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Get TOP Results from Fusing Your Devices to Wonderware

Get TOP Results from Fusing Your Devices to Wonderware. John Weber - President Kevin Rutherford – Application Engineer. Agenda. TOP Server Overview, Updates & Plans OmniServer Overview & What’s New Case Study– Duens Bakery(AMR) Case Study– Assmang Khumani (Iritron)

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Get TOP Results from Fusing Your Devices to Wonderware

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  1. Get TOP Results from Fusing Your Devices to Wonderware John Weber - President Kevin Rutherford – Application Engineer

  2. 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

  3. TOP Server Overview

  4. TOP Server Gets You Connected! Fisher ROC Fuji Flex PLCs GE Focas1 Ethernet GE SRTP Ethernet GE EGD Ethernet GE CCM Serial GE SNP GE SNP-X Serial Honeywell UDC & HC900 Idec IOTech PointScan Ethernet KraussMaffei MC4 Ethernet Mitsubishi FX Serial Programming Port Mitsubishi FX-Net Multidrop Serial Mitsubishi A Series Serial Mitsubishi A Series Ethernet Mitsubishi Q/QnA Series Ethernet Modbus RTU & ASCII Serial Master, Modbus RTU Serial RTU Slave Modbus Plus Modbus Ethernet Master & Slave ODBC Client Driver Omron Hostlink & FINS Serial Omron Process Suite Omron FINS Ethernet Optimation OptiLogic I/O Opto 22 Ethernet Oracle MES Connector Plug-in Oracle MOC Plug-in Partlow ASCII Philips PC8/PC20 Profibus (Hilscher Universal) Red Prairie Logistics Systems Sattbus & Sattbus Ethernet Scanivalve Ethernet Siemens S5 AS-511 Siemens 3964R Siemens S7-200 PPI & Modem Siemens S7-300/400 MPI Siemens S7-200/300/400 Ethernet Siemens S7-300 Ethernet Slave Simatic/TI 5x5 Serial & Ethernet Simatic/TI Unilink TIWAY Host Adapter Driver SIXNET UDR & EtherTRAK Ethernet SquareD Serial System Monitor Driver Telemecanique Unitelway Thermowestronics Serial & Ethernet Torque Tool Ethernet Driver Toshiba PLCs Serial & Ethernet Toyopuc PC2 Serial Toyopuc PC2/PC3 Ethernet Triconex TSAA Ethernet User Configurable Driver Wago 750 Ethernet I/O Wonderware Intouch Client Driver Yaskawa MemoBus Plus Yaskawa MP Serial & Ethernet Yokogawa CX Yokogawa DX100/200 & Darwin Serial Yokogawa DX(P)100/200 Yokogawa Darwin Ethernet Yokogawa DXP Yokogawa HR Yokogawa MW Yokogawa MX Yokogawa YS100 Serial AB Bulletin 1609 UPS AB Bulletin 900 Temp. Controllers AB DF1 Full & Half-Duplex Serial AB Radio Modem AB Data Highway Plus (DH+) AB PLC5,SLC5/05 Ethernet AB 1761-NET ENI AB ControlLogix Ethernet & Gateway AB CompactLogix, FlexLogix Advanced Simulator Analog Devices 6B Aromat Serial & Ethernet Automation Direct Serial DirectNet Automation Direct Serial K-Sequence Automation Direct ECOM Ethernet Automation Direct EBC Ethernet BACnet Bailey Fisher & Porter Beckhoff TwinCAT (ADS API) Busware Ethernet I/O Contrex/Fenner CX1000 Contrex/Fenner M Series Cutler Hammer D50/100 Cutler Hammer ELC Ethernet Cutler Hammer ELC Serial Dataforth isoLynx DDE Server to OPC Client Bridge DeviceNet (Hilscher Universal) DNP Serial & Ethernet Suite

  5. It’s About Reducing Engineering + Startup Time and Saving Money 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

  6. 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

  7. OPC, Suitelink, DDE TOP Server OPC & I/O Server Beckhoff TwinCAT Ethernet 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 • 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!

  8. TOP ServerBeckhoff TwinCAT Ethernet • Connectivity to TwinCAT Soft PLC’s or Bus Terminal Controllers

  9. TOP ServerBeckhoff TwinCAT Ethernet • Configurable Ports Enable Connectivity to Up to Four Runtime Engines on the Same TwinCAT Controller

  10. TOP ServerBeckhoff TwinCAT Ethernet • Tag Import from Device or Configuration File • Benefits • Convenient • Flexible (Online or Offline) • Guarantees Correct Syntax

  11. TOP ServerBeckhoff TwinCAT Ethernet • OPC Item Filtering on Tag Import (Online or Offline) • Benefits • Ease of Conversion • Saves Time on Import • Eliminates Unnecessary Tags on Import

  12. 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… OPC, Suitelink, DDE TOP Server OPC & I/O Server System Monitor Driver TOP ServerSystem Monitor Benefit: Provide your HMI operators with critical performance information about the underlying systems your software is running on so they can keep them running!

  13. 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

  14. WonderwareInTouch Suitelink= Easy! PLC Drivers TOP Server OPC & I/O Server OPC Client Driver OPC Server Vendor A OPC Server Vendor B OPC Server Vendor C Additional New Drivers • OPC DA Client Driver • Connect to OPC DA Servers supporting OPC DA 1.0 and 2.0 • SNMP Suite • SNMP Driver (SNMP Managed Devices) • Ping Driver (Unmanaged Devices) • Benefits • Knowledge at Point of Action • Faster Troubleshooting • Increased Uptime • Benefits • Reduced Integration Costs • Increased Choices for Suitelink Connections

  15. 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 • Provides Useful Calculations without Scripting • Saves Time!

  16. 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

  17. TCP/IP connection Configuration – No changes from the way you do it now! Runtime separated from config 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

  18. 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

  19. 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 NOTa 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

  20. 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

  21. OmniServer Professional: Expanding the Possibilities… • OmniServer Wedges Enable Solutions • Text File Wedge • Database Wedge • Keyboard Wedge • E-Mail Wedge (New!)

  22. 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!

  23. OmniServer V2.6: New Features • Removed NetDDE Dependency • Necessary for Systems Requiring NetDDE to be Disabled

  24. OmniServer V2.6: New Features • TCP Keep Alive • Useful for Maintaining Unsolicited Connectivity to TCP Devices supporting this functionality

  25. OmniServer V2.6: New Features • Increased Logger Buffer Size • Useful For Capturing All Diagnostic Data

  26. OmniServer V2.6: New Features • Enhanced Viewability in I/O Monitor and Logger • Configurable Fonts • Shaded Line Address Background (Configurable)

  27. 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

  28. OmniServer V2.6: New Features • New Email Client Wedge (Professional Version) • Send Email/SMS Notifications

  29. OmniServer V2.6: New Features • Need to Keep Count of How Many Times a Command/Request has Completed? • New Message Count Items

  30. 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

  31. 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

  32. 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)

  33. Barcode Scanner Moxa Ethernet Serial OmniServer I/O Servers Case Study – PepClo & AMR

  34. Case Study – PepClo & AMR

  35. 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

  36. Case Study – Duens Bakery (Epping) & AMR

  37. 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

  38. 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

  39. What is ASSMANG Khumani? On-Grade W&S Sample Tower Thickener HPGR Main Plant Paste Thickener Jig Plant Overland Conveyor Primary Crusher Off-Grade W&S ROM Stockpiles

  40. ASSMANG KhumaniArchitecture

  41. 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

  42. 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

  43. 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 • support@softwaretoolbox.com • Kevin Rutherford • krutherford@softwaretoolbox.com • John Weber • jweber@softwaretoolbox.com • Order licenses from the Wonderware South Africa team!

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