ILS Integrates IDEC Microsmart MicroSmart PLC for Batch Control of Bioreactor

Choosing a PLC Vendor for Bioreactor Control ILS is a solution provider and system integrator for supervisory control, data acquisition, and information system storage, retrieval and reporting for the process industries. ILS specializes in solutions for the batch process industry, in particular, fermentation or biological applications for food, energy, pharmaceutical and biotechnology. Their primary focus had been software, with solutions based upon the ILS Batch Expert supervisory control and data acquisition (SCADA) platform. ILS saw the opportunity to introduce bioreactor control hardware utilizing the benefits of modern programmable logic controllers (PLCs). Their goal was to introduce a stand-alone bioreactor control box that included sensor inputs, control outputs, a touchscreen HMI and Ethernet port for OPC communication. A PLC was chosen as the platform for data acquisition and control as a PLC provided the greatest value for both development and support from both ILS and the customers perspective. The optimum solution should rely on off-the-shelf parts to minimize cost and provide an open platform for the customer to support and maintain. The control box offered by ILS is labeled the AFC 900 Series of bioreactor control systems. For ILS to be successful, a hardware vendor and PLC solution had to meet the following basic criteria: 1. Hardware meeting the technical requirements for batch control 2. Cost-effective hardware and programming software 3. Excellent customer service and support The IDEC MicroSmart Pentra Slim line FC5A-D32 PLC was the basis for the ILS AFC 900 Series. The IDEC Pentra Slim line series met technical requirements, and at a costeffective price for both the hardware and software. More importantly, IDEC provides direct support and introduced ILS to a third-party partner willing to assist in the development of AFC 900 Series. IDEC introduced ILS to Electrical Control Distributors (ECD), a company dedicated to the design and manufacture of specialized controls. ECD provided the hardware design and integration services based upon the requirements of ILS and based upon IDEC components. PLC Technical Requirements ILS wanted to meet specific hardware requirements that would differentiate the AFC 900 from competitors. The key was to provide processors a solution that included as many off-the-shelf components as possible. Many customers can maintain their own systems and proprietary systems are expensive, if not impossible, to maintain over time. The

ILS : P.O. Box 1309 : Warrenville, IL 60555 : USA Phone: (732) 715-2359 : Email: info@ils-automation.com Web: www.ils-automation.com

following table lists some of AFC 900 technical requirements with corresponding IDEC Pentra Slimline functionality: AFC 900 Requirement Ethernet Port for programming and OPC communication IDEC Pentra Functionality The IDEC Web Server Module facilitates PLC programming/monitoring and OPC communication. End-users can switch between programming and OPC communication through the HMI port. The IDEC WindSRV OPC server software in combination with the Ethernet module allows for communication through a LAN. The Pentra Slim line models support numerous simultaneous PID controllers. Flexible PID that includes all the hooks and auto-tuning capabilities. Up to two pulse outputs allows for control of two stepper motors. The stepper motors allow for variable speed RPM control of peristaltic pumps. The built-in IDEC high-speed counters allow the PLC to calculate RPMs based upon a motor encoder and the PWM allows the PLC to drive the DC motor. The IDEC FC4A-J8C1 high-density analog input module includes 8 16-bit analog inputs for current and voltage The IDEC FC4A-K2C1 includes 2 analog outputs for either current or voltage.

OPC communication through Ethernet for direct communication with SCADA over local area network (LAN) PID Control for temperature, pH and dissolved oxygen

Pulse Output for controlling peristaltic pump stepper motors

High-speed counting and Pulse Width Modulation (PWM) for controlling DC agitator motor 16-bit analog inputs for reading temperature, pH, DO

Analog outputs for controlling gas flow controllers

Serial input module for reading probes and scales

The IDEC FC5A-SIF2 serial module for reading values from scales and serial probes. The available serial command set within the PLC has been able to manage a variety of different vendor specific communication protocols.

Figure 1 is a picture of the ILS AFC 901 MF bioreactor control system. The AFC 901 MF includes an AC motor drive for agitation, cooling water feed/recycle valve for temperature control, variable RPM peristaltic pumps for substrate control, and fixed RPM on/off pumps for pH and foam control. Analog inputs include gas flow, temperature, pH and DO. Serial inputs include ports for Mettler-Toledo ISM serial probes.

ILS : P.O. Box 1309 : Warrenville, IL 60555 : USA Phone: (732) 715-2359 : Email: info@ils-automation.com Web: www.ils-automation.com

Figure 1 AFC 901 MF reactor Figure 2 shows a picture of the internal AFC 901 MF including the IDEC MicroSmart Pentra FC5A-D32 PLC, IDEC Web Server Module for programming and OPC communication, IDEC FC5A-SIF2 RS232C expansion modules, and FC4A-J8C1 highdensity analog input module.

Figure 2 IDEC PLC and communication modules

IDEC WindLDR - PLC Programming Software The IDEC WindLDR PLC programming software provides ILS engineers an easy-to-use and fully-functional platform for development, monitoring and maintenance of PLC operation. ILS realizes that the human resources to develop and maintain software, including PLC code, are a significant portion of project costs. The effort is made costeffective with the IDEC WindLDR software, IDEC training services, and IDEC documentation.

ILS : P.O. Box 1309 : Warrenville, IL 60555 : USA Phone: (732) 715-2359 : Email: info@ils-automation.com Web: www.ils-automation.com

Ease-of-use: WindLDR software maintains its ease-of-use even considering the many advanced instructions and features provided. Documentation: The manuals and other documentation, including web-based materials, are well written and detailed. This allows ILS engineers to make quick reference when the need arises. Support: If required, ILS emails IDEC technical questions. Training: IDEC provides convenient hands-on training throughout the year. PLC Programming Instructions: WindLDR software includes a rich set of PLC instructions and programming capability. Software Updates: IDEC provides automatic software updates as they are made available. IDEC routinely provides bug fixes and new features. On-Line PLC Monitoring: WindLDR software allows developers to monitor PLCs running within a PLC. Without this feature, the software testing and debugging effort is significantly larger. Off-line Simulation: WindLDR software allows the developer to simulate PLC code before downloading and testing with the PLC. This speeds the initial development effort. IDEC WindLDR - PLC Instructions The AFC control box takes advantage of many of the WindLDR PLC programming instructions, from simple to advanced. Below is a list of a portion of the instructions utilized: 32-bit floating-point math: Advanced control, instrumentation calibration, etc. are often easier to develop and maintain in float format as opposed to integer or Word format. The 32-bit floating point math capabilities make development and use by personnel, such as chemical engineers and scientists, much easier. User Communication: ILS customers often request that the PLC communicate with serial devices, such as a scale or instrument. The PLC serial commands allow ILS engineers to quickly develop new communication interfaces. For example, in less than a day an engineer was able to develop an interface to a Mettler-Toledo scale or even more advanced devices such as Mettler-Toledo ISM pH/DO probes. Coordinate Conversion: Conversion allows for multiple-point conversion for instrument calibration. This is used for pH, DO, temperature and flow calibration. Program Branching: Branching reduces code complexity and provides more flexibility to traditional ladder-logic.

ILS : P.O. Box 1309 : Warrenville, IL 60555 : USA Phone: (732) 715-2359 : Email: info@ils-automation.com Web: www.ils-automation.com

PID Instruction: ILS customer applications require PID control. The IDEC PLC PID implementation is fully features and well documented. Pulse: Motors for agitation and pumps are controlled through pulse outputs including a PWM command. Dual Timers: Dual timers that provide on/off type pulses are applied to control outputs such as pumps, valves and heaters. This feature is widely applied and reduces overall program complexity. Data Conversion/Data Comparison/Arithmetic/Shift and Rotate: Many of the advanced instructions have been applied. New Features: IDEC often adds new features that add significant benefit for ILS development and testing. For example, IDEC provided an update with a random number generator. This allowed ILS engineers to simulate how controllers would perform in the presence of a noisy instrument. The IDEC Advantage for ILS ILS customers often speak in terms of credits when performing a cost benefit analysis. IDEC easily provides the straight-forward credit. For a direct comparison of technical requirements IDEC PLC hardware and software provide, the value for the dollars spent. For ILS and its customers this initial credit is often only part of the final analysis. ILS labor costs to develop, maintain and deploy applications are not insignificant. IDEC offers easy-to-use products, documentation, training and support, which reduce this cost and add significantly to the credit. In addition, ILS often provides custom solutions and/or improvements to the application as the customer needs evolve. IDEC solutions make this possible. ILS customer credit is in the performance and long-term maintenance of the system. IDEC provides robust hardware and software that can perform over the long-term. In addition, the majority of ILS customers perform their own maintenance. IDEC software gives ILS customers the advantage of non-proprietary components. This provides the credit of long-term support through lower-cost access to parts and service. ILS Products and Services ILS offers automation products and system integration services. ILS products can include the following. 1. AFC 900 series control systems for batch and continuous processes based upon IDEC Pentra PLCs. 2. Batch Expert SCADA software that communicates through OPC to the AFC 900 and other OPC compatible control systems. Batch Expert provides supervisory control, batch recipe management (ISA S88), data historian and batch reporting.

ILS : P.O. Box 1309 : Warrenville, IL 60555 : USA Phone: (732) 715-2359 : Email: info@ils-automation.com Web: www.ils-automation.com

ILS system integration services include the following: 1. IDEC PLC and HMI integration and programming with emphasis on the process industries. 2. SCADA and OPC communication and integration with IDEC PLCs. This includes SCADA system from a variety of vendors. 3. Serial-based communication and system integration with IDEC PLC including Modbus and specific serial protocols. About ILS ILS has been providing automation and software solutions since 2001. Our expertise started with real-time, rule-based systems for laboratory, batch, manufacturing and business applications. ILS saw the need to integrate laboratory and hardware control systems with SCADA software and databases. With our background in process control and software, we have extended our products and services to control hardware, with emphasis on reliable and affordable integration with software and enterprises. We make sure integration can occur through accepted hardware protocols that can communicate easily with OPC and Modbus communication protocols. About ECD ECD was founded in 1992 by Mary and Fred Schwan as a distributor of products and services for the fabrication and maintenance of Electrical Control equipment. ECD is an IDEC partner and distributor providing integration services. Visit ECD on the Web at http://www.ecdcontrols.com . About IDEC IDEC designs and manufactures control automation products that are sold to original equipment manufacturers. Our goal is to meet our customers' ever-changing needs with quality products at a competitive price. Visit http://www.idec.com/usa for further information regarding IDEC products.

ILS : P.O. Box 1309 : Warrenville, IL 60555 : USA Phone: (732) 715-2359 : Email: info@ils-automation.com Web: www.ils-automation.com