radio network owned by spread spectrum. A wider range requires some form of public network. The most common method is to dial up the cellular, Cellular Digital Packet Data (CDPD) network or by using the Specialized Mobile Radio (SMR) or private wireless network operators.