chapter

10 Data treatment and

software
Presentation of actual architecture examples
(schematics, products and softwares)
Presentation of an application generator in a
collaborative environment

232
10. Data treatment Summary
and software

10.1 Dfinition 234

3
10.2 Introduction 234

10.3 Programming, configuration and languages 235

4

10.4 Application categories 236

5
10.5 UAG: Application generators 250

10.6 Definition of the main abbreviations used 254 6

10

11

12

233
10. Data treatment 10.1 Definition
and software 10.2 Introduction

This section deals with the processing function discussed in the first section and
includes a description of industrial software and its interaction with automation
system processes. Unlike other sections, we shall not go into details about concepts
such as systems, programming languages, etc. Many publications are available to
the readers.

10.1 Definition
Programmable Logic Controller (PLC) is the name used for a
programmable electronic device for controlling industrial systems by
sequential processing.
It sends operators (Operating Section or OS) commands based on input
data (sensors), setpoints and a program.
A PLC is a device similar to a computer and is used for instance to
control machines on an industrial assembly line. A single PLC is enough
to do what older automation systems did with hundreds or thousands of
relays and cams. The people who program PLCs are called automated
systems engineers.

10.2 Introduction
Programmable Logic Controllers (PLCs) were first developed in the 1970s.
They were initially designed to deal with the sequential logic required to
run machines and processes. At first with, their cost confined them to
large systems. Major technological developments have radically
restructured the processing function:
- the languages have been unified and standardised; the IEC 61131-3
standard defines the different types;
- the system approach is now widespread and the diagram principle
has been superseded by function blocks;
- digital systems are now widely used to process digital values as well
as analogue values with prior analogue-to-digital conversion;
- the cost of electronic components has dropped so much that PLCs
can now be used instead of relays even in simple systems;
- the communication buses used for data exchange are a competitive
alternative to conventional wiring;
- the software technology used in offices and business are increasingly
used in industrial automation systems;
- human-machine interfaces have also progressed in becoming
programmable for greater flexibility.

234
10. Data treatment 10.3 Programming, configuration and languages
and software

10.3 Programming, configuration and languages

An automation program consists of a set of instructions to be run in a
specific order by a processor. The word program is often used as a synonym
for software. Though software does largely consist of programs, it often
requires resource files containing all sorts of data which are not part of the
program.
This is where configuration comes in. Configuration is not programming, it
completes software by giving it the data it requires to run properly.
As an example, a water treatment system can range from very basic to highly
complex, starting with a simple program to maintain the level of water in a
reservoir between two limits by opening and closing an electric valve.
A slightly more complex arrangement could involve a flow controller (incoming)
and a flow controller (outgoing) to keep the water flowing at a set rate. An
industrial application, such as wastewater treatment, will control several
reservoirs. Each reservoir must meet a set of conditions, such as:
- level between the minimum and maximum limits;
- pH factor within a given range;
- have a certain output rate, etc.

b Standard languages
The International Electrotechnical Commission (IEC) has developed the
standard IEC 61131 for Programmable Logic Controllers. Part 3 of this
standard (IEC 61131-3) defines the programming languages:
IL (Instruction List) is very similar to assembler language, working in
close touch with the processor by using the arithmetical and logical unit,
its registers and accumulators;
ST (Structured Text) is similar to C language used in computing;
LD (Ladder Diagram) resembles electrical diagrams and can quickly
convert an old electromechanical relay program. This way of programming
gives a visual approach to problems;
FBD (Function Block Diagram) is a suite of blocks which can be linked
together and perform any type of function from the simplest to the most
advanced;
GRAFCET (acronym for GRAphe Fonctionnel de Commande
Etapes/Transitions or Step/Transition Control Function Chart) is an automation
system representation and analysis mode particularly well adapted to sequential
systems because it can be broken down into steps. In PLC programming,
SFC can be used in a very similar way to G (Grafcet IEC848 became an
international standard in 1988 with the name of Sequential Function Chart
(SFC)). Behind each action there is an associated program written in IL, ST,
LD or FBD.
10

235
10. Data treatment 10.4 Application categories
and software

10.4 Application categories

Technological progress impelled by user requirements has given rise to a
wide range of PLCs which can feature:
- hardware such as processing power, the number and characteristics
of inputs/outputs, execution speed, special modules (axis control,
communication, etc.);
- software which, apart from the programming language, has higher
functions and capacities for communication and interaction with other
business software.
These will be described through typical applications to help direct the readers
choice. Our advice is then to refer to the individual documentation of each
product.
In the introduction to this guide, we looked at the principle of automation
system architecture and implementation based on the customer profile.
The solutions described can be divided into four categories.
A - Electrician solutions
Applications are simple, standalone and fixed. The choice criteria should
be based on products that are easy to use, inexpensive and undemanding
in maintenance.
B - Automated/mechanical systems engineer solutions
Applications are demanding with regard to mechanical performance (precision,
rapidity, movement control, range changes, etc.). Their architecture and
processing systems will largely be chosen for performance.
C - Automated systems engineer solutions
Automated systems are made complex by the volume and variety of the
information to process such as adjustment, interconnections between
PLCs, number of inputs/outputs, etc.
D - Automated/production systems engineer solutions
Automated production systems must be integrated into the plants
management system architecture. They must interface with each other and
exchange data with production and management software, etc.
In figure 1, these categories are positioned over the implementations
described in section 1 of the Guide to Industrial Automation Systems.

A Fig. 1 Applications categories and users profiles

236
10. Data treatment 10.4 Application categories
and software

b Electrician solutions
Simple solutions use a few electromechanical relays to run automation
sequences. The latest generation of small PLCs are easy to use,
competitively priced starting from a few inputs/outputs and offer new
capacities without requiring any expertise in programming.
Typical applications are in the following sectors:
- industry: simple machines and additional functions in decentralised
systems;
- buildings and services: lighting management, access, control,
premises surveillance, heating, ventilation, air-conditioning.

v Application with a Zelio PLC

This configuration is suited to the following applications figure 2.
Application Description Example
Mobile pumping station An application to fill and
empty tanks.
Use of a speed controller
helps to adjust to degrees
of viscosity in fluids.

Automatic gate To open and close factory

gates.

Electric window To control the air in a

garden centre.

A Fig. 2 Examples with Zelio PLC

In the diagram (C Fig. 3), motor operation is governed by a speed

A Fig. 3 Application based on Zelio PLC controller. For discrete control, all it requires is a contactor linked to its
thermo-relay.
This unit comprises:
- a Zelio Logic PLC;
- 24V DC Phaseo power supply;
- an Altivar 11 speed controller;
10
- a GV2 motor circuit breaker;
- an XVB light tower;
- a Vario VCF switch.
The variables of the speed controller (time, speed, control) can be set
directly on the Altivar 11 or with Powersuite software.
The Zelio can be programmed directly on the module or with Zeliosoft
software installed on a PC. The latter option is illustrated by the screenshot
in figure 4 which shows a logical process run by FDB (Function Block
A Fig. 4 Screen shot of a logical FBD Diagram).

237
10. Data treatment 10.4 Application categories
and software

v Application with a Twido PLC

This type of PLC is used to build simple applications which can be
monitored or controlled remotely via a modem connected to the
telephone network (PSTN). Figure 5 present some examples:

Application Description Example

Ventilation Control of a ventilation
system in an industrial
building. Temperature
measurement governs
the starting and
stopping of the system.
Heating Heating system control
in a building.

Remote control Control of a fountain

of a fountain infrastructure of a
service company.
The system is remote
controlled via a modem.

Control of filter cleaning The application controls

in a water distribution and cleans the filter in a
plant. water distribution plant
with an air-cleaning
sequence followed by
clean water. The system
can also be remotely
controlled via a modem.
A Fig. 5 Examples with Twido PLC

v Typical diagram
The system is developed from a Twido PLC (C Fig.6) and controlled and
viewed via a Magelis keyboard/screen. Security is ensured by an emergency
stop on the main switch.
The system is hardwired and the PLC controls the starter and the messages
from the alarm module.

A Fig. 6 Application based on Twido PLC

238
10. Data treatment 10.4 Application categories
and software

The following components make up the system:

Hardware:
- Twido Modular (PLC);
- Phaseo power supply (PS);
- TeSys-U Starter Controller (SC);
- Magelis XBT-N (HMI);
- Standard 3-phase motor.
Software:
- Twidosoft Version 2.0;
- Magelis XBTL1003M V4.2.
The screenshot in figure 7 of the Twidosoft program illustrates programming
in Ladder which can be switched to List. The software includes a large set
of instructions and an embedded browser is used to access all the objects
directly.

A Fig. 7 Screen shot of Twido Ladder program

b Automated/mechanical systems engineer solution

Some applications require performances that are difficult to achieve without
their being closely linked to processing, acquisition and power control
functions. For this reason, linkage is directly processed by the power control
function, either in analogue, by fast bus (CANopen, etc.) or special bus
(Sercos, etc.). This type of architecture is found in speed controllers for both
asynchronous and synchronous motors (close loop systems). 10
The need to link a sequential process of analogue and discrete variables
means that manufacturers have had to add to speed controllers:
- input/output cards;
- communication cards;
- PLC processing cards.
These solutions can be used equally for industrial applications and in
infrastructure.
We will illustrate this solution by a speed controller with a built-in PLC.

239
10. Data treatment 10.4 Application categories
and software

v Processing built into a speed controller

A programmable card option (C Fig. 8) can be used to convert Altivar
speed controllers into proper automation production cells. This card,
called "Controller Inside" has all the PLC functions built into to it:
- the Codesys programming software with standardised IEC 61131-3
graphic language capacity;
- processing close to the motor controls for rapidity of movement;
- master CANopen bus to govern other speed controllers (Altivar 31,
Altivar 61 and Altivar 71) and exchange all requisite data;
A Fig. 8 Altivar 71 with Controler Inside card - the card has its own inputs/outputs and access to Altivar I/Os;
- graphic terminal display functions are stored to inform and configure;
- supervision available via Ethernet, Modbus or other communication
networks.
CoDeSys is a programming tool used with Windows. It supports the five standard
IEC 61131-3 languages. CoDeSys produces a native code for most current
processors and can be used on different controller platforms.
It combines the power of advanced programming languages like C and Pascal
and PLC programming system functions. The programming kit includes a manual
and online help and is available in English, French and German.
Many manufacturers use it and Schneider Electric has chosen it for its Altivar and
Lexium speed controllers.

v Applications
This configuration is suited to the following applications (C Fig 9).

Application Description Exemple

Infrastructure network Usedin pumping station to
feed user's with fresh water

Dedicated machines Several applications:

- winders
- automatic assembly
machines
- wood working machines.

Conveyors Used in combination with

hosting equipments and
shuttles.

A Fig. 9 Applications for PLC enbended in the Speed drive

240
10. Data treatment 10.4 Application categories
and software

v Typical diagram
To make the illustration of this solution clearer, the power section and its
supply are not shown figure 10.
In the diagrammatic illustration, the system comprises:

A Fig. 10 Application with a ATV71 + Controler Inside

Hardware
- Controller Inside card installed in an Altivar 71; the speed controller is
the master on a CANopen bus;
- ATV31 and ATV71 speed controllers with built-in CANopen interface;
- Lexium05 servo-drive with built-in CANopen interface. The HMI is
managed by a Magelis XBT-GT graphic terminal and linked to the
production cell by a Modbus link;
- Advantys STB distributed input/output production cells.
Software
10
- PS1131 (CoDeSys V2.3);
- PowerSuite for ATV31, ATV71 and Lexium05;
- Vijeo-Designer V4.30 for Magelis;
- Advantys Configuration Tool V2.0.

b Automated systems engineer solution

Modern automation systems require a great many inputs and outputs of
different types. They must be able to process automation sequences and
provide the information needed for management and maintenance.
The complexity of the systems entails lengthy and costly design and
implementation. Manufacturers offer a dual approach to help cut costs:
- modular offers of hardware and software to reduce the end cost of
learning all the applications;
- software tools to boost productivity, manage logs and ease system
maintenance and upgrading.

241
10. Data treatment 10.4 Application categories
and software

This type of automation solution is used in industrial processes where

several machines are linked together or in infrastructures. Some examples
are shown in the table figure 11.

Application Description Example

Handling equipment. Used in a process with
several conveyor
systems and which uses
external information.

Packaging machines, Used for cutting and

textile machines, folding machines
special machines. integrated into a
production line.

Pumps and fans. Used for water

circulation and
refrigeration systems
governed by external
measurements such as
output rates.

A Fig. 11 Industrial process applications

v Applications
We do not intend to describe an application from end to end, but to
illustrate its working principle we will make a description of a significant
part of it.
A Premium PLC is used to control a local production cell (C Fig.12).
This is a platform made up of Advantys STB inputs/outputs, four speed
controllers and external input/output modules. Each element is connected
to a CAN bus. This implementation can easily be expanded by adding
more speed controllers and inputs/outputs. The PLC is linked to the
production cell by a Modbus/TCP bus. The controllers and motors are
powered from a 230VAC network. Another source is used for a 24VDC
supply.
v Typical diagram (C Fig.12)
List of system components:
- TSX Premium (PLC),
- Phaseo (24V supply),
- ATV31 (speed controllers),
- Advantys STB (input/output cell),
- Advantys FTB IP67 input/output module,

A Fig. 12 Application based on PLC Premium

242
10. Data treatment 10.4 Application categories
and software

- 3-phase squirrel cage motors.

Software:
- Unity Pro V2.0.2 (PLC),
- Advantys configuration software V1.20 (I/O cell),
- PowerSuite V2.0 (ATV31 speed controller configuration).
v UNITY PRO software workshop
Unity Pro is the common programming software for debugging and operating
Modicon Premium, Atrium and Quantum PLCs. Based on the standards of
PL7 and Concept, Unity Pro opens the way to a comprehensive set of new
functions (C Fig. 13) for a greater productivity and software collaboration.

A Fig. 13 Screen shot of Unity Pro

Main features of Unity Pro

- Windows 2000/XP graphic interfaces;
- Custom icons and toolbars;
- user profiles;
- graphic design of hardware configurations;
- integrated PL7 and Concept converters;
- automatic generation of synchronisation variables on Ethernet (Global
Data);
- 5 native IEC61131-3 languages supported with graphic editors;
- integration and synchronisation of program editors, data, user function
blocks;
- drag & drop reuse of library objects;
- XML import/export and automatic data reassignment;
- automation of repetitive tasks by VBA macros;
- plug & play Hot Standby redundancy system.
Unity Pro offers a comprehensive set of functions and tools to match the
structure of the application to the structure of the process or the machine.
The program is divided into functional modules which, assembled with
hierarchical priority, form the functional view and contain:
10
- program sections;
- animation tables;
- operator screens;
- hyperlinks.
The basic functions, used repetitively, can be encapsulated into user
function blocks (DFB) in IEC61131-3 language.
To create an application reference database, Unity Pro supports project
and application libraries locally or on server.
It has around 800 standard function, and can be enhanced with customers
standards (variables, data types, function blocks).

243
10. Data treatment 10.4 Application categories
and software

It also includes:
- symbolic variables independent of the physical memory;
- structured user-defined data types (DDT);
- DDT and DFB function block version management in the library;
- a library of pre-animated graphic objects for operator screens;
- read/write protection of programming data to prevent any
modification;
- function block development available in C++ with the Unity EFB
Toolkit option.
Put in libraries on a local PC or a remote server, the application objects
and their properties are used and shared by all programs and any
changes made to an object in a library is effective in the programs that
use it:
- the functional modules can be used in the application or between
projects by XML import/export;
- function blocks are instantiated by drag & drop from the library;
- all instances automatically inherit library changes (as the user
chooses);
- graphic objects for operator screens are selected and configured by
drag & drop.
A PLC simulator on PC is integrated into Unity Pro and is used to fine-
tune the application as much as possible before it is commissioned on
site. It exactly reproduces the behaviour of the target program. All the
debugging tools can be used in simulation:
- step by step program execution;
- sreak and view point;
- dynamic animations to view the status of variables and the logic in
execution.
Operating screens facilitate debugging by views representing variable
status in graphic object form: indicators, trend curves, etc.
The same as for configuration, application-specific modules have special
screens to debug them: the functions available are adapted to the type of
module implemented (discrete, analogue, counter, communication I/Os,
etc.).
Operator actions are logged and archived in a standard secured Windows
file. Hypertext links are used to link the application to all the documents
and tools required for operation and maintenance.
Diagnostics tools
Unity Pro provides a library of application diagnostic DFBs. These are
integrated into the program and, depending on their function, are used to
monitor the permanent safety conditions and the progress of the process.
A viewing window displays any system and application defects explicitly
and chronologically in real time from the source. A click on the window
opens the editor of the program where the error was triggered (search for
conditions missing at the source).
Online changes can be grouped consistently in local mode on a PC and
transferred directly to the PLC in one operation to be included in the
same cycle run.
Hypertext links integrated into the application give remote or local access
to working resources (documentation, additional tools, etc.) to cut
stopping time.
There is a full range of functions to control operations:
- unity Pro operator action log in a secured file;
- user profile with a choice of accessible functions and password
protection.

244
10. Data treatment 10.4 Application categories
and software

Operating screens and functional views for direct graphic access to

application elements (C Fig. 14).
The Unity client/server architecture gives access to the software
resources via programming interfaces in VBA, VB or C++; here are two
examples:
- automation of repetitive tasks (input, configuration, translation, etc.);
- integration of specific applications (code generator, etc.).
Cross-software exchange
The XML format, the universal W3C standard for data exchange via the
internet, is used as the source format for Unity applications such as
variables, programs, inputs/outputs, configurations, etc. (C Fig. 15).
Simple import/export is used to exchange all or part of the application
with other software in the project (CAD, etc.).
Unity Developer's Edition (UDE) and its programming interfaces in C++,
Visual Basic and VBA can be used to develop custom solutions such as
interfaces with electrical CAD, a variables generator, a PLC program or
repetitive design task automation. Many software publishers use UDE to
simplify data exchange with Unity Pro; here are some examples (C Fig. 16).

A Fig. 14 Screen shot of various Unity Pro vues Domain Company Product
Electrical CAD ECT Promise
Electrical CAD EPLAN EPLAN
Electrical CAD IGE-XAO SEE Electrical Expert
Electrical CAD AutoDesk AutoCAD Electrical
Electrical CAD SDProget SPAC Automazione
Process Simulation Mynah Mimic
Change Management MDT Software AutoSave
Application Generator TNI Control Build
SCADA/Reporting Iconics GENESIS BizViz Suite
SCADA EuropSupervision Panorama
SCADA Arc Informatique PCVue32
Graphical User Interface ErgoTech ErgoVU
SCADA Areal Topkapi
SCADA Afcon P-CIM
MES Tecnomatix/UGS XFactory
Historian/RtPM OSISoft PI
Web Services Anyware PLC Animator

A Fig. 16 Sofware publisher using UDE 10

A Fig. 15 Screen shot of steps for cross software

exchange

245
10. Data treatment 10.4 Application categories
and software

Compatibility with existing applications

PL7 and Concept IEC61131 applications are imported into Unity Pro by
an integrated converter as a standard feature. Operating system update
provided with Unity Pro is available for most Premium and Quantum PLC
processors.
Existing I/O peripherals, application-specific, communication and field bus
modules remain compatible with Unity Pro.

b Automated/production systems engineer solutions

Here we discuss complex architectures implementing several PLCs which
communicate with each other and with supervisory workstations
(SCADA). These architectures also interface with corporate management
systems.
System optimisation requires a global approach to interrelate all the
business departments, partners and means. We can distinguish two types
of interaction:
- real time: in the operating stage, this characterises the link with
customer relationship management systems (CRM), stock and
production management (MES) and accounts management for
optimising flows;
- collaborative: software tools support the relationship between the
relevant players in the design, building, operating and maintenance
stages to cut the time and cost of the production tool and improve its
quality.
Applications are so diversified that it is not easy to grasp their individual
positions in their environment. The need for cross-software exchange
leads to a collaborative approach throughout the business.

v Real time and corporate software

The illustration figure 17 shows the most common software used in a
workshop or factory. It can be separated into four levels:

A Fig. 17 Software used in a factory

246
10. Data treatment 10.4 Application categories
and software

the corporate level is characterised by a very large flow of information.

Office automation and internet standards are now basic requirements. The
software is run on PC or on more powerful servers;
the shop floor level is mainly characterised by supervisory tools and the
PLCs which govern the process. Ethernet is now the standard means of
communication between the computer and PLC domains;
the machine level where the principle of real time conditions the choice
of communication tools. Tasks are allotted to industrial PCs and PLCs,
links are made by field buses (CANOpen for Schneider Electric) or by
Ethernet associated to specific application layers;
the sensor level where hardwired links compete with the ASi bus which
is particularly well suited to this kind of use.
v Collaborative design and building
The PLC software described above is confined to the control of assemblies
designed separately to work as standalone units, even though communication
links are sometimes required.
New tools have been developed around the programming software to deal
with the constraints of working in parallel on design and building. These help
developers to simplify and speed up their work, keep track and reduce the
number of errors.
Consider the cycle from the study stage to the end of the life of a machine
or process (C Fig. 18). The range of different types of work involved in this
lifecycle requires collaboration between departments. This collaboration is
made possible by tools such as mechanical and electrical CAD, ERP, MES,
SCADA and others.
Unity Pro and UAG (application generator) at the core of the Schneider
Electric offer provide a software and hardware automation platform based
on openness and collaboration between the tools which cover the range of
needs from the study stage right up to system maintenance (C Fig. 18).

A Fig. 18 The two platforms UnityPro and UAG

10
The Unity Pro software workshop has already been described so we will
devote the next paragraph to UAG and how it works.

247
10. Data treatment 10.4 Application categories
and software

Several additional software tools have been developed to ensure

collaboration. The table figure 19 describing their functions is followed by
a brief explanation of how they work.
The main computing standards such as Ethernet TCP/IP, Web, OPC,
SOAP, XML, etc. are used to facilitate vertical collaboration at every
corporate level and offer:
- more visible information in real time;
- interoperability between the process and the information systems
(MES, ERP, etc.);
- exchange with design tools such as CAD.
Components Function
Unity Pro Single PLC application development workshop in a
collaborative environment
UAG Object-oriented multiple PLC application
Unity Application development and SCADA
Generator Complies with standard ISA S88
UDE Software for development in VBA, VB and C++
Unity Developer Edition programming languages
OFS Schneider OPC server to interrelate the desktop
OPC Factory System and PLC environments
Factory Cast Ensure that information passes between a PLC
Web Environnement environment and a desktop environment
CITEC SCADA SCADA software
AMPLA MES software
Ethernet card Cards using Factory Cast services
Organisation of additional
configuration and setting
software
XBT L1000 HMI creation
Vijeo designer HMI creation
Vijeo Look Mini SCADA
Power Suite Configuration of Altivar speed controllers and Altistart
and Tesys U starter units

A Fig. 19 Complementary software tools

UDE: Unity Developers Edition

The Unity range is enhanced with Unity Developers Edition (UDE), specialist
software for programmers in VBA, VB or C++. It provides access to all the
object servers in Unity Pro software for developing custom solutions such
as interfaces with an electrical CAD or an automatic application generator.
UAG: Unity Application Generator
UAG is a design tool based on a reusable module approach (PID, valve,
motor, etc.) and is compliant with standard ISA 88. UAG generates the code
of the PLCs in the architecture and the SCADA graphics. In addition, with a
single input it manages a database, common to all the elements, to ensure
application consistency.
Single data input ensures speed and consistency between the two
environments.
With this structured modular design approach, UAG offers significant savings
in development costs and facilitates validation and maintenance of automation
projects.

248
10. Data treatment 10.4 Application categories
and software

OFS: OPC Factory System

OFS, OPC (OLE for Process Control) adapted to the Schneider Electric
environment, is a program for communication between the desktop
environment and the industrial automation systems. It originated with
Microsoft and derives from DDE, then OLE to OLE Automation using
Windows COM/DCOM.
A foundation made up of software providers and publishers manages OPC
upgrades and guarantees upward compatibility and interoperability between
different software products.
Upgrades are conditioned by the following industrial requirements:
- application interfaces based on open standards offering simple common
access to shop floor data;
- greater interoperability between automation and control applications, site
equipment and IT applications;
- multiple Client/Server architecture;
- access to a local or remote server;
- information flow in real time.
Factory Cast: Web environment
A set of tools to enable applications to communicate via internet and
meeting the following requirements:
- communication between applications;
- web and internet compatibility;
- standard-based non-proprietary solutions;
- easier implementation.
The applications must be able to communicate whatever:
- language they were developed in;
- operating system they run on.
The internet-compatible technology is based on a standard XML SOAP
protocol (Simple Object Access Protocol) cohabiting with HTTP and enables
applications to communicate with each other.
A standard description of services and interfaces is provided by a WSDL
application (Web Service Description Language) which is a library of standard
and self-documented data access functions.
The combination of these technologies is known as WEB SERVICES and
is independent of platforms, languages and operating systems.
SCADA: supervision software
SCADA (Supervisory Control And Data Acquisition) is industrial software
designed to optimise production management. It is used to run a production
workshop in real time, based on production requirements and the means
available.
Ethernet cards
The ranges of Ethernet cards offer modern architectures open to different
current software technologies and provide users with tools to build their
10
own functions. This makes it possible to organise objects in a way fully
compatible with MES and ERP IT environments.

249
10. Data treatment 10.5 UAG: Application generators
and software

10.5 UAG: Application generators

Unity Application Generator (UAG) is both design software and a generation
tool to integrate PLCs and supervisory systems (SCADA) or human-machine
interfaces (HMI). To do this, it uses the basic single database technique of
hybrid control systems combining DCS and PLC functions. Though UAG
is used for single PLC applications, it is especially useful in multiple PLC
architectures. It uses the full power of UNITY Pro which it closely associates
with supervisory systems such as Monitor Pro, I-Fix and so on.

b Significant savings in development time

UAG and its underlying concepts enable developers to get involved with
the customers at a very early stage. Reusable objects and easy updating
and testing can cut project time by 20 to 30% (C Fig. 20), which can mean
several months for big projects.

A Fig. 20 Time and cost reduction

b Main features of UAG

- A single input for the PLC/HMI database (SCADA);
- use and reuse of library objects;
- process application configuration;
- incremental generation for SCADA;
- global resource mapping;
- PLC application (code, variables, configuration, communication, etc.);
- SCADA application (symbols, mimic diagrams, variables, attributes,
alarms, etc.);
- communication management (Ethernet, ModBus+);
- generic interface in XML.
Note: Generic Plug-in Interface is an open interface for other SCADA systems.

250
10. Data treatment 10.5 UAG: Application generators
and software

b UAG operation
Unity Application Generator is made up of three tools (C Fig.21).

Tool Field Library

SCoD Editor. Libraries. Specification of control modules,
DFB or EFB import, attribute
specification and screen
configuration definition (within
UAG).
UAG Customisation Customisation Definition of user profiles in a
project including: naming rules,
hardware specification
catalogues, libraries.
Unity Application Projet Project design, functional analysis
Generator and application generator.
A Fig. 21 UAG tools

The links between tools is summed up in figure 22.

v ScoD object editor

Unity Application Generator (UAG) is an object-oriented tool based on
control modules. A control module describes a process unit and covers all
aspects of the automation task:
- PLC logic;
- representation for the operator in the supervision system;
- mechanical and electrical properties of the unit;
- maintenance and troubleshooting;
- multi-facet representation of these elements in UAG is called Smart
Control Device -(SCoD), the equivalent of control modules in standard
ISA 88.
Control instantiation has an equivalent physical representation which can
be:
- an actual component, which can be held and inspected, such as a
motor, a valve, a temperature transmitter, etc.;
- a control element used to adjust other functions such as a PID loop,
timer or counter.
Control modules are defined and used in type libraries; the SCoD editor is
A Fig. 22 UAG synoptic
the tool which creates, updates and groups specific customer controls in
the objects (Smart Control Device).
Definition of rules and properties in the SCoD editor based on the
DFB/EFB interface includes:
- graphic user interface (GUI);
- mandatory configuration of the SCoD instance;
- optional configuration of the SCoD instance; 10
- SCoD instance inheritance;
- simple and complex relations inherited by the selected module and
other ScoDs;
- definition of data transmitted to and from the HMI;
- definition of data related to the topological model;
- specific HMI information such as alarm texts, measurement units;
- access levels:
- per module reference to specific HMI information such as
ActiveXs and symbols;
- per module reference to specific PLC information such as
DFBs/EFBs;
- SCoD documentation.

251
10. Data treatment 10.5 UAG: Application generators
and software

An example of a Smart Control Device could be a valve. A valve is

generally used as a cut-off device to prevent or allow the flow of a fluid or
gas in a pipe. It is usually linked to three digital signals:
- limit switch open or closed (2 signals);
- the signal for the actuator.
There are many different standard valves ranging from the smallest
actuated by solenoids to the largest actuated by motors.
A Fig. 23 Screen shot of UAG editor The properties are assigned for the type of valve from the PLC interface
(API).
The default valve insert mode is Energise-to-Open, though the user can
specify Energise-to-Close.
The Travel Time-out operating time must be within the [min Value.. max
Value] interval.
Figure 23 shows a screenshot of the editor.
v UAG Customisation Editor
This editor (C Fig. 24) is used to define a common language for different
people (operation, automation, maintenance). It describes the list of
elements used and their definition, objects (SCoD) and human-machine
interfaces (HMI).
Customisation starts with:
- the list of SCoD libraries;
- the list of authorised hardware modules;
- the access level;
- definition of process element names;
- specific HMI or SCADA properties.
To return to the valve example, the user has to define the valve exactly so
that it cannot be confused with another in the system. The user is going
to standardise the structure of the system component names: <position in
A Fig. 24 List elements description
4 digits> <English abbreviation in 3 digits> <Type of element from 1 to 6>.
A given valve will have a single name such as 2311VAL4.
All elements can thus be defined by:
- the location of the SCoD corresponding to the valve;
- the section of the program in the PLC;
- the hardware modules linked to the PLC, etc.
In the PLC and HMI applications, standardisation is defined for all operators
and experts in automation and the process. The project follows the rules
without exception and maintenance staff can be trained with the tools.
Project management is facilitated by knowing the number of valves.

v Application generator
Unity Application Generator is a design and functional analysis program
generating applications for PLCs and SCADAs (C Fig. 25).

A Fig. 25 Screen shot UAG physical model and

control model parameter setting

252
10. Data treatment 10.5 UAG: Application generators
and software

There are two independent tasks to generate the physical and topological
models:
- The physical model describes the process in a tree structure of elements
as shown figure 25.
- The typological model describes the hardware of the automation process,
including the PLCs, inputs/outputs, networks, PCs, etc. as shown
figure 26.

b UAG and ISA88 standard

v Standard ISA 88: Advanced process control organisation
Advanced control focuses on the basic algorithm used to enhance the
behaviour of automatic control devices. It also takes into account
organisational and economic disruptions and can go as far as casting doubt
A Fig. 26 Screen shot of UAG topological model
on the equipment, methods and results of the manufacturing process.
The ANSI/ISA-88 standard offers efficient concepts for the functional
organisation of applications to achieve the degree of robustness required
for ongoing adaptation of systems subjected to such constraints.
This standard focuses on a number of essential points:
- flexibility, development that is less complex and shorter and mastery
of the process;
- object-oriented approach and reusable object classes;
- separation of the procedure and the process;
- separation of process control and equipment automation control.
Detailed information on this standard is available on http:// www.s88.nl.
Unity Application Generator uses the ISA 88 batch processing terminology
in Part 1: Models and Terminology . With the structure of this standard,
UAG users can break down process tasks to fit their own rules and then
use UAG and the elements defined to rebuild the process.

10

253
10. Data treatment 10.6 Definition of the main abbreviations used
and software

10.6 Definition of the main abbreviations used

DCS Distributed Control System
HMI Human Machine Interface
PLC Programmable Logic Controller
SCADA Supervisory Control And Data Acquisition (see the paragraph on
SCADA)
UAG Unity Application Generator
MES Manufacturing Execution System, a computing system primarily
designed to collect complete or partial factory production data in real
time. These data are then used for a number of analysis exercises:
- tracking, genealogy;
- quality control;
- production monitoring;
- sequencing;
- preventive and remedial maintenance.
ISA has standardised the MES structure.
An MES is often situated between the industrial automation system and
the ERP systems like SAP.
ERP Enterprise Resources Planning, software to manage all the processes
in a company by integrating all its functions such as human resources
management, accounting and financial management, decision-aiding tools,
sales, distribution, supplies and e-commerce.
CRM Customer Relationship Management, a new paradigm in the field of
marketing.
The purpose of CRM is to create and maintain a mutually beneficial
relationship between a company and its customers. In this commercial
relationship system, the company focuses on winning customer loyalty
by offering them service of a quality they cannot find elsewhere.
The image frequently used to illustrate this concept is the relationship
between small shopkeepers and their customers. Customers are rewarded
for their loyalty by the fact that the shopkeeper knows their habits and
acts accordingly (like a baker who puts aside a loaf baked the way you
like it and allows you credit).

254
 10

255