Profitable Growth Together
MasterLogic Series 200 PLC
Overview.
Presenter – Avisek Maitra
Reliance Industries Ltd.
Honeywell.com
Agenda
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Introduction.
Modular Systems Range.
MasterLogic 200 Series Target Applications.
System Architecture.
CPU & Net Work Options.
IEC61131 - 3 PLC Programming Standard.
Module Options.
Open Networks - Fast Ethernet, UTP/Fiber-Optic, serial RS232C/422/485.
Open Protocols - Profibus-DP, DeviceNet, MODBUS ASCII/RTU/TCP.
Peer-to-peer Networks - Fast Ethernet via UTP/Fiber-optic.
Soft Master Engineering Software Tool.
Honeywell Experion Integration.
Q & A.
Summary.
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System Architecture
Experion HS
(Redundant)
Redundant I/O bus @ 100 MBPS
(dual path)
Experion HS
100m UTP or 2km Fiber-optic
network
Combination of local and remote I/O
Peer-Peer Communication
Master CPU
Backup CPU
Redundant Power
Non-Redundant
CPU
High Speed Synchronization
Local
IO
(1 Gbps) Switching time < 50 ms
(Full Load)
Local IO
Local IO
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Modbus
(TCP/RTU)
Digital Device(s)
DeviceNet
Max I/O base: 31 stations
Max Base I/O: 23,808
Max Network I/O: 128,000
Analog Device(s)
Profibus-DP
• All I/O Rack Mounted
• No combination – Seamless Integration
Remote IO
• Redundant Power Supply at Each I/O Rack
• In Built Fibre Port in NIU for easier configuration of Remote I/Os
• Profibus/Devicenet/Serial/Modbus/Modbus TCP support
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Key Features
Hi-Speed synchronization (1-GbPS) between primary and secondary PLC
processors.
Automatic update of program, configuration and data from primary to
secondary PLC through synchronization cable. No separate download
operation required for secondary PLC.
Hi-Speed I/O communication (100 MbPS).
Software simulator available for testing your application without availability
of actual hardware.
PLC stores all Tag Names, Bit/Word Addresses and description in program
memory. In the situation of loss of program back-up, entire configuration /
program along with tags , addresses and descriptions can be uploaded
from PLC
CPU Replacement on Failure – No config. Req/No program store Req.
Communication module within CPU module with independent electronics
– Optimized Control Hardware
All I/O RACK Power Supplies Redundant
All I/Os are Rack Mounted. CPU & I/O of Same Family.
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I/O Bit Forcing data available with primary &
secondary PLC (Every scan update)
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Extended Base USB connection from I/O Rack
(Any RIO Location)
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PLC program upload / download option available from remote I/O rack USB port.
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Remote PLC Connection
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Using ports of the available PLC, remote PLC on the network (Serial or Ethernet) can be connected.
Remote connection up to 2 levels can be achieved.
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System architecture / diagnostic information in
graphics form
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Rack & Module wise diagnostic information, communication module information-all in graphics/tabular form.
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Variable Trend Monitoring for easy logic debugging
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PID loop graphical / tabular monitoring
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Custom Events and SOE option
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Custom events and Sequence of events (SOE) with 1 ms scan option available for advanced event analysis.
Up to 300 events per SOE module and 3000 events per PLC can be stored in the controller memory for
critical event analysis.
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Small Footprint
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CPU pocket size modules ( 55*98*90 mm) = ( W*H*D )
Saves cabinet and premium floor space
Shipping costs and storage space saver
Main Base available in 6 slots
– Supports power modules, CPU, Ethernet modules only
• Expansion base available in 12 slots
– Supports expansion modules, communication modules,
I/O(s)
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CPU & I/O Network Options
CPU – I/O Network Options
I/O Base Network Options (i.e. Slave Module)
CPU Options
2MLR-CPUH/T – CPU, TP
2MLR-CPUH/F – CPU, FO
I/O Network Options
2MLR-DBSF – I/O Ntw, FO
2MLR-DBST – I/O Ntw, TP
Fiber-Optic
UTP
Fiber-Optic
UTP
Hybrid
• Flexibility in I/O network of CPU
– Fiber-Optic - long distance 2km, outdoor, field use
– UTP – short distance 500m, indoor, low cost networking
• Flexibility to inter-mix fiber-optic and UTP networks
– By use of hybrid slave I/O network module
– Both local and remote I/O can be in a single I/O network
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2MLR-DBSH – I/O Ntw, FO/TP
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CPU Key Features
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High Speed CPU
42 nanosec/step – typical 15-20 ms scan time for ~2500 I/O
High Memory
7 MB program, 2 MB Data, 2 MB System, 16 MB Built-in Flash
IEC 61131-3 Std.
LD, IL, SFC, ST, FB programming languages
CPU Restart
Cold or Warm Restart Option
Program Types
Cyclic Scan programs, Interrupt Task Programs, INIT task program
Max I/O capacity
Base I/O: 23,808 (using 64 ch); Using Network I/O: 128,000
Function Blocks
Max 256 PID loops and a large library of function blocks
IEC Data Types
BOOL, BYTE, WORD*, INT*, REAL*, TIME, DATE, STRUCT, ARRAY…
Memory Variables
Direct Variables (Input, Output, Registers), Symbolic Variables (Named)
CPU Modes
RUN / STOP / DEBUG; LOCAL / REMOTE control of mode
Maintenance
Online Editing, Force I/O, Fault Mask, Skip I/O, Hot-swapping
User-Defined
User Defined Function Blocks, Data Types for special applications
Redundancy
CPU / Power / Network Redundancy
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CPU Key Features
Output Control
Clear / Hold option upon error or mode change conditions
Direct I/O
Immediate I/O instruction for time-sensitive applications
Retention Memory Emulates Flash; Configurable %M address range; clears upon cmd
Program Ports
CPU Built-in USB@12MBPS / RS232C, via Ethernet Module
MODBUS slave
CPU Built-in RS232C port
RTC Clock
Read / Write capability via program or with Experion SCADA
Self-Diagnostics
CPU LEDs
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Battery Failure
Module type mismatch Error
Scan time Watchdog Error
Module Fuse Error
Module Disconnect Error
Base Power Error etc…..
RUN/STOP, Local/Remote, Error , Prog. Status, Battery Fail, Check Program
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Digital I/O Modules
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24VDC input modules (sink/source or source only type)
AC input modules (110V or 220V AC)
Relay, Triac, transistor output modules (sink or source type)
8, 16, 32, 64 points I/O module
Photo-coupler isolation
Individual LED for DI/DO status
Response time is as low as 1ms
Output hold upon CPU fail/stop or I/O module fail
Easy maintenance: Terminal & connector type
Field Termination made
easy for connector type
modules
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Digital I/O Modules
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2MLI2MLI-D21A
8Pts. DC24V Input (Sink/Source Type)
2MLI2MLI-D22A
16Pts. DC24V Input (Sink/Source Type)
2MLI2MLI-D22B
16Pts. DC24V Input (Source Type)
2MLI2MLI-D24A
32Pts. DC24V Input (Sink/Source Type)
2MLI2MLI-D24B
32Pts. DC24V Input (Source Type)
2MLI2MLI-D28A
64Pts. DC24V Input (Sink/Source Type)
2MLI2MLI-D28B
64Pts. DC24V Input (Source Type)
2MLI2MLI-A12A
16Pts. AC 110V Input
2MLI2MLI-A21A
8Pts. AC 220V Input
2MLQ2MLQ-RY1A
8Pts. Relay Output, 2A , 1Pts./COM
2MLQ2MLQ-RY2A
16Pts. Relay Output, 2A
2MLQ2MLQ-RY2B
16Pts. Relay Output, 2A , BuiVaristor
2MLQ2MLQ-SS2A
16Pts. Triac Output, 1A
2MLQ2MLQ-TR2A
16Pts. TR Output, 0.5A (Sink Type)
2MLQ2MLQ-TR4A
32Pts. TR Output, 0.1A (Sink Type)
2MLQ2MLQ-TR8A
64Pts. TR Output, 0.1A (Sink Type)
2MLQ2MLQ-TR2B
16Pts. TR Output, 0.5A (Source Type)
2MLQ2MLQ-TR4B
32Pts. TR Output, 0.1A (Source Type)
2MLQ2MLQ-TR8B
64Pts. TR Output, 0.1A (Source Type)
Digital Input
Digital Output
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Analog I/O Modules
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Voltage module and current module
High speed A/D conversion & processing i.e. 250µs/channel
High resolution (16 bit 0 ~ 16,000)
Easy configuration via SoftMaster and avoid programming
LED status displays for RUN / ERROR conditions
Each channel can be individually enabled / disabled
Improve maintenance and overall processing speed by disabling all
un-used channels
Model
Specification
2MLF-AV8A
Voltage Input, 8channels
2MLF-AC8A
Current Input, 8channels
2MLF-AD8A
Analog Input
Voltage/Current Input, 8channels
2MLF-AD4S
Voltage/Current Input, 4channels, Isolated
2MLF-AD16A
Voltage/Current Input, 16channels
2MLF-RD4A
RTD Input
2MLF-TC4S
TC Input
RTD Input, 4channels
Thermocouple Input, 4channels, Isolated
2MLF-DV4A
Voltage Output, 4channels
2MLF-DC4A
Current Output, 4channels
2MLF-DC8A
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Type
Analog Output
Current Output, 8channels
2MLF-DV8A
Voltage Output, 8channels
2MLF-DC4S
Current Output, 4channels, Isolated
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Special Modules
High Speed Counter (pulse input)
• Incremental encoder
• Supporting various pulse input
voltages (5V, 12V, 24V)
• Preset / totalizer function. Two builtin transistor outputs
• LED status displays for input, output
and module READY condition.
Event Input (Sequence-Of-Event, SOE)
• Detects the events from the field devices and records
the event with a 1ms resolution time tag
• 1ms scanning at modular level
• 300 events per card (max. 3000 events)
• Tight integration with Experion Server
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Power Supply & Rack Options
• Power Supply
Power Supply
module for
Redundant Rack
2MLR-AC13
8.5A, AC110V
2MLR-AC23
8.5A, AC220V
2MLR-AC12
5.5A, AC110V
2MLR-AC22
5.5A, AC220V
2MLR-DC42
7.5A, DC24V
Redundant CPU
rack
2MLR-M02P
2 slots*
2MLR-M06P
6 slots*
Redundant IO rack
2MLR-E12P
12 slots*
• Rack
*slots available for I/O, communication, special modules
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Open Networking
Fast Ethernet (FEnet)
Serial Communication
(Snet)
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Twisted Pair or Fiber-Optic Media option
Experion Integration, Peer-2-Peer, MODBUS TCP, User defined protocol
Two ports with RS232C, RS422/485 options
MODBUS RTU/ASCII, SoftMaster, User-defined protocol
Profibus--DP
Profibus
RS485 communication with Profibus-DP devices
Sycon configuration
DeviceNet
CAN bus communication with DeviceNet devices
Sycon configuration
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Fast Ethernet FEnet Module - Applications
RUN
I/F
TX
RX
10/100
2MLF-EFMF
HS
PC
P2P ERR
PADT
TX
RX
2MLF-EFMF
2MLL-EFMT
100BASE-TX
UTP/CAT5
2MLL-EFMF
100BASE-FX
Multi-mode Fiber-Optic
•Supports both TCP/IP and UDP/IP protocols
•Twisted Pair and multi-mode Fiber-optic media are available
Configuration
Application
SoftMaster
service
SoftMaster (PADT) service runs automatic by default in FEnet
modules and does not require configuration. This means any
SoftMaster PADT PC can communicate with any MasterLogic
PLC’s FEnet module provided they are on the same network.
MLDP Server
(MasterLogic
Dedicated
Protocol)
For Experion PKS to communicate with MasterLogic PLCs for
process and system alarms & events including SOE information.
The PLC clocks can also be synchronized with server clock
HSL service
Peer-to-Peer
For MasterLogic PLCs to have peer-to-peer communication with
few simple configuration steps. Diagnostics available to monitor
frames and other communication status
MODBUS TCP
(Slave)
For SCADA HMI or other MODBUS TCP master devices to
initiate communication with MasterLogic PLCs on MODBUS
TCP protocol
MODBUS TCP
(Master)
For MasterLogic PLCs to act as MODBUS TCP master and
initiaite communicate with other MODBUS TCP slave devices
User-defined
Communication
To send and receive user-defined TCP-IP communication
packets
Functionally, more than one service can run simultaneously on a single FEnet Module e.g.
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SoftMaster service and MLDP server run together at the same time.
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Peer-to-Peer – Easy to Configure
HSL (High Speed Link) Setting
In case of SEND mode, station# should be self
Block 1
(%MW200 ~ %MW231)
Station #1
Block 0 (%MW100 ~ %MW115)
OK
OK
Station #2
Station #5
In case of RECEIVE mode, Source (SEND) station# & Block #
should be used. (Station 5 will receive data block 0 from station 1)
Reject !!!
OK
OK
Station #4
Station #3
Only the RECEIVE station decides to accept or reject data being
broadcasted to it based on how blocks are configured.
Station 3 will receive both data block 0 & 1 from Station 1
Station 2 will receive data block 1 from Station 1
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MODBUS TCP Master/Slave
• Modbus TCP is the most widely used open protocol specification based on TCP/IP and UDP/IP.
• MasterLogic PLC provides both Modbus TCP slave (server) or master (client) function
• Commands supported are:
– Read Coil (Code 1) & Input status (Code 2)
– Read Holding Register (Code3) & Input Register (Code4)
– Force Single Coil (Code5) & multiple Coil (Code15)
– Preset Single Register (Code6) & multiple register (Code16)
• Max. 250 bytes of data can be read or written by a single command.
• Direct Variable (%I, %Q, %M, %R) corresponding to the MODBUS address by parameter.
Modbus TCP Frame
Modbus TCP Client (Master)
HMI /SCADA
/DCS etc…
Modbus TCP Server (Slave)
MasterLogic PLC
Request (Command)
Response
Third Party Device.
MasterLogic PLC
Network
Service
Name
MasterLogic-200 PLC parameters required to be set for MODBUS TCP
service
Standard
Parameter
Ethernet
Modbus Client (Master)
Modbus Server (Slave)
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○
○
HSL
Parameter
Remarks
P2P Parameter
P2P Ch.
X
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X
X
P2P Block
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X
User Frame
X
X
○: Required
X: Not required
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FEnet Sample Applications
Architecture
100BASE-TX or FX network of MasterLogic PLCs
SoftMaster connected to one PLC via RS232C or USB port
connection
Application
• SoftMaster PC (PADT) communicates with PLC1 on local
RS232C/USB but communicates with other PLCs on remote
via Ethernet network for programming.
• Peer to Peer communication among PLCs.
PC
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PLC [1]
IP:210.206.91.188
PLC [2]
IP:210.206.91.189
PLC [n]
IP:210.206.91.190
USB or RS-232C
Ethernet network
Local Connection
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Logical connection via Ethernet communication module (remote)
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Snet Module - Serial Communication Applications
Each Snet module has 2 serial ports. Each port
can be configured as:
Configuration
2MLL-CH2A
Port1: RS232C
Port2: RS422/485
2MLL-C22A
Port1: RS232C
Port2: RS232C
2MLL-C42A
Port1: RS422/485
Port2: RS422/485
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Application
MODBUS Master
(ASCII / RTU)
For MasterLogic PLC to communicate with other open 3rd
party devices having MODBUS RTU/ASCII slave protocol
and update PLC CPU memory
MODBUS Slave
(ASCII/RTU)
For SCADA HMI PC to communicate with MasterLogic PLCs
for update HMI database.
SoftMaster-service
For SoftMaster (PADT) to communicate with MasterLogic
PLCs on local, remote connections (remote level 1 and
remote level 2)
For Proprietary Protocols (e.g. devices not
supporting MODBUS):
User-defined
protocol
communication
(Master)
For MasterLogic PLC to communicate with other open 3rd
party devices on proprietary ASCII protocols and update
PLC CPU memory
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Snet module – Sample Application
Architecture
RS232C and RS422 network communication
Application
• RS232C port can be used either SoftMaster interface or MODBUS RTU/ASCII slave device.
• RS422 port used as MODBUS RTU/ASCII master to communicate with 3rd party MODBUS RTU slave
devices e.g. MOSAIC PANEL.
MOSAIC PANEL
7-SEGMENT
7-SEGMENT
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7-SEGMENT
8
7-SEGMENT
8
7-SEGMENT
8
7-SEGMENT
8
8
7-SEGMENT
8
7-SEGMENT
8
HMI-PC
Snet # 1 station
7-SEGMENT
7-SEGMENT
8
RS-232C
communication
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7-SEGMENT
8
RS-422 communication
RS-422
communication
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7-SEGMENT
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Profibus Interface module
• Profibus-DP protocol
• Multi master
• Max. 126 slave stations available (32 stations
per segment)
• Transmission speed: 9.6Kbps ~ 12Mbps
• Transmission distance: Max. 1,200m
• Use SoftMaster-NM & Sycon for
communication settings
• Providing ‘Auto Config’ and various
information with configuration tool (SyCon)
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DeviceNet Interface module
• DeviceNet Master device
• Control 63 slave modules with max. 28,000 I/O
points
• Support Multi-drop and T-diverged connection
• Use SoftMaster-NM & Sycon for communication
settings
• Max. 12 module installation per CPU
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Open Network Summary Specifications
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Profitable Growth Together
Master Logic 200R PLC
Softmaster
Reliance Industries Ltd.
Honeywell.com
SoftMaster
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Programming
Configuration
Debugging
Controller Simulation
Monitoring
Trouble-shooting
Documentation
Maintenance etc.
Docking toolbar groups
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Project Window
Function Block List
Main window
Programming Editor (LD, SFC, ST)
Parameter config
Variables config etc
Message Window Tabs
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Variable Monitoring – 4 windows
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SoftMaster
Project Management
• Multiple Controllers through a single window
• One project file (.xgp) as central storage of complete controller info
• Compare project files to detect minor differences
• Import / Export entire controller or selectively individual component
• Flexible documentation – entire controller data or selectively
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SoftMaster
Online Functions
• Two levels of remote connection
• RS232C (CPU or Snet), USB, Ethernet (FEnet) connection
• Online Editing of program during RUN
• RUN/STOP/DEBUG mode change, breakpoints setting
• Selective download - only changes
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SoftMaster – Monitoring Tools
Ladder Monitor
Variable Monitoring
System Monitoring
Force I/O
Special Module Monitoring
Trend Monitor
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SoftMaster
Program Simulator - test and program the controller without the need of
a physical controller
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Support all type languages (LD/IL/SFC/ST / FB)
Program simulation
Online editing function
Debugging function
Module Simulation
External I/O condition
• A single menu click from SoftMaster: “Start Simulator”
• No need to modify user program just for simulation purposes
• No need to configure I/O module database separately - integrated with SoftMaster
configuration.
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Scan Programs, Interrupt Programs
Program Type
Max #
Remarks
INIT Program
1
One time exec at startup
Timer interrupt
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Time interval @ 1 ms resolution
Device interrupt
32
Internal flag on/off conditions
Scan Programs
Balance
Total
Once every scan
256
Program Execution Process
Power ON
INIT task
Input Refresh
Scan
Program A
condition
Timer Interrupt
Task Program D
Scan
Program B
Scan
Program C
Flexible Programming
Language for scan / interrupt task
programs
condition
Device Interrupt
Task Program E
Output Refresh
End processing
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Interrupt Task Programs
User Defined Function Block
& Data Type
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IEC 61131-3 Programming Language - LD (Ladder)
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An IEC 61131-3 standard programming language
Ideal language for logical / relay / timer / counter operations
User-friendly graphical editor for ladder language
Library comprising hundreds of functions/function blocks for various
control requirements
• Monitor mode
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IEC 61131-3 Programming Language - SFC
(Sequential Function Chart)
• An IEC 61131-3 standard programming language
• Ideal language for state transition/step action based batch applications
e.g. simultaneous operations
• Graphical configuration of steps / transition diagrams
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IEC 61131-3 Programming Language - ST
(Structured Text)
Syntax Coloring
Break points
Auto tabulator
(indentation)
Bookmarker
Tooltip support
Auto identifier
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Monitoring Window
Split View
• An IEC 61131-3 standard programming language
• PASCAL or BASIC like high level language
• Reduces eng, easy to understand, portable
• Ideal language for user-defined functions/function blocks
• Compatibility with other IEC languages e.g. a ladder
program can call a sub-routine written in ST language
• Supports named variables
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IEC 61131-3 Programming Language - IL
(Instruction List)
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An IEC 61131-3 standard programming language
A mnemonic programming language
View only mode
Toggling view with LD program editor
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Functions / Function Blocks
Logic Instructions
INPUT CONTACTS, RELAY COILS, SET, RESET, TRANSITION…
ARRAY data functions
MOVE, COMPARE, ROTATE, FILL…
Comparison functions
GT, EQ, GE, LT, LE, NE…
Data type conversion functions
Data MOVE/COPY functions
STACK functions
LIFO_***, FIFO_***
Bit functions
AND, OR, XOR, NOT, SHIFT LEFT, SHIFT RIGHT…
Timer / Counter Functions
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STRING Functions
CONCAT, LEFT, RIGHT, MID, INSERT, DELETE, REPLACE...
Mathematical Functions
EXPT, DEG/RAD, ADD/MUL/DIV/SUB, ABS, SIN/COS, SQRT…
Date / Time Functions
ADD, SUB…
SELECT functions
MIN, MAX, LIMIT, MUX…
System Control Functions
STOP, ESTOP, DIRECT I/O, OUTOFF, MCS, WDT_RST…
Process Control Functions
AVERAGE, LIMIT, PID, DELAY, RATIO, TOTALIZER,
ANALOG_SELECTOR…
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MasterLogic in Experion Architecture
Experion PKS Servers
Experion HS/LS Process & SCADA
Third Party
SCADA
Experion
Stations
SoftMaster
Control Builder
Engineering
Wireless
Devices
Safety
PLC
F
T
E
F
T
E
C200E
C300
F
T
E
F
T
E
F
T
E
SIL-3
Safety
PLC
F
T
E
Peer-toPeer
F
T
E
F
T
E
F
T
E
ESVT
APP
HC900
ML200 controllers
Rail I/O
PM I/O
Peer-to-Peer
MODBUSTCP
Direct
integration with
TPS
TPS, TDC2000,
TDC3000
(Investment Protection)
Digital Video Manager
SCADA Devices
(OPC, Modbus)
Smart
Remote I/Os
Local
Panel
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Touch
Screen Panel
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Experion Integration
Experion HS/LS
PKS Servers
Clock synchronization
with all MasterLogic
PLCs in the network
FTE
MasterLogic Dedicated
Protocol
Dual
Ethernet
PLC System Alarms/ Events
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Cascade PID
PLC Modeling
User
Cascade Loop
SV (ML)
MV (ML)
Block
#
Master Loop (0)
SV (SL)
Slave Loop (1)
MV (SL)
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Master
Loop #
Slave
Loop #
PV (SL)
PV (ML)
Master Loop PV
Slave Loop PV
Slave Loop MV
Oven Temperature
Quantity of Fuel Flow
Valve Signal
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Communication with HMI
(Dedicated Protocol Service with Fixed IP)
One IP solution for fixed IP of primary CPU irrespective of physical CPU
After switch over of
CPU from CPUA to
CPU B IP address
will remain same
for primary CPU
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Auto Tuning of PID
(6) Slave loop #1: Turn AT_EN on for Autotuning.
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Communication between ML 200 and Modbus Slave Device
ML 200
support user
defined
communication
protocol
In other words, if slave device support Modbus ASCII communication, select ‘Modbus ASCII client’ and if slave device
support Modbus RTU communication, select ‘Modbus RTU client’ here.
Click ‘Close’ button after confirming that selected driver (Modbus RTU client here) is registered.
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Other Special Feature
1. 3 different type noise filtering for Analog input
2. Common analog module for current and voltage
3. Enrich feature for logic diagnostic
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Conditional Pausing of logic execution
• Address traceability
• Fare and data packet monitoring for serial communication
• Automatic program optimization for reducing the PLC scan time
• Scanning or control strategy as per criticality of the system.
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Expansion Redundancy – Two Point Failure
1.2 GBPS Inter CPU Redundancy Communication Link
100 MBPS I/O
LAN
Supports Any
Two Point LAN
Failure
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Thank You!
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Profitable Growth Together
MasterLogic Series 200 PLC verview.
Presenter – Avisek Maitra
Reliance Industries Ltd.