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Start here if you have never integrated PLCcontrol with the FactorySuite, or just want to quickly understand connectivity options. The following communication options are discussed:
Wonderware Products
For serial communications: AB Serial I/O Server For DH, DH+ and DH485 communications: AB 1784-KT I/O Server SST 5136-SD I/O Server ABDHPlus DAServer For Ethernet communications: ControlLogix Gateway I/O Server ABCIP DAServer AB Ethernet Direct I/O Server ABTCP DAServer
3rd Party
INGEAR OPC DA Server for AllenBradley
OEM
Rockwell Automation RSLinx
foreign protocol translation service into FastDDE and SuiteLink, the native protocols for the FactorySuite, (and in the case of DAServers also into OPC DA). I/O Servers and DAServers also manage (i.e., optimize) the communications between plant floor devices or industrial networks and MS Windows-based applications. Additionally, a number I/O Servers and OPC Servers are available from third party companies. Most DAServers and I/O Servers can be configured to regularly poll PLCs for the most up-
to-date sensor value (known as request/response data acquisition), or wait for the PLC to push data only when the sensor value changes (known as the unsolicited data acquisition). The size and complexity of the system greatly determines where the DAServer or I/O Server should be installed. On small systems, the I/O Server or DAServer and the client application(s) typically run on a single computer. Larger systems often employ distributed computing to increase reliability and performance.
Note NetDDE should only be used for legacy support. SuiteLink and OPC protocols provide far greater performance and robustness capabilities. SuiteLink is Wonderwares standard communication protocol. Wonderware SuiteLink uses a TCP/IP based protocol. SuiteLink is designed specifically to meet industrial needs, such as data integrity, high-throughput, and easier diagnostics. This protocol standard is only supported on Microsoft Windows NT 4.0, Windows 2000 and Windows XP Professional. SuiteLink was designed specifically for high speed industrial applications and provides the following features: Value Time Quality (VTQ) places a timestamp and quality indicator on all data values delivered to VTQ-aware clients. Extensive diagnostics of the data throughput, the server loading, computer resource consumption, and network transport are made accessible through the Microsoft Windows NT operating system performance monitor. This feature is critical for the scheme and maintenance of distributed industrial networks. Consistent high data volumes can be maintained between applications regardless if the applications are on a single node or distributed over a large node count. The network transport protocol is TCP/IP using Microsofts standard WinSock interface. OLE for Process Control (OPC) is a standard set of interfaces, properties, and methods that extend Microsofts OLE and COM technologies for use in process control applications. The implementation of the OPC DA Specification for the FactorySuite comprises the following components: Wonderware OPCLink I/O Server, which is a DDE/FastDDE/SuiteLink to OPC gateway for all DDE/SuiteLink Wonderware clients that need to communicate with an OPC Data Access Server. Wonderware OPC TagCreator, which is used from within InTouch WindowMaker to browse registered OPC Data Access Servers on the network and generate InTouch tags linked to OPC items. Wonderware DAServers, which are native OPC DA v2.05 servers and also are SuiteLink/DDE
servers compatible with all Wonderware DDE/SuiteLink clients, FactorySuite A clients and OPC Clients. ArchestrA Application Server OPC Client, ArchestrAs native OPC Device Integration Object for connectivity to OPC DA Servers. Note When defining an InTouch I/O Address, OPCLink requires a special syntax for the Item Name. Each item name must be prefixed with a d, r, i, or m to indicate a discrete, real, integer, or message value, respectively. For more information on using and setting up any of these protocols, see your FactorySuite Administrators Guide.
There are many servers on the market. Deciding which server to use comes down to the one that best answers the following questions: 1. Can the server communicate with the controller? 2. Is the server scalable for my application? 3. Does the server provide simultaneous connectivity via multiple network protocols?
4. Does the server include additional features important to me? Once a controller and factory floor network is chosen, use the tables included at the end of this note to identify supported servers. Remember some protocols require special network interface cards (for example, a 1784-KT card for DH+). Another important qualification is if the server provides the desired scalability. What does scalability mean? Scalability refers to the ability of the server to handle the required polling rate(s), the maximum number of connections, and ease-ofuse. It also addresses the level of openness if you want to use OPC or connectivity to other systems and protocols. A scalable architecture provides an effective means of managing your factory floor network to meet the changing needs of your operation. Some servers provide features beyond simple Topic definitions and connectivity. You may want a simulation mode, data monitoring or Tagname browsing capability. Added features usually mean added costs, so be sure to carefully plan your system and identify the needs early in the design cycle. The best approach may be a combination of several servers. For example, the architecture below shows a feature-rich and cost effective solution. As shown below, the Engineering Desk has the ABCIP DAServer installed to provide direct communications to a ControlLogix system. The DASABCIP DAServer does not require RSLinx as middleware to communicate with ControlLogix PLCs. Additionally, this computer hosts the DAServer Manager, which allows remote monitoring and diagnostics for all DAServers on the network.
Out on the plant floor, where only connectivity is required, the ABDHPlus DAServer can be used for DH+ connectivity to the PLC5 controller.
slow response time. Therefore, you should set the Update Interval to a value that makes sense according to the nature of the tags in the topic. Reasonable values for operator displays are between 300 to 1200 ms. This allows time for the value to be read from the PLC, transferred to the I/O Server or DAServer, copied to the HMI workstation and refresh the monitor screen. The best approach is to create multiple topics for each device, setting the Update Interval to different values, and then assign different items to different topics depending how quickly the values change, and how quickly you want to see an update of those changes. For example, points that indicate an alarm condition certainly should be polled more frequently then less-important measurements. Safety, human ergonomics and business drivers are all part of the equation when determining appropriate Update Intervals. Alternatively, you can rely on the PLC to inform the server when a critical event has occurred. This approach is called Unsolicited Messaging. Unsolicited Messaging is a programming technique (i.e., using the MSG or PLC-5 Typed Write commands in ladder logic) that generates a reply message to a poll that never occurred. In other words, it can answer the I/O servers question before the server has chance to ask it. Unsolicited Messaging should be restricted to monitoring points that are important, but change very infrequently, such as alarm bits or batch completion states. In the case of alarms, you may require very fast updates when they do change, as due to the nature of the tags you may want to be immediately notified of the change but realistically you may only see them change once a day or week, at best. Because you do not know when this may happen, you may be inclined to set the Update Interval to some small value, approaching 0 milliseconds, which may impact overall system performance. It is recommended that a separate topic be created to group tags used for unsolicited messages.
Sample Architectures
The following architectures demonstrate popular ways to integrate Allen-Bradley controllers with the FactorySuite, namely: Serial communications via: the Wonderware AB Serial I/O Server. DH, DH+ and DH485 communications via: the Wonderware AB1784-KT I/O Server. the Wonderware SST 5136-SD I/O Server. the Wonderware ABDHPlus DAServer. Ethernet communications via: the Wonderware AB Ethernet Direct I/O Server. the Wonderware ABTCP DAServer. the Wonderware ControlLogix I/O Server. the Wonderware ABCIP DAServer Communications via: the InGearTM OPC server Rockwells RSLinxTM Refer to these samples to help choose the best approach for your application. If your application is not represented here, please ask your local Wonderware Distributor for additional connectivity options.
The Wonderware Allen Bradley 1784-KT I/O Server has been a popular choice for many years. It allows FactorySuite and other MS Windows application programs access to data in selected PLCs attached to the DH+, DH, and DH485 networks. The server requires the use of an AllenBradley 1784-KT, 1784-KTX, 1784-KTXD, 1784-PKTx, or 1784-PKTxD card to communicate with the DH+ (Data Highway Plus) network. The server can access data in PLC-2, PLC-3, PLC-5, PLC-5/250, and SLC 500 either directly or indirectly (depending on the PLC type) through the Data Highway Plus network.
The Wonderware Allen-Bradley Serial I/O Server is a Microsoft Windows application program that acts as a communication protocol server. It allows other MS-Windows application programs access to data from certain Allen-Bradley PLCs either directly or indirectly (using the Data Highway, Data Highway Plus or DH485 with the appropriate Allen-Bradley communications interfaces.
DH+ Communications via the Wonderware SST 5136-SD I/O Server (PLC-2, PLC-3, PLC-5, PLC-5/250 and SLC 500)
DH+ Communications via the Wonderware AB 1784-KT I/O Server (PLC-2, PLC-3, PLC-5, PLC-5/250 and SLC 500)
The Wonderware SST 5136-SD I/O Server allows FactorySuite and other Windows application programs access to data in PLCs attached to the Data Highway Plus (DH or DH+) networks. The server requires the use of a SST 5136-SD card. The server can access data in PLC-2, PLC-3, PLC-5, PLC5/250 and SLC-500 PLCs through the Data Highway/Plus (DH or DH+) networks.
Wonderware Allen-Bradley Ethernet Direct I/O Server is a great choice. It allows the FactorySuite and other MS-Windows applications access to data from certain PLCs attached to an Ethernet network running the Allen-Bradley Client Server (CSP) Protocol.
The new Wonderware Allen Bradley ABDHPlus DAServer provides FactorySuite, OPC clients and other MS-Windows application direct and indirect connectivity to the Allen-Bradley families of PLC-5 and SLC-500 controllers attached to a Data Highway Plus network directly or through the corresponding bridge module. If you are leveraging Ethernet as your communications process medium and only have PLC-5/xE and/or SLC 5/05 controllers, the Wonderware Allen-Bradley DASABTCP DAServer is a great choice. It allows the FactorySuite, OPC clients and other MS-Windows applications access to data from certain PLCs attached to an Ethernet network running the Allen-Bradley Client Server (CSP) Protocol.
Ethernet Communications (CSP) via the Ethernet Direct I/O Server. (PLC-5/x E, SLC-5/05)
If you are leveraging Ethernet as your communications process medium and only have PLC-5/xE and/or SLC 5/05 controllers, the
If you are leveraging Ethernet as your communications process medium and need connection to a ControlLogix Gateway or 5000 Controller, the Wonderware Allen-Bradley ControlLogix I/O Server is a great choice. It allows the FactorySuite and other MS-Windows applications access to data from certain PLCs
applications access to data from certain PLCs attached to an Ethernet network running the new Allen-Bradley Control and Information (CIP) protocol. Note ControlLogix Native Tag addressing not supported in this server.
If you are leveraging Ethernet as your communications process medium and need connection to a ControlLogix 5000 Controller, the Wonderware Allen-Bradley ControlLogix DA Server is a great choice. It allows the FactorySuite, OPC clients and other MS-Windows applications access to data from certain PLCs attached to an
Ethernet network running the new Allen-Bradley Control and Information (CIP) protocol using ControlLogix native addressing. Note PLC5 emulation is not supported by the ABCIP DAServer. ControlLogix native tag addressing is.
Note When interfacing Wonderware products with RSLinx via OPCLink, there are several simple things you can do to dramatically improve performance: 1. Confirm you are using the most recent available released versions of RSLinx and OPCLink. 2. Use a single instance of RSLinx to optimize communication packets. Multiple instances of Rslinx to a single ControlLogix processor will prevent the optimization routines to operate correctly. 3. Group tags into topics of similar polling rate requirements. See Choosing the Right Data Polling Rate. 4. Leverage register addressing in blocks for the PLC ladder-logic to minimize the number of packets needed to be transmitted. 5. If you notice slow data updates when switching windows, use the Rockwell OPC Client Tool to put the tags on continuous scan and to avoid occasional read/write errors. For additional strategies and recommendations, refer to the RSLinx 2.1 Service Pack Notes: ControlLogix Optimization document available from Rockwell Software. http://www.software.rockwell.com/download/ comms/rslinx/clx_perf.zip For more information regarding RSLinx, refer to the Rockwell Automation website: http://www.software.rockwell.com/rslinx.
RSLinx, from Rockwell Automation, supports communication services for all Allen-Bradley controllers. Both the OEM and Professional versions provide DDE and OPC connectivity, which is required to use RSLinx as a "middleware" component for the FactorySuite. In small systems where the HMI and RSLinx run on the same computer, use DDE to transfer data. As your system expands and clients are distributed on the control network, install OPCLink on the same computer running RSLinx.
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INGEAR OPC DA Server for Allen-Bradley (Any ControlLogix, PLC-5, SLC-5, or MicroLogix)
The INGEAR OPC DA Server for AllenBradley is a Microsoft Windows application program that acts as a communication protocol server. It allows other MS-Windows application programs access to data from certain Allen-Bradley PLCs using the OPC Foundation protocol. INGEAR fully supports native tag addressing for ControlLogix and has excellent performance and management tools, including a Simulation Mode. INGEAR is a registered Wonderware Partner and additional information is available on the Wonderware website, or visit INGEAR directly at http://ww.ingear.cimquest.com/allen-br.htm.
Note The Wonderware Allen-Bradley ControlLogix Gateway and WWRSLinx I/O Servers require the use of Rockwell's RSLinxTM as middleware.
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PLC-5 Processors
Number of Remote/Extended Local-I/O/DH+ Ports 1 DH+/Remote I/O (Adaptor Scan) 1 DH+/Remote I/O (Adaptor Scan) 2 DH+/Remote I/O (Adaptor Scan) 4 DH+/Remote I/O (Adaptor Scan) 2 DH+/Remote I/O (Adaptor Scan) 1 Extended Local I/O 4 DH+/Remote I/O (Adaptor Scan) 2 DH+/Remote I/O (Adaptor Scan) 1 Extended Local I/O 4 DH+/Remote I/O (Adaptor Scan) 1 DH+ 1 DH+/Remote I/O (Adaptor Scan) 4 DH+/Remote I/O (Adaptor Scan) 4 DH+/Remote I/O (Adaptor Scan) 1 Ethernet 1 DH+ 1 DH+/Remote I/O (Adaptor Scan) 1 Ethernet 2 DH+/Remote I/O (Adaptor Scan) 1 Ethernet 2 DH+/Remote I/O (Adaptor Scan) PLC-5/40E (1785-L40E) PLC-5/80E (1785-L80E) ABKF2, AB1784KT, SS5136SD, ABTCP ABKF2, AB1784KT, SS5136SD, ABTCP PLC-5/80 (1785-L80B) PLC-5/26 (1785-L26B) PLC-5/46 (1785-L46B) PLC-5/86 (1785-L86B) PLC-5/20E (1785-L20E) ABKF2, AB1784KT, SS5136SD ABKF2, AB1784KT, SS5136SD ABKF2, AB1784KT, SS5136SD ABKF2, AB1784KT, SS5136SD ABKF2, AB1784KT, SS5136SD, ABTCP PLC-5/60 (1785-L60B) PLC-5/60L (1785-L60L) ABKF2, AB1784KT, SS5136SD ABKF2, AB1784KT, SS5136SD Processor (Catalog No.) PLC-5/11 (1785-L11B) PLC-5/20 (1785-L20B) PLC-5/30 (1785-L30B) PLC-5/40 (1785-L40B) PLC-5/40L (1785-L20L) Wonderware I/O Server ABKF2, AB1784KT, SS5136SD ABKF2, AB1784KT, SS5136SD ABKF2, AB1784KT, SS5136SD ABKF2, AB1784KT, SS5136SD ABKF2, AB1784KT, SS5136SD Notes
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RSLinx + OPCLink
RSLinx + OPCLink
RSLinx + OPCLink
RSLinx + OPCLink
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1. SLC 500 or SLC 5/01 processors can only receive messages and send reply messages to command messages sent from other nodes on the DH-485 network; it cannot initiate communication. 2. SLC 5/03 has an RS-232 port, which can also be configured for a DH-485 network, enabling the
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Notes
OPCLink+ RSLinx
DeviceNet I/O1
Logix5555
ABCIP, DASABCIP2,3
OPCLink+ RSLinx
DeviceNet I/O1
1. These are not on-board ports. They are available only thru communication interface modules. 2. In its first releases (v1.0 and v1.1) our ABCIP DAServer supports only direct connection to ControlLogix controllers using CIP over EtherNet/IP
communications. It does not support the use of the ControlLogix as gateway to sub-networks (/ControlNet, DeviceNet, DH+, etc.). This capability will be added to subsequent releases. 3. The ABCIP DAServer does not require RSLinx as middleware.
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References
For more information, please refer to the User Guides, help files and release notes for the corresponding I/O Servers and/or DAServers. Additionally, the following Allen-Bradley related Tech Notes are available for download from our website, http://www.wonderware.com/Support/MMI/ technotes.htm.
Title "Troubleshooting Wonderware Serial DDE Servers" "Troubleshooting Allen-Bradley Status Code (STS) Error Messages" "Troubleshooting Allen-Bradley Status Code (STS) Error Messages" "Configuring the AB1784KT DDE Server with the 1784-KTx card" "Configuring the ABTCP DDE Server on Windows NT 4.0" "Configuring the WWRSLinx I/O Server for the AB1784-KT communications card" "Configuring and using OPCLink with the RSLinx OPC server under Windows NT 4.0" "Configuring and using Emulation Mode with the ABCIP (ControlLogix) I/O Server" "Configuring the INGEAR Allen Bradley DA OPC Server, OPCLink, and OPC Tag Browser" "Configuring ABTCP DAServer to Communicate with AB PLC5 Using SuiteLink Protocol" "Configuring the AB1784KT I/O Server With the PKTX Card"
Contact Wonderware or your local Distributor for information about software products for industrial automation. Wonderware Corporation 26561 Rancho Parkway South, Lake Forest, CA 92630 Tel: (949) 727-3200 Fax: (949) 727-3270 www.wonderware.com
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