New PLCs Help Speed the Deployment of Complex and Critical Automation Processes

New programmable logic controllers (PLCs) have been launched that combine advanced features with the flexibility to develop and deploy complex critical infrastructure and automation processes quickly.

That’s an important development for diverse uses from renewable energy and microgrid controls to industry 4.0 industrial internet of things (IIoT) transformations (even in small factories), oil and gas, machine design, and process equipment automation found in bottling, packaging, textiles, and similar applications.

To deliver the best solutions, the latest technology is needed. These PLCs feature a dual-core, 64-bit processor to handle the most challenging automation requirements. The Linux operating system is a plus, and the code is portable and interoperable with IEC 61131-3 compliant systems. Simplified configuration is enabled using a web-based management system.

Also required will be a choice of communication interfaces, support for multiple fieldbus protocols, IIoT connectivity, cloud connectivity, energy management software, and comprehensive security tools that provide the flexibility required to address a range of critical development and integration scenarios.

Introducing the PFC300

Wago has launched the PFC300 PLC to help speed up deploying complex and critical automation processes. This introduction starts by diving into the features and benefits of the PFC300 and closes with examples of how it fits into smart factory and microgrid installations.

The modular design of the PFC300 can be quickly adapted to support changing needs and future requirements in complex and critical Industry 4.0 factories, microgrids, and building automation. Various analog, digital, and specialty input/output (I/O) modules for specific automation demands can be selected. The system can also be scaled up or down in complexity by adding or deleting I/O modules.

These PLCs are environmentally rugged, so that they can be installed in demanding environments. They are rated for operation from -25°C to +60°C at up to 95% relative humidity (RH, non-condensing) and have a pollution degree 2 rating according to IEC 61131-2.

They have vibration resistance of up to 4g per IEC 60068-2-6 and shock resistance of 15g per IEC 60068-2-27. Electromagnetic compatibility (EMC) performance includes immunity per EN 61000-6-2 and emissions per EN 61000-6-3. They can withstand exposure to pollutants per IEC 60068-2-42 and 60068-2-43.

Figure 1: The PFC300 is modular, scalable, and environmentally rugged. (Image source: Wago)

Fieldbuses and edge connectivity

The wide range of fieldbuses, EtherNet protocols, and telecontrol protocols supported by the PFC300 simplify tasks when building control networks for critical and complex automation processes.

Integrated fieldbuses include Modbus TCP master/slave, Modbus (UDP), Modbus (RTU), EtherNet/IP Adapter (slave), EtherNet/IP Scanner, EtherCAT Master, PROFINET Controller (limited), OPC UA Server/Client, and OPC UA Pub/Sub (can be installed).

There is also the option of licensing telecontrol protocols like DNP3, used for SCADA systems in critical infrastructure, IEC 60870 and IEC 61850, both used for automation of electrical substations, or BACnet, widely used in building automation.

The front panel's D-sub 9-pin RS 485 connector is used for CANopen, Modbus RTU, and other serial communication protocols. The USB-C connector behind the service interface provides direct access for programming, configuration, and firmware updates. The two RJ-45 Gigabit Ethernet ports and an integrated switch support line topology wiring.

In addition to communication interfaces and access to the USB-C connector, the front panel of the PFC300 includes an access port for a secure data (SD) card, status lights, and power connectors (Figure 2).

Figure 2: The front panel of the PFC300 includes communication interfaces, status indicators, power connections, and other access points. (Image source: Wago)

Reaching the cloud

Cloud connectivity is needed when designing and deploying complex critical infrastructure and automation processes. The PFC300 leverages the message queuing telemetry transport (MQTT) protocol for secure and efficient cloud connections.

That also allows for use of various cloud services like Microsoft Azure, Amazon Web Services (AWS), IBM cloud, SAP cloud, and the Wago cloud. The Wago cloud provides a simple and intuitive solution for managing machine data and visualizing trends and graphics without extensive programming support.

Data transmission is encrypted using transport layer security (TLS), and the cloud connection data can be configured using Wago’s web-based management (WBM) system. WBM allows users to monitor, configure, and control the PFC300 and remote I/O modules through a web browser interface, offering easy access and management without requiring local software installation. WBM allows for selecting which data should be transferred to the cloud and which should be processed locally.

To further facilitate cloud connectivity, Wago’s libraries can be used for CODESYS 2.3 based on IEC 61131-3 and e! COCKPIT, Wago's integrated development environment that supports all automation tasks, from hardware configuration and programming to simulation, visualization, and commissioning, and is optimized for use with Wago PLCs like the PFC300.

Standardization speeds development

Wago provides several paths for developing software for the PFC300. They include high-level programming languages like C and C++ for system integration and the CODESYS V3.5 platform that supports standard IEC 61131-3 control programming languages, including Structured Text (ST), Function Block Diagram (FBD), Ladder Diagram (LD), Instruction List (IL), Sequential Function Chart (SFC), and Function Chart (CFC).

The Wago operating system (OS) in the PFC family controllers, including the new PFC300, is based on real-time Linux, enabling flexible and powerful automation solutions. In addition to support for C and C++, programs can be created in any Linux-supported language and executed directly on the controller.

The same CODESYS software that supports all the standard IEC 61131-3 programming languages also allows for creating web visualizations, enabling machine operators and maintenance personnel to access the machine through a web browser on a tablet computer or PC.

Expandable storage

The PFC300 also includes a memory card slot with a push-push mechanism and a sealable cover. It can handle SD, SDHC, and SDXC formats (all guaranteed properties are only valid with a Wago memory card). The cards are versatile and have several uses like:

• General data storage
• Firmware updates using a bootable SD card that automatically initiates the update when the PFC300 boots
• Store large images for use in web visualization applications
• Backing up the PLC’s image for storage or for transferring device files and parameters from one controller to another to speed deployments
• Access the memory card remotely using FTP

Layered security tools

Deployment of complex critical infrastructure and automation processes requires the highest levels of security. The PFC300 controller delivers the multiple layers of security tools needed.

It supports virtual private networks (VPNs) for secure communication using transport layer security (TLS) encryption to protect data. The integrated firewall protects against unauthorized access.

The WBM is implemented using HTML5, secured by TLS 1.3, and the PFC300 supports secure protocols like SNMP v3, SFTP, FTPS, HTTPS, and SSH, ensuring secure data exchange. The USB-C port ensures secure access for updates, and fieldbus protocols ensure secure communication with connected devices.

Industry 4.0 and smart factories

PFC300 PLCs provide comprehensive fieldbus connectivity, real-time data capabilities, and IIoT and cloud integration, enabling flexible manufacturing, optimized processes, and predictive maintenance. These are hallmarks of smart factories in Industry 4.0. Islands of automation can be eliminated and energy consumption optimized in complex and critical industrial processes.

PFC300 PLCs can be combined with Wago Energy Data Management (EDM) software for resource optimization and energy monitoring from individual devices on the factory floor to compiling facility-wide data on the edge and pushing it up to the cloud for deeper analysis (Figure 3).

• EDM provides real-time monitoring and energy consumption feedback to support efficiency maximization and proactive maintenance.
• Broad-based integration and flexible communication options enable seamless data integration across devices and throughout the factory network.
• Visualization tools make the data easily accessible and speed analysis.

Figure 3: The PFC300 has all the capability needed for Industry 4.0 automation from the field to the cloud. (Image source: Wago)

EDM is a web-based application that lets users monitor, analyze, and report energy consumption details without programming. It can automatically interface with energy meters and sensors to collect, compile, and store data for future analysis.

Data can be presented as line plots like time series or bar charts and exported as comma-separated values (CSV) files compatible with a wide range of analysis software packages. EDM software and related hardware components like meters and sensors are modular and scalable and can be quickly adapted to changing equipment and infrastructure in an industrial facility.

EDM software enables facility engineers to identify the most fruitful opportunities for improving energy consumption and implementing energy-saving programs. The system can also set energy consumption limits and send alerts if these limits are exceeded. The data from EDM software is an important element in overall energy management in complex Industry 4.0 facilities and critical infrastructure like microgrids.

Microgrids and energy management

Microgrids and comprehensive energy management schemes are increasingly important to support sustainability. The PFC300 PLCs provide powerful tools well-suited for critical green energy infrastructure, including building automation, microgrid substations, energy data management, load management for electric vehicle charging, and other green energy applications (Figure 4).

• These PLCs can control heating, ventilation, and air conditioning (HVAC) systems in buildings and monitor local energy generation, storage, and usage.
• They can record and analyze energy consumption patterns to optimize available energy resources throughout a microgrid from the substation that connects the microgrid to the utility grid and at specific load locations like EV chargers or buildings.

Figure 4: Microgrids supported by the PFC300 can improve sustainability and energy security. (Image source: Wago)

Dynamic load management can be implemented with Wago’s Application Load Management (ALM) software to integrate EV charging, renewable energy sources like photovoltaics, energy storage systems, and grid power. For example, ALM can be used to regulate the total charging power at a grid connection point, like a customer substation, mitigating load peaks and valleys and preventing grid overloads.

The software can dynamically distribute EV charging loads based on the number of vehicles, charging priorities, time of day, available grid capacity, and other factors. It can be configured to prioritize the use of local power generation and storage resources during peak utility rates, reducing high-demand charges.

The PFC300 can record and analyze energy consumption data, and its web-based management system and support for IIoT communication protocols enable data visualization and monitoring of energy consumption locally and remotely.

Conclusion

The environmentally rugged PFC300 has all the features to develop and deploy complex critical infrastructure and automation processes quickly. Its modular and expandable design provides flexibility to suit a variety of application scenarios. Comprehensive, secure communication options support connectivity from the floor to the cloud.

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