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)
Case Study – Pepclo (AMR)
Summary
TOP Server Overview
TOP Server Gets You Connected!
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
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
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 Server
Beckhoff TwinCAT Ethernet
► Devices Supported
▪ TwinCAT PLC
▪ Bus Couplers (BC9xxx/BX9xxx)
Why
Use ADS
ThisAPI
Driver
instead
► Uses
Beckhoff
for best
of Beckhoff’s
performance
OPC Server?
► Built with support of Beckhoff
OPC,
Germany,
US,than
& South
Africa OPC Server
• Faster
Beckhoff
Suitelink,
► Structured Tags/Symbolic
DDE
•
During
Startup
Addressing
TOP Server OPC & I/O Server
► Automatic
database
generation
• After
Startup
Beckhoff TwinCAT Ethernet
▪ From device if available
▪ •From
*tpy file
for offline =
import
Native
Suitelink
No FS Gateway/OPC Link!
▪ Structure import support in online
►
offline mode,
withhere
filtering
using
•&
Beta
Testing
at
Beckhoff South Africa
Beckhoff style
showed
it was to
just
easier to configure!
Support
for connecting
multiple
Beckhoff Runtime engines in same
controller
► AMS Routing Support
TOP Server
Beckhoff TwinCAT Ethernet
► Connectivity to TwinCAT Soft PLC’s or Bus Terminal
Controllers
TOP Server
Beckhoff TwinCAT Ethernet
► Configurable Ports Enable Connectivity to Up to Four
Runtime Engines on the Same TwinCAT Controller
TOP Server
Beckhoff TwinCAT Ethernet
► Tag Import from Device or Configuration File
Benefits
• Convenient
• Flexible (Online or Offline)
• Guarantees Correct Syntax
TOP Server
Beckhoff TwinCAT Ethernet
► OPC Item Filtering on Tag Import (Online or Offline)
Benefits
• Ease of Conversion
• Saves Time on Import
• Eliminates Unnecessary
Tags on Import
TOP Server
System Monitor
► Uses Microsoft
Performance Data
Helper API
Benefit:
► Item Import Browser
allows Auto Provide
Tag
your HMI
OPC,
Generation
Suitelink,
operators
with
critical
DDE
▪ Performance Objects
▪ Instances performance information
TOP Server OPC & I/O Server
▪ Counters about the underlying
System Monitor Driver
► Monitor Health
of
systems
your software is
Underlying Systems
running on so they can
▪ Network Interfaces
keep them running!
▪ Memory Utilization
▪ CPU Usage
▪ So Much More…
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
Wonderware
InTouch
Benefits
• Knowledge at Point of Action
• Faster Troubleshooting
• Increased Uptime
Benefits
Suitelink=
Easy!
PLC Drivers Integration Costs
• Reduced
•
TOP Server OPC & I/O Server
Increased
Choices
OPC Client
Driver for
Suitelink Connections
OPC Server
Vendor A
OPC Server
Vendor B
OPC Server
Vendor C
Additional New Drivers
► Torque Tool Ethernet Driver
Benefits
▪ Torque Tool Open Protocol
• Expands TOP Server to
QC Data Collection Realm
• Expands TOP Server
Reach
► Advanced Tag Plug-in • Reduces Integration Costs
Benefits
▪ Mathematical operations on any existing tags
• 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
TCP/IP connection
▪ Windows
Configuration – Vista (includes service support)
No changes from2008
the
▪ Windows
Server (includes service support)
way you do it now!
▪ 64 Bit OS (Vista, 2008)
Runtime separated from config
▪ 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
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.
Such
as…
► Solves the
problem
of polling for multiple
devices.•Bar Code Readers
•Weigh Scales
► Is NOT a
replacement
for existing drivers.
•RFID
Readers
•Printers that have no drivers.
Use for devices
•Security systems
► Use OmniServer to interface computers with
•Intercom control
other computers
or devices
with other
•Video surveillance
control
devices.•Laser Markers and more…
•Serial, Ethernet, Master or Slave
OmniServer
Functionality Overview
► User-Configurable Data
Acquisition Tool
► OPC/DDE Server
▪ OPC Server Interface
▪ DDE Server Interface
Benefits
▪ FastDDE/SuiteLink
Interface
► Hardware Interfaces
• Custom drivers at a very
▪ RS-232, RS-422, RS-485
low cost
▪ Winsock (TCP/UDP/Telnet)
▪ LPT
• Improved plant integration
► Communicate to almost any
device, including custom
designed devices
• Reduced
▪ Variable length, character
▪
delimited Protocols
Known/Fixed Length protocols
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 V2.6
Summary of New Features
►
►
►
►
Vista / 2008 Support
Benefits
No NetDDE Requirements
• Forward
More
objectsProgression
– expandedwith
fromOS
512 to 2048
TCPCompatibility
“Keep Alive” signals to control the
Status bit.
• Increased Project Sizes for Enhanced
► Logger
buffer size can be change - up to 999
Scalability
kb.
Diagnostics
for
► I/O• Improved
Monitor and
Logger changes
for better
clarity.
Troubleshooting and Design
► Retry counts can now be set.
• More Flexibility and Functionality
► New Email Wedge for Professional Version.
► “Message Count” items for Host, Unsolicited,
and Error Messages.
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
Barcode
Scanner
Moxa
Ethernet
Serial
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
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?
On-Grade W&S
Sample
Tower
Thickener
HPGR
Main
Plant
Paste
Thickener
Jig
Overland
Plant
Conveyor
Primary Off-Grade W&S
Crusher
ROM Stockpiles
ASSMANG Khumani
Architecture
ASSMANG Khumani
Galaxy: 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 Khumani
IO 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
“The TOP Server AB Suite was easy to setup,
works great with Wonderware System
▪ 2.0 GHz Core 2 Duo
Platform and has performed flawlessly for us.
▪ 2GB of RAM
The Software Toolbox team has always been
quick and on the spot with their response to
▪ CPU Utilisation:
• AOS1 – Max 24%
• AOS2 – Max 15%
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
▪ support@softwaretoolbox.com
▪ Kevin Rutherford
• krutherford@softwaretoolbox.com
▪ John Weber
• jweber@softwaretoolbox.com
► Order licenses from the Wonderware South Africa
team!