Exponentially Great Results Require the Right “Box of Tricks”

1. Exponentially Great Results Require the Right “Box of Tricks” John Weber - President Kevin Rutherford – Applications Engineer

2. Agenda Symbol Factory ArchestrA/Gadget Wizards Information Integration Solutions Case Study – BHP Hillside/CSS Case Study - Green IT Case Study - Task Force Tips Summary

3. Symbol Factory ArchestrA Overview • Over 4,000 ArchestrA Symbols for InTouch 10 • Vector Graphics! • Resolution Independent • Deployable • Embeddable • Vertical Industries • Easily joined pipe pieces • Over 60 categories • Let us focus on graphics, you focus on your system!

4. Symbol Factory for ArchestrA Licensing • Runtime Free Distribution - Licenses Only Needed for InTouch 10 Development Workstations • Works with • InTouch10 Managed • InTouch10 Managed with System Platform • No Licenses needed for deployment! • Catalog of Symbols on DVD you can pick up at our stand at the Expo • Come by Expo Stand for a 1-to-1 demo • Benefits • Reduced Engineering Time • Improved graphics quality

5. Gadget Wizards for Wonderware • Ideal for InTouch 10 Compact Edition & Wonderware Panels • Photorealistic Buttons, Lights, Switches, Meters, Sliders, Fills & Panels • Economical - Runtime free licensing

6. Is this you daring to face your challenges without the proper tools? Data Integration Challenges Connect to non-Wonderware MES databases Connect Live OPC Data to Excel Bridge Data Between OPC Servers? Log to non- InSQL/ Historian Databases Move data w/o DCOM? Monitor & Advise if Processes stop or restart Connect OPC to non-Windows OS?

7. The Swiss Army Knife of OPC!The Perfect Tool to Leverage Your ArchestrA Investments Data Integration Solutions

8. Multiple & Varied Data Sources OPC Clients OPC Data Aggregation Without Data Aggregation… • Multiple Data Sources & Clients • Each Client makes it’s own connection to each OPC Server • Redundant data flow • High network utilization, negative impact on control network

9. OPC DataHub OPC Clients Multiple & Varied Data Sources OPC DataHub AggregationWith Aggregation • Reduced # Connections • Common connection for multiple data sources • Efficient data flow • Benefits: • Unified data • Controllable update rates • Isolate control network from unruly client applications • Limit # of OPC connections • Common tag naming from projects • Reduce network traffic • Improve system performance • Overcome OPC server or client limitations • Single separable point of troubleshooting for clients • Save money on OPC client & server licensing (Hint – ABB robotics)

10. PC – 1 OPC Client COM run-time COM run-time OPC Client Security Provider Security Provider OPC without TunnellingFull of Challenges • OPC remote connections without tunneling • Many points of failure • Forget working through firewalls • Does not recover well from network issues I want to connect to you X My user name is “vernon_koekoemoer” and password is “bleddie_lekker” Or you might get: Han Weg – this is a no Vernon Zone! Yes, you are on my list… I will grant you access! Jislaaik, you are so last year…I’ll check my access list just now PC – 2 OPC Server Howzit boet: Tell me your login name and password! OPC Server

11. 3 Steps to Tunnelling with OPC DataHub • Step 1: Connect Master to OPC Server • Step 2: Connect Master to Slave • Step 3: Connect OPC Client to Slave Or… Windows NT, 2000, XP, Vista, or 2008 Or… Windows NT, 2000, Vista, 2003, or 2008

12. OPC TunnellingWhy Tunnel with DataHub? • Clean Network Interruption Handling • Heartbeat and reconnect settings • OPC transactions all local • Reduce Network Traffic for Low Bandwidth Connections • No polling – event driven transfers • Single connection for multiple tunnels • Improve System Performance & Reliability • Mirrors data – both side share data • Clients connected to OPC DataHub always get an answer • Non-blocking calls

13. DatabaseServer OPC Server TCP/IPTunnel OPC Tunnelling Why Tunnel with DataHub? • Increase Data security (passwords & SSL) • Connecting to Non-Windows Systems • Multiple clients on same PC, • One remote connection to remote OPC sources, managed by OPC DataHub • Competing solutions N clients = N connections • Connect from NT forward to any current Windows OS • OPC DataHub tunnels DATA • Any data source – OPC DA, DDE, ODBC • Any data that DataHub can read • Competing solutions tunnel only OPC

14. OPC Tunnelling But wait – can’t I use these… • VPN - Does not solve problems of • DCOM, Network stability, bandwidth and crossing domains – only provides security • OPC XML/DA • Not secure, more overhead, not for high speed, limited products, OPC UA replaces XML/DA • OPC UA • Requires all products involved to support it • Only tunnels OPC • You can use DataHub TODAY! and it will be adding OPC UA to give you more choices • Benefits of OPC DataHub Tunnelling • Tunnel any type of data • Recover from network issues easily • All other features of DataHub included free • Fast – 30 to 50k points/sec in field, have done 100k in test • Less time on DCOM = More time on things that generate profits

15. OPC DataHubSystem Monitor Function • Monitors any windows performance monitor counter & makes it available via OPC, web, & can alarm/notify off of it • Combine with tunnelling to monitor remote systems

16. Multiple & Varied Data Sources OPC DataHub Send message based on Conditions and Triggers from any source OPC DataHub Email / SMS Notifications • Easy to configure • Flexible • Get data from almost any source

17. Drag & Drop DDE Connections to OPC DataHub Anyone’s Desktop PC OPC Data HubConnecting Excel to OPC • Value – Quality – Timestamp • Array tag support • Combine with tunnelling for easy remote data access! • Writes without scripting

18. DataHub ConnectorsMore Sources = More Solutions • OPC DA • Acts and OPC Server and OPC Client • DDE • Acts as a Local DDE Client or Server • ODBC • Can write to ODBC systems or Read from using scripting • API’s – lets you make TCP connections • C++ - Windows or Linux • JAVA – support web browser applications • .NET – C#, but works with any • TCP Socket connection with DataHub protocol • Linux/QNX via Cascade Data Hub • Connect to your custom application Now that we have all this data into the DataHub – what if we want to move it between systems?

19. X DA Server DA Server Bridging Solutions: Moving Data Doesn’t Have to Be Like Mountains • What Can Bridging Mean? • Simple Data Exchange Between Control Systems • Data Exchange and Manipulation Between Systems • Timed or Triggered Data Exchange between Control Systems • Data Exchange Between HMI Systems OPC Bridging Tool Control System A (DCS / PLC / Etc.) Control System B (DCS / PLC / Etc.)

20. Bridging Solutions: Moving Data Doesn’t Have to Be Like Mountains • Traditional Solutions • Scripting in the SCADA/HMI • Read from one system • Write to the other system • Scripted calculations or formulas to modify the data • Custom Application • Development Expertise • Scripting • Resulting in: • More Time • More Money

21. Bridging Data Made Easy • Software Toolbox Solutions • OPC Data Hub • On Change Transfers Only (without scripting) • Checkbox Configuration for Forward/Inverse Transfers • Simple Linear Transformations (Multiply/Add) • OPC Gateway • On Change/Polled/Triggered Data Transfer • Complex Calculations/Transformations on Source Values

22. Bridging with OPC Data Hub • Move Data Between Many Different Disparate Systems • Email/SMS Notifications • Avoid DCOM via Tunnelling

23. OPC DataHub: Diversity of Connection Types • OPC DA • Acts and OPC Server and OPC Client • DDE • Acts as a Local DDE Client or Server • ODBC • Can write to ODBC systems or Read from using scripting • API’s – lets you make TCP connections • C++ - Windows or Linux • JAVA – support web browser applications • .NET – C#, but works with any • TCP Socket connection with DataHub protocol • Linux/QNX via Cascade Data Hub Bottomline: Once you get the data into OPC Data Hub – You can move it ANYWHERE!!!

24. Bridging Solutions: OPC Gateway • OPC-to-OPC Bridging • Data Transfers via: • Data Change Events • Specified Polling Period • Monitored Item Condition • Data Transformations • Simple & Complex • Wide range of Mathematical Operators to use for calculations • Transform data values prior to transfer

25. OPC Gateway: Update Methods • Multiple Update Methods Available • On Data Change • Polled • Monitored Item Trigger

26. OPC Gateway: Transformations • Simple & Complex Calculations • Formulas • Conversion to Engineering Units • Scaling • Test Transform Expressions • Confirm that your formula has the desired result

27. OPC Data Hub & OPC Gateway: How to Choose

28. Case Study – CSS & BHP Billiton Hillside • Cast first metal June 1995. • 685 000 tons per annum. • Largest smelter in the southern hemisphere • One of the world's most advanced and efficient smelters • Major Wonderware User

29. Case Study – CSS & BHP Billiton Over 230 PLCs Over 230 000 tags! 1 second scan rates Entire Hillside facility on TOP Server

30. InTouch View Nodes Redundant I/O Servers Topserver Redundant Historian Servers Mass Auto Save Server Case Study – CSS & BHP BillitonSystem Detail

31. 4 systems/line, 5 lines • Skimmer • Stacker • Label Applicator • Gantry TOP Server OPC Client Driver TOP Server OPC Client Driver • Data needed: • Position • Status • Sequence • Fault Status • Used in Paste Plant for anode production • Adjusts setpoints to adapt process • Need data on control status, setpoints, process variables, and fault indications Case Study – CSS & BHP Billiton2009 System Improvements Problem – ZAR 200 000 For non local OPC connections!

32. Send messages & reports based on Conditions and Triggers from any source ODBC OPC DataHub Case Study – CSS & BHP Billiton2009 System Improvements • Added OPC DataHub to do notifications directly from TOP Server AB Suite • Monitoring about 100 points • Plans for same in other 3 plant areas • Future: Direct connect to Oracle DB for existing plant MES system – no added cost!

33. Green IT - Monitoring Data Center HVAC Systems • System Integrator • Industry – IT Data Center Management • Background • Data centers accounted for 1.2% of energy used by the United States in 2005 and is expected to be 2.5% by 2011. • Objective • Minimize cost of running Data Centers. • Key requirements • Allow operators to view a graphical interface with real-time data.

34. Green IT - Monitoring Data Center HVAC Systems • Lower Energy Cost with Real-time Data • Operating at higher temperatures • Controlling air flow between server rack aisles • Using cold outside air for cooling

35. Case Study – Task Force Tips • Problem • Robotic picker • Controlled by COBOL program on a Linux system • Slow response times • High downtime • Solution – revamp the robot • AB ControlLogix PLC & Servos • Challenge! • Can’t rewrite the pick program easily • Must interface it with the ControlLogix • How????

36. Case Study – Task Force Tips • Benefits • Improved efficiency • Nearly eliminated downtime “It is magical what this has done for our application. The OPC DataHub and TOP Server allow the PLC to share any data point. The possibilities that this opens up for real-time connections between PLCs and corporate data processing systems will bend your imagination. It is so much faster than what we had before! Now we are trying to find other problems to solve. This solution has been VERY effective for our business results.” Stuart MacMillan – President, Task Force Tips

37. Dankie - Thank You! • Visit our stand at Expo • Free demo DVD with training videos & trial software • Discuss your integration challenges • Contact us to discuss your challenges • support@softwaretoolbox.com • Kevin Rutherford • krutherford@softwaretoolbox.com • John Weber • jweber@softwaretoolbox.com • Order licenses from the Wonderware South Africa team!