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Get TOP Results from Fusing Your Devices to Wonderware
John Weber - PresidentKevin Rutherford – Application Engineer
Agenda
TOP Server Overview, Updates & Plans
OmniServer Overview & What’s New
Case Study– Duens Bakery(AMR)
Case Study– Assmang Khumani (Iritron)
Case Study – Pepclo (AMR)
Summary
TOP Server Overview
TOP Server Gets You Connected!AB Bulletin 1609 UPSAB Bulletin 900 Temp. ControllersAB DF1 Full & Half-Duplex Serial AB Radio ModemAB Data Highway Plus (DH+)AB PLC5,SLC5/05 EthernetAB 1761-NET ENIAB ControlLogix Ethernet & Gateway AB CompactLogix, FlexLogixAdvanced SimulatorAnalog Devices 6BAromat Serial & EthernetAutomation Direct Serial DirectNet Automation Direct Serial K-SequenceAutomation Direct ECOM Ethernet Automation Direct EBC EthernetBACnetBailey Fisher & PorterBeckhoff TwinCAT (ADS API)Busware Ethernet I/OContrex/Fenner CX1000Contrex/Fenner M SeriesCutler Hammer D50/100Cutler Hammer ELC EthernetCutler Hammer ELC SerialDataforth isoLynxDDE Server to OPC Client BridgeDeviceNet (Hilscher Universal)DNP Serial & Ethernet Suite
Fisher ROC
Fuji Flex PLCs
GE Focas1 Ethernet
GE SRTP Ethernet
GE EGD EthernetGE CCM SerialGE SNPGE SNP-X SerialHoneywell UDC & HC900IdecIOTech PointScan EthernetKraussMaffei MC4 EthernetMitsubishi FX Serial Programming PortMitsubishi FX-Net Multidrop SerialMitsubishi A Series SerialMitsubishi A Series EthernetMitsubishi Q/QnA Series EthernetModbus RTU & ASCII Serial Master,Modbus RTU Serial RTU SlaveModbus PlusModbus Ethernet Master & SlaveODBC Client DriverOmron Hostlink & FINS SerialOmron Process SuiteOmron FINS EthernetOptimation OptiLogic I/OOpto 22 EthernetOracle MES Connector Plug-inOracle MOC Plug-inPartlow ASCIIPhilips PC8/PC20Profibus (Hilscher Universal)Red Prairie Logistics Systems
Sattbus & Sattbus EthernetScanivalve EthernetSiemens S5 AS-511Siemens 3964RSiemens S7-200 PPI & ModemSiemens S7-300/400 MPISiemens S7-200/300/400 EthernetSiemens S7-300 Ethernet SlaveSimatic/TI 5x5 Serial & EthernetSimatic/TI Unilink TIWAY Host Adapter DriverSIXNET UDR & EtherTRAK EthernetSquareD SerialSystem Monitor DriverTelemecanique UnitelwayThermowestronics Serial & EthernetTorque Tool Ethernet DriverToshiba PLCs Serial & EthernetToyopuc PC2 SerialToyopuc PC2/PC3 EthernetTriconex TSAA EthernetUser Configurable DriverWago 750 Ethernet I/OWonderware Intouch Client DriverYaskawa MemoBus PlusYaskawa MP Serial & EthernetYokogawa CXYokogawa DX100/200 & Darwin SerialYokogawa DX(P)100/200 Yokogawa Darwin EthernetYokogawa DXPYokogawa HRYokogawa MWYokogawa MXYokogawa YS100 Serial
Why TOP Server?
► Customer’s Top 4 Reasons:▪ Broad Choice of Drivers▪ SINGLE Interface into your systems▪ Scalability▪ Support & Customer Commitment
► Other reasons▪ Functionality▪ Reliability▪ Flexibility ▪ Diagnostics▪ Documentation▪ Commitment to Standards
It’s About Reducing Engineering + Startup Time and Saving Money
TOP Server: New Drivers
► Beckhoff TwinCAT Ethernet Driver► System Monitor Driver► AB Bulletin 1609 UPS Driver► Cutler Hammer ELC Ethernet Driver► Opto 22 Ethernet Driver► SNMP Suite► OPC DA Client Driver► Torque Tool Ethernet Driver► Advanced Tag Plug-in
TOP ServerBeckhoff TwinCAT Ethernet
► Devices Supported▪ TwinCAT PLC▪ Bus Couplers (BC9xxx/BX9xxx)
► Uses Beckhoff ADS API for best performance
► Built with support of Beckhoff Germany, US, & South Africa
► Structured Tags/Symbolic Addressing
► Automatic database generation▪ From device if available▪ From *tpy file for offline import▪ Structure import support in online
& offline mode, with filtering using Beckhoff style
► Support for connecting to multiple Beckhoff Runtime engines in same controller
► AMS Routing Support
Beckhoff TwinCAT Ethernet
OPC, Suitelink,
DDE
TOP Server OPC & I/O Server
Why Use This Driver instead of Beckhoff’s OPC Server?
• Faster than Beckhoff OPC Server
• During Startup
• After Startup
• Native Suitelink = No FS Gateway/OPC Link!
• Beta Testing here at Beckhoff South Africa showed it was just easier to configure!
Why Use This Driver instead of Beckhoff’s OPC Server?
• Faster than Beckhoff OPC Server
• During Startup
• After Startup
• Native Suitelink = No FS Gateway/OPC Link!
• Beta Testing here at Beckhoff South Africa showed it was just easier to configure!
TOP ServerBeckhoff TwinCAT Ethernet
► Connectivity to TwinCAT Soft PLC’s or Bus Terminal Controllers
TOP ServerBeckhoff TwinCAT Ethernet
► Configurable Ports Enable Connectivity to Up to Four Runtime Engines on the Same TwinCAT Controller
TOP ServerBeckhoff TwinCAT Ethernet
Benefits
• Convenient
• Flexible (Online or Offline)
• Guarantees Correct Syntax
Benefits
• Convenient
• Flexible (Online or Offline)
• Guarantees Correct Syntax
► Tag Import from Device or Configuration File
TOP ServerBeckhoff TwinCAT Ethernet
Benefits
• Ease of Conversion
• Saves Time on Import
• Eliminates Unnecessary Tags on Import
Benefits
• Ease of Conversion
• Saves Time on Import
• Eliminates Unnecessary Tags on Import
► OPC Item Filtering on Tag Import (Online or Offline)
TOP ServerSystem Monitor
► Uses Microsoft Performance Data Helper API
► Item Import Browser allows Auto Tag Generation
▪ Performance Objects▪ Instances▪ Counters
► Monitor Health of Underlying Systems
▪ Network Interfaces▪ Memory Utilization▪ CPU Usage▪ So Much More…
System Monitor Driver
OPC, Suitelink,
DDE
TOP Server OPC & I/O Server
Benefit:
Provide your HMI operators with critical performance information about the underlying systems your software is running on so they can keep them running!
Benefit:
Provide your HMI operators with critical performance information about the underlying systems your software is running on so they can keep them running!
Additional New Drivers
► AB Bulletin 1609 UPS▪ AB Bulletin 1609-U500N UPS 2▪ Generic SNMP Devices
► Cutler Hammer ELC Ethernet▪ Cutler Hammer ELC (PV Series)▪ Cutler Hammer ELC Suite (Ethernet & Serial)
► Opto 22 Ethernet▪ SNAP Industrial Controllers, Brains, Brain
Boards▪ MMIO and CONT Protocols
Additional New Drivers
► SNMP Suite▪ SNMP Driver (SNMP
Managed Devices)▪ Ping Driver
(Unmanaged Devices)
► OPC DA Client Driver▪ Connect to OPC DA
Servers supporting OPC DA 1.0 and 2.0
OPC Client Driver
OPC ServerVendor A
OPC ServerVendor B
WonderwareInTouch
Suitelink= Easy!
TOP Server OPC & I/O ServerPLC Drivers
OPC ServerVendor C
Benefits
• Reduced Integration Costs
• Increased Choices for Suitelink Connections
Benefits
• Reduced Integration Costs
• Increased Choices for Suitelink Connections
Benefits
• Knowledge at Point of Action
• Faster Troubleshooting
• Increased Uptime
Benefits
• Knowledge at Point of Action
• Faster Troubleshooting
• Increased Uptime
Additional New Drivers
► Torque Tool Ethernet Driver▪ Torque Tool Open Protocol
► Advanced Tag Plug-in▪ Mathematical operations on any existing tags
Benefits
• Expands TOP Server to QC Data Collection Realm
• Expands TOP Server Reach
• Reduces Integration Costs
Benefits
• Expands TOP Server to QC Data Collection Realm
• Expands TOP Server Reach
• Reduces Integration Costs
Benefits
• Provides Useful Calculations without Scripting
• Saves Time!
Benefits
• Provides Useful Calculations without Scripting
• Saves Time!
TOP Server Driver Enhancements
► ControlLogix Ethernet (V4.500.462)▪ MicroLogix 1400 Device Model Added▪ ASCII File Support Added
► DNP Serial/Ethernet (V4.500.462)▪ Event Buffering with Playback
► Siemens Ethernet (V4.300.449)▪ New System Tags (Rack # / Slot #)
► UCON▪ Now Supports Data Length Field in Variable
Length Device Responses
What’s Coming in TOP Server V5?
► Everything you love about V4 plus…► Expanded Operating System Support
▪ Windows Vista (includes service support)
▪ Windows 2008 Server (includes service support)
▪ 64 Bit OS (Vista, 2008)▪ Still supporting Windows 2000, 2003, XP
► Configuration separated from runtime▪ Connect via TCP/IP port 32402 (or other user
choice)▪ Remote event log access (port 56233)
► Improved Terminal Services Support
TCP/IP connectionConfiguration –
No changes from the way you do it now!
Runtime separated from config
What’s Coming in TOP Server V5?
► DNS device names support► V4 configurations “just straight work!” ► 1st Release of V5 – May 2009► Official Maintenance & Support program► Platform for adding OPC UA (Q2 or Q309)► Watch for webcasts in April/May► Come talk with us at our stand in the Expo
So What is OmniServer?
► Created and first sold in 1995.► Solves the problem of writing custom drivers
for unique devices.► Solves the problem of polling for multiple
devices.► Is NOT a replacement for existing drivers.
Use for devices that have no drivers.► Use OmniServer to interface computers with
other computers or devices with other devices.
Such as…•Bar Code Readers•Weigh Scales•RFID Readers•Printers•Security systems•Intercom control•Video surveillance control•Laser Markers and more… •Serial, Ethernet, Master or Slave
Such as…•Bar Code Readers•Weigh Scales•RFID Readers•Printers•Security systems•Intercom control•Video surveillance control•Laser Markers and more… •Serial, Ethernet, Master or Slave
OmniServerFunctionality Overview
► User-Configurable Data Acquisition Tool
► OPC/DDE Server▪ OPC Server Interface▪ DDE Server Interface▪ FastDDE/SuiteLink Interface
► Hardware Interfaces▪ RS-232, RS-422, RS-485▪ Winsock (TCP/UDP/Telnet)▪ LPT
► Communicate to almost any device, including custom designed devices
▪ Variable length, character delimited Protocols
▪ Known/Fixed Length protocols
Benefits
• Custom drivers at a very low cost
• Improved plant integration
• Reduced engineering costs
Benefits
• Custom drivers at a very low cost
• Improved plant integration
• Reduced engineering costs
OmniServer Professional: Expanding the Possibilities…
► OmniServer Wedges Enable Solutions▪ Text File Wedge▪ Database Wedge▪ Keyboard Wedge▪ E-Mail Wedge (New!)
OmniServer Professional: …Without Breaking the Bank
► For only a bit more than the Server Edition you get:▪ More than just Data via OPC
or Suitelink▪ Make your OmniServer work
for you:• Log your data to Access, SQL, or
any other ODBC Database
• Log your data to text file (.csv) for Excel access
• Pass your data into any application via keystrokes
• Be notified of the condition of your system with Email or SMS alerts!
OmniServer V2.6: New Features
► Removed NetDDE Dependency► Necessary for Systems Requiring NetDDE to be
Disabled
OmniServer V2.6: New Features
► TCP Keep Alive► Useful for Maintaining Unsolicited Connectivity to
TCP Devices supporting this functionality
OmniServer V2.6: New Features
► Increased Logger Buffer Size► Useful For Capturing All Diagnostic Data
OmniServer V2.6: New Features
► Enhanced Viewability in I/O Monitor and Logger▪ Configurable Fonts▪ Shaded Line Address Background (Configurable)
OmniServer V2.6: New Features
► Configurable Retry Count▪ Increase or Decrease How Many Times a Failed
Command is re-sent▪ Useful for Controlling Communications with Systems
Known to Fail
OmniServer V2.6: New Features
► New Email Client Wedge (Professional Version)► Send Email/SMS Notifications
OmniServer V2.6: New Features
► Need to Keep Count of How Many Times a Command/Request has Completed?
► New Message Count Items
OmniServer V2.6Summary of New Features► Vista / 2008 Support► No NetDDE Requirements► More objects – expanded from 512 to 2048► TCP “Keep Alive” signals to control the
Status bit.► Logger buffer size can be change - up to 999
kb.► I/O Monitor and Logger changes for better
clarity.► Retry counts can now be set.► New Email Wedge for Professional Version.► “Message Count” items for Host, Unsolicited,
and Error Messages.
Benefits
• Forward Progression with OS Compatibility
• Increased Project Sizes for Enhanced Scalability
• Improved Diagnostics for Troubleshooting and Design
• More Flexibility and Functionality
Benefits
• Forward Progression with OS Compatibility
• Increased Project Sizes for Enhanced Scalability
• Improved Diagnostics for Troubleshooting and Design
• More Flexibility and Functionality
OmniServer V2.6: Need to Upgrade?
► Upgrading from Previous Versions?▪ V2.6 Installer Makes the Process Painless▪ Using V2.0 or Higher, you have to do NOTHING!▪ Using V1.x?
• Copy configuration and protocols
• Change the Application Name or ProgID defined in InTouch or ArchestrA (V1.x Only)
– “OMNISRV” changes to “OSRVPOLL” for Suitelink / “OSRVDDE” for DDE
– “DSSI.OmniOPCServer.1” changes to “SWToolbox.OmniServer” for OPC
• You’re Done!
► NEW! Maintenance Plan▪ Low Annual Fee▪ Free Upgrades / Technical Support
Case Study – PepClo & AMR
► Clothing Manufacturing (part of Pepco)▪ Lower end market – Pep and Ackermans▪ High Volume School Wear
► Wonderware System▪ Redundant Application Servers▪ Historian▪ Information Server▪ 4 x View Nodes
► Challenge▪ Improve internal tracking via barcodes
► Solution▪ OmniServer – chose because of
• Easy-to-use – out of the box example working in minutes • Native Suitelink Connection to system platform• Very fast sub-second responsiveness• Support for Ethernet/Serial Convertors• Diagnostics facilities (I/O Monitor)
Case Study – PepClo & AMR
MoxaEthernetSerial
BarcodeScanner
OmniServer I/O Servers
Case Study – PepClo & AMR
Case Study – Duens Bakery (Epping) & AMR
► Challenge:▪ Wonderware ArchestrA + Information Server +
TOP Server Omron Suite system only controlling flour transfer to holding bins
▪ No visibility to bakery Tweedy mixers & bakery distribution
▪ Independent reporting systems▪ Scales on bins and mixers controlled by
separate PLCs (Omron & GE)▪ Mass balance discrepancies = waste, money
► Solution▪ Add TOP Server GE Fanuc driver to existing
TOP Server Omron Installation▪ Wonderware Equipment Operations Module
logs data from both systems
Case Study – Duens Bakery (Epping) & AMR
Case Study – Duens Bakery (Epping) & AMR
Benefits
Minimal costs/engineering time
The existing system was not modified
Data capturing is taking place on the Wonderware ArchestrA platform (one platform)
Reports can be viewed on the intranet using the Wonderware Information Server
Benefits
Minimal costs/engineering time
The existing system was not modified
Data capturing is taking place on the Wonderware ArchestrA platform (one platform)
Reports can be viewed on the intranet using the Wonderware Information Server
Case Study – Iritron/Assmang
► Khumani Iron Ore Mine▪ Best iron ore resources in South Africa▪ 40+ year life expectancy▪ Started up in 2008▪ Northern Cape province, 25km from
Kathu▪ 8.4 mm tons/year expected output▪ Expandable to 16.8 mm tons/year
► Large System Platform 3 project► Learn More at
▪ http://www.assmang.co.za/o/iron/khumani.asp▪ www.iritron.co.za
What is ASSMANG Khumani?
HPGRHPGR
Jig Plant
Jig Plant
SampleTower
SampleTower
On-Grade W&SOn-Grade W&S
Off-Grade W&SOff-Grade W&S
ROM StockpilesROM Stockpiles
ThickenerThickener
Main Plant
Main Plant
Primary Crusher
Primary Crusher
Overland Conveyor
Overland Conveyor
Paste Thickener
Paste Thickener
ASSMANG KhumaniArchitecture
ASSMANG KhumaniGalaxy: Size Does Matter!
► Phase 1 (September 2008): 165 Templates 6,746 Object Instances 48,358 IO 33,636 Historised Tags
► Phase 2 (2011): 200 Templates 13,000 Object Instances 90,000 IO 65,000 Historised Tags
ASSMANG KhumaniIO Servers
► TopServer for ContolLogix PLCs▪ 37,065 tags on AOS Node 1▪ 31,949 tags on AOS Node 2▪ 53 PLCs on 1 Gb Ethernet Network▪ Scan rates 400 to 600 ms▪ Used OPC Proxy Object to connect
► Round trip SCADA to AOS to PLC, back to AOS, back to SCADA, all system parts, about 2 seconds
► Redundant Application Servers:▪ Dual CPUs▪ 2.0 GHz Core 2 Duo ▪ 2GB of RAM▪ CPU Utilisation:
• AOS1 – Max 24%
• AOS2 – Max 15%
“The TOP Server AB Suite was easy to setup, works great with Wonderware System Platform and has performed flawlessly for us. The Software Toolbox team has always been quick and on the spot with their response to any of our support inquiries”
Johan Pienaar, Managing Director, Iritron
Thank You!
► Visit our stand at Expo▪ Free demo DVD with training videos & trial software▪ Discuss your integration challenges
► See our 2nd presentation on Tuesday► Contact us to discuss your challenges
▪ [email protected]▪ Kevin Rutherford
▪ John Weber• [email protected]
► Order licenses from the Wonderware South Africa team!
