SoftPLC

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• Company Overview

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SoftPLC Corp. - A Brief History

• 1983 Tele-Denken Resources Founded
• By former A-B employees
• 1984 TOPDOC PLC programming/documentation
  software
• For PLC-2, then PLC-3 and PLC-5
• 1985 SoftWIRES PLC emulation/simulation
  process modeling
• To run A-B Logic in a computer
• 1988 SoftPLC Open architecture control software
• A combination of existing proven technologies
  new ideas, based on PLC-5 SoftWIRES
• 1993 SoftPLC Processor Systems
• PC I/O hardware catches up to software
  technology
• Combination of industrial computers and embedded
  SoftPLC software
• 1996 Company renamed to SoftPLC Corporation
• 1997 SoftPLC In Tealware
• Traditional PLC hardware form factor, industrial
  I/O with SoftPLC software features
• 2000 Released Linux Version
• 2009 Release of SmartControllers
• Including SoftPLC brand of A-B RIO protocol
  interface

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SoftPLCInnovators Visionaries

• Many industry first software inventions
• Embrace open technologies
• Apply technologies developed for fast moving
  software/computer industries to controls industry
• Reliability and deterministic performance always
  comes first

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SoftPLCCustomer Partnerships

• Privately held, small business
• Treasure customer feedback
• Focused, experts in our chosen area
• Excellent customer service support
• "I can't remember a time in the last 20 years
  that a vendor went to the lengths that SoftPLC
  Corp. did to ensure our projects were a success.
  (US Army Corps of Engineers)
• Worldwide network of distributors and system
  integrators
• No case numbers, responsive phone/email support
  from field experienced application engineers/
  programmers

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• Products

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SoftPLC Corp. Products

• SoftPLC Controllers
• SoftPLC is the runtime control software
  (firmware) included in each controller
• Stand-Alone Controllers - use w/ remote I/O or
  PC-bus I/O
• SoftPLC Hardbooks Processors
• DIN/Rack-Mounted Controllers - traditional PLC
  form factor
• Smart SoftPLC
• SoftPLC In Tealware
• TOPDOC
• The configuration/application development/troubles
  hooting software for SoftPLC based systems

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SoftPLC Products

• Industrial I/O
• Tealware modular rack mounted system for local
  systems or remote I/O
• A-Series low cost serial/ethernet/wireless I/O
• Drivers and interface cards to industrial
  networks
• Profibus, DeviceNet, CANopen, SERCOS, A-B RIO,
  etc.
• Auxiliary Equipment
• Power protection
• Ethernet switches, fiber converters, etc.
• Gatecraft Industrial Firewalls
• Network Protection, Modem Gateway, Wireless
  Access Point

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SoftPLC CPU Options

• Smart SoftPLC
• SoftPLC In TealwareTM
• SoftPLC Hardbook ProcessorsTM

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Smart SoftPLC

• DIN rail mount CPU w/ 4 serial ports, 2 ethernet
  interfaces (fiber option), modem or RS-485 port
  option
• Selectable daughter board interfaces
• 3 local Tealware Modules
• Tealware LocalPorts Board
• PC/104 board
• A-B RIO interface (mid-2009 release)
• Built-in ethernet switch

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SoftPLC In Tealware

• Compact backplane mount CPUs wide range of I/O
  modules
• Traditional PLC packaging
• Can use Tealware I/O w/ industrial PCs
• Local, Remote or Ethernet configurations
• Hot Standby Option

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Tealware CPU Modules

• CPU resides in single slot on base
• 32MB RAM, 32MB Flash
• (2) serial ports, 10MB ethernet port
• 128 Kwords battery-backed RAM retentive memory
  area
• SoftPIPETM Remote I/O interface port (optional)

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Hardbook SoftPLC Processors

• Compact Stand-Alone CPUs
• Dual Ethernet ports
• Ideal for Ethernet I/O
• Some models have PCI slot(s)
• Profibus, DeviceNet.
• Addl Serial Ports
• Motion Control Cards
• A-B RIO Interface Cards
• USB, Serial
• Fanless, diskless

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Tiny Hardbook Processor

• Small, low cost industrial CPU
• 1 Ethernet, 2 serial, 3 USB ports
• 802.11GB Wireless option
• Fanless, diskless

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SoftPLC Processors

• Node-box Industrial CPUs
• 486, Pentium Celeron class CPUs
• 2, 4, 6, 8 slot enclosures or 19 rack mount
• ISA and/or PCI bus
• Good when multiple add-in
  interface cards are required

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I/O

• TealwareTM
• Remote Bus
• A Series

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I/O Options

• Tealware - Local Remote
• Modbus TCP
• A-B RIO -1771, SLC-500 (1746), Flex, Block
  compatible devices
• Profibus, DeviceNet, CANOpen, Interbus, etc.
• Variety of PC I/O (eg PCI, PC/104 bus)
• Serial/USB Wireless I/O

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Tealware I/O Modules

• Wide variety of digital, analog,
  specialty modules
• Detachable terminal block for easy module
  replacement w/o re-wiring
• Diagnostic LEDs
• Wide angle swing connector - easy installation
• Digital modules hot swappable under power
• IEEE C37.90.1 Surge Withstand

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Local Systems

• Up to 3 expansion bases per local interface
• 6 or 8 I/O module Local Expansion bases
• Max. 30 feet from first base to last base
• Smart CPU w/ Localports Daughter Board
• Up to 12 expansion racks per Smart CPU
• Tealware CPU in Base
• 4, 6, or 8 modules in CPU Base plus up to 3
  expansion bases

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Remote I/O

• Up to 15 remote drops in addition to local drop
• Up to 1024 I/O per drop (x 16 16K I/O capacity)
• Two Options (Fiber options available for both
  network types)
• Ethernet ModbusTCP
• SoftPIPETM (Hot Standby applications)
• Smart CPU can be Ethernet Adapter
• 3 modules/Smart with 3 module daughter board
• 12 racks/Smart with local ports daughter board
• Hardbook CPU to Tealware Ethernet I/O
• Remote Base (4, 6, or 8 slots) with Adapter
  (EIOA11) plus up to 3 expansion bases
• Up to 64 Adapters per Hardbook

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Example Configurations
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Example Configurations

• Hardbook/Processor with Bus I/O

BASE0x (Backplane)
Profibus ASI DeviceNet Interbus CANOpen SERCOS etc
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Hilscher Interface Card
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Example Configurations

• Hardbook/Processor with A-B Remote I/O

BASE0x (Backplane)

1785-PKTX/PKTXD
1771-ASB or other A-B RIO Adapter
A SoftPLC interface board for the Smart CPU to
be developed in 2009 as an alternative to this
solution
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Example Configurations

• Hardbook/Processor with Tealware I/O
• or other ethernet I/O on ModbusTCP

BASE0x (Backplane)
I/O Modules
Ethernet ModbusTCP
EIOA11 I/O Adapter
PWSxx (Power Supply)
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Example Configurations

• Smart SoftPLC w/ 3 module daughter board

BASE0x (Backplane)
I/O Modules
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Example Configurations

• SoftPLC In Tealware System

BASE0x (Backplane)
I/O Modules
PWSxx (Power Supply)
SPLC-2A-y (CPU)
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• Open Architecture
• Control Software

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SoftPLC Architecture
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What is SoftPLC?

• SoftPLC control software turns an industrial
  computer into an open architecture automation
  controller
• Embedded software, runs on dedicated system
• Headless system (eg no monitor, keyboard)
• Features of proprietary PLCs (I/O control, PID)
  PLUS features of computers (flexibility,
  networking, speed)

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Operation

• SoftPLC turns PC into PLC, it is not PC-based
  control
• Deterministic scan (hard realtime)
• Online run-mode program changes
• Troubleshooting tools like PLC (Runtime Fault
  detection/correction, I/O Forcing)
• Runs on embedded Linux, no Windows

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Data Table

• PLC-5/SLC-500 Data Table Addressing
• Binary, integer, floating point, timers,
  counters, PID, strings and others
• 10,000 Data Table Files of 10,000 elements each
• Status File for fault analysis,
  system time/date, etc.
• Output/input file size determined by
  size of runtime purchased (LT, 1K, 2K or 8K)

except for O, I, S files
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UserLogic

• PLC-5/SLC-500 ladder logic programming
• Up to 10,000 subroutines of 10,000 rungs each
• Instruction set combines PLC-5, SLC-500, and
  unique SoftPLC functions
• Logic documentation stored in SoftPLC

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TOPDOC Loadable Modules (TLMs)

• Loadable functions can be instructions or drivers
• Created using SoftPLC Programmers Toolkit
• Written in C/Java
• Example SoftPLC provided TLMs
• .001 TIMERS - Very fast/high resolution timing
• COMGENIUS ASCII/Serial Communications
• LOG DATA - Selected data to file

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Other Example TLMs

• Computations
• Fourier transforms, load balancing, . . .
• Special non-PLC functions
• DCS process blocks, SENDMAIL
• Device interfaces
• Modbus, Motion Controller Interfaces, PC I/O
  boards, Intelligent UPS
• Proprietary logic embedded in functions

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Remote File Access

• SoftPLC can be a file access client to a server
  (eg Microsoft Windows File Sharing, Samba, NFS,
  Novell Netware)
• This means SoftPLC can easily read or write
  production data to a remote disk
• Databases (eg SQL, Oracle)
• Data Files/Reports/XML

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Properties Memory Area

• Internal relational database
• Ladder instructions to read and/or
  process data
• Ideal for warehousing,
  sorting, recipe, RFID
  applications

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I/O Support

• Total digital I/O maximum 16K
• Analog I/O above and beyond digital total
• Up to 16 I/O drivers can be loaded at once
• Available Drivers
• Tealware local remote
• Modbus TCP
• A-B RIO -1771, SLC-500 (1746), Flex, Block
  compatible devices
• Profibus, DeviceNet, Interbus, etc.
• Variety of PC I/O (ISA, PCI, PC/104 bus)
• Serial Wireless I/O (ICO-7000 Series)
• Third party drivers also available

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Communications

• Networks for HMI/SCADA, program monitoring, PLC
  peer-to-peer, etc.
• SoftPLC appears as PLC-5
• Virtually all HMI/SCADA and many other 3rd party
  devices supported
• Up to 32 networks per system
• Ethernet
• Serial (DF1)
• Data Highway Plus or Data Highway

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FTP/SSH Servers

• Used for TCP/IP exchanges of files, system
  maintenance
• Use with any FTP/SSH client (many are free)
• Example uses
• Update/backup SoftPLC configurations files
• View/retrieve SoftPLC files, documentation
• Run command line programs

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Syslog

• A complete log record for user messages
• User Messages include operating mode, startup
  status or faults, runtime faults
• Syslog messages can be directed to any output
  (eg ram fifo, local file/disk/ramdisk, remote
  file on a windows PC)
• Helps users comply with FDA 21CFR11

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Web Server Module

• Add-on software module for SoftPLC
• Allows browsers to access SoftPLC data
• Applets (run in browser, but reside in SoftPLC)
• Servlets (run in SoftPLC, good for remote
  applications, secure)

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Gatecraft Firewall Technology

• Feature-rich industrial firewall
• Stateful inspection, NAT/IP masquerading,
  blacklisting
• Multiple VPN tunnels
• Ethernet-to-Ethernet, Modem, Wireless options
• Runs embedded in SoftPLC

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SoftPLC Architecture
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A-B Conversions
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A-B Conversions

• Most convert 90-100
• SLiCk Convert - 195 web based utility to convert
  SLC-500 applications to SoftPLC
• PLC-2, PLC-5 conversion services from SoftPLC
• SoftLogix, PLC-5/250 PLC-3 conversion services
  quoted per application

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A-B Conversions

• PLC-5
• Send TEXT version of logic and documentation to
  SoftPLC for conversion (150 minimum fee)
• Use a Hardbook-PCI or a SoftPLC Processor with
  1785-PKTX card
• Replace PLC-5 CPU w/ 1771-ASB Remote I/O Adapter

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A-B Conversions

• PLC-2/30, -2/20
• Replace CPU with Hardbook-PCI or SoftPLC
  Processor with 1785-PKTX card
• Send program and documentation to SoftPLC
• Upload logic with TOPDOC PLC-2
• Text version of documentation files if available
• 750 fee includes loan of TOPDOC PLC-2 package
  and conversion services

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A-B Conversions

• PLC-2 with Remote I/O
• Existing I/O can remain
• PLC-2 with Local I/O
• Change 1771-AL Adapters to 1771-ASB/ASC Adapters
• Racks Power Supplies must be Series B

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A-B Conversions

• Mini-PLC-2
• Cost of 1785-PKTX and Remote I/O Adapter makes
  upgrade often not cost justifiable
• May be opportunity to replace entire system
  instead
• Especially if older 8 point I/O modules were used

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A-B Conversions

• SLC-500
• Customer uses SliCk Convert Utility on SoftPLC
  Website to convert logic documentation
• Conversion provides equivalent Tealware I/O
  modules
• If customer wants to re-use SLC I/O
• Use Hardbook-PCI or SoftPLC Processor with
  1785-PKTX interface card
• Replace CPU w/ 1747-ASB Remote I/O Adapter

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A-B Conversions

• Any system using Flex or block I/O, same
  principle applies
• 1794-ASB Remote I/O Adapter

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