Plcopen Iec61131-3 Feb2014

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for efficiency in automation
Introduction in IEC 61131-3

Check also the notes coupled to each slide
for further explanation
Page 1 printed at 1/12/2015
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PLCopen TC1 : Standards

links to IEC 61131-3
Harmonizing the way people look to
control
the future is here
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Fiction?
Imagine
*
*
*
*
you are in industrial control

working with 4 different brands of controls
using different dialects in their programming languages
struggling to match the level of your software engineers with
the operators and maintenance people on the factory floor
* & seeing that your competitor does better
Why? Whats wrong ?
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Out of the jungle
The current variety of problems can be

vastly reduced via standardization
... and such a standard is available
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IEC 61131-3
The best thing that happened
to industrial control
Sugar Lantic on Automation Maillist
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The 9 parts of the IEC 61131 Standard

Project
Title
Valid till
61131- 1, Ed 2.0
General information,
2003-05
2013
61131- 2, Ed 3.0
Equipment requirements and tests,
2007-07
2012
61131- 3, Ed 3.0
Programming languages (Currently CDV - Committee Draft for Voting)
2012+5
61131- 4, Ed 2.0
User guidelines (TR),
2004-07
2010
61131- 5, Ed 1.0
Communications,
2000-11
2013
61131- 6, Ed 1.0
Functional safety for PLC
61131- 7, Ed 1.0
Fuzzy control programming,
2000-08
2013
61131- 8, Ed 2.0
Guidelines applic. & implem. progr. languages (TR),
2003-09
2008
61131- 9, Ed 1.0
Single-drop digital communication interface for small sensors

and actuators (SDCI) aka IO-Link (Currently CD - Committee Draft)
(Currently CDV - Committee Draft for Voting)
2012+5
2012+5
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IEC 1131 versus IEC 61131

The good news is there is no difference
It is an international harmonization of all the IEC standards
and the localized versions
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IEC 61131-3 Programming languages /

Industrial Control Programming
Standardizing the way people work with controls
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IEC 61131-3 Programming languages /

Industrial Control Programming
...with support for people
with different backgrounds
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The IEC 61131-3 Standard

Common Elements
Programming Languages
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IEC 61131-3 : Common Elements

Variables & Data Types
What is this?
01010101 10101010
Historically
Reference to a physical memory location
Reference to a physical Input
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Variables & Data types
Temperature_Sensor_1 : Integer
Symbolic representation via labels
Restricted area for I/O mapping
Hardware independent software code
Result: higher transparency & readability
And less errors
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Software Model
Configuration
Resources
Tasks
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IEC 61131-3 Software Model

Configuration
Communication Function
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Configuration
Resource
Resource
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Configuration
Resource
Task
Resource
Task
Task
Task
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Configuration
Resource
Resource
Task
Task
Task
Task
Program
Program
Program
Program
Execution
control path
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Configuration
Resource
Task
Variable
access path
Resource
Task
Task
Task
FB
Function
Block
Program
Program
FB
Program
FB
Program
FB
Global and direct variables
Variable
FB
Execution
control path
Access path
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IEC 61131-3 vs conventional PLC

Configuration
Resource
Task
Variable
access path
Resource
Task
Task
Task
FB
Function
Block
Program
Program
FB
Program
FB
Program
FB
Global and direct variables
Variable
FB
Execution
control path
Access path
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Conventional PLC vs IEC 61131-3

Time based
Task 1
Resource
Task
Endless Loop:
Task 2
Events based
Read inputs
Do Calculations
Task 3
Events based
Program
Set Outputs
Time based
Task 4
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Common Elements: Tasks

PLCs
DCS
PC based
Control
Embedded
IEC 61131-3
Drives
LON nodes
SoftLogic
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Common Elements : Tasks & Datatypes

Multi functional Operator Panel
Windows CE or any other
RPM =2000
IEC 61131-3 tasks

SCADA & HMI tasks
I/O Communication tasks
OPC UA
I/O Communication bus
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COMMON ELEMENTS
a.o.
Data Types
&
Variables
Configuration, Resources, Tasks

Programming Organization Units, POUs
* Functions
* Function Blocks
* Programs
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Functions ..
* Standard functions
ADD, SQRT, SIN, COS, GT, MIN, MAX, AND, OR, etc.
* Your own defined functions:

FUNCTION SIMPLE_FUN : REAL
VAR_INPUT
A, B
: REAL;
C
: REAL := 1.0;
END_VAR
SIMPLE_FUN := A*B/C;
END FUNCTION
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. & Function Blocks

Standard Function Blocks
I NPUT OUTPUT I N_OUT EXTERNAL
FUNCTION_BLOCK
Type Local
Hysterisis
REAL
XIN1
REAL
REAL
XIN2
BOOL
EPS
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. & Function Blocks

Additional supplied
Function Blocks
FUNCTION_BLOCK
Type Local
Hysterisis
REAL
XIN1
REAL
REAL
XIN2
BOOL
EPS
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. & Function Blocks

Additional supplied
Function Blocks
Your own defined Function
Blocks
FUNCTION_BLOCK
Type Local
Hysterisis
REAL
XIN1
REAL
REAL
XIN2
BOOL
EPS
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. & Function Blocks

Additional supplied
Function Blocks
Your own defined Function
Blocks
All FBs are highly re-usable
in same program, different
programs or project
FUNCTION_BLOCK
Type Local
Hysterisis
REAL
XIN1
REAL
REAL
XIN2
BOOL
EPS
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Function Block example

REAL
REAL
REAL
Hysterisis
XIN1
Q
XIN2
EPS
BOOL
Q
1
0
EPS
EPS
XIN2
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Function Block example

REAL
REAL
REAL
Hysterisis
XIN1
Q
XIN2
EPS
Q
1
BOOL
FUNCTION_BLOCK HYSTERISIS
VAR_INPUT
XIN1, XIN2 : REAL;
EPS : REAL; (* Hysterisis band *)
END_VAR
VAR_OUTPUT
Q : BOOL := 0
END_VAR
IF Q THEN
IF XIN1 < (XIN2-EPS) THEN
Q := 0 (* XIN1 decreasing *)
END_IF;
ELSIF XIN1 > (XIN2 + EPS ) THEN
Q := 1; (* XIN1 increasing *)
END_IF;
END_FUNCTION_BLOCK
0
EPS
EPS
XIN2
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Programs : design via building bricks

Start : BOOL;
Emergency : BOOL;
Limit : INT;
Automation
application
INPUT
OUTPUT
IN_OUT
EXTERNAL
FUNCTION_BLOCK
PROGRAM
Type
Type
Local
Local
GLOBAL
INPUT
FUNCTION
Type
Local
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Structure & Advantages of POUs

Create own Function Block Libraries (per application area)
FBs are tested and documented
Make libraries (world wide) accessible

Re-use as much as possible
Change programming to creating networks of FBs

Save 40% on next project
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Sequential Function Chart, SFC

Powerful graphical technique for
describing the sequential
behavior of a control program
Step 1
Used to partition a control

problem
Shows overview, also suitable for
rapid diagnostics
FILL
Transition 1
Step 2
Empty
Transition 2
Step 3
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Sequential Function Chart, SFC

Powerful graphical technique for
describing the sequential
behaviour of a control program
Step 1
Used to partition a control

problem
Shows overview, also suitable for
rapid diagnostics
The basic elements are STEPS
with ACTION BLOCKS and
TRANSITIONS
FILL
Transition 1
Step 2
Empty
Transition 2
Step 3
Support for alternative and

parallel sequences
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SFC : alternative sequences

Step 1
Transition 1a
Step 2 a
Empty
FILL
Transition 1b
Step 2 b
Transition 2a
Empty
Transition 2b
Step 3
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Common Elements
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The IEC 61131-3 Programming Languages

Instruction List
LD
ANDN
ST
C:= A AND NOT B
Function Block Diagram

AND
A
Structured Text
Ladder Diagram
A B
-| |--|/|----------------( )
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Top Down
Common Elements
Bottom Up
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IEC Programming Environments

Many of them offer:
graphical programming
screens
support for multiple
windows
mouse operation
pull-down menus
built-in hypertext help
function
software verification during
design
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What are the benefits ?
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Users? Which Users?

Discrete Mnf
Process cntrl
YOU ??
System Integrator
Education
Programming
Maintenance
Installation
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Users? Which Users?

Automobile production lines
Water treatment plant
Food processing and packaging machinery
Cable manufacturing
Semi-conductor clean room automation
Theme-park roller coasters
Nuclear waste treatment plant

This wide range encompass different skills
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Benefits
Reduced waste of human resources (in training,
debugging, maintenance and consultancy)
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Benefits
Reduced waste of human resources (in

training, debugging, maintenance and
consultancy)
Creating a focus to problem solving via software re-usability

(reduced application investment and supplier dependency)
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Benefits

consultancy)
Creating a focus to problem solving via
software re-usability (reduced application
investment and supplier dependency)
Reduced misunderstandings and errors
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Benefits

consultancy)
Programming techniques usable in more environments

(general industrial control)
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Benefits

consultancy)
Programming techniques usable in more
environments (general industrial control)
Combining harmoniously different components from different

locations, companies or countries, or projects
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Benefits

consultancy)
Combining harmoniously different
components from different locations,
companies or countries, or projects
Increased connectivity (investment protection)
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Benefits

consultancy)
Combining harmoniously different
components from different locations,
companies or countries, or projects
Increased connectivity (investment
protection)
Software
Library
Function Block
"Heating"
Function
"LIMIT"
Function
"TEST"
Function Block
"Turning"
Function Block
"Feeding"
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How to use IEC 61131-3

an example:
Structuring Software Development

with IEC 61131-3
7 steps to success
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Software Development Cycle

Design
/
Development
/
Installation
/
Maintenance..
phases
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software development cycle...

enhancements..
.. new requirements ...
. new functionality .
. new wishes ...
the never ending story of software
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Whats the topic here?

Structuring Software Development with IEC 61131-3
meaning: internal Software Quality
In the sense of:
Understandable, Reusable, Verifiable, Maintainable, Isolation
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Managing Complexity
100 10,000 1mio 100mio Lines of Code
Exponentially increasing complexity

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Why Structuring ?
The ever increasing role of Software on system quality:
errors cost money
Requirements increased dramatically: 100 lines of codes now
10,000 lines
SW development: not a one-man job anymore, but a team
with different know how and background
Commissioning, Installation, Maintenance, and Improvements
are essential parts of the development process
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Advantages of Structuring
Better Overview
Better Basis for (internal) Communication
Better Focus to problem solving
Basis for reusable software
Self-documenting
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Software Program vs. Software Product

Made by an individual
for own use
Made by a group for

usage by others
Limited functionality
Larger functionality
User interface less

important
User interface very

important
Little documentation
Well documented
Individual development Accepted SW engineering

style
methods
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Exploratory Style vs.

Software Engineering Method
Based on error
correction
Finding errors during
final product testing
Coding is the goal,
creating quickly a
working system, and
modifying till
satisfactory
Focused to error
prevention
Find errors as early as
possible
A structured approach,
clear specifications,
clear phases
Periodic reviews during
all stages of the project
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(Costly) Engineering Habits

Reuse work from similar former projects
Include them into the new project
And start adapting them to the new project

requirements
Copy - Paste & Modify
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Dangers of copy paste & modify
The not-invented-here syndrome only own

artifacts (developed in the past)
Non-predictable quality
Prone to errors and reuse potential is wasted
Unsystematically
Difficult to maintain and manage
Very costly over the life cycle
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Modern Software Development

Process
A small overview
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Modern Software Development Process

Defined in several clearly separated phases - project
definition
Top-down approach
Multiple disciplines involved
Multiple people involved
Different backgrounds
Based on Functional Requirements
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Example of Software Development Process

Different Phases
Analysis
Design
Development
Installation
Maintenance..
Waterfall model
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Example of Software Development Process
V-model
Link between
Specification
and testing
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The X-Model for SW Development

System
Design
Sub-system
Design
Module
Development
Sub-system
Integration
and Testing
System
Installation
and Testing
Component
Development
Library
Construction
Catalogue
Management
Component
Design
Component
Identification
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Application Software
System
Design
Sub-system
Design
Module
Development
Sub-system
Integration
and Testing
System
Installation
and Testing
Component
Development
Library
Construction
Catalogue
Management
Component
Design
Component
Identification
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System
Design
Sub-system
Design
Module
Development
Sub-system
Integration
and Testing
System
Installation
and Testing
Component
Development
Library
Construction
Catalogue
Management
Component
Design
Reusable Components (FBs)
Component
Identification
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Requirements on Engineering Tools

1.
Support creation and reuse of technical, non-technical and

combined entities
2.
Support creation of a structured domain repository (like a

library)
3.
Enable multi-user access on the components
4.
Provide configuration management
5.
Cover more than one engineering phase and discipline
6.
Encourage a reuse on different levels of granularity
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Decomposition and Reuse
Automation
application
INPUT
OUTPUT
IN_OUT
EXTERNAL
FUNCTION_BLOCK
Type
Local
PROGRAM
INPUT
Type
Local
FUNCTION
GLOBAL
Type
Local
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Decomposition
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Reuse via Standardized Function Blocks
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A hierarchy of abstraction
Topdown
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Bottom-up after top-down

First decompose then fill it in
Top-
Bottom
down
up
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How does that look in IEC 61131-3 ?

7 Steps to Success
with a
Fermentation Control System
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Fermentation Process
Agitator
Feed valve
Acidic reagent
Alkali reagent
Temperature
sensor
pH sensor
Heater band
Harvest valve
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How to create a control program

for this
in a structured way?
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Step 1 :
Identification of external Interfaces to the System
Feedback from the temperature sensor
Feedback from the pH sensor
Feedback from the valve positions
Feedback from the motor (speed)
Output to the valves

Output to the motor
Output to the heater band
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Step 2:
Definition of the main signals between System and Plant
In this example there is no coupling to the plant, but it could
have been, like:
coupling to main vessels with liquids
coupling to transportation system / filling station after
harvesting
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Step 3:
Definition of all Operator interactions, overrides and
supervisory data
For the operator we define:
a Start button
a Stop button
a Duration input
Now we have defined all the interfaces

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Step 4:
Brake down from top in logical partitions
MainSequence - filling, heating, agitating, fermenting, harvesting, cleaning.
ValveControl - operating valves used to fill and empty the vessel's
TemperatureControl - for controlling the temperature
AgitatorControl - agitator motor control
pHControl - PH-control
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Step 5:
Definition of the required POUs
(Programs and Function Blocks)
Using the definitions above and
representing it in the graphical way
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Fermentation Control Program

TempControl
Heat
Heat
Cool
SetPoint
TempSensor
PV
Cool
pHSensor
pHControl
AddAcid
MainSequence
Start
Stop
Duration
Start
Temp
Stop
pH
Duration
Agitation
AddAcid
SetPoint
PV
AddAlkali
AddAlkali
AgitateControl
MotorSpeed
FillState
SetPoint
MotorSpeed
PV
AgitateSpeed
ValveControl
Fill
State
Fill
ValvePositions
Harvest
Harvest
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MainSequence in
Sequential Function
Chart, SFC
Presenting the main
process states
S1
Initialisation
S2
Filling
S3
Heating
S4
Fermenting
S5
Harvesting
S6
Cleaning
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The Actions Blocks

and Transitions
can be programmed
in any of the four
IEC Programming Languages

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The IEC 61131-3 Programming Languages

Instruction List (IL)
LD
ANDN
ST
C:= A AND NOT B
Funktion Block Diagram (FBD)

AND
A
Structured Text (ST)
Ladder Diagram (LD)

A B
-| |--|/|----------------( )
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Step 6:
Definition of scan cycle time requirements
for the different parts of the application
In this example we have only one cycle in continuous mode
The remaining time can be used for other cycles like:
. the filling / transportation system
checking boundaries and error conditions (in a parallel

sequence)
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And last but not least: Step 7:

Configuration of the System:
Definition of Resources, Tasks
and linking of programs with physical I/O
Depending on the system involved

Includes physical mapping of symbols to I/O
Mapping of the resource (read: CPUs in the system)
Definition of the scan cycles and events (as defined in Step
6)
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Conclusion
The Software development process has changed:
more requirements..
more functionalities..
more code..
more people involved..
more requirements / wishes
Structuring and Decomposition are essential parts of

modern software development
IEC 61131-3 has the right basis to fulfill your requirements
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The association PLCopen

Together we can make it happen:
Standardization in Industrial Control Programming

WE NEED YOUR SUPPORT FOR THIS !
Join the organization PLCopen
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More Information...
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Free-of-Charge electronic Newsletter PLCopening (in english)
email: evdwal@PLCopen.org
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PLCopen

for efficiency in automation

Introduction in IEC 61131-3

Page 1 printed at 1/12/2015

PLCopen TC1 : Standards

Page 2 printed at 1/12/2015

for efficiency in automation

you are in industrial control

Out of the jungle

The current variety of problems can be

for efficiency in automation

The 9 parts of the IEC 61131 Standard

Equipment requirements and tests,

Programming languages (Currently CDV - Committee Draft for Voting)

User guidelines (TR),

Functional safety for PLC

Fuzzy control programming,

Guidelines applic. & implem. progr. languages (TR),

Single-drop digital communication interface for small sensors

Page 6 printed at 1/12/2015

(Currently CDV - Committee Draft for Voting)

IEC 1131 versus IEC 61131

and the localized versions

Page 7 printed at 1/12/2015

IEC 61131-3 Programming languages /

Standardizing the way people work with controls

Page 8 printed at 1/12/2015

IEC 61131-3 Programming languages /

Page 9 printed at 1/12/2015

The IEC 61131-3 Standard

Page 10 printed at 1/12/2015

IEC 61131-3 : Common Elements

Page 11 printed at 1/12/2015

IEC 61131-3 : Common Elements

Symbolic representation via labels

Restricted area for I/O mapping

Hardware independent software code

Result: higher transparency & readability

And less errors

Page 12 printed at 1/12/2015

IEC 61131-3 : Common Elements

Page 13 printed at 1/12/2015

IEC 61131-3 Software Model

IEC 61131-3 Software Model

IEC 61131-3 Software Model

IEC 61131-3 Software Model

IEC 61131-3 Software Model

Global and direct variables

IEC 61131-3 vs conventional PLC

Global and direct variables

Conventional PLC vs IEC 61131-3

Page 20 printed at 1/12/2015

Common Elements: Tasks

Common Elements : Tasks & Datatypes

IEC 61131-3 tasks

Page 22 printed at 1/12/2015

IEC 61131-3 : Common Elements

Configuration, Resources, Tasks

Page 23 printed at 1/12/2015

* Your own defined functions:

. & Function Blocks

I NPUT OUTPUT I N_OUT EXTERNAL