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GMP Subsystem Interfaces

This document discusses subsystem interfaces for a manufacturing facility. It describes various hardware and software used for interfacing including Ethernet cards, RS485 cards, and OPC servers. Interface protocols discussed include Modbus, ControlLogix, SLC5, and proprietary interfaces. Specific subsystems interfaced include burners, boilers, compressors, safety systems, and more. Custom interfaces are also developed for specialty equipment using C++ programs and ASCII protocols.

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Alessandro Robotec
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
16 views

GMP Subsystem Interfaces

This document discusses subsystem interfaces for a manufacturing facility. It describes various hardware and software used for interfacing including Ethernet cards, RS485 cards, and OPC servers. Interface protocols discussed include Modbus, ControlLogix, SLC5, and proprietary interfaces. Specific subsystems interfaced include burners, boilers, compressors, safety systems, and more. Custom interfaces are also developed for specialty equipment using C++ programs and ASCII protocols.

Uploaded by

Alessandro Robotec
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Subsytem Interfaces

Ernest M Smith
Engineer
Good Manufacturing
Practices Inc.

<date>
Interface Hardware and Drivers

Ethernet: ALE111 card


– Modbus
– Control logix
– SLC5
– DAQ Station
RS485: ALR121 card
– Modbus
RS232: ALR111 card
– Modbus
OPC: ethernet
– Kepware and Linkmaster
Custom interfaces:
– Ascii based interfaces

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Interface Hardware

ALE111 ALR111
1 driver/card (Modbus, Control Logix, DAQ, MW100, etc.)
1000 words/card 4000 words/controller
<Subsystem Interfaces 2009 User Conference& Technology Fair
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Ethernet: ALE111 card

Modbus
– MW100
Control Logix
– BMS system
– Interface to Drive subsystem
SLC5
– Burner Management System for Boilers
DAQ Station
– Existing terminations of Data
Atlas Copco Compressors
- Utilized RS485/ethernet convertors for physical layer

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Interface Software

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Interface Software

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Interface Software

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Interface Software

Analog Tags
– IOP if communication failure to Subsystem

Digital Tags
– If connected to MC Block Output then OOP when loss
of communication to Subsystem.

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Interface Software

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Ethernet: ALE111 card

Ethernet Modbus
To RS485 convertor

RS485
Subsystem

<Subsystem Interfaces 2009 User Conference& Technology Fair


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<Subsystem Interfaces 2009 User Conference& Technology Fair
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RS485: ALR121

RS485
– GE Pacesetter (Modbus)
• Multi Drop system with Bidirectional communication.
– Moore Quadlog Safety controller (Modbus)
• Redundant Modbus communication.
– YS170 (Proprietary)
• Yokogawa Standard Driver.

<Subsystem Interfaces 2009 User Conference& Technology Fair


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RS485: ALR121

YS170 Quad Log GE Pacestter

<Subsystem Interfaces 2009 User Conference& Technology Fair


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OPC: Ethernet

HIS OPC Server to Kepware OPC Server


– Utilized Kepware (Kepserver and LinkMaster)
• Kepserver with Contrologix.
– Demineralization system.
• Kepserver GE Series 6 PLC.
– Fire Safety System
• Kepserver for AB SLC5.
– Burner Management system.
• Kepserver for YS170.
– Boiler Controls
• Kepserver for DAQ stations.
– Balance of Plant information

<Subsystem Interfaces 2009 User Conference& Technology Fair


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OPC: Ethernet

Link Master

Kepserver OPC for HIS

Ethernet V-net
V-net 2

C Logix SLC5 GE

YS170

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Link Master

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Link Master

KepServer
Tag name

CS3000
Tag name

<Subsystem Interfaces 2009 User Conference& Technology Fair


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Link Master

<Subsystem Interfaces 2009 User Conference& Technology Fair


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OPC: Ethernet

HIS OPC Server to Subsystem


– OPC to Yewpak
• Custom Basic program in Yewpak sending data out printer
port. OPC server configured to receive unsolicited data
streams and parse data into OPC tags.
• Custom C++ program to communicate to Yewpak Gateway.

<Subsystem Interfaces 2009 User Conference& Technology Fair


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OPC: Custom Interfaces

HIS OPC Server to Custom Interfaces


– OPC to Compressor controls RS485 Ascii
• Custom C++ program in HIS requesting data directly from
RS485 network.
– OPC to Bar code scanner.
– Storage of data transactions from Bar code Scanner via
RS232 interface to CS3000 data base.

<Subsystem Interfaces 2009 User Conference& Technology Fair


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