The Development Tools of CoDeSys

Powerful IEC 61131-3 development tools are provided for writing, maintaining and debugging application programs. This development environment will assist you in writing your program application by providing automatic variable declaration, syntax coloring, automatic code formatting, and global search/replace functionality. There are tools for exporting and importing code modules, and a Library Manager for adding additional system libraries to your project.

The Input Assistant identities possible entries for function calls, input variables and IEC keywords. A simulation mode is available for testing your program logic without needing the controller and other hardware.

A watch window is provided for writing and monitoring variable values to debug your application, along with tools for setting real time program break points, single cycling or single stepping through the program. A digital storage scope provides cyclic or single shot storage and can display up to eight program variables to monitor your machine during operation.

The development environment of CoDeSys provides tools for creating visualizations which can be used to build diagnostic displays and operator entry useful for testing and debugging the application.

When your application program is complete, all the supporting files and the source can be downloaded to SMLC. The files of Application program source can be password protected to limit access to authorized personnel only, and the controller acts as a medium storage for the software application, making field maintenance a snap.

A key strength of the CoDeSys development environment is the different types of text and graphical based programming tools it provides for a particular job, simplifying both the software development process and support of the machine by engineering and plant personnel.

Programming tools simplify software development, such as:
CoDeSys Development Tools
• Suite of charting tool and programming languages simplifies machine development support.
• Program motion control and logic using standard IEC 61131-3.
• Select among text and graphical based languages.

Industrial Sectors and Interdependencies

Both the distribution grid and electrical power transmission industries use geographically distributed SCADA control technology to operate highly dynamic systems and interconnected consisting of thousands of public and private utilities and rural cooperatives for supplying electricity to end users. SCADA systems control and monitor electricity distribution by collecting data from and issuing commands to geographically remote field control stations from a centralized location. SCADA systems also used to control and monitor water, oil and natural gas distribution, ships truck, pipelines and rail systems.

DCS and SCADA systems are often networked together. This is the case for electric power generation facilities and electric power control centers. Although the electric power generation facility operation is controlled by a DCS. The DCS must communicate with the SCADA system to coordinate output of production with transmission and distribution demands.

Electric power is often thought to be one of the most prevalent sources of disruptions critical infrastructures interdependent. For example, a cascading failure can be initiated by a disruption of the microwave communication network used for an electric power transmission SCADA system. The lack of control and monitoring capabilities could cause a large generating unit to be taken offline, an event that would lead to the loss of power at a substation of transmission.

DeCoSys Development Utilizes PLCOpen and IEC 61131-3

Developing I/O programming and motion control using a standard set of software tools streamlines software development and creates application programs that are easier and more effective to support in the field. The DeCoSys Development Software utilizes PLCopen motion function blocks and standard IEC 61131-3 programming to provide proven, open standard tools for developing application programs for I/O control and motion control, running on a single controller.

The advantage of IEC 61131-3 is that it provides an integrated set of graphical interfaces and software tools to meet a wide range of software development needs:
• LD (Relay Ladder Logic).
• FBD (Function Block Diagram).
• SFC (Sequential Function Chart).
• ST (Structured Text).
• IL (Instruction List).
Developing application program using IEC 61131-3 offers the following advantages:
• Provide flexibility for selecting the best programming approach and methods for specific application requirements and tasks.
• Reduces training cost by learning one set of programming languages used by multiple control vendors.
• Offer the ability for the programmer to deploy and develop reusable function blocks which can reduce future software development cost and protect your company’s intellectual properties.

PLCOpen is promoting IEC 61131-3 as an independent worldwide association that has defined standard motion programming function blocks which cover all the IEC 61131-3 languages programming.

ORMEC’s implementation of motion programming (ServoWire Motion Blocks) conforms to the PLCopen motion block definitions and provides flexible, powerful functionality beyond that defined in the standard. A variety of applications can be written in any of the IEC 61131-3 programming languages using the ServoWire Motion Blocks.

The ServoWire Motion Blocks provide the enhanced functionality as following:
• Move relative in time.
• Move relative at velocity.
• Move absolute in time.
• Move absolute at velocity.
• Gear relative at ratio.
• Gear relative in master distance.
• Cam relative.
• Plus administrative function blocks including enhanced diagnostic capabilities.

Control Components of ICS

Below is the list of the major components of an Industrial Control Systems (ICS):
• Master Terminal Unit (MTU) or SCADA Server. In a SCADA system the SCADA server is device that acts as the master. PLC and RTU located at remote field site usually act as slaves.
• Control Server, the control server hosts the PLC or DCS supervisory control software which is designed to communicate with lower level control devices.
• Remote Terminal Unit, RTU is also called as a remote telemetry unit. It is special purpose control unit and data acquisition designed to support SCADA remote stations.
• Programmable Logic Controller, the PLC is a small industrial computer originally designed to perform logic function that executed by electrical hardware such as, switches, relays, and mechanical timer or counters.
• Intelligent Electronic Devices, IED is a smart actuator or sensor containing the intelligence required to acquire data, perform local processing and control, and communicate to others devices.
• Human Machine Interface, the HMI is hardware and software that allows human operators to monitor the state of a process under control.
• Data Historian, the history of data is a centralized database for logging all process information within an ICS.
• Input/Output Server, the IO server is a control component responsible for collecting, providing and buffering access to process information from control sub components such as, IEDs, PLCs, and RTUs.

ICS Control Systems for Critical Infrastructures

ICS is including supervisory control and data acquisition (SCADA) systems, DCS, and other control system configuration such as skid-mounted PLC which often found in industrial control. ICS are generally used in industries such as oil and natural gas, water and wastewater, electric, chemical, transportation, pharmaceutical, pulp and paper etc.

SCADA systems are usually used to control dispersed asset using centralized and data acquisition and supervising control. DCS are typically used to control the system of production within a local area such as factory using supervisory and regulatory control. PLCs are usually used for discrete control for specific applications and generally provide regulatory control.

These control systems are very vital and important to the operation of critical infrastructures that are often highly interconnected and mutually dependent systems. Firstly, ICS had little resemblance to traditional of information technology (IT) systems. In that ICS were isolated systems running proprietary control protocols using specialized software and hardware. Low cost Internet protocol devices are replacing proprietary solutions now, it makes increasing the possibility of cyber security vulnerabilities and incidents.

ICS are adopting IT solutions to promote corporate business systems remote and connectivity access capabilities, and are being designed and implemented using operating systems, standard computers and network protocols.

Network Components of ICS
There are different network characteristics for each layer within a hierarchy of control system. Network topologies across different ICS implementations vary with modern system using enterprise integration strategies and internet based IT. Control networks have merged with corporate networks to allow control engineers to control and monitor systems from outside of the network of control system. Below is a list of the major components of an ICS network:
• Fieldbus Network. The fieldbus network links sensors and other devices to a PLC, use of fieldbus technologies eliminates the need wiring point to point between controller and each device.
• Control network. The control network connects the supervisory to lower level control module.
• Communication routers. A router is the communicating device that transfer messages, it can be LAN or WAN.
• Firewall. A firewall protects device on the network by controlling and monitoring communication packets using predefined filtering policies.
• Modems. A modem is device used to convert serial data digital and a signal suitable for transmission to allow devices to communicate. Modem is often used in SCADA systems to enable serial communication between remote field devices and MTUs.
• Remote Access point. Remote access points are distinct areas, devices and locations of a control network for remotely accessing process data and configuring control systems.

The Security between ICS and IT

There is a significant difference between the philosophies of security of enterprise ICS and IT. The purpose of enterprise security is to protect ability of the facility to securely operate and safely, regardless of what may be fall.

Cyber refers to communication of electronic between individual and/or systems. This term applies to any electronic device with network or serial connections. The term cyber addresses all electronic impact on ICS operation including:
• Unintended consequences such as from worms or viruses.
• Targeted attacks.
• EMP (Electro magnetic Pulse).
• EMI (Electro Magnetic Interference).

The terms of ICS includes:
• ACS ( Automated Control Systems)
• DCS (Distributed Control Systems)
• PLC (Programmable Logic Controller)
• SCADA (Supervisory Control and Data Acquisition) systems
• Intelligent electronically operated field devices, such as controllers, valves, instrumentation.
• System of network computer.
The design and operation of IT systems and ICS are different. The IT designers are generally the skilled scientist in the IT world. They view the enemy of the IT system as an attacker and design in extensive security controls and checks. The ICS designers are generally the skilled engineers in the controlling of ICS. They view the enemy of the ICS is system failure not as an attacker.

Programming PLC with CoDeSys

CoDeSys consists of two parts: a runnable under Microsoft Widows operating systems, a complete graphical PLC software development environment, and a PLC runtime kernel for the RTOS-UH real time operating system. RTOH-UH guarantees for a proven and stable runtime environment for the CoDeSys kernel, featuring:
• IEC task with pre-emptive multitasking.
• Integration of PEARL and ANSI-C.
• Programming PLC according to the standard IEC 61131-2, with 5 languages of PLC programming: LD, FBD, SFC, ST, IL.
CoDeSys combines a PC’s ease and comfort of use with the flexibility of a PLC and the reliability of the real time system RTOS-UH.

A broad spectrum of efficient tools for program development is at hand with CoDeSys. Programming is possible on line as like as off line. An integrated simulator of PLC allows testing critical program sections offline without interrupting production systems.
• Syntactic coloring of elements language.
• Automatic formatting of the source code of program.
• Smooth integration into the GUI concept of the development operating system. All of 5 programming languages LD, FBD, SFC, ST, IL, are supported.

For test debugging, all modern programming tools are at hand:
• Detailed supervision of the PLC with single cycle or continuous forcing variables.
• Monitoring inputs/outputs as an internal variables, even though with the control being online.
• Change the PLC program online without interrupting a running process.
• The control single cycle.
• The PLC’s inspection state at discrete program steps by breakpoints.
• Full flow control by single stepping the control from statement to statement.
• State visualization with program flow and continuous display of line states.
• Watching of variables to catch sporadic error conditions.

Graphical display and operating is provided by the CoDeSys user interface:
• Visualization of the state of program and plant.
• The operation setting conditions by batch processing and recipe administration.
• Archiving and charting of plant data by variable trace.
The control is independently operated from the user interface. Manual operating and headless are supported.

Assuring Industrial Control System Cyber Security

Industrial Control Systems (ICS) are an industrial infrastructure integral part that providing for the national good. Theses systems include Supervisory Control and Data Acquisition Systems (SCADA), Distributed Control Systems (DCS), Programmable Logic Controller (PLC) and devices such as remote telemetry units (RTU), smart meter, and intelligent field instruments including remotely programmable valves and intelligent electronic relays. ICs are administratively, technically, and functionally more complex and unique than business IT systems while sharing basic constructs with information technology (IT).

To secure these critical systems are too diffuse and do not specifically target the unique ICS aspects. The following recommendations provide steps to improve the reliability and security of the very critical systems:
• Need to develop a clear understanding of ICS cyber security.
• Need to define cyber threats in the broadest possible terms.
• To develop best practices and security technologies for the field devices.
• Develop the curricula of academic in ICS cyber security.
• Leverage best practices and appropriate IT technologies for securing workstations.
• Establish standard certification metrics for ICS systems, processes, personnel and cyber security.
• Establish, support and promote an open demonstration facility dedicated to best practices for ICS systems.
• Change the manufacturing culture in critical industries so that security is considered as important as safety and performance.

PLC Program with easySoft CoDeSys

The Moeller philosophy consistently follows: a software package both for creating the visualization screens and for programming. No additional visual package is required. PLC visualization and program are created on one user interface. The designer only has to play around wit a package of software.

easySoft CoDeSys is an IEC 61131-2 compliant system programming based on CoDeSys from 3S for industrial PLCs. Matured technical features, simple handling and the widespread use of this software in the components automation of different manufacturers make it a guarantee for success. This success is demonstrated impressively with Moeler’s new 5.7” multi function display.

The MFD4-5-XRC-30 enables existing visualization functions to be used on separate target hardware. The MFD4 is also equipped with a web server naturally. The special feature: web visualization and target visualization can be run simultaneously. The benefits of only a software package for visualization and programming are obvious: the direct access to the variables of the PLC provides for greater clarity and reduces the project design work required. No separate software of visualization is required. The otherwise unavoidable and often error-prone export and import of symbolic variable lists is necessary. The software for everything is the principle and that is easy to use.

The visualization editor integrates a number of functions such as alarm management, recipe management, password management, language selection and online project simulation on the PC. The following elements enable the design of sophisticated visualization screens ellipse, polygon, rectangle, polyline, pie, curve, button, table, bitmap, bar, display, meter, trend. Complete visualizations can be stored in libraries and then called up in different project as POUs library.

Alarm tables can be tailored in easySoft CoDeSys to the specific requirements of each application. You can build table using an alarm parameters host. For instance, you can define the acknowledge procedure in alarm classes. For each alarm group you define a file in which the alarms are store. You can switch simply between the alarm and the history list online.

Electric Power SCADA Systems

Control systems are the brains of the monitoring and control of the bulk electric system and other critical infrastructures, but they were designed for performance and functionality, not security. Most Control Systems assume an environment of implicit and complete trust. The protocols, devices and communication media do not support the ability to adequately prevent cyber attacks against our critical infrastructures.

Currently, hundreds of SCADA protocols exist, some of protocols are capable to support more than just control functions and telemetry. SCADA protocols were designed with noisy serial communication environment and use cyclic redundancy codes (CRC) or similar technology. It is present for detection and correction of errors. The message sender will calculate the CRC and compare it to the value received with the message.

Another characteristic for SCADA protocols is the inability to provide validation or authentication services. This is the primary reason why SCADA systems assume an implicit trust level. For instance, when a message is received by an RTU then the source of the message is checked. And if that source is known then the request is enacted. The trends of protocol are a concern as well. DNP3 is becoming the de facto standard in the electric distribution world and DNP is an open standard.

Omron PLC for Serial Communication and Networks

Communications between micro and small controllers and networks or other devices has never been easier. Many models have built in communication ports or can be upgraded via adapters or inner boards, enabling communications with Omron’s larger PLCs in an environment of distributed control. Most Omron controllers are accessible via a single programming cable, eliminating the need for multiple cables to support the installation.

Serial communications
The Omron models offer RS-232C communications, some with built in ports, others use an adapter. Multiple ports are available for simultaneous communication to barcode readers, modems, HMIs, handheld programmers and other devices. To connect your personal computer for programming the controller can be used RS 232 port. The communication adapters can convert the peripheral port to use the RS 232C.

Serial Networks
RS 485 and RS 422 communication ports can be implemented into your controller system for an easily configured multi drop serial network.

Protocol Macro
This advance serial communication feature incorporates a separate co processor that allows a programmer to customize the string of serial communication that will communicate with any serial devices virtually.

Direct HMI connection
High speed communications with NT/NS series message displays and touch screens using plug and play connection to the peripheral port or an RS 232C port is offered direct by Omron. The NT2S message display gets both power and data from the peripheral port. Machine operators get real time data on work in process to keep the high productivity.

Controller link
Omron’s high speed Controller Link network transfers information at 2 Mbps to up to 32 nodes. Open up the included network configuration tool from PC, identify the nodes, and watch the network develop in front of your eyes. The programmable controllers that support Controller Link include: CV Series, CS1, CJ1, and COM1H.

Field network
Both proprietary and open device level architecture can be implemented within Omron’s micro and small controller families. Whether your application requires an interface to AS-I, DeviceNet, or Omron’s fast CompoBus/S network, Omron can meet your needs.

DynaStar DX Migration to Secure IP Routed Networking

The transition to IP can happen in two separate phases, creating different issues. First phase, central servers will move from serial interfaces to Ethernet interfaces within the control center before remote devices using Ethernet are deployed at substations. These Ethernet-based Master systems will assume that remote devices are accessed by remote Serial-IP terminal servers and that the WAN network is based on IP. A serial-IP is not supported non-routable WAN.

DynaStar can resolve the above issue. DynaStar can enable the central server migration to Ethernet without disrupting the Serial-FR non-routable approach to remote substations. A DynaStar network node can act as a gateway between TCP/IP traffic originating from Serial-FR and Master Systems SCADA Frame Forwarding traffic to the remote substation.

The second phase, IP migration occurs at the substation where eventually Ethernet devices will be deployed requiring IP based connectivity to central systems. There will be increasing pressure over time to provide administrative and engineering access to substation of IEDs and RTUs via an IP network, both to serial devices (using Serial-IP) and to substation Ethernet devices. Magnum and DynaStar products integrate Ethernet, WAN and serial interfaces with frame relay and IP routing in a single compact device. Serial devices via Serial-IP, Ethernet-based IEDs, and serial devices via SCADA Frame Forwarding can all be attached to the same DynaStar/DX within a substation.

Big Controller Features Scaled for Small Machine Control of Omron PLC

The functions below listed to help you integrate more sophisticated control into your machine design using the programmable controller.

Online editing
Omron’s CX programmer software has an online of function editing that lets you change ladder instructions within your program without have to stop PLC scanning. This does not interrupt production operations and shorten debugging time. This feature is available at all Omron PLCs except ZEN.

Expandability
The ports expansions are standard on most of the controllers. This feature gives the ability to the user to add expansion modules via a single cable connection giving your system more flexibility and I/O control. Use specialized or discrete expansion modules to add I/O as your application requires it.

Removable terminals
Removable terminals are ideal for Manufacturers and integrators to make your maintenance and installation as efficient as possible. By wiring terminal strip you save time in the field when its time to replace or install the controller.

Specialized I/O
Micro and small control systems offer specialized I/O:
Analog I/O – apply or monitor analog signals within your application. Multiple input and output points can be added to the most controllers of Omron. Modes are standard in high or standard resolution enabling you to maximize the efficiency of the process.

Temperature sensor input – Monitor process temperature then use the input to start the corrective action through the controller.

Temperature controller – these modules allow you to control and monitor multiple process loops directly within your control system. The operation of multiple modes and heater burn out detection are also available.

Linear sensor interface – these modules handle length measurement automatically by converting linear analog inputs and built in alarm features that you can use to work with your process.

Synchronized pulse control
This function use to match conveyor speed or in closed loop control for coordinated positioning. Scale the frequency of output pulse to multiple of the frequency of input pulse with just a single instruction.

Weighing Machine Using PLC Mitsubishi

PLC Type FX, Name Input / Output PLC :

INPUT PLC :
X000 ; Sensor Object
X001 ; Sensor for empty containers
X002 ; Sensor for detection position of the Rotary container
X003 ; Weighing : GO/OK

OUTPUT PLC :
Y000 ; Output to Yellow Lights for the Empty
Y001 ; Output to Red Lights for Weighing Not OK
Y002 ; Output to Green Lights for Weighing OK
Y003 ; Output to Contactor for Electric Motor
Y004 ; Weighing : Digital Zero Reset

PLC Programming for Weighing Machine using PLC Mitsubishi

Reading Ladder PLC Programming for Weighing Machine using PLC Mitsubishi :

Step 1 :
ALL Process ON/OFF
a.If X000 = ON Then M0 = ON (PLS)
b.If M0 = ON AND X000 = ON AND M9 = OFF Then M1 = ON (ALL PROCESS ON)
c.If X000 = OFF (ALL PROCESS OFF)
d.If X001 = OFF AND M2 = ON Then M9 = ON ( ALL PROCESS OFF )

Step 2 :
Red Lights = OFF
Green Lights = OFF
a.If M0 = ON AND M1 = ON AND M3 = OFF Then M2 = ON
b.If M2 = ON Then M7 = OFF (RST M7 = ON) AND M8 = OFF (RST M8 = ON)
c.If M7 = OFF Then Y002 = OFF (Green Lights = OFF)
d.If M8 = OFF Then Y001 = OFF (Red Lights = OFF)

Step 3 :
Digital Zero Reset = ON
a.If M2 = ON AND T000 = ON AND M1 = ON AND M4 = OFF Then M3 = ON
b.If M3 = ON Then Y004 = ON (Digital Zero = ON)

Step 4 :
Rotary container = ON / OFF
a.If M3 = ON AND T001 = ON AND M1 = ON AND M5 = OFF Then M4 = ON (Hold ON)
b.If M4 = ON Then Y003 = ON (Electric Motor = ON)
c.If X002 = OFF AND M4 = ON AND M1 = ON AND M5 = OFF Then M10 = ON (Check Sensor position = OFF)
d.If M4 = ON AND Y003 = ON AND M10 = ON AND X002 = ON AND M1 = ON AND M6 = OFF Then M5 = ON ( Electric Motor = OFF )
e.If M5 = ON Then M4 = OFF
f.If M4 = OFF Then Y003 = OFF ( Electric Motor = OFF )

Step 5 :
Weighing : GO/OK = ON/OFF
a.If M5 = ON AND T002 = ON AND M7 = OFF AND M8 = OFF AND M1 = ON Then M6 = ON (Judgment OK/NOT OK)
b.If M1 = ON AND M6 = ON AND X003 = ON Then M7 = ON (SET M7 = ON) =>Weighing OK
c.If M1 = ON AND M6 = ON AND X003 = OFF Then M8 = ON (SET M8 = ON) =>Weighing NOT OK
d.If M7 = ON Then Y002 = ON (OK)
e.If M8 = ON Then Y001 = ON (NOT OK)

Step 6 :
Empty Containers
a.If X001 = OFF AND M2 = ON Then M9 = ON (ALL PROCESS OFF)
b.If X001 = ON Then Y000 = ON (Yellow Lights = ON)

Please Download Programming for GX Developer :
Weighing Machine using PLC Mitsubishi

See : Weighing Machine

GarretCom’s SCADA Frame Forwarding

GarretCom’s substation routers have two principal modes of serial communications of transporting over a WAN, one routed and one non-routed. These two modes will co-exist on a common WAN in many implementations. SCADA Frame Forwarding is referring to the non-routable transport mode and some times call as Serial over Frame Relay (or Serial FR). This may best be thought of as a Frame Relay Multiplexing technology in the context of NERC CIP. Serial-FR encapsulates each RS232 or RS485 based serial data connection at a substation into a unique Serial-FR logical connection as a multiplexing technology. Each Serial-FR connection is then converted back to a native RS232/RS485 based serial interface, and then connected to a master of Serial-based SCADA. GarretCom has two families of substation routers, Magnum DX and DynaStar.

DynaStar/DX SCADA Frame Forwarding will work equally whether implemented using a frame relay network (cloud) or using point to point digital circuits from substation to control centers – either a carrier provided Frame Relay Service or a private frame relay network. No IP routing is provided over frame relay. The protocol ‘stack’ remains Serial over FR also without IP. The common trunks merge to frame relay PVCs via intermediary frame relay switching nodes when using a frame relay network. Serial FR using a relay network of frame, rather than relay of frame over dedicated digital circuits. Some GarretCom DynaStar can also provide relay of frame switching s well as frame relay access functionality.

The Compact Controllers Package from Omron

Now micro and small controllers offer processing and communications technology formerly found in large rack systems. These compact controllers let you control at each machine process and distribute intelligent I/O. Omron has the solution for simple timing control to complete machine operation.

Fast troubleshooting, more uptime
• Set the protectors levels to prevent from tempering.
• Built in alarms and status indication simply monitoring and troubleshooting for fast response.
• Simpler to troubleshoot and more economical compared with installing discrete controls.
• The testing performance assures 100% long reliable operation.

If size crucial to your machine design or the convenience of having all the components in one simple to assemble package then Omron can provide the package that will work for you.
Brick
An all in one brick style package contains the I/O, CPU, and power supply in a compact housing that mounts on track rail of DIN. Most brick packages are expandable and offer specialized I/O modules for temperature and analog input. Ease of use, centralized control and convenience all make the brick package a popular choice with most designers.

Modular
A modular design lets you choose the power supply, CPU, and mix of discrete and specialized I/O separately. The CPU has built in communication ports and discrete I/O that provide a common platform for multiple machine designs. Expand the capabilities with additional simple programming and specialized I/O.

Board
The level of board programmable controller offers the capabilities of a brick style system in an open board package. Use the board level controller in place of embedded the designs of control and in applications where space requirements and the appearance of a proprietary controller are warranted.

Omron offers self contain course package completely to learn programming techniques hand on. Each kit contain a compact input simulator, micro PLC, and easy to follow guide to ladder logic programming.

TOPKAPI Industrial SCADA Programming

AREAL has constantly perfected its TOPKAPI software over 20 years of innovation, turning it into the most advanced industrial SCADA software in the world, easy implementation, reliability, high power processing.

TOPKAPI had copied installed for thousands, it is used both by direct operators as well as engineers and automation specialists designing and developing industrial applications. TOPKAPI is running in Windows operating system as the de facto standard. It extends beyond fashionable concepts and providing users with means to integrate supervision into the global corporate information processing chain, shared databases, ERP and MES systems, web access, etc.

TOPKAPI software offers a solution to all user’s needs, from a basic graphic for workshop control to architectures controlling and redundant applications several dozens of interconnected stations.

The features of TOPKAPI are as following:
• Communication remote or local through field controller and devices.
• Data formatting and calculation.
• Fault and alarm processing.
• Measurements and logging events.
• Operating stations, remote and local.
• Display with graphic editor.

TOPKAPI is particularly appreciated for programming interfaces (Softlink concept) and its high quality graphics, its redundancy and client/server mechanisms, and for remote communication management. The built in function and calculation power can be used to create applications by easy parameters setting without the need for laborious programming.

Control the Contactors with PLC

A typical application for contactor of DC operated is the direct control from the PLC. Hereby the contactor of a semiconductor output is supplied directly with control voltage. Typical semiconductor outputs of PLC’s provide a power of 500 mA at 24 Volts. Contactors up to 32 A can be operated directly by semiconductor output of this type without the additional coupler relays need.

The engineering cost of power DC supplies can be reduced by the use of electronics. The power supply no longer needs to be engineered as with conventional contactor coils according to the sum of the powers pick up. The power supply is engineered according to the considerations as following: the sums of the switch on powers of all contactors which pick up simultaneously are added to the sum of all holding the powers of all contactors which is switched on simultaneously. As the holding powers are very low the power supply can be smaller significantly.

The direct control of contactor coils from the PLC reduces the coupler relays costs and reduces the wiring effort involved. For this the output must provide both the holding and pick up power for the contactors coils. PLCs with different outputs are available on the market. There are also semi-conductor outputs are offered with 0.1 A or 0.5 A and the most common are the semi-conductor outputs with 500 mA, in addition to expensive relay outputs.

A significant difference between PLC’s for control of safe PLC’s and normal operational functions is the cyclic monitoring of the PLC outputs in safety PLC’s. The outputs of master drives are typically controlled and cyclically briefly interrupted in safety PLC’s. The interruption is in the order of just 10 – 5 ms, so that actuators of connected (valves, contactors) do not shut off. During the interruption it is monitored if the voltage of output drops below a defined level.

OPC Server to Communicate with Communication Server

An Industrial PC is connected to the Wide Area network (WAN) each of the major components in system is described as following: the software components that located on the PC must be able to expand as the system grows without modifications and major upgrades.

One of the component keys is the OPC server. OLE for process control is a set of interfaces based on technology of DCOM and OLE/COM, for truly open software application interoperability between field devices/systems automation/control applications and business/office applications and field systems/d devices. The OPC server collects data form the IEDs or the communication processor and makes it available to any other application located on the connected LAN or the PC.

The OPC Server can use a protocols variety to communicate with the communication processor. However a single server can communicate with multiple devices using different protocols those are the powerful aspect of an OPC server. An intuitive user interface, HMI, efficiently implement a user interface that offers all the features of a system traditional SCADA.

Any number of OPC compatible software applications can be run to accomplish specific tasks since the relay data is available in the OPC Server. The paging of the software can be set up to monitor digital alarm bits in the OPC Server.

Function Block Diagram PLC programming

The IEC (International Electrotechnical Commission) identifies five standard programming languages as the most common for both discrete programmable controllers and process. They are LD (Ladder Diagram), FBD (Function Block Diagram), SFC (Sequential Function Chart), IL (Instruction List), ST (Structured Text). In this article we will describe on the Function Block Diagram (FBD) programming language.

Although Ladder Programming may be the most widespread language, a survey conducted by Control Engineering magazine several times ago highlighted growth in the use of programming languages other than Ladder. Function Block Diagram is a sample. Even though the adoption rate for this language has slowed relative recently to other languages such as Structured Text, Function Block Diagram Programming is probably the second most used language widely.

This graphical language is resembling a wiring diagram even more so than Ladder code. The blocks are wired together into a sequence that is easy to follow with Function Block Diagram. It uses the same instructions as Ladder Diagram, but visually is more understandable to a viewer who is not versed in relay logic.

The major advantage is that programs written in the Function Block Diagram tend to be easy to follow, just follow the path. This programming language is ideal for simpler programs containing of digital inputs such as sensors of photoelectric, and outputs such as manifolds of valve, and could be appropriate in any applications where Diagram Ladder is ideal.

However this programming language is not ideal for large programming using special functions and I/O. the large amount of the space screen required by this style of programming language can make quickly a program unwieldy if it reaches any substantial size. And also writing a program using Functional Block Diagram requires more preparation upfront to understand the program and how the program will flow before any code is need to write into it, since it can be more difficult to make corrections later.

Relay Based SCADA

The convergence of Ethernet based communication channels, hardened secure communications equipment and improved software tool has made relay system communications more reliable, capable, and less expensive. Ethernet based integration goes beyond SCADS to support engineering access to makes valuable capabilities visible and to protective relays.

This system offers distinct advantages over both dial up engineering access and proprietary SCADA. Ethernet based integration takes advantage of each tasked to support a specific requirement, the channel’s ability to support multiple communication sessions. The technology offers a simple method for migrating to new channels and protocols in the future and supports a wide variety of communication channels.

The system is identical to the local integration up to the communications processors. This means the relay system design for a station with local integration is identical to system with wide integration of the system. The communication processor flexibility allows this system to be implemented with both local a PC at central locations and touch screen HMI.

The Ethernet switch is connected to the processor of communication twice. One supports connection remote data acquisition by the industrial PC. The Ethernet switch is connected to a network of wide area. Many control center and sites session. The Ethernet switch is connected to a wide area network (WAN). Additional devices can be connected to each switch at each site, including digital video cameras, communications processors, weather stations, etc.

Sequential Function Chart PLC Programming

SFC (Sequential Function Chart) programming resembles the computer flowcharts that many will remember drawing up in their college. An initial step is always “action box”, the starting point of a flow chart is followed by a series of transitions and additional steps of action. The SFC concept is simple. An action box, with code written inside in any language of the programmer’s choice, is active until the transition step below it activates. The existing action box is turned off, and the next one in the sequence is active. The transition step is also has code to check that the necessary conditions are met to allow the program to advance for next step.

For appropriate applications which have a series of repeatable processes or repeatable multi steps process, this programming form is the easiest to implement. For instance would be a pick and place application, where product is constantly picked up from one area, moved through a specific path, and placed in another area.

While exception exist, since there is only typically one active piece of code and one transition to be concerned with, condition checking and the process control should be achievable without large rungs. The language is also easy to maintenance engineers because the program visual nature plus code segmentation makes it easy to troubleshoot. For instance, in the mechanism in a pick and place application has moved to the product but not picked it, the troubleshooter could bring up the program and look at the transition condition between the move to product box and the pick product box to see what is holding up the process.

This programming style is not suitable for every application, as the structure that is forced on a program could add unneeded complexity. A large time amount must be spent up front preparing and planning before any programming is attempted or else the function charts could become difficult to follow and unwieldy.

EtherMeter Standards based SCADA

The EtherMeter integrates easily into the vast majority of modern SCADA systems due to its incorporation of both Modbus and Allen-Bradley. Modbus or DF1 can be user selected as the active industrial protocol on the serial port. Modbus and Ethernet/IP are both available on the Ethernet port. The EtherMeter features an always on internal web server for added functionality that can be used to display meter data on remote web browsers within an internet or in the intranet.

Modbus was selected as one of the flagship industrial protocols for the EtherMeter and it becomes a de facto standard of industrial communication protocols. It is the most common of connecting industrial electronic devices.

EtherMeter is user friendly initial setup. Centrally manageable setup menu is available for the System Integrator either the serial port or Telnet. The configuration of EthernetMeter requires only a terminal emulation software and notebook computer.

Setup commands are type-written and intuitive at a command prompt. A wide settings are available the System Integrator, only a handful will need modification by any one particular Integrator. The EtherMeter is equipped wit 4 auxiliary outputs and inputs, making it suitable for deployment as a RTU’s standalone at low complexity locations, such as simple pumping stations or master meter vaults.

Security Approaches for Enhancing SCADA Security

We divide the security approaches into three categories:
1. Solutions that wrap the DNP3 protocols without making changes to the protocols.
2. Solutions that alter the DNP3 protocols fundamentally.
3. Enhancements to the DNP3 applications.
The solutions that wrap the protocols include SSL/TLS and IPsec, which would provide a low cost and quick security enhancement. The solutions that would require altering the DNP3 protocols tend to be more time consuming to implement and expensive but provide better end to end security. Such solutions can either be deployed at either a protocol level, or within an application.

From the studied SCADA of security enhancement by using an open source implementation OpenSSL of SSL (Secure Socket Layer)/TLS (Transport Layer Security) protocols. Communication channels of SSL/TLS secure for any reliable communication over TCP/IP and has been in use for about a decade providing virtual private network for the internet users. SSL/TLS secures communication between a server and a client by allowing mutual authentication and provides integrity by using digital signatures and privacy via encryption. The SSL/TLS protocols were designed specifically to protect against both man in the middle and replay attack. Other SSL/TLS features include error encryption, transparency and data compression. The protocols are administered by a standards international organization. SSL is well established in areas of Web servers, Web browser, and other Internet systems that require security.

These inherent SSL/TLS benefits, wrapping DNP3 with SSL/TLS has the following benefits:
1. The implementation would be fast, straightforward, and cost effective.
2. SSL/TLS covers the most necessary components expected at a protocol level.
3. The IEC technical committee has accepted SSL/TLS as a part of a security standard for their communication protocols. This endorsement is noteworthy and relevant especially considering DNP3’s similarity with IEC protocol.
4. Since UCA/MMS protocols can share the same lower level protocols with DNP3, any security enhancement done via securing TCP/IP would secure UCA/MMS transmission too.

EtherMeter Eliminate Problem in Pulse Technology

SCADA system integrators have struggled to eliminate the errors which resulted from using pulse-output flow meters. The most common problem with pulse technology is the inevitable discrepancies between the SCADA system and the readings displayed on the physical meters themselves.

SCADAmetrics has eliminated these errors with the introduction of the EtherMeter. EtherMeter is telemetry appliance that can ensure absolute agreement between the SCADA system and its connected meters.

The EtherMeter effectiveness is based upon an embrace of the latest Automatic Meter Reading (AMR) technology. It works by translating and flow rate signals from modern, encoder based flow meters into industrial protocols which SCADA systems can understand, such as Modbus, Ethernet/IP, and Allen Bradley DF1.

The connection of SCADA signal can be via 10BaseT Ethernet, RS485 twisted pair, RS232 serial cable and the gateway is compatible with most Ethernet switches and routers and most radio, telephone modems, satellite and fiber optic.

The EtherMeter has features with two meter ports, each of which is capable of pulse output flow meters and reading most absolute encoder. The EtherMeter automatically recognizes the connected meter’s communication protocol on the encoders. It would be plug and play. Compatible encoder based flow meters produced by Actaris, ABB, Elster-AMCO, Badger, Rockwell, Siemens, etc.

VT250 HMI Support CoDeSys

The 200 MHz/32Bit RISC processor not only provides the power of communication, but also enough resources for the controlling and visualizing software that may be run on Turck’s new HMI as well. Hilscher’s visualizing hardware, thus allowing to fully utilizing the power of controller’s computing. QVIS enables the user to create and arrange graphical user interfaces and provides all functions of a system of modern visualizing, such as composition management, alarm handling, history, password protection, trending and simulation. Thanks to an integrated variable interface for the CoDeSys controller that is also integrated into the VT250, both system works together perfectly, the more so as the system of run time CoDeSys SP is already implemented into the netXcontroller.

Same as the programmable gateways Turck offers for its distributed I/O systems BL67 and BL20, the new HMI support fully the very popular CoDeSys software. The hardware independent application software enables users to create their own controlling solution. Based on the international standard IEC 6113103, CoDeSys supports all common programming languages for this standard and provides complete back ends, including compilers, for all common types of processor. In this way, CoDeSys helps create and operate software controlling applications virtually every possible hardware.

The VT250 is one of the first automation solutions to support CoDeSys V3. This version combines all of the functionality of proven software with brand new options like object orientation PLC programming. CoDeSys V3 supports the operating system Windows CE for more applications of visualizing; Hilscher’s operating system provides enough power for more complex controlling tasks.

Turck once again confirms its comprehensive solution know-how with the new HMI series. The first model VT250 excels in flexibility and superior communication characteristics. It provides application oriented controlling and visualizing functionality with enough power to handle communication between every fieldbus system virtually and real time Ethernet. The new HMI can even be configured as master or slave, regardless of the direction of communication.

Wonder Ware HMI Software

In touch software provides graphic visualization that takes your operation management, optimization and control to a whole new level. In Touch HMI reputation stands above compare to the rest. What the industry knows as Human Machine Interface (HMI) all began with Intouch software over twenty years ago. This HMI can match InTouch software for architectural integrity, leading innovation, unequaled device integration and connectivity, uninterrupted software version migration path.

All this leads to well designed the systems of standards driven that maximize productivity, increase quality, optimize user effectiveness, and lower development, maintenance, and operational cost helping to make the best it can be.

The features of Wonder Ware HMI are:
• Ease of use enabling operators and developers to easily and quickly be more productive.
• Unequaled connectivity and device integration to virtually every system and device.
• Interaction and stunning graphic visual representation with your operation brings the right information to the right people at the right time.
• Uninterrupted version software migration path that means the HMI application investment is protected.

The key capabilities of Wonder Ware HMI are:
• Intelligent symbol and resolution independent.
• Sophisticated scripting.
• Real-time distributed alarming.
• Real time and historical trending.
• Etc.

Multi Function Display of HMI MFD4-5-XRC-30

The MFD4-5-XRC-30 multi function display is a new component in range automation of Moeller. The device from the easyHMI device series features a full graphics 5.7 inch color STN display with 256 colors, resistive touch technology as well as a communication options host.

The MFD4 can be used both as and HMI and as an HMI control device to the integrated PLC functionality. Only software, easySoft-CoDeSys, is needed for the PLC application and the visualization. The Windows CE based panel comes with a 64MB SRAM memory. Flash memory 6 MB is provided for visualization tasks and 2 MB flash memory for the PLC program.

The MFD4 comes with an Ethernet, combined RS232 interface and CANopen/easyNet. The Ethernet interface (10/100 MB) ensures downloads with fast program and can also be used for communication to other controllers. An OPC connection, file transfer via FTP access or visualization via web browser access completed the range of communication options available. The RS 232 is designed as an alternative programming access and can be also used for communication with peripheral devices such as barcode scanners and models. The combine CANopen/easyNet interface fully integrates the MFD4 in the automation world of Moeller. This means that easy-Control EC4, easy800, or XC100/XC200 can be interconnected without any problem. Start motor starters can be directly connected to the MFD4 via SmartWire by means of a gateway.

MMC enables universal use. The complete project, trend data, recipe data and alarm data as well as the operating system can be stored on a Multi Media memory card if required. This important feature enables the simple and reliable data exchange worldwide without any programming device required.

The MFD4 can be run as master network or also as slave on the CANopen bus. The SmartWire gateway enables motor starters, for instance, to be accessed directly from a PLC.

Vijeo Citect HMI Software

SE Vijeo Citect Human Machine Interface (HMI) Software is flexible, reliable and high performance supervisory control and data acquisition (SCADA) system with the features as following:
• The HMI is having special quality for reliable architecture in factory automation and other mission critical applications, hardware failure can lead result in potentially hazardous situations and can lead to production loss. Vijeo Citect will tolerate failure anywhere in your system with no loss of performance and functionality.
• Powerful graphics, the graphic capabilities of SCADA system are critical factors in overall usability. Using this you can develop true color, easy to use graphic that provides the operator with a consistent, intuitive user interface.
• Intuitive process analysis tools, is an intuitive process analysis too; that sits directly in the SCADA system, delivering actionable insight to the operator faster and improving their efficiency and productivity.
• Object based configuration for rapid development, it is made quick and easy to configure the tools such as page templates, genies and super genies, and SpeedLink which link the configuration in your control system.
• Engineering with ease, it offers targeted and flexible system engineering tools to help more efficient. Vijeo Citect also allows close integration with a complete Schneider Electric solution.

The Family of Modicon from Schneider Electric

Schneider Electric Solution contains the following product families:
1. Modicon Quantum PLC-140:
Quantum provides the good balanced CPU able to provide leading performance from Boolean to 1 instruction of floating point.
• High level of multitasking system.
• There are 5 IEC languages as standard: LD, ST, FBD, SFC, and IL.
• Capacity of memory up to 7 Mb using PCMCIA extensions.
• I/O modules and safety processors.
• Plug and play high performance with LCD keypad for local monitoring.
• Numerous built in ports such as, ISB port, Ethernet TCP/IP port, Modbus plus etc.

2. Modicon Premium PLC-TSX 57:
• There are 5 IEC languages standard: LD, ST, FBD, SFC, and IL.
• It has a high performance CPUs. It contains 37ns per instruction and up to 7Mb of program.
• High level of multitasking system.
• A compact system particularly at ease in extended architectures.
• High end processors.
• It is ready services for Ethernet TCP/IP transparent: IO scanning, global data, web server, direct access to databases, TCP Open, Network Time Protocol.
• Numerous built-in ports: Ethernet TCP/IP port with web server, USB port, CANopen or FIP master port, Modbus Serial port.

3. Modicon Mirano PLC-M340
• Multitasking system for reflex time guaranteed.
• USB port for HMI and programming.
• There are 2 additional ports: Ethernet, CANopen, and Modbus.
• Programming code up to 70Kinst.
• Comfortable memory.

High Level Standard of Modicon PLC

Modicon Programmable Logic Controllers (PLC) are microprocessor based, state of the art, programmable and modular units for application of industry that demand continual control and monitoring of a remote process and its variables.

Modicon PLC maintains the standard high levels of integrity a product performance including:
• Power supplies, redundant controllers and I/O cabling provide highest system availability for critical applications.
• Tightly technology of integrated automation including process control and motion.
• Very high speed rates of scan with fast controllers.
• Output configuration “fail” states for predictable performance in critical applications.
• High isolation levels for noise immunity in severe environments electrically.
• High accuracy analog I/O for tighter process control and monitoring.
• High speed turn off, turn on circuits, combined with interrupt processing for higher system performance.
• Design of “Hot Swap” for simplified maintenance and increased system availability.

This combination of flexibility, performance, and scale make Modicon the best solution for the most demand applications, yet cost effective enough to fit the other automation needs. Connectivity to different network levels is assured with 8 networks, from Ethernet to ASCII.

Modicon offers the right software tool for optimal efficiency and productivity with support for multiple programming languages. Modicon delivers this productivity by providing process languages for continuous control or batch, ladder logic and sequential languages for discrete control for three level languages to optimize openness and flexibility.

Touch Screen HMI of VT250 from Turck

The HMI (Human Machine Interface), the communication between machine and man, will always play in a major role for an efficient system operation – despite all automation efforts. Previously, huge switchboards were used to establish a communication channels between machine and man. Currently, most users rely on modern computers screens. So far they do have a good reason: modern touch screens with integrated PLC functionality provide flexibility. New programming simplifies plant upgrade and even simple signal in the field may be replaced with small HMIs that are more versatile and becoming a less expensive option.

Turck has been working for decades to develop a comprehensive knowledge in the field level where sensor, PLCs and fieldbus systems work together. During this time Turck has extended its interface, sensors, and fieldbus portfolio with DeCoSys programmable gateways with integrated PLC functionality. This technology enables certain tasks to be performed in the field directly, like writing and reading RFID data carriers. These compact PLCs support decentralized concept automation. After intense market inquiries Turck decide to extend its portfolio with a new HMI series that not only provides visualization and controlling functionalities but also outstanding communication characteristics. The first new model VT250 will be launch at the SPS/IPC/ Drives.

The VT250 is a 5.7 inch thin film transistor touch screen (QVGA) in a compact plastic housing. Its assembly semi standardize dimension 212x156x50 mm enables user to apply the new HMI to various applications in no time. Even the HMIs sophisticated back side provides a new practicability. Unlike many established HMIs, the VT250 allows accessing the back up battery and the SD memory card from outside the housing, users may replace both components without a hassle.

Counter sunk fieldbus port support CANopen and Profibus, DeviceNet, and allows the sub-d 9-pin connector cable to be conducted in the same direction exactly as all the other cables. The HMIS bottom side provides a 24V power supply, supporting RS-232 and RS-485, communication port and additional USB port.

G3 Series HMI for Multi Vendor Protocols

G3 Series HMI is produced by Red Lion incorporate communications, data management and remote access into a single product that communicates data seamlessly with multiple vendor device level products including drives, PLCs, Serial peripheral and PID. G3 Series HMI move across different industrial protocols including Profibus, DeviceNet, and CANopen/J1030. It is powerful protocol conversion and data acquisition tools transparently refine and capture the data you need to trend, control and monitor your process efficiently.

G3 Series HMIs easily manage the devices of multi vendor and provide the ability to network and web enable these different hardware types via the most integrated Ethernet and on board communications. It has high quality in class PLC, PCs, Drives, and PID controllers. The G3 will make sure they communicate seamlessly to the HMI and between devices.

G3 HMI has one RS 422/485 port and two RS 232 ports. Integrated Ethernet provides communications with up to four additional device types, facilitating communications with seven different protocols simultaneously. It has added an expansion slot let you add wither two or more serial ports, CANopen/J1939, DeviceNet, Profibus or a cellular modem.

G3 HMI has featured a powerful protocol converter to exchange data between the connected devices. You can map a setpoint from a PLC to a variable speed drive, or provide a PLC program with information to the status of a PID controller.

HMI Development Using Adobe Flash Technologies

The use of Adobe Flash Platform offers several advantages for automakers. Car manufacturers have created highly quality-mockups of in-car interfaces using Adobe Flash Professional software for years. They recorded the back end functionality of the system in a language like C or C++ previously. Nut now they can leverage the code they have developed in Adobe Flash Professional to produce the full solution and deliver it to market faster.

Many auto design shop now use a variety of graphic design and animation tools including Adobe Flash Professional in the initial stages of automotive HMI (Human Machine Interface) design and then recode the interfaces using alternate technologies such as Java or C/C++. This creates inefficiencies due to the whole HMI has to be created twice. Car makers can go from a graphical prototype created using Flash technology to a final product without HMI recording.

QNX software systems adopted an HMI development approach using Adobe Flash technologies that unifies the overall graphic design and subsequent development cycle. The entire HMI required for in-car functions can be prototype and then taken into production in Adobe Flash Professional, greatly reducing development effort and time with the QNX Aviage HMI Suite. In-car applications already created in C and C++ languages can also be easily integrated with the QNX CAR platform so that carmakers can leverage previous software development efforts and further accelerate time to market.

A key reason the Systems of QNX software is leveraging the Adobe Flash Platform is its easy integration with HMI (Human Machine Interface). The HMI services provided by the QNX Neutrino RTOS offer a great deal of flexibility, allowing system designers to implement a mix of user output and input methods, including tactile control, touch screens, and speech recognition. The operating system enables HMI displays to be composed of video in FVL format, OpenVG, and OpenGL ES from a display perspective.

Engineering Software of L-force Automation Machine

L-force PC based automation is centralized machine control suited to a large number of axis, L-force is produced by Lenze UK. Engineering software of L-force is need for planning, parameter setting and diagnostic of Lenze L-force products. It is available as freeware or a powerful multi axis tool. The software is including multi channel software oscilloscope.

Visualization requirements are covered by VisiWinNet and HMI Designers for the intelligent EL100 panels. Drive PLC Developer Studio is using commissioning of PLC products to IEC61131-3 and used for no-nonsense programming. Cam Designer software makes the tasks to generate cam profiles easier for cyclic linear motion.

Lenze also gives you to choose of fieldbus to best match your system needs. The CAN system bus is integrated into Lenze controllers, drives and accessories to achieve easy connectivity with low cost. The standard fieldbus can be made for fieldbus connection at device level and higher level from Ethernet, Profibus, DeviceNet, CANopen and ASi.

Precise motion control can be achieved with real-time high speed fieldbuses for data connection between the controller and the drive. Lenze also offer PowerLink, Profinet, and Ethercat.

Remote maintenance can access to drive controllers from worldwide. It can reduce downtimes and costs. There is available options include modems, Ethernet, and OPC server connections.

L-force PC based Automation from Lenze
L-force PC-based automation is centralized machine produced by Lenze UK. It is machine control suited to a large number of axes. Precision and high performance can be achieved. There is choice between Motion control to PLC Open part 1+2 and PLC Logic control to IEC61131-3.

Robust Embedded Line IPCs complete with TFT displays can be individually configured. Control cabinet PCs are suitable and modern for use as servers or control room computers. IP65 protected Command Stations can be desk or arm mounted with options of keyboards and keypads.

Lenze HMI makes machines safe and easy to operate. It has an easy to configure software and connect through to Lenze system bus (CAN). The text displays look suit simple applications. Graphic displays are for graphical displays of data and recipe management. Touchscreens include handheld with interface of user which have a very flexible lay out.

The Lenze ETC system controls between 2 and 12 axes either as a PLCopen motion controller or as a CNC path controller meeting DIN66025. Twin Can ports are also enables high speed motion.

The Lenze I/O system connects to the system bus of CAN. There are two versions: the Modular system which is easily customized for complex applications and the Compact system for up to 32 channels.

PLCopen Safety Function Blocks

Currently, PLCs are increasingly being used to implement safety function for safety critical systems. One of the preferred languages in this area is FBD (Function Block Diagram) according to IEC 61131-3. There are many research projects in the verification and implementation field of function block libraries according to this standard. However safety issues are not addressed in IEC 61131-3 and PLC programming software packages have only library function blocks dealing in general with communication, mathematical operations, logic and so on. As step for building safety application in IEC 61131-3 FBD according to IEC 61508, PLCopen specifies a set of called SFBs (Safety Function Blocks). Several manufacturers of IEC 61131-3 programming tools have already implemented libraries according to this specification.

The main goal of the presented work is to ease the verification of safety application built up using the PLCopen SFBs in one of the commercially available tools. To this end a modular of function block oriented approach is taken. For all specified SFBs a corresponding formal model is built using TA (Timed Automata). The formal model of the application is derived by combining the previously specified TA in the same structure as the original SFBs are combined in the PLC software to verify a safety application.

Before application can be verified, it has to be assured that the formal models are actually describing the behavior of the SFBs correctly. The description of SFBs by PLCopen consists three parts for each SFB respectively:
1. The internal states graphical description and behavior using a state diagram.
2. A properties list described in natural language.
3. Timing diagrams describing the temporal behavior for some specific scenarios.

In the presented approach the graphical description is translated into a TA in the language of the Upload tool. Simulations of the model are performed and the results are compared to the timing diagrams to validate the temporal behavior.

Constructing the Safety Function Block Library
Uppaal allows analysis of networks of timed automata with binary synchronization. It consists three main parts. First, timed processes are described using a graphical editor. Second, systems can be simulated by a graphical simulator. Third, reach ability properties can be verified using the verifier.

The process depicted is followed to formalize an SFB. First of all the input or output variables of the SFB are declared according to the interface description in the PLCopen document. Next, the state diagram is transferred to TA using the graphical editor of Upaal. Depending on the TA and the input sequence scenario extracted from the timing diagram, a simulation is executed to validate the temporal behavior using the graphical simulator. Thereafter, the textual properties are translated into TL (Temporal Logic) formula. The properties of the safety function can be verified using the verifier. The use of symbolic model actually checking in combination with TA would be sufficient to verify the behavior of the formalized SFBs. However, the additional use of simulation is useful for two distinct reasons. First all to validate specific scenarios presented in the specification it is the more direct approach. Second, and much more important, it allows users not familiar with formal models to assess the results directly. All twenty SFBs defined by PLCopen have been formalized according to this procedure in the frame of the presented work.

A Textual Functional description of the SFB is as follows: this function block convert two equivalent SAFEBOOL inputs to one SAFEBOOL output with discrepancy time monitoring. Both input Channel A and B are interdependent. The function block output shows the result of the evaluation of both channels. If one channel signal changes from TRUE to FALSE the output switches off immediately for safety reasons.

The inputs are used as transition guards and the outputs are updated according to the state location. The input of time is assumed as a clock.

Human Factors in SCADA Systems

Design of HMI for SCADA systems must be including consideration of Human Factors Engineering (HFE). It is estimated around 50% or more of all loss of load events in mission critical facilities involves action of human. A reported scenario begins wit a single correct response and component failure by the automatic control system to isolate the failure and maintain service to the load, however resulting in an off normal system condition. Intervention of incorrect human in attempting to restore the system to normal conditions after that the result in loss service to the load. HFE consideration in the lay out of operator controls can help prevent these occurrences.

1. Labeling: all control devices must e labeled clearly that are large enough with high contrast. The primary designation should be the functional description. The labels also carry the device tag number.
2. Layout: control should be arranged and grouped in logical and intuitive manner. Some of technique to design intuitive layout as below:
• Grouping control associated with individual pieces of equipment.
• Placing control switches top to bottom or left to right in which the operators are operated during a normal shutdown or startup.
• Spacing devices are far enough apart.
• Arranging controls in the electrical or physical process order.
• Color control coding devices.
• Colored backgrounds or borders.
3. Color schemes: used for controls and for graphic screens used within the process.

The Quantum Safety PLC

The Quantum Safety PLC is a system of safety related certified according to IEC 61508 by TUV Rheinland Group. This is based on the Quantum family of PLCs (Programmable Logic Controllers). For programming, the unity Pro XLS software programming of Schneider Electric must be used. Unity Pro XLS provides the all functionality of Unity Pro XL and is able to program additionally the Quantum Safety PLC.

The IEC 61508 is a technical standard that concerning to the Functional Safety of electronic, electrical, and programmable electronic Safety Related Systems. A Safety Related System is a system that is required to perform 1 or more specific functions to ensure the risks are kept a an acceptable level. Such functions are defined as a Safety Function.

A system is defined safe functionally if systematic, random, and common cause failures do not lead to malfunctioning of the system and do not result in injury or death of humans, loss equipment and production and spills to environment.

Safety Functions are executed to achieve and maintain a system of Safe state. The IEC 61508 specifies the Safety performance in 4 levels for a Safety Function. These are called SIL (Safety Integrity Level), ranging from 1, the lowest, to 4, the highest. The Quantum Safety PLC is certified to use in SIL 2 applications in which the de-energized state is the Safe state, for instance in an Emergency Shutdown (ESD) system.

You can also use the Schneider Electric Safety product for creating a HSBY (Hot Standby) solution if you require high availability for a Safety Related System. The Quantum Safety PLC consists of Safety modules which are allowed to perform Safety Functions. However, it also supports called non interfering modules, thereby enabling you to add non safety parts at your SIL 2 projects. Therefore, the products of Schneider Electric must be distinguished into:
• Safety modules
• Non interfering modules.

HMI Controller Program

Human Machine Interface (HMI) for SCADA systems is providing the functions of status indication, operator intervention in control action. Alarm reporting, and data storage and programming. Several layers or levels of operator interfaces are required to provide a maintainable and reliable system: controller level, equipment level, and supervisory level. At the supervisory and controller level, HMI may also provide capability to modify the controller program.

Equipment level HMI should consist at minimum of the control indicators and switches necessary to permit an operator to control manually the equipment in the absence of communications from the controller or for maintenance purposes. The capability of manual control to be provided for mechanical and electrical system components:
1. Manual control substitutes the operator facility for the automatic control system in the feedback loop, and leads to the risk system or equipment mis-operation due to human error. Safety interlocks, such as high pressure switches, motor overload, fire detection etc. switchgear protective relaying required for fault protection should always be hard-wired in the circuit breaker.
2. Hard-wired manual controls for entire facilities have been located in a bench board or control panel at the control room. Although this simplify the operator intervention upon complete failure of the automatic control system.

The Fundamental of Safety PLC

The systems of safety have traditionally required hard wiring and the use of electro-mechanical components, as required by the National Fire Protection Association “Electrical Standard for Industrial Machinery” (NFPA79). It states that a category 0 stop shall only have hard wired electro-mechanical components and shall not depend on electronic components (software and hardware) or the transmission of commands over a communications network. Both redundant standard PLCs and safety PLCs have begun replacing the other safety related hard wired circuits, although this requirement is stipulated for emergency stop circuits.

There are many applications where the PLC (Programmable Logic Controller) has been used to control equipment including the safety related parts of the system control. Standard PLC controllers typically used to support a safe and orderly shutdown in the event the primary controller fails. Safety applications designed using standard PLC utilize additional I/O inputs to monitor system of safety output signals, and more outputs to generate test pulses for the safety system’s input modules. Applications designed around standard PLCs require custom software to control, monitor, and diagnose the system. Designing the systems of safety around standard controllers require additional I/O hardware, engineering time, and wiring to support the safety portion of the application. In addition the software and hardware required to run the application.

Redundant PLC based packages are available that reduce drastically engineering effort and eliminate the certification of controller phase by providing complete hardware and software kits certified for use in press control application. For instance, Rockwell Automation’s Clutch or brake control package based on redundant MicroLogix processors has been certified by TUV as “suitable as a monitoring and control system for mechanical presses according to EN 692-1996 and ANSI B11.1-1998.” To use two PLCs provides redundancy to improve the safety integrity of the systems. The inputs and outputs are cross wired to provide self checking and monitoring of the operation.

Visual Basic as an HMI

Visual Basic has two rights out of the box. The first item is Visual Basic has inherent ability to create windows with automated graphics. Visual Basic is a programming language designed to create programs with powerful interface graphic such as is used in most Windows program. In realty Visual Basic has many of the same tools that you will see in any Windows program. The most programs are developed using Visual Basic.

The second item is the database that is called the Jet Engine. The Jet Engine is the core of the database of Microsoft Access. The Jet Engine has the same power as Access to handle data but it doesn’t have the operator interface windows that Access has. Widows and code required for the Jet Engine in the Parijat HMI the data tables to do what it has to do already in place.

Parijat Controlware has developed the communication drivers. There are about 40 drivers available. The driver for the ControlLogix PLC is under development. The data collector is an integral of the HMI development package. Unlike WonderWare Intouch it is not limited to a certain number of TAGs based on licensing fees. The limitation on the TAGs is the machine ability to deal with high quantities of data.

The Development Framework by PLCOpen

The specific proposed by PLCOpen for the framework differentiate between three user levels: Basic, System and Extended level. I the Basic level, the program consists of certified interconnect blocks although they must be validated or certified before being used in the basic level. System Level is provided for suppliers of safety controls. The blocks can be programmed in any language, so this level is not the specification part.

IEC 61508 defines a reduction in the preferred languages programming for different SILs. Base on the PLCOpen has selected in the Ladder specification and Function Block IEC 61131-1 languages for Basic and Extended levels. Instruction Lists, SFC, and Structured Text are more complex to validate and to test. Function blocks and Data type functions from the IEC 61131-3 are also reduced. The reduction is stronger in the basic level.

The PLCOpen safety specification defines a generic SRFB. Specific safety related FB’s should be derived from this one the behavior and interface of this FB are the following:
• An active input to enable the function of safety.
• A Reset that can be used for different purposes: “error reset”, restoring the initial state, or as a “manual reset” of restart interlock by the operator.
• S_Inputs (variable of specific profess).
• A Ready output indicates if the FB is activated and the outputs are valid.
• S_Outputs (variable of specific profess).
• Error output indicates that the FB is in error state.
• The DialogCode is very useful for debugging. It represents all the states.

PLCOpen has developed a library composed of 20 SRFB’s (e.g. safe stop category 1 and 2, two hand control, emergency stop, mode selector, sequential and parallel muting, etc).

Refer to complexity of controller, there are 2 aspects contribute to increase this functional complexity:
• Running states or multiple operation modes of the process and the controllers.
• The use of distributed control systems in coupled applications highly.

The IEC 61131-3 Programming
The IEC 61131-3 describes a centralized, or multi centralized, architecture, e.g. a control system composed by several configurations running different applications each one, but in coordinated way. IEC 61499 proposes applications hosted and running is some devices. Function Blocks is running in different devices within a distributes application, must be strongly coupled, so it is required to have more methods of sophisticated synchronization than IEC 61131-3 defines, e.g. in contrast with the Send or Receive function or Networked variables, the IEC 61499 offers publisher or subscriber and client/ server services.

In the other word, along its operational life, a process or a machine can be placed in many different operating states and modes. A very popular design reference to define them is Guide d’Etude des Modes de Marches et d’Arrts (GEMMA). GEMMA is a general schedule that describes the process with up to 16 states. Engineers must decide which states are present or not. Each state is a different automation problem and describes the process in specific situation. For instance: F1 is the normal production mode, F4 represents a manual mode, where some elements can be controlled by operators order. A6 state signals a set of sequentially ordered operations for process restarting.

Following the methodology of traditional structuring, and IE 61131-3 FB’s, each state will be programmed with a different FB. A scheduler FB will call the right FB depending on the state of operating process. This can be done using the input of EN of FB’s, or using actions in SFC main program. When an FB is deactivated it is not executed and stores the state of process. When the block is activated again, the state of real process will likely not match with the stored one, so the FB’s must be restarted. But FB’s in the IEC 61131-3 have no special input to achieve that. Each vendor defines specific inputs of non-standardized to control their execution.

The Major Components of HMIs

Operator control computers run a program with graphic screens and popup windows which allow the operator to control the process systems. These operators of programs interface are referred to as Man Machine Interfaces (MMI) or Human Machine Interfaces (HMI). Then next we will call it as HMIs.

There are four major components in HMIs. They are:
1. Communication Drivers
PCs have different language with PLCs. In order to make them communicate with each other a translator is needed. The translator is communication driver. Each different type of communication network and each different type of PLC requires a specific communication driver.

2. The data collector
The data collector gathers data from and sends data to determine that data needs to be updated and then initiates the data transfer by using the device drivers to perform actual communication.

3. The database
The database is a reference for the data collector and data display windows. Both data configuration and real time data is stored in database. The real time data is the process data from the production line, via the PLC, and the data configuration consists of data devices by the programmer when the application was designed.

4. The data display
The data display consists of popup windows and Windows. The operator interacts with the graphic on the popup windows to control and monitor the process system.

The Fundamental Differences between Standard PLC and Safety PLC

The first part of seven part international standards was published in 1998 to define the requirements for programmable of electronic systems used in the safety related parts of systems controls. This standard is known as IEC 61508, “Functional safety of electrical/electronic/programmable electronic safety related systems”. This seven part standard is driving the direction for future the developments of safety PLC.

There are three fundamental differences between a standard PLC and a safety PLC in terms of inputs, outputs and architectures.

Inputs
Compares a PLC input to a safety PLC inputs, the standard PLC inputs provide no internal means for testing the functionality of the circuitry of inputs. While Safety PLCs have an internal “output” circuit associated with each input for the purpose of exercising the input circuitry. Inputs are driven both low and high for very short cycles during runtime to verify their functionality.

Outputs
Compares the circuitry of output digital of a PLC to a safety PLC, the PLC has one output switching device whereas a safety PLC digital output logic circuit consists a test point after each of two safety switches located behind the driver of output and a third test point downstream of the driver of output. Each of the two safety switches is controlled by a unique microprocessor. If a failure is detected at either of the two safety switches due to microprocessor or switch failure, or at the test point downstream from the driver of output, the operating system of a safety PLC will acknowledge system failure automatically. At that time, a safety PLC will default to a known state on its own, facilitating an orderly equipment shutdown.

Architecture
Comparison of the two architectures of the two architectures of PLC and Safety PLC, a PLC has one microprocessor which executes the program, a Flash area which stores the program, ports for communications, RAM for making calculations and I/O to detect and control the machine. In contrast, RAM and Flash those are monitored continuously by a watchdog circuit and a synchronous detection circuit.

The Functional Process and Safety Application of PLC
In these standards the philosophy of IEC 61508 is integrated with specific safety functions and measures, specific recommendations and specific failure estimation methods. PLC Open has developed a wide work to include the IEC 62061 and IEC 61508 strategies within the IEC 61131-3 programming languages. The work is organized into four topics:
• A set of recommended reductions in the framework of development.
• A software model.
• General rules for Safety-Related Function Blocks.
• A certified library of Safety Function Blocks.

The software model describes the application of functional process and the safety application in a generic way in order to allow that upcoming and existing safety systems can be covered. No safety control hardware architecture should be excluded on one device or there could be several devices which are less or more coupled.

The PLC Open main objective is to merge the developer environment for the functional part and with an integrated safety part, including reductions in functional and language programming for safety section. Safety is integrated with process control functions at the beginning of the stages development. Safety signals processing and safety I/Os are separate clearly from the process I/Os and the functional application. The functional application can read safety inputs, but it can not be connected to the outputs of safety directly, it can only control the data flow to them.

The new data type with the designation SAFEBOOL was defined to achieve this separation. SAFEBOOL is not simple new Boolean variable. It can include additional information in order to calculate the SIL with the tools of programming. SAFEBOOL represents a single output and input channel, regardless of the internal hardware structure lool (“1 oout of 1”), 1002D, 2oo2, or 2oo3. The hardware which executes the FBs with the SAFEBOOL I/Os has to be separately certified.

Supervisory Level HMI

The devices of supervisory level HMI are typically personal computer workstations located in the central control room and/or engineering and management offices. The function and quantity of these workstations depends on the size and complexity of the facility. Simple facilities may be provided with a single workstation which may be located in the main mechanical or electrical space in the absence of a central control room. Complex or large facilities should be provided with a minimum of two workstations in the control room to permit operators to back one another up.

Multi building campuses should provide workstations in the electrical or mechanical space of each major building to permit operations staff to obtain status and alarm information for the entire facility from any building.
1. Graphical screens displayed is used supervisory level HMI on the computer monitor to communicate alarm conditions and system status. Screens should be provided for subsystem, system overview, facility overview and equipment screens for all major components of the facility. Remote supervisory control and manual control is typically performed at the supervisory level HMI under security access control.

2. Data storage capability and trending should be included an all SCADA systems to provide a permanent log of facility performance. All critical parameters, such as humidity, temperature, current, voltage should be stored every 15 minutes.

Standards Certification of Safety PLC

The several bodies of safety validation are driving the design parameters behind safety controllers. Factory Mutual (FM) from United States, Health and Safety Executive (HSE) from the United Kingdom, and TUV from Germany each test for adherence to the stringent standards safety PLCs must meet. For instance, TUV typically tests products against IEC 61508, a standard that defines SILs (Safety Integrity Levels) 1 through 4. Safety PLCs are suited for applications at SIL2 and SIL 3 where they can be certified for use in common safety applications. SIL 4 addresses applications beyond standard industrial safety; it defines requirements controller for flight system (fly by wire) control, reactors nuclear or any number of applications whose failure would be catastrophic.

International and European standards finding their way into ANSI and OHSA standards in the United States are IEC 61508 and EN 954-1. IEC 61508 provides an exacting definition for safety of functional in programmable electronic systems. EN 954-1 outlines the requirements for the control systems of safety critical parts in machinery.

Specific standards of application for robotic devices are provided by ANSI-RIA 15.06. Mechanical stamping control requirements presses and other machines are defined in the ANSI-B11 series of standards.

Although there are some differences between the standards supported of each the primary validation bodies, each take total system approach. Specifications for entire systems of safety control take hardware, software, and operating systems into consideration. Some standards take the additional step of providing guidelines for specific applications.

Developers should be aware that architectures of specific control based on standard PLCs have been certified by safety governing bodies to use in specific applications. In specific examples, it may prove more cost effective to use the certified package versus taking new control architecture through the process of certification. And also end user need to evaluate the training needs, stocking and maintenance costs incurred by implementing a new system.

Programming Restrictions and Functional Safety of PLC
Functional and reliability safety are always problems present in industrial controller. IEC 61131 defines software and hardware characteristics to achieve this goal. Although, programming languages and programmers habits are likely sources of failures. To reduce failures it is necessary to limit the variability of the languages jointly and with clearly methodology. FVL (Full Variability Languages) like Pascal, C++ or Java, allow the programmers great freedom to define the program structure, the data and the program flow, so the probability of failure is greater compared to Limited Variability Languages (LVL) that are more restricted, and combine predefined and application specific functions.

The IEC 61131-3 languages are good sample for LVL’s. But the standard also includes additional restrictions to increase reliability, e.g. by limiting the program access and by fixing the program structure to hardware resources directly. This late restrictions means:
• The I/O channels are updated through Directly Represented Variables, e.g. the programs never write or read the I/O channels.
• The programs are not often compiled to a processor native code program. It is translated to a Pseudo assembler language or to Instruction List that runs in a supervised or interpreted mode.

IEC 61131-3 languages have been studied well in several papers, and they are known for their inconsistencies. For instance in SFC languages the state evolution can fall into unsafe states or impossible conditions derived from jumps from simultaneous divergences.

Dynamic problems like non deterministic execution time or critical races have to be avoided for better reliability, too. Critical races can be present in any language if simultaneous accessing to shared feedbacks or variables is used in FB’s. The result can depend on the order of execution. Non-deterministic execution time or infinite loops can be caused by classical structuring instruction like FOR or WHILE. In consequence, execution and language model restrictions must be stronger in those cases where reliability should be higher.

Industry Standard OPC Interface

National Instruments has a large number of drivers and servers for interface applications to industrial devices such as Programmable Logic Controllers (PLCs). The drivers are available on the NI Industrial Automation OPC Servers CD as well as in all NI Developer Suite Control Editions and NI Lookout development systems.

The Industrial Automation OPC servers provide software of industry standard connectivity to a wide variety of industrial automation industrial and devices networks. An important function of industrial automation system is integrating real-time manufacturing information from plant floor devices with the HMI/SCADA system. Every device and software component would have an identical interface and speak the same language through plug and play connectivity.

In fact, hundreds of systems and devices exist in a typical plant or factory, each has own unique communication protocol and hardware interface. The Industrial Automation OPC Servers provide a consistent, an OPC interface, industry standard method for accessing real-time data from all servers provided.

The NI Industrial Automation OPC Servers reduce system development and integration cost dramatically because you do not have to spend time programming the low level communication interface to industrial automation devices.

The LabView Datalogging and Supervisory Control Module and Lookout both provide built in OPC clients capable to communicate with any OPC server on the market. The Industrial Automation OPC servers work with variety of protocols and factory-floor devices, enabling you to connect to the existing devices and systems.

OPC Data Access Automation Wrapper DLL
A reference sample of the Data Access Automation interface has been provided by the OPC foundation for the OPC foundation members use in providing an automation interface to OPC data access custom interface servers. The reference sample was provided as a DLL complete with the Visual C++ source code. And vendors also may provide the DLL directly with their product.

Vendors which choose to modify the source code, or just build the DLL from the source code must do the following prior to including or shipping the DLL:
1. Vendors must change the name of the OPC Automation DLL from OPCDAAuto.dll to a vendor specific unique name.
2. Vendors should change the name of the OPC automation IDL (opcauto.idl) file to a vendor specific unique name.
3. Vendors must change the helpstring (“OPC Automation 2.0”) in the IDL file to reflect the vendor specific OPC automation interface. The name that shows up in the Automation Type Library. Visual Basic applications which use the vendor build OPC automation interface DLL will include the DLL by using the type library.
4. Vendors must change all guid’s in the IDL file to new values that are generated by using the Guidgen tool. It is required to prevent the vendor built interface of automation library from being confused with another vendors automation library or the OPC foundation provided automation library.