In 2015 GP Systems GmbH presented innovative developments in industrial automation field – programmable logic controllers REDUL, series B600 and B500. In 2016 the company extended its product line with two more controllers: B400 and B200.
REDUL B400: Operational Control and Visualization
REDUL B400 controller is a combination of the human-machine interface and a CPU module with a power supply module. This controller is used to create local and distributed automation systems with a requirement for a local HMI.
In the first version of the REDUL B400 controller is used an Intel Atom processor with 1.46 GHz speed, 2 GB RAM, 4 GB SSD. It is possible to connect other devices over the additional interfaces: RS-485, 2 USB-host ports, 2 Ethernet ports, 2 Redul bus ports for connection of I/O modules.
An external monitor or a KVM-extender could be connected to the DVI port of the controller, to provide a remote desktop. And this screen will display the same image as the controller itself.
Image 1. Front panel of Redul B400
The B400 controller has metallic housing and is mounted on a front panel of the device rack or in a door of the automation cabinet. The front panel is protected from dust and water in compliance with the IP66 standard. The operating temperature range is from -20 to +60 °C.
The controller holds a capacitive touchscreen with a resolution of 800 x 480 pixels and a size of 7″, as well as a foil keyboard.
REDUL B400 can operate in one system with input/output modules of any series of REDUL controllers.
Image 2. Example of a system with B400 and I/O modules from B500 and B200
The development environment for the REDUL BX00 controllers, Sigma LD, has built-in functionality for the implementation of the human-machine interface, and it can be configured directly from the software.
Image 3. Example of the screen in Sigma LD
Functional Capabilities of Redul B400
For controlling a technological process, the REDUL B400 controller is similar to central processor unit (CPU) modules of other series (B500 and B600), except support for redundant operation.
In addition to the process control application in REDUL B400 could be implemented all the functionality of the human-machine interface, required for a local automation system:
- Creation of mimic diagram of the technological process
- Display of current values for the parameters
- Implementation of alarms
- Control of equipment with manual commands from the operator
- Viewing trends and event logs
- Diagnostics of the equipment in the system
- Implementation of access permissions
PLC for Small and Mid-Size Control Systems
Image 4. Redul B200 in a rack
In all industries, a large share of the equipment requires local automation. There is also a significant number of sites with a low number of I/O signals that should be integrated into a common control system. And in these cases, dimensions, and price of the automation equipment for such sites come to the front. The Redul B200 series was designed specifically for these applications.
The distinguishing factors of the REDUL B200 PLC from the B600 and B500 series are:
- Support of only one internal bus
- A low number of channels in input/output modules
- Compact dimensions of the modules (only 12.9 x 101 x 109 mm)
- Installation on a 35-mm DIN-rail
- Wide operating temperature range (-40 … +60 °C)
- Convenient terminal block, allowing a replacement of module with disconnection of cables
Module Types in B200 Series
The idea behind the REDUL BX00 controller family is the use of the same software for configuration and programming – Sigma LD, and, whenever possible, to have the same approaches to the hardware platform.
REDUL B200 controller, as well as B500, has a modular design, consisting of one or several lines, each including modules of different types, installed onto a DIN-rail.
Module – is a main element of the controller and, depending on its type, it performs a specific function. The REDUL B200 series has the following types of modules:
- Central processor unit modules
- Power supply modules
- Interface modules
- Analog and digital input/output modules
- Frequency measurement and counter modules
Power supply modules provide conversion of the power from 24 V DC to the operating voltage of the internal bus, 5 V DC, filtering, and electromagnetic compatibility. Individual power supply modules are used in case of a large number of modules in one rack.
The internal bus is extended with the interface modules. The connection can be made in the form of “star” or “ring.” There are two RJ45 slots for it: IN and OUT. Each interface module is supplied in pairs with a power supply module.
Since B200 PLC, as are B600/B500 series, operates on a high-speed Redul bus, it can be used as a remote terminal unit (RTU) connected to the controllers from higher series.
Each CPU module has built-in protocols for communication with third-party equipment: Modbus RTU/TCP, IEC 60870-5-101/104. To connect devices in different racks or to get more ports for connection, there are also communication processor modules, providing required interfaces.
Input/output modules create an interface between the CPU module through the mutual conversion of physical and logical signals. Digital input/output modules provide up to eight channels for connection. Analog input/output modules have two or four channels.
Counter modules provide a measurement of frequency on one channel, up to 100 kHz, and have software-configurable digital input/output channels.
Image 5. Use of B500 together with B200
Design of the B200 Controller Modules
Central processor unit (CPU) modules were developed to be both fast and highly functional. Each CPU module provides:
- Logical processing of data and issue of control signals, according to the application program from the user
- Exchange of data with interface and input/output modules
- Exchange of information with third-party equipment, via built-in interfaces
- Verification of system configuration and functionality of the modules
The main engineering feature of these modules is the use of SOM-modules designed completely by our engineers and using ARM-based processors. This allowed us to reduce the price of the modules, compared to the CPU modules of higher REDUL series.
Image 6. B200 module
In the electronic block is performed conversion of the external signals into data, transmitted to the CPU, and vice versa. Also, the electronic block provides galvanic isolation of the external channels from the internal busses of the controllers. The indication panel of each electronic block provides information on the presence of signals in the input/output channels, and diagnostic information. The design of the modules allows hot-swap replacement of the electronic blocks – without stopping the running application.
In the case of the power supply module, powering voltage is converted to the operating voltage of the internal bus, 5 V, inside the electronic block.
Chassis block is part of the internal data bus and provides a connection of the input/output module or communication processor to the internal data bus of the controller.
Chassis is designed for the mechanical connection of the controller modules among themselves and with DIN-rail. It provides switching for the internal data bus and is part of the internal and external power busses of the controller.
Chassis also has a terminal field to which are connected all the external signals.
Each chassis can be coded with two keys to avoiding the mistaken installation of the electronic block into the chassis, designed for a connection of the electronic block of a different type. Each key consists of two components, one of which is inserted into the electronic block, another – into the chassis.
Keys are supplied together with the modules and are pre-configured according to the type of the module. In case a chassis should be used for a different type of module, the keys could be reconfigured.
Modules, installed into a rack, could be sealed. For this purpose, each electronic block has a special hole, with a diameter of 2 mm.
Image 7. Coding electronic blocks
Image 8. Sealing element in the module
CPU Modules in B200 Series
Central processor unit (CPU) modules were developed to be both fast and highly functional. Each CPU module provides:
- Logical processing of data and issue of control signals, according to the application program from the user
- Exchange of data with interface and input/output modules
- Exchange of information with third-party equipment, via built-in interfaces
- Verification of system configuration and functionality of the modules
The main engineering feature of these modules is the use of SOM-modules designed completely by our engineers and using ARM-based processors. This allowed us to reduce the price of the modules, compared to the CPU modules of higher REDUL series.
The main principle of the REDUL controllers remained intact – programming from one common development environment – Sigma LD. Thanks to this, the algorithms, developed earlier or developed for other controllers, could be implemented in the B200 series.
All CPU modules of the B200 series have the same processor and differ by the number of communication ports. Depending on the task, the engineer can select one of the modules presented in the table.