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A Ascendancy Architectonics clairvoyant writes: Our bulb had affiliated on Siemens (Moore) 353 and the Procidia i|pac (353R) action automation controllers. The controllers accept been retired and are no best accessible for purchase, so I charge article to alter them.

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We were appliance them for boiler control, affiliated action and batching applications in our plant. The ambassador was basically a mini DCS with a faceplate that could be acclimated for bounded agreement and operation. Assorted controllers are affiliated on Ethernet with anchored HMI platforms, such as Procidia i|station, advance throughout the plant. It has larboard us with a huge aperture affective forward.

While the absolute controllers use Boolean action blocks or ladder argumentation programming, I do not adore autograph code. However, I am actual acceptable at configuring controllers with the accepted languages. Any suggestions on a ambassador and HMI to affluence our advancement activity from both a accouterments and a software standpoint? Please help.

 

I would advance they attending at the Siemens S7-1200 or 1500 controllers appliance TIA Portal for programming. It has the structured languages bare to alter the action blocks in 353s and Procidia. There are others, but if they are accustomed with the Siemens articles this in the “family.”

I would additionally advance they attending at accomplishing a FEED abstraction to analysis the options and argumentation and how best to admission the migration. Best acceptable the accumulation advantage is simple compound administration or sequencing which can calmly be handled in the PLCs mentioned. If it is added circuitous batch, again they may charge to accede a accumulation server which would be afterpiece to the PCS 7 system. My assumption is the S7-1200 or 1500 will handle what they have.

Jeff Morton / sales manager, action ascendancy affiliation accumulation / Cross / Control Arrangement Integrators Association (CSIA) member

In acknowledgment to your concern for advance your Siemens (Moore) 353 and the Procidia i|pac (353R) controllers, I accept accomplished out to Siemens to see what they recommend. They declared that they performed a allegory on the 353 controllers back they went anachronistic and begin that all of their functionality could be performed by the newer S7-1200 controllers they now offer. This will crave absolutely a few agreement changes, but they additionally action casework to abetment with that, as do we if you are attractive for an integrator. It is accessible that you would be able to alter assorted 353 controllers with a distinct S7-1200 PLC as the accouterments is alteration from a single-loop ambassador to a multi-loop controller. The aforementioned is accessible with the 353R, but that depends on the I/O agreement there; they may crave a one-to-one backup for anniversary one.

Jerry Flynn / principal architect / Concept Systems

 

I am borderline what is meant by “standard languages.” It seems this clairvoyant does “not adore autograph code,” I accept in advertence to the Siemens 353 appliance action blocks for programming, and conceivably additionally acquisitive to not use ladder logic, as is accepted in best programmable argumentation controllers (PLCs). If, by “standard languages,” this clairvoyant agency article like C or C#, again the clairvoyant may be a acceptable applicant for the IEC 61131 programming environment.

IEC 61131, or added properly, IEC-61131-3, is a programming ambiance which, by definition, has bristles programming languages:

Obviously, IEC 61131 contains two of the languages that may be abominable to the reader, LD and FBD. But it additionally contains ST and IL. ST is added like programming in C. It is a actual accustomed architectonics to addition who is adequate programming in a Microsoft .NET environment. To me, IL consistently seemed article like programming in the Microsoft Macro Assembler (MASM), with instructions, such as LD for “load the accumulator” or JMP for “jump to addition area in the program.” These may be abundant added adequate programming languages for this reader.

The two best accepted IEC 61131 environments are produced by German companies, CodeSys fabricated by 3S-Smart Software Solutions and CodeSys fabricated by KW-Software, which was acquired by Phoenix Contact some years ago. Advantech offers both of these software solutions in some of its accouterments solutions. It is account advertence that CodeSys added a sixth programming accent to its IEC 61131 ambiance alleged affiliated action blueprint (CFC).

There is addition aggregation that produces an IEC 61131 band-aid alleged ISaGraf fabricated by a aggregation name ICS Triplex, which was acquired by Rockwell Automation some years ago. Although ISaGraf may not be as able-bodied known, it is notable because it incorporates both IEC 61131 and IEC 61499 programming environments. IEC 61499 is added like a action block language, but it graphically incorporates the accouterments acclimated with the programming accent to facilitate broadcast ascendancy methods. Centralized ascendancy methods are added frequently begin in North America, area broadcast ascendancy methods are added frequently begin in Europe. A attenuated band-aid may become the best accepted of all, but IEC 61499 is apparently not a acceptable band-aid for this reader’s needs. ISaGRAF is begin on a cardinal of Rockwell Automation’s Micro PLC products.

The Siemens 353 is basically a bend controller. There are abounding brands of bend controllers accessible from abounding manufacturers. Back this clairvoyant says he or she does “not adore autograph code,” the clairvoyant may be attractive for a accouterments band-aid with fill-in-the-blank blazon simple programming or configuration. This blazon of bend ambassador frequently has actual little flexibility. The Siemens 353 had cogent programming adequacy and flexibility, which agency it was apparently custom-configured to board the reader’s application. It is actual acceptable that the clairvoyant will accept to either advertence engineering documents, which specify how these ascendancy loops were programmed and what the operating ambit are, or the appliance will accept to be reverse-engineered to actuate every allusive aspect of the application. The affairs are that article added than simple preconfigured bend controllers will be needed, and the clairvoyant will accept to do some programming.

Finally, Advantech offers a cardinal of articles able of accomplishing bend control. We action the ADAM-3600 Series, which comes with a chargeless lite adaptation of KW with chargeless development software. We additionally action the APAX-5580 Series which comes with CodeSys (Figure 1). The APAX-5580 is a able PC-based arrangement with options of a Celeron processor or amount i3 or i7 processors. It has a modular congenital I/O arrangement with the archetypal analog and agenda modules and the processing assemblage has an HDMI anchorage that allows affiliation of a affectation such as Advantech’s FPM collapsed console touchscreen monitor. CodeSys does abutment an alternative HMI software bore alleged Target Visu, which would accommodate an all-in-one band-aid to alter the Siemens 353 bend controller.

Figure 1: Article added than simple preconfigured bend controllers will be needed, and the clairvoyant will accept to do some programming.

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(Source: Advantech)

Chuck Harrell  / IIoT artefact business / Advantech

Your botheration is a accepted one. According to ARC Advisory Group, there are $65 billion in installed action automation systems advancing or accomplished end of life. Abounding users like you accept auspiciously maximized automation investments by befitting systems active continued accomplished the point of obsolescence.

Why do users abide modernizing? You account a brace of accepted reasons. You are still able to run your plant, accomplished in configuring absolute accessories and not aflame about acquirements a new system. Added accepted barriers accommodate banking absolution and blow concerns.

However, the allowances of automation addition abundantly outweigh the challenges. You can accept a accurate arrangement with accessible genitalia from the architect and beneath failures. A addition done appropriate generally after-effects in bigger artefact quality, added production, lower abutment costs and beneath action upsets. As you’ve apparently noticed, not abounding bodies are accomplished in old 353 controllers. The ones who abide are abutting to or already accomplished retirement age. Being on a avant-garde belvedere helps accomplish abiding you can acquisition assets to advice with your ascendancy system.

So, what avant-garde automation arrangement makes the best faculty for your application? Making the alternative can be a alarming assignment accustomed rapidly alteration technology and abundant options available. Rockwell Automation helps adviser engineers through the alternative and absolution process.

There are a few options, but based on the advice in your inquiry, the PlantPAx broadcast ascendancy arrangement (DCS) from Rockwell Automation ability be your best choice. Abounding users adore the scalability, affluence of agreement and abundant abutment options. The PlantPAx arrangement additionally brings assorted accessories into one arrangement to advice abbreviate maintenance.

An automation arrangement addition is a once-in-a-generation adventitious to accomplish a abundant advance in your facility’s operation. The automation arrangement is the academician of your plant, so an advancement can accomplish a cogent impact.

Lee Swindler / program manager, Maverick Technologies / Rockwell Automation

Boiler control, affiliated action and batching are three actual altered applications, so you will charge a arrangement that has a array of ascendancy functionality. Back you are accomplishing boiler controls, you may additionally crave article that can handle burner administration controls for blaze apprehension and ammunition shutoff to accede with NFPA rules. Your appliance sounds like a accepted arrangement in which you accept islands of automation. A artefact like EcoStruxure Hybrid DCS has the capabilities to accommodated anniversary of your requirements. Let me explain how.

1. Our arrangement can calmly absorb ladder-logic cipher and detached action blocks into a abounding action block strategy. Benefit: Simplified argumentation conception through the pre-created ascendancy blocks that will fit the needs for these applications such as analog, digital, sequence, PID and valve blocks. These ascendancy blocks are accessible in a accepted accurate library for quick access. This additionally makes troubleshooting actual accessible because of the formatted attributes of the blocks, acceptation they will be constant today and abutting year. Back you brace this with our Run Time Navigation Services, your troubleshooting capabilities are added alike further.

2. Bounded HMIs and axial HMIs (Figure 2). This is a accepted botheration that is apparent by the EcoStruxure Hybrid DCS. The DCS is maintained in a axial appearance but the bounded HMIs are artlessly structured as nodes. Benefit: You actualize and administer the bounded HMI screens on our Magelis HMI arrangement and arrange them from the axial location. This ensures that bounded HMI panels are consistently up to date and constant back there is no abstracted apparatus to body cartoon at anniversary bounded panel.

Figure 2: Actualize and administer the bounded HMI screens and arrange them from the axial location.

(Source: Schneider Electric)

3. Through our accumulation software integration, we can do abounding accumulation administration solutions, beneath circuitous compound applications or alike simpler arrangement argumentation all with the aforementioned controllers, I/O and software. Benefit: You will crave alone one belvedere for all the applications (Figure 3).

Figure 3: Through integration, beneath circuitous compound applications or alike simpler arrangement argumentation can be done with the aforementioned controllers, I/O and software.

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(Source: Schneider Electric)

4. A brace of things that you didn’t acknowledgment that I’d like to abode accommodate lifecycle management. First, you acclaimed that your Moore accessories are obsolete. We advance a Continuously Current technology philosophy, acceptation we will consistently advance accoutrement that acquiesce users to advance the absolute basement and argumentation for their ascendancy system. They can drift to newer versions while still advancement the cipher they accept affiliated on and the base they accept installed, mitigating a actual high-risk and big-ticket accomplishment if bare to be afflicted with the new system. Second, we accept done abounding Moore migrations and because our arrangement is so compact, we can usually fit the controllers and I/O into the aforementioned chiffonier space, extenuative money and risk. Third, we accept done projects with Moore accessories area we accept migrated the exact HMI cartoon into the HMI of the EcoStruxure Hybrid Ascendancy System. This will accomplish any training abundant simpler. Fourth, the beheading action for cutover can be managed in a staged fashion. Fifth, there are abounding asset administration functions that are anchored that will advice you antithesis the uptime of your assets with the aliment of your basic equipment.

5. Finally, as an alignment Schneider Electric’s Action Automation analysis has completed hundreds of boiler projects and burner administration projects (Figure 4). We can abutment any architectonics requirements or recommendations to advance the action or the architecture. We additionally assignment with able system-integrator ally who can advance these strategies for you, as well.

Figure 4: Boiler projects and burner administration projects can be accurate and improved.

(Source: Schneider Electric)

Mark Grant / business development administrator / Schneider Electric

 

Siemens has a cardinal of automation options that would be a acceptable backup for the Siemens (Moore) 353, Procidia i|pac (353R) action automation controllers. For example, our new AS 410E CPU was advised accurately for the baby action applications that crave continuous, accumulation and alike assurance functionality and leverages the exact aforementioned PID algorithm acclimated by the 353 controller. The 410E CPU is seamlessly chip in our accurate action ascendancy system, Simatic PCS 7. Its robust, able accouterments makes it adjustable to use, alike beneath ambitious conditions. It comes accepted with bifold Profinet interfaces to accommodate fault-tolerant and reliable communications, all the way to the acreage akin area you could advantage our decentralized Simatic ET 200SP HA I/O modules altogether tailored to the requirements of the action industry today and for the agenda plants of tomorrow.

Charlie Fialkowski / process assurance administrator / Siemens

There are abounding new easy-to-use controllers on the bazaar today that can ample the abandoned and alter the retired controllers. New on the bazaar is the Opto 22 GRV-EPIC-PR1 on-the-rack ambassador for the groov edge-programmable automated ambassador (EPIC) system.

The ambassador is an anchored Linux real-time ambassador with aperture functions.

The avant-garde architectonics of the groov EPIC processor offers a abridged and athletic assemblage that appearance a resistive-touch, high-resolution LCD display. The LCD affectation lifts to accommodate accessible admission to the ability button, ability accumulation connectors, arrangement interfaces, ports and cachet LEDs.

Dual, absolute Gigabit Ethernet arrangement interfaces accredit the processor to advance abstracted admission to your back-office arrangement and your controls network.

Dual USB ports extend the capabilities of the processor, so it can handle consecutive communications, acquaint with touchscreen monitors or affix to your arrangement with accustomed Wi-Fi adapters.

HDMI anchorage displays agreement and groov View HMI on an alien ample screen, which is additionally advantageous for OEM applications area the EPIC arrangement is congenital into a machine.

The processor can accomplish through a advanced ambit of operating temperatures (-20 to 70 °C), and, with its athletic design, it can be acclimated in a ample array of applications and operating environments. It runs on an industrial, quad-core ARM processor with a real-time, accessible antecedent Linux operating system.

Software accoutrement include:

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You can run circuitous ascendancy programs on the groov EPIC processor developed with PAC ascendancy or your own custom applications.

The groov Administer app is your axial command to your groov EPIC system, allowance you configure, troubleshoot and agency your controller, I/O modules and arrangement interfaces. The bendability in interface architectonics amid the groov Administer app active on the groov EPIC processor and the groov Administer app active on your computer, smartphone or book ensures a seamless acquaintance amid devices. You don’t accept to bethink to do article altered for anniversary accessory to accomplish the aforementioned result.

Groov View offers accessible browser-based development of a custom HMI with trending, events, and user notification. Communications are anchored with user affidavit and encryption. And, because the HMI is absolute of operating system, what you body can be beheld on any accustomed device.

The GRV-EPIC-PR1 is allotment of the groov EPIC system, which provides a complete ascendancy and communications arrangement at the network’s edge, including:

The groov EPIC arrangement builds on decades of field-proven architectonics and avant-garde accessible standards to accord you reliable automated automation additional a abounding Internet of Things (IoT) advice structure, built-in.

The arrangement includes processor, software, I/O modules, anatomy and ability supply.

The anatomy holds the ability supply, processor and added I/O modules you charge for your application. Ability food are accessible for ac power, dc about-face and pass-through admission from a ability accumulation you already own.

Danny Weiss / senior artefact administrator / Newark element14

 

The new groov EPIC ambassador from Opto 22 has a congenital HMI on the advanced with a high-resolution touchscreen. You can configure and analysis the assemblage appropriate from the advanced of the unit. You can alike accompany up electrical base diagrams of all the I/O.

Figure 5: There are abounding new easy-to-use controllers on the bazaar today that can ample the abandoned and alter the retired controllers.

(Source: Opto 22)

To configure the HMI, EPIC includes groov View, a codeless, drag-and-drop HMI architect to actualize screens that your accustomed users can see and collaborate with, both on the bounded touchscreen or via a Web browser active on any computer, adaptable accessory or acute TV. Groov View additionally provides trends, contest and notifications.

Second, you can affairs the EPIC ambassador in abounding ways. You can use the congenital PAC Ascendancy flowchart programming environment, which is included for chargeless and acclimated by action ascendancy users all over the world. PAC Ascendancy is actual intuitive, so it’s accessible and quick to get up and running. Addition programming advantage is SSH, carapace admission to the Linux OS, which agency you can affairs in Python, C# or C , for example. And you can use the congenital Node-RED to affix to databases or added billow casework either on bounds or off, appropriately enabling your batching applications and boilers to become IIoT-ready.

Third, EPIC controllers appear with four, eight or 16 modules of high-density guaranteed-for-life I/O, in both abandoned and non-isolated configurations.

Ben Orchard / senior appliance architect / Opto 22 

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Mike Bacidore is the editor in arch for Control Design magazine. He is an award-winning columnist, earning a Gold Regional Award and a Silver National Award from the American Society of Business Publication Editors. Email him at mbacidore@putman.net.

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