Design, Operate, and Maintain Your Logix/Factory Talk HMI System

Transcription

1 Design, Operate, and Maintain Your Logix/Factory Talk HMI System Fred Habenschuss & Tim Menge Rev 5058-CO900C

2 Design, Operate, and Maintain Your Logix/Factory Talk HMI System Session Description This workshop will provide the attendees with tools and recommendations for designing, operating, and maintaining a Logix/FactoryTalk HMI system. A live demonstration on a running system will show how to use the tools available to design your system, monitor it's operational performance, and diagnose software, hardware, and network problems. The system will include the L7x controller, FactoryTalk View SE, I/O, a drive on EtherNet/IP, and a Stratix 8000 switch. Copy 2

3 Logix-based Control Architecture Traditional DCS Global Access to data Deterministic control Distributed HMI Extensive Process Library Redundancy Programmable Automation Controller Traditional PLC High speed logic Standalone operation Scalable architecture Interfaces to many devices Logix Adds Beyond Hybrid System - single platform for all control disciplines Source stored in controller, tag based NetLinx as integration infrastructure High functionality I/O: RIUP, Diagnostics, Isolation Wide range of I/O platforms: Rack-based, Distributed, Intrinsically Safe SIL 2 Rated for Critical Control Applications RA Integrated Architecture and Logix provides all the control you need in one package Copyright 2012 Rockwell Automation, Inc. All rights reservedċopy 3

4 Workshop Agenda 1. Workshop System Configuration 2. Design Recommendations and Tools 3. System Performance Monitoring Tools 4. System Maintenance Tools Copyright 2012 Rockwell Automation, Inc. All rights reservedċopy 4

5 Workshop System Configuration Software Software Loaded Factory Talk View SE (2) Data Servers RSLinx Classic RSLinx Enterprise FT Alarm Server Windows7 Counter Monitor Software RSLogix5000 L_CPU Instruction NetlInx Diags Code - Devicenet StratixAOP HTTrack software Wireshark Logix Diagnostics tool Logreader Utility EventLog Export Tool Presentation Laptop Powerpoint for Session IAB/PSE Accelerators EtherNet Capacity Tool Copyright 2012 Rockwell Automation, Inc. All rights reservedċopy 5

6 Workshop System Configuration Hardware Hardware List L73 controller EN2TR PA72 Power Supply A4 4 slot chassis DNB DeviceNet Bridge Module US05T Stratix 2000 switch XLSDNET4 Power Supply VLF02-01RA XM121 Dyn. Measurement Module D-8CFGM12 DeviceNet I/O Block P-T7C4D2 PanelView Plus 700 Hardware List EMS08T Stratix 6000 Switches 1-10 port 1783-MS10T Stratix 8000 Switch 1794-PS3 power supply Copyright 2012 Rockwell Automation, Inc. All rights reservedċopy 6

7 Design Recommendations and Tools Rev 5058-CO900C

8 Design Recommendations and Tools 8

9 Logix Selection Guides Pub.# 1756-SG001_-EN-P Pub.# 1769-SG001_-EN-P.9

10 Logix5000 Controllers Design Considerations Focused on designing a Logix application Loaded with design tips and considerations Pub.# 1756-RM094_-EN-P Downloadable from: /idc/groups/literature/documents/rm/175 6-rm094_-en-p.pdf 10

11 Example - Anatomy of a Logix Controller Two 32Bit CPUs interact to perform control Logix CPU executes application code and performs message processing Backplane CPU communicates with I/O and sends and receives data from backplane Because this CPU is operating independently from the Logix CPU, all I/O information is sent/received asynchronous to program execution 11

12 Logix Design Considerations Logix Controller Selection Tips Determine the memory requirements before selecting your Logix controller Considerations: I/O, Logic, Tag Data, ControlLogix Redundancy, future application growth, Operating System changes Additional runtime memory usage: Message processing - Buffers incoming messages RSLinx Data Handling - Storage of tag groups On-Line Edits - Storage of multiple edit rungs Graphical Trends Buffered data Tools available to help with estimation Equations available to estimate memory usage RSLogix5000 Off-line Memory Estimation capability Logix Selection guides provide memory and other specifications CompactLogix 1769-SG001_-EN-P (L2x, L3x, & L4x Controllers) ControlLogix 1756-SG001_-EN-P (L6x & L7x Controllers) 12.

13 PlantPAx Selection Guide and Reference Manual The PlantPAx Selection Guide is used to assist with equipment procurement after system requirements are defined. Pub. # PROCES-SG001_-EN-P The PlantPAx Reference Manual elaborates on what you need to know to set up a PlantPAx system, from configuring system elements to developing applications. Pub. # PROCES-RM001_-EN-P 13.

14 Factory Talk View SE System Design Recommendations - AID This document is supplemental to the View SE documentation that is installed with the software. It is intended to make system developers aware of the fundamental best-practice guidelines for designing and implementing a distributed application. Available from Rockwell s Knowledgebase under document Download the document that matches your version of the software Latest version available is: FactoryTalk View SE v6.0 (CPR9 SR3) Design Considerations b.chm 14

15 Product Selection Toolbox Applications Seen as umbrella package from which all PST applications can be launched. Used for proposal generation with catalog number validation, pricing, supplementary information, product drawings, etc. User can price to a granular level, dynamically generate spare parts, and choose services. (IAB) is for configuring Logix-based automation systems. Select hardware for applications that include controllers, I/O, networks, Powerflex drives, On- Machine cabling and wiring, motion control, and other devices. Outputs include BOMs and reports with graphics and export to ProposalWorks. Assistance in crossing competitive numbers. Gives users the ability to submit crosses directly to PST and they will provide a cross or can be located on ab.com (10 crosses at a time, no ability to submit). Provides access to thousands of drawings for AB products. Can work directly in AutoCAD or user can get CAD like drawings to add to proposals, using the ecadworks clipboard. Used by customers, sales and distributors. Application is specifically for designing MCCs. It gives a user-friendly interface for design, reducing user error and saving time. Automatically produces all documentation, allows upload to RA for ordering. Tool can maximize ratios, inertia, and mechanical alternatives for motor control applications. Heavy mathematical algorisms and calculations in background allow highly advanced optimization utilities. For MCS starters. Provides the catalog numbers, wiring diagrams, and layouts. Allows you to lay out a system and place components on a busbar where you want them. Simplified design of DIN Rails. Select and place terminal blocks on DIN rails. Application automatically selects end barriers, partition plates and will print a consolidated report. All Tools are Current update enabled. This allows users to have the most up to date applications, product, price, and supplementary information. Compares file dates on user machine to RA server, if different an update occurs. Scheduled every three weeks. 15

16 Integrated Architecture Builder - IAB Rules-based, Helps Insure Valid Configurations Performs rule-based checking for controller, I/O, network, including Ethernet capacity Comprehensive Hardware Configuration Controllers, I/O, networks, Network physical media, On- Machine cabling and end devices, Encompass Partner products, PowerFlex Drives, ArmorStarts, and more.. Detailed Hardware, Network, and Architecture Views Included in reports for presentation to customers Quickly Compare Alternative Solutions Ability to change controllers, I/O, networks, etc. to provide customer alternative configurations for comparison Create Detailed System Configuration Individual device-level configuration, including costed bill of material, graphics & customized report Integrated with other Selection Tools Export to ProposalWorks, RSLogix Architect Punch-out to Motion Analyzer, RAISE configurators Built-in Learning Aids Product documentation, lab exercises, quick starts Differentiation: Enables users to efficiently generate configurations of networks, controllers, I/O, Visualization and other devices with a bill of material Quickly create a system configuration to visualize and quote the RA solution 16 Copy 16

17 What can you configure in IAB Logix Controllers ControlLogix, CompactLogix MicroLogix Controllers Micro800 Controllers NetLinx Networks DeviceNet, ControlNet, EtherNet I/P Other Networks DH+, DH485, RIO & other Non-CIP networks. On-Machine Cabling 3-Phase, Control, & Auxiliary Power Media PlantPAx Process System Estimator - PSE Software (add to BOM) Motion Control Axes via Motion Analyzer PowerFlex Drives via RAISE configurator DeviceNet enabled devices Sensors, switches, etc. EOI/HMI PanelView, PanelView Plus, computers, etc. Encompass Partners AMCI, Hardy, HELM, HIPROM, HMS, Mettler & Toledo, Molex, OLDI, ProSoft, Pyramid Solutions, Spectrum, WRC 17 17

18 How Do I Get IAB? Product Selection Toolbox DVD PST-SG001G-EN-V (January 2011) The Internet 18

19 EtherNet/IP Capacity Tool Rev 5058-CO900C 19

20 EtherNet/IP Capacity Tool Co 20 py 20

32 RSLogix5000 as a Design Tool Off-line Controller Memory Estimation Each controller has a different memory capacity. Great tool to use before purchasing controller I/O Memory Estimate Data / Logic Estimate 32

33 Additional Memory used: RSLinx Example Application has 500 scattered integer tags on scan using the RSLinx OPC Test Client. Before tags are placed on scan. Memory consumed = 487,544 bytes After tags are placed on scan. Memory consumed = 513,520 bytes 487, ,520 = 25,976 byte difference or 5.3% more memory consumed by RSLinx. Memory is consumed when RSLinx is online and polling data. 33

34 System Performance Monitoring Tools Rev 5058-CO900C

35 System Performance Monitoring Tools Monitoring Controller Performance Task Monitor tool provided with RSLogix5000 Aid Logix 5000 Task Monitor Tool RSLogix5000 software - Minor and major faults monitoring, task and program monitoring, Controller properties page, obtaining device properties using RSLinx, etc. L_CPU and faceplates Available from KnowBase #62682 Logix controller diagnostics available to RSLogix5000 program and FTView ME/SE Stratix Add On Profile (AOP) The AOP provides easy access to configuration and diagnostics NetLinx Diagnostics sample code and Faceplates DeviceNet, ControlNet, and EtherNet faceplates on FTViewSE and PanelView Plus RSLinx Counter Monitor Performance monitoring Copyright 2012 Rockwell Automation, Inc. All rights reservedċopy 35

36 RSLogix5000 Controller / Module Properties Controller Properties Fault Information Memory Consumption Redundancy Status Module Properties Connection Status Fault Status Module Specific Information 36

37 RSLogix5000 Task and Program Properties Task Properties Task Elapsed Time Elapsed Time Between Triggers Task Overlap Count Program Properties Program Execution Time 37

38 Logix5000 Task Monitor v3.0 Tool User Tasks Tab 38

39 Logix5000 Task Monitor Tool Performance 39

40 Sample Code, AOIs, AOPs, and Faceplates PlantPAx - L_CPU AOI and faceplates Available from AID The Sample Code Library is also a great resource! 40

41 Sample Code, AOIs, AOPs, and Faceplates Stratix Add On Profile (AOP) The AOP provides easy access to configuration and diagnostics 41

42 System Maintenance Tools Rev 5058-CO900C

43 System Maintenance Tools Logix Controller diagnostics Logix5000 Task Monitor Tool Using the tool to troubleshoot system issues RSLogix5000 Software Minor and Major Fault bits how to use these for troubleshooting Connection error codes available from RSLogix5000 Help RSLogix5000 Fatal Error Handling - Knowbase ID# Networks System Ferret obtains catalog numbers and firmware revisions for networked products and creates xml file exportable to Excel EtherNet Web Pages diagnostics data available for RA EtherNet modules HTTrack and Wireshark How are these tools used to troubleshoot systems and gather data NetLinx Diagnostics sample code and Faceplates Copyright 2012 Rockwell Automation, Inc. All rights reservedċopy 43

44 System Ferret System Ferret is used to gather information for all devices on an ENET/IP, CNET, or DeviceNet network. The tool generates an XML file which can be converted to excel report like below : Download System Ferret from the Integrated Architecture Tool Page : 44

45 Ethernet Module Embedded Webpages Additional Ethernet/IP Information Available from AID

46 HTTrack HTTrack is a shareware utility to copy websites. Useful for recording Ethernet module diagnostics. Copy 46

47 Wireshark Wireshark is a shareware utility that will capture and analyze Ethernet traffic. It is useful for evaluating and troubleshooting networking problems. Copy 47

48 System Maintenance Tools cont d FactoryTalk Diagnostic Tools Factory Talk Diagnostic Viewer Factory Talk Live Data test client Predefined tags Counter Monitor Logreader / Event Logs FT Log File Collector Aid Tool for Collecting Event Log Files FT Log File Viewer Aid Eventlog Export Tool Copyright 2012 Rockwell Automation, Inc. All rights reservedċopy 48

49 FactoryTalk Diagnostics Viewer FactoryTalk Diagnostics Viewer Displays the FactoryTalk Diagnostics log in an easy to read format. Copy 49

50 Live Data Test Client Start Rockwell Software FactoryTalk Tools Rockwell Software Data Client Similar functionality to OPC Test Client, only supports Live Data and OPC. Use to check data connectivity to data servers Copyright 2011 Rockwell 50

51 Information Diagnostic items made available by ControlLogix to help you evaluate controller memory and performance. Check FactoryTalk Help for more information! Useful to provide controller diagnostics on HMI screens Also available on FT Live Data Test Client Copyright 2011 Rockwell 51

52 Counter Monitor Tool Installed with FactoryTalk Services Platform Program Files Common Files Rockwell countermonitor.exe Diagnostics Counter Monitor provides the ability to check the status of tags and to monitor the runtime values of counters and strings that are made available by network clients for diagnostic purposes. Save a Snapshot and send to Tech Support! Copyright 2011 Rockwell 52

53 Counter Monitor Useful Counters Data Provider Version Data Items Optimized Packets Connections Open Connection Open (attempted, rejected, failed) Downloads Performed Invalid Items 53 Copyright 2012 Rockwell Automation, Inc. All rights reservedċopy

54 FactoryTalk Gateway Diagnostics (Counter Monitor) Available in Counter Monitor tool if you have FactoryTalk Gateway installed. Live Data server RSLinx Enterprise and FactoryTalk Gateway have extensive diagnostic counters available for checking and troubleshooting communications. Similar to Linx Classic OPC Group Diagnostics Copy 54

55 Log Reader LogReader Collects the following: System, Application, Security, and FactoryTalk Diagnostics event logs. Dr. Watson Logs & Dump Files RSSQL Logs RSLinx Classic Communications Log (if configured) IIS Logs Local machine or a remote machine (if you have network administration access). Optionally Clears the System, Application, Security, and FactoryTalk Diagnostics event logs. Aid Tool for Collecting Event Log Files Requires Tech Connect Contract 55 Copyright 2012 Rockwell Automation, Inc. All rights reservedċopy

56 Useful Logs IIS Logs Logs related to Internet Information Services. FactoryTalk Diagnostics Log Contains user activity, application event, and system diagnostics records for many Rockwell Automation products. Windows Event Logs System - contains events logged by Windows system components. Application - contains events logged by applications or programs. Security - records events such as valid and invalid logon attempts, as well as events related to resource use such as creating, opening, or deleting files or other objects. RSLinx Classic Communications Event Log Contains records of events related to communications with the devices specified in the DDE/OPC configuration. Dr. Watson Logs/User Dump Files Logs/files related to applications hanging or crashing. Copy 56

57 Configuring Logging Copy 57

58 Questions? Rev 5058-CO900C