SCHNEIDER Modicon Premium Automation Platform and Unity Software

SCHNEIDER Modicon Premium Automation Platform and Unity Software

Platform architecture and processor selection

The core of the Modicon Premium platform is its high-performance processor series, all of which are programmed and configured using Unity Pro software. The platform supports multiple processor models ranging from TSX 570p to TSX 575p, divided according to processing capacity, I/O capacity, communication interface, and storage space, forming a complete product line covering application requirements of different scales and complexities.

Overview of Processor Series:

TSX 570p series: entry-level processor suitable for small control tasks. Like TSX P57 0244M, it integrates CANopen bus master station function and is usually supplied as a pre assembled set with a 2-channel 40kHz counting module TSX CTY 2A and a non expandable 6-slot rack TSX RKY 6.

TSX 57 1p series: single slot processors such as TSX P57 104M, TSX P57 154M (integrated Fipio bus), and TSX P57 1634M (integrated Ethernet TCP/IP port). This type of processor can manage up to 4 expansion frameworks, support 192 to 512 discrete I/O points, and have a storage capacity of 96Kb to 224Kb programs.

TSX 57 2p/3p series: Dual slot high-performance processors such as TSX P57 204/254/304/354M and TSX P57 2634/3634M with integrated Ethernet. They have stronger control capabilities, can manage 16 expansion frameworks, handle 1024 discrete I/O points and 80-128 analog I/O channels. The storage capacity has significantly increased, with program capacity ranging from 768Kb to 1792Kb. The TSX P57 3p/3634M model supports up to 128 event tasks, making it an ideal choice for handling complex logic and high-speed events.

TSX P57 4p/5p series: flagship processor that provides ultimate processing performance and scalability. Can manage 16 extension frameworks, supporting 2048 discrete I/O points and 256-512 analog I/O channels. The storage capacity is huge, with a program capacity of up to 2048Kb to 7168Kb. The TSX P57 4v4/5p4M processor supports auxiliary tasks (AUX) for processing slow operations such as process control and HMI. Integrated Fipio (TSX P57 454/554M) or Ethernet (TSX P57 4634/5634M) interfaces, equipped with USB programming ports, achieve high-speed and convenient connection and debugging.

Atrium coprocessor:

In addition to standard rack mounted processors, the platform also offers the Atrium TSX PCI 57 2p/3p coprocessor, which is a PCI bus card. It integrates the control logic of Premium PLC into a PC running Windows 2000/XP, achieving a close integration of control with PC computing, communication, and monitoring functions. The Atrium coprocessor can manage the same I/O modules, dedicated modules, and fieldbus as the Premium processor, with processing performance comparable to the TSX P57 2p/3p processor, and supports power supply through the PC's PCI bus or an independent 24V power supply (TSX PSI 2010).

Storage Structure and PCMCIA Expansion

The flexible storage architecture is a prominent feature of the Modicon Premium platform. Each processor is equipped with two PCMCIA card slots for expanding program and data storage space, greatly enhancing the system's adaptability and maintainability.

Storage organization method:

Internal RAM storage: Applications (programs, symbols, constants) and data are stored in the processor's internal RAM. The capacity varies from 96Kb (TSX 57 0p/1p) to 640Kb (TSX 57 5p) depending on the processor model. In this mode, program modifications need to be made online.

PCMCIA card storage: Applications and symbols are stored on PCMCIA cards located in the upper slot (No. 0) of the processor, while internal RAM is primarily used for data storage. This mode supports the use of Flash EPROM cards, which facilitates the solidification, backup, and updating of applications. For online program modifications, SRAM cards are required.

PCMCIA card types and functions:

Application memory card: used to store programs, symbols, and constants. Divided into SRAM cards (such as TSX MRP series) and Flash EPROM cards (such as TSX MFP series). SRAM cards support online modification and require battery backup; Flash EPROM cards are used for long-term storage of solidified programs.

Data storage card: A large capacity (such as 4Mb or 8Mb) SRAM card dedicated to storing application data files such as production formulas and historical data. This type of card can be inserted into the upper or lower slot of the processor to free up program storage space.

Communication card: inserted into the lower slot (No. 1) of the processor, used to expand network communication functions, such as Modbus Plus（TSX MBP 100）、Fipio（TSX FPP 10/20）、Uni-Telway（TSX SCP 11p）、CANopen（TSX CPP 110） Wait.

Online program modification function:

The online program modification function in the Unity Pro environment allows for direct addition or modification of program code while the PLC is running. This requires the processor to have sufficient spare storage space. For processors using PCMCIA expansion cards, it is necessary to select an appropriate capacity SRAM card based on the processor model (for example, TSX P57 2p recommends TSX MRP P384K or C768K); For processors without expansion cards, it is necessary to choose processors with larger internal RAM based on the application size and expected modification amount.

Modular I/O and dedicated functions

The Modicon Premium platform offers a comprehensive range of discrete and analog I/O modules, as well as various specialized functional modules, to meet a wide range of on-site control needs.

Discrete I/O module:

Supports multiple voltage levels (24V DC, 48V DC/AC, 100-120V AC, 200-240V AC) and current specifications. The module provides 8, 16, 32, or 64 channels, with isolation methods including point-to-point isolation or group isolation. The connection methods include spiral terminals (for bare wires) and HE10 connectors (for ribbon cables and multi-core cables). The platform also supports fast and standardized on-site wiring through the Telefast 2 pre wired system and Tego Dial/Power installation system.

Analog I/O module:

Provide high-precision and flexible configuration capabilities. The input module supports thermocouple (B, E, J, K, N, R, S, T), thermistor (Pt100, Pt1000, Ni1000), as well as high-level voltage (± 10V, ± 5V, 0-10V, etc.) and current (4-20mA, 0-20mA) signals. The output module supports voltage (± 10V) and current (4-20mA, 0-20mA) output. All modules have high inter channel and channel to ground isolation to ensure measurement accuracy and system anti-interference capability.

Specialized functional module:

Counting/measuring module: such as TSX CTY series, providing 2/4 channels, with a maximum counting frequency of 1MHz, supporting incremental/absolute encoder connections, and having functions such as measurement, comparison, and frequency output.

Electronic cam module: such as TSX CCY 1128, used for complex motion control, supporting up to 128 cams and 32 trajectories, suitable for precise position synchronization of mechanical equipment such as packaging and printing.

Motion control module: including TSX CFY series (1/2 axis) for stepper motors and TSX CAY series (2/3/4 axis) for servo motors, as well as TSX CSY 84 module (8/16 axis) supporting SERCOS digital links, achieving multi axis collaborative control from simple point to positioning to complex.

Weighing module: such as TSX ISP Y101/Y111, supports up to 8 sensors, integrates weighing algorithms, simplifies system integration in applications such as batching and packaging.

Safety module: Used in conjunction with XPS or XBS Preventa safety relays to achieve functions such as emergency stop, safety door monitoring, and dual hand control, meeting industrial safety standards.

Communication module: In addition to PCMCIA cards, the platform also provides standard slot communication modules such as Ethernet TSX ETY series, Modbus Plus TSX FPP series, Fipio TSX FPP series, etc.

Distributed I/O (TBX&Momentum):

Modicon Premium supports connecting distributed I/O nodes through fieldbus such as Fipio, Modbus Plus, CANopen, Profibus DP, Interbus, etc.

TBX module: directly installed on equipment or on-site, providing discrete, analog I/O ranging from simple to complex, as well as sturdy modules that are dustproof and moisture-proof (IP65/67).

Momentum I/O: Modular design, including adapters and I/O substrates, supporting hot swapping for flexible configuration and system expansion.

Communication and network capabilities

Strong networking capability is the key to building integrated automation systems. The Modicon Premium platform supports multiple industrial communication networks and protocols, achieving seamless information integration from device level to management level.

Integrated communication interface:

Ethernet TCP/IP: The high-performance processor (TSX P57 pp34M) is equipped with a built-in 10/100Mbps adaptive Ethernet port, supporting protocols such as Modbus TCP, Uni TE, Global Data, I/O Scanning, and a built-in web server for remote monitoring and diagnosis.

Serial port: The processor front-end provides two serial ports, TER (programming/debugging terminal) and AUX (auxiliary equipment), supporting protocols such as Uni Always and Modbus (RTU/ASCII), making it easy to connect programmers, touch screens, or third-party devices.

Fieldbus Master Station: Some processors have built-in Fipio (TSX P57 154/254/354/454/554M) or CANopen (TSX P57 0244M/1634M) bus managers.

Network and bus module:

The following networks can be expanded through PCMCIA cards or standard slot modules:

High speed industrial Ethernet: Ethernet TSX ETY series modules that support transparent factory services such as FactoryCast (Web/HMI server), Global Data, I/O Scanning, SNMP, etc.

Fipway/Modbus Plus: TSX FPP 20 or TSX MBP 100 PCMCIA card, used to build a high-performance token ring network for high-speed data exchange between controllers.

Fieldbus:

Fipio/Modbus Plus: As a fieldbus master station, it connects distributed I/O or driver devices.

CANopen: As the V4.02 master station, it integrates motion control and device diagnostics.

Profibus DP/Interbus: TSX PBY 100 or TSX IBY 100 module, used as a master station to connect a wide range of third-party slave devices.

AS-i: TSX SAY 100/1000 module, directly connected to the sensor/actuator level as the main station.

BUS X bus remote expansion:

For applications that require remote I/O deployment (exceeding the standard 100m), the TSX REY 200 module can be used to extend the length of the BUS X bus to 2x350m without affecting performance. The REY 200 module is divided into "master" (installed in the CPU framework) and "slave" (installed in the expansion framework), connected by a dedicated cable TSX CBRY 2500, providing a flexible hardware expansion solution for large distributed systems.

Unity Pro software platform

Unity Pro is the core programming and configuration software for the Modicon Premium automation platform. It is an integrated development environment that complies with the IEC 61131-3 standard, used for designing, programming, debugging, and maintaining applications for Atrium, Premium, and Quantum PLCs.

Software architecture and functionality:

Project management: Provide structured and functional views. The structural view organizes projects based on the physical configuration of the PLC (hardware, programs, data, communication); The functional view decomposes the project according to the process, making the program logic more closely aligned with the actual control flow.

5 IEC programming languages: Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST), Instruction List (IL), and Sequential Function Diagram (SFC). Users can choose the most suitable language for different tasks and program segments.

Multi tasking: Supports a multi tasking architecture that supports primary tasks (MAST), fast tasks (FAST), auxiliary tasks (AUX), and event triggered tasks (EVT). Different tasks have different priorities and execution cycles, which can optimize the computing resources of the processor while meeting the requirements of real-time control and complex algorithms.

Data Management: The integrated data editor is used to declare and manage all variables, including basic types, exported data types (DDT), and function block instances. Support symbolic programming to improve program readability.

User Function Block (DFB): Allow users to create their own reusable function blocks using 5 IEC languages, encapsulate specific control algorithms or device logic, simplify program structure, and improve code standardization.

Debugging and diagnostic tools: provide powerful debugging functions such as breakpoints, single step execution, and dynamic monitoring (through variable tables or program windows). The built-in diagnostic system can monitor system bits, I/O module status, and SFC step execution time, and automatically generate alarm information with timestamps.

Integrated emulator: It can simulate the execution of application programs on a PC without connecting to a real PLC, greatly reducing the development and testing cycle.

Related software components:

Unity Studio: A design suite for distributed automation projects, integrating Unity Pro XL, OFS data server, PowerSuite (frequency converter tool), Magelis HMI tool, and implementing graphical design and collaborative development of the entire project (PLC, HMI, network, equipment) based on MS Visio 2003.

Unity Application Generator (UAG): Expert software used to generate batch process control applications that comply with the ISA S88 standard.

Unity EFB Toolkit: Based on C language and Microsoft Visual C++, it is used to develop user-defined Basic Function Blocks (EFBs) to extend the instruction library of Unity Pro.

Unity SFC View: An ActiveX control used to dynamically display and diagnose the execution status of SFC program segments in HMI applications such as Vijeo Look, Monitor Pro.

OFS (OPC Factory Server): A data server that complies with the OPC DA standard, allowing standard OPC client applications (such as SCADA, Excel) to access real-time data from Premium, Quantum, and Micro PLCs.

System Integration and Power Management

Framework and power supply:

The TSX RKY series framework is the foundation for installing all modules and provides specifications such as 4/6/8/12/EX slots. The framework is interconnected through the BUS X bus to form a local or distributed control system. Each framework must be equipped with a TSX PSY power module that provides 5V logic voltage and 24V sensor/actuator power. The power module is divided into multiple models based on output power and input voltage (24V DC, 24-48V DC, 100-240V AC), and integrates alarm relays and batteries (for RAM data backup). For high-power configurations or high-temperature environments, TSX FAN fan modules should be selected for forced cooling.

Installation and environmental adaptability:

Modular design supports multiple installation methods and can be fixed on perforated plates or DIN rails. The system operates within a temperature range of 0 ° C to+60 ° C, with a relative humidity of 10% -95% (no condensation), and has excellent electromagnetic compatibility (EMC) and anti-interference performance, meeting international standards and certification requirements such as IEC 61131-2, UL 508, CSA C22.2, etc. The product complies with the requirements of the European Low Voltage (LVD) and Electromagnetic Compatibility (EMC) directives.