PLC is a fundamental element of industrial automation, enabling the control of machines, technological processes, and building systems. PLCs are used in industry, energy, HVAC, BMS systems, and many other fields.
Our services
PLC programming
ASSPIRE develops control applications mainly on controllers from:
| Manufacturer | Controllers |
| Johnson Control | MS-FAC2513-0, MS-FEC2611-0, MS-FEC2621-0, MS-FAC2611-0, MS-FAC2612-1, MS-FAC2612-2, MS-FAC3613-0, MS-FEC1611-1, MS-FEC1621-1, FCD2612-1, M4-CGM09090-0, M4-CGM09090-0H, M4-CGM04060-0, M4-CVM03050-0, M4-CVM03050-0P, MS-FAC4911-0, M4-CGE04060-0, M4-CGE09090-0, M4-CGE09090-0H, M4-CVE03050-0P, EASYIO-FS-20, FS-32, FW-08, FW-08V, FW-14, FW-28, FW-VAV, FT-04A-5, FT-04B-5 |
| WAGO | CC100, BC100, PFC100, PFC200, PFC300 |
| ISMA CONTROLLI | iSMA-B-FCU, iSMA-B-2D, iSMA-B-AAC20, RAC18-IP, VAV14-IP, iSMA-B-MAC36PRO, iSMA-B-MAC36NL |
| DISTECH | ECY-103, ECY-203/253, ECY-300/350, ECY-400/450, ECY-600/650, ECY-IOM, ECY-S1000, ECY-APEX, ECY-Display |
| TRIDIUM | Niagara EDGE 10, Niagara JACE 8000, Niagara JACE 9000 |
| HONEYWELL | Optimizer VAV: VAA-VA75IB24NMC, VAA-VA75TB24NMC, VAA-VA75MB24NMC; Unitary Controllers: UN-RS0844ES230NMC, UN-RL1644ES230NMC, UN-RS0844ESB24NMC, UN-RL1644ESB24NMC; Optimizer Advanced: N-ADV-134-H-C, N-ADV-133-H-B-C |
| ALLEN BRADLEY | ControlLogix 5570, CompactLogix 5370 L1, L2, L3 |
What is PLC programming?
It is the process of creating controller logic using languages compliant with the IEC 61131-3 standard, which defines standard PLC programming languages.
Basic PLC programming languages
| Language | Description |
| LD (Ladder Diagram) | Graphical language resembling a relay logic diagram |
| FBD (Function Block Diagram) | Function blocks – ideal for analog and sequential control |
| ST (Structured Text) | Text-based, similar to Pascal – suitable for complex logic |
| SFC (Sequential Function Chart) | Step-based structure – ideal for staged processes |
| IL (Instruction List) | (Deprecated) low-level textual language, similar to assembly |
Popular PLC programming platforms and environments
| Manufacturer | Controllers | Software |
| Siemens | S7-1200, S7-1500 | TIA Portal |
| Rockwell (Allen-Bradley) | CompactLogix, ControlLogix | Studio 5000 Logix Designer |
| Schneider Electric | Modicon M340, M580 | EcoStruxure Control Expert (Unity Pro) |
| WAGO | PFC200, 750 Series | e!COCKPIT, Codesys |
| Beckhoff | CX, Embedded PCs | TwinCAT |
| Omron | NX, NJ, CP1, CJ | Sysmac Studio, CX-One |
What does the work cycle with a PLC look like?
- Control logic design
- Process or schematic analysis
- Defining inputs, outputs, and conditions
- Programming in an engineering environment
- Language selection (e.g. LD or ST)
- Code development and testing
- Simulation / test logic
- Program behavior verification before deployment
- Uploading the program to the PLC
- Via USB, Ethernet, RS-232, etc.
- Diagnostics and commissioning
- Monitoring variables, errors, and alarms
Configuration of BMS/SCADA supervisory systems
Configuring BMS/SCADA systems involves creating a structure that supervises and manages the entire technical infrastructure of a building or industrial facility – the so-called supervisory layer. These systems collect data from automation devices (PLCs, BMS controllers, sensors) and enable visualization, archiving, alarming, and analysis.
ASSPIRE develops BMS systems for building automation based on the following applications:
Configuration steps
1. Requirements and system architecture analysis
- Determining the scope of functions (HVAC, lighting, energy, security)
- Determining the number of data points (tags), locations, and devices
- Selection of the platform (e.g., Niagara, ASIX, Desigo CC, FactoryTalk View SE, WebHMI)”
2. Integration and communication
- Protocol configuration:
– BACnet/IP (BMS standard)
– Modbus TCP/RTU (often for HVAC devices, meters)
– KNX, M-Bus, OPC UA/DA, MQTT (for various integrations) - Creating communication maps – assigning tags to addresses
3. Creating a data structure (tags)
- Defining:
– analog points (AI, AO)
– digital points (DI, DO)
– alarms, states, counter values - Name conventions consistent with standards (e.g., AHU1_Temp_Ret, CH1_Run_Status)
4. Creating a visualization (HMI/SCADA GUI)
- Designing synoptic screens:
– HVAC, lighting, and utility flowcharts
– dashboards with KPIs and energy consumption
– alarm screens, reports, trends - Tools: Niagara Workbench, ASIX Designer, Desigo CC, WebHMI Designer, etc.”
5. Configuring alarms and schedules
- Setting alarm thresholds and actions (e-mail, SMS, signal)
- Configuring device operation schedules (e.g., air conditioning only during business hours)”
6. Data registration and archiving
- Selecting the points to log (often only key variables)
- Sampling period (e.g., every 1 minute, every 10 seconds)
- Selection of storage location: local server, cloud, SQL, InfluxDB
- Selecting the points to log (often only key variables)
7. User and security management
- Creating accounts and roles (operator, engineer, administrator)
- Authentication, event logging (login, parameter changes)
- HTTPS, VPN, IT/OT network separation
8. Final testing and commissioning
- Checking the operation of visualization and communication
- Simulating alarms and value changes
- End-user training
Computer Systems Validation
Computerized System Validation (CSV) is a documented process that ensures that an IT system (e.g. BMS, SCADA, EMS, PLC control systems, HMI) functions as intended, meets user requirements and meets standards and regulations – especially in regulated industries (pharmaceuticals, food production, medical devices).
Legal and normative basis of validation
| Standards / guidelines | Description |
| GAMP 5 (Good Automated Manufacturing Practice) | The most widely used methodology for computerized systems validation (CSV) |
| FDA 21 CFR Part 11 | Requirements for electronic data systems in the United States |
| EU GMP Annex 11 | European requirements for computerized systems in the pharmaceutical industry |
| Journal of Laws item 1816 | Polish Ministry of Health regulation (December 4, 2024) on Good Manufacturing Practice requirements |
| ISO 13485, ISO 14971 | Standards for medical devices (quality and risk management) |
Computerized system validation (CSV), main steps:
1. URS – User Requirements Specification
Collecting and documenting user requirements
Example: “The SCADA system shall retain alarm data for a minimum of 12 months.”
2. RA – Risk Assessment
Identification and assessment of risks associated with the system
Prioritization of components for validation (in accordance with the “risk-based approach” principle – GAMP 5)
3. FS/DS – Functional/Design Specification
Description of the system’s functionality and architecture (operational logic, interfaces, reports)
4. DQ – Design Qualification
Confirmation of compliance of the Functional Specification (FS) and Design Specification (DS) with the user requirements (URS)
5. IQ – Installation Qualification
Validation of correct system installation: hardware, software, connections, versions. Confirmation of compliance with the Design Specification (DS).
6. OQ – Operational Qualification
Functional testing: whether the system operates as required under typical conditions. Confirmation of compliance with the Functional Specification (FS).
7. PQ – Performance Qualification
Confirmation that the system meets the requirements under real-world production conditions.
8. Final Report and Approval
Summary of evidence, tests, deviations, and validation decision
Systems subject to validation:
- BMS systems in pharmaceutical facilities (e.g., temperature, humidity, pressure control)
- SCADA + Historian for production lines (monitoring critical parameters)
- PLC / HMI for packaging, mixing, etc. machines
- Data archiving systems (logs, availability, backups)”
Benefits of validation:
- Meeting GMP, FDA, and ISO requirements
- Reducing the risk of production errors
- Evidence of system quality and reliability
- Readiness for audits and inspections (e.g., URPL, FDA)”
Computer Systems Validation offer
- Development of Functional Specifications (FS)
- Development of Design Specifications (HDS)
- Development of Design Specifications (SDS)
- Development of Risk Analysis (RA)
- Preparation of IQ/OQ/PQ protocols
- Performance and documentation of IQ/OQ/PQ tests
- Preparation of IQ/OQ/PQ test reports”
Commissioning of equipment on construction sites
Construction equipment commissioning is a key step in the implementation of building automation systems (BMS), HVAC, electrical, plumbing, and industrial systems. It involves testing, commissioning, and confirming the correct operation of all installed equipment under real-world conditions, in accordance with the technical documentation and detailed design.
Stages of commissioning equipment on site
1. Preparation for start-up
- Checking the completeness of the installation (mechanical, electrical, signal)
- Verifying markings and connections (compliance with documentation)
- Reporting readiness for commissioning (installer’s reports)
Example: Checking the correct connection of the temperature sensor to the BMS controller”
2. Pre-Commissioning Tests
- Checking power supply voltages, protections, and communication (e.g., BACnet, Modbus)
- Testing signal and cable continuity
- Checking device addressing
Example: Testing HVAC inverter communication with PLC via Modbus RTU”
3. Commissioning
- Device start-up (e.g., air handling unit, chiller, DALI lighting)
- Testing response to control signals (ON/OFF, speed change, setpoints)
- Calibration of sensors and controllers
- Verification of control logic with the BMS/SCADA system
Example: changing the setpoint temperature in the SCADA and checking the operation of the mixing valve”
4. Integration tests
- Checking the interoperability of systems (e.g., HVAC and SAP, UPS and SCADA)
- Simulating emergency states and alarms
- Testing schedules, priorities, and operating modes (manual/automatic)
Example: testing the transfer of power from the mains to the generator and monitoring it in SCADA”
5. Documentation and protocols
- Preparing commissioning reports (for each device or system)
- Recording output parameters (setpoints, addresses, reference values)
- Submitting as-built documentation (diagrams, configurations, access passwords)”
Prefabrication of control cabinets
Control cabinet prefabrication is the process of designing, assembling, and testing prefabricated automation, power, and control cabinets—performed off-site, most often in a specialized workshop. The finished cabinet is then transported to the construction site and installed as a complete, tested module.
What is a control cabinet?
It’s a closed enclosure (metal or plastic) containing components responsible for:
- powering devices,
- process control (e.g., via PLC, BMS),
- protection (circuit breakers, relays, contactors),
- communication (switches, routers, Modbus/BACnet gateways)”
Elements of a typical control cabinet
| Component | Function |
| Power supply | Converts mains voltage (e.g. 230VAC → 24VDC) |
| PLC / BMS controller | Controls device logic |
| Relays, contactors | Switch motors, pumps, valves |
| Fuses, circuit breakers | Circuit protection |
| Terminal blocks | Signal and power connections |
| Communication modules | Interfaces for BACnet, Modbus, KNX, etc. |
| HMI or operator panel | Local operation interface |
| Cabinet ventilation / air conditioning | Maintains proper thermal conditions |
Stages of control cabinet prefabrication
- Electrical schematics (CAD: EPLAN, SEE Electrical, WSCAD)
- Component selection (in accordance with standards: PN-EN 61439, PN-HD 60364)
- Verification of compliance with facility and master system (BMS/SCADA) requirements
- Procurement and preparation of components
- Equipment selection and procurement
- Preparation of enclosures and mounting plates
- Mechanical and electrical assembly
- Mounting devices on the mounting plate
- Cable routing, labeling, conduit installation
- Marking wire ends, terminals, and cables according to the schematic
- Testing and quality control
- Connection verification (continuity, short circuits, isolation)
- Power-up and functional testing (e.g. I/O signals, communication)
- Commissioning documentation (FAT – Factory Acceptance Test protocols)
- Delivery and on-site installation
- Transport under appropriate conditions (e.g. IP protection)
- Installation in control room, cable connections, grounding
- Integration with other systems (BMS, HVAC, SCADA)
Advantages of prefabricated control cabinets
- Reduced commissioning time on site
- Improved quality of workmanship in workshop conditions
- Pre-delivery testing – reduced errors
- Improved cost and logistics control
- Possibility of batch prefabrication (for multiple facilities)”
Design projects for automation installations
(BMS, HVAC, lighting, utility systems, etc.) is detailed technical documentation specifying the construction, configuration, and commissioning of a building automation system. They form the basis for the contractor’s installation, prefabrication of control cabinets, and programming and commissioning of master systems.
We prepare designs documentation for building automation systems: control panels, cable routes, and master BMS systems.
Contents of the building automation design documentation
1. Technical description of the system
2. Schematic (functional) diagrams
3. Connection (wiring) diagrams
4. Floor plans with device locations
5. List of automation points (I/O list)
6. Control cabinet diagrams
7. Address tables and communication maps
8. Description of control algorithms and logic
9. Programming and commissioning guidelines
Additional elements of construction documentation:
- Bill of Materials (Cables, Sensors, Actuators, Panels)
- Device and Component Specifications
- Assembly and Health and Safety Instructions
- Guidelines for Cross-Discipline Coordination (e.g., HVAC–Automation)”
Typical tools used to create a project:
- AutoCAD / Revit – floor plans, diagrams
- EPLAN / WSCAD – electrical cabinet diagrams
- Excel – point lists, address tables
- Visio / Draw.io – logical or communication diagrams
Practical advice:
Design documentation should be:
- current and consistent with other disciplines (HVAC, electrical),
- clear and unambiguous – especially for contractors and integrators,
- compliant with the investor’s requirements and standards (e.g., PN-EN 15232 – Energy efficiency of building automation).”
Concepts of Automated Systems
Building automation system concepts are a document or set of assumptions describing the architecture, functionality, and implementation of automation for a new building, technical installation, or facility modernization. They constitute the first step before technical design is completed—often as part of a multi-discipline concept or feasibility study.
What does the automation system concept include?
1. Scope of the automation system (BMS/IBMS)
- What systems will be automated?
➤ HVAC, lighting, blinds, utility consumption, power supply, security (fire alarm system, access control, CCTV) - Will there be one integrated system (IBMS) or several independent ones?
2. Description of functional requirements
- What functions should be implemented:
➤ control, monitoring, alarming, scheduling, reporting, energy optimization - Should the system support different modes (comfort, night, emergency)?
3. Creating a data structure (tags)
- Communication topology (distributed, centralized, hybrid)
- Location of control cabinets and devices (technical rooms, switchboards)
- Connection to the SCADA/BMS master system
- Block diagram (topology divided into layers: devices → controllers → SCADA)
4. Selection of technologies and protocols
- Recommended communication standards:
➤ BACnet/IP, Modbus RTU/TCP, KNX, DALI, M-Bus, OPC UA - Preferred automation system manufacturers: e.g., Niagara, Siemens Desigo, Schneider EcoStruxure, Distech, WAGO
5. Interdisciplinary integration
- Connections with other systems (SAP, DSO, UPS, HVAC, elevators, photovoltaics)
- Description of data interfaces and exchange scope (e.g., BACnet server/client, OPC gateway)”
6. Preliminary list of I/O points
- Estimated number of signals (DI, DO, AI, AO)
- Division into zones/installations (e.g., AHU, boiler room, parking lot lighting)”
7. Programming assumptions
- Automation level (manual, semi-automatic, fully autonomous)
- Control strategies (e.g., HVAC: PID + scheduling logic + CO₂ sensors)
- Energy management – need for integration with a Class A/B BMS (according to PN-EN 15232)
8. SCADA/BMS Requirements
- User interface (Web, desktop, mobile)
- Trend history, alarms, archiving, data export
- Remote access, user authorization, IT network integration
Technical Consulting
Technical consulting in the context of building and industrial automation systems provides professional, substantive support to investors, designers, contractors, and end users at various stages of the installation lifecycle – from concept to operation.
We support our clients in selecting equipment for controlling and monitoring ventilation and air conditioning processes.
The scope of technical advice may include:
- Pre-investment stage (analysis and assumptions)
- Design stage
- Implementation and commissioning stage
- Operation and modernization stage”
Forms of consulting:
- Technical meetings (online or onsite)
- Audits and expert reports
- Documentation reviews (with opinions and comments)
- Creation of technical guidelines (e.g., company automation standards)
Benefits of technical consulting:
- Avoiding costly design or implementation errors
- Better tailoring solutions to user needs
- Saving energy and operating costs
- Assured that the system will be scalable and modern
Sale
Sales in the building and industrial automation industry include technical and commercial consulting, quotations, solution presentations and contract finalization for systems such as BMS, SCADA, PLC controllers, automation cabinets, communication components, software and engineering services.
Authorized distributor of Johnson Controls International
ASSPIRE is an authorized distributor of Johnson Controls International. Our business includes the sale and distribution of automation equipment for process control in:
- Ventilation
- Air Conditioning
- Heating
- Refrigeration
The scope of sales includes:
- PLC controllers (e.g., Siemens, WAGO, Allen-Bradley)
- I/O modules, power supplies, HMI
- BMS systems (e.g., Niagara, Desigo, Metasys, Eclypse)
- Sensors, actuators, relays, inverters
Technical sales process step by step:
- Client needs analysis
- On-site visit or online meeting
- Collecting key information: facility type, industry, scale, required functions
- Solution selection
- Technology proposal tailored to budget and requirements
- Comparison of options (e.g. local SCADA vs. cloud-based, PAC vs. PLC controller)
- Technical and commercial offer
- Specifications, scope of work, schedule, pricing
- Limitations / exclusions / design assumptions
- Negotiations and contract signing
- Agreement on payments, deadlines, warranties
- Formal documents: purchase order, contract
- After-sales support
- Service, training, updates, system expansions
- Ongoing client satisfaction monitoring
