design, operate, and maintain your logix/factory talk … · considerations: i/o, logic, tag data,...

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Rev 5058-CO900C

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

Fred Habenschuss & Tim Menge

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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 1756-L7x controller, FactoryTalk View SE, I/O, a drive on EtherNet/IP, and a Stratix 8000 switch.

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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Copy3

Logix-based Control Architecture

Global Access to data

Deterministic control

Distributed HMI

Extensive Process

Library

Redundancy

High speed logic

Standalone operation

Scalable architecture

Interfaces to many

devices

RA Integrated Architecture and Logix provides all the control you need in one package

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, IsolationWide range of I/O platforms: Rack-based, Distributed, Intrinsically Safe SIL 2 Rated for Critical Control Applications

Traditional DCS Traditional PLCProgrammable Automation Controller

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Workshop Agenda

1. Workshop System Configuration

2. Design Recommendations and Tools

3. System Performance Monitoring Tools

4. System Maintenance Tools


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• Stratix AOP• HTTrack software• Wireshark• Logix Diagnostics tool• Logreader Utility• EventLog Export Tool

Presentation Laptop• Powerpoint for Session• IAB/PSE• Accelerators• EtherNet Capacity Tool


Workshop System Configuration –Hardware

Hardware List• 1 - 1756-L73 controller• 1 - 1756-EN2TR• 1 - 1756-PA72 Power Supply• 1 - 1756-A4 4 slot chassis• 1 - 1756-DNB DeviceNet Bridge Module• 1 - 1783-US05T Stratix 2000 switch• 1 - 1606-XLSDNET4 Power Supply• 1 - 1440-VLF02-01RA XM121 Dyn. Measurement Module• 1 - 1732D-8CFGM12 DeviceNet I/O Block• 1 - 2711P-T7C4D2 PanelView Plus 700

Hardware List• 2 – 1783-EMS08T Stratix 6000

Switches• 1 - 10 port 1783-MS10T Stratix 8000

Switch• 1794-PS3 power supply


Design Recommendations and Tools

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 8

Design Recommendations and Tools


Logix Selection Guides

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Pub.# 1756-SG001_-EN-P Pub.# 1769-SG001_-EN-P


Logix5000 Controllers Design Considerations

Focused on designing a Logix application Loaded with design tips and

considerations

Downloadable from: http://literature.rockwellautomation.com

/idc/groups/literature/documents/rm/1756-rm094_-en-p.pdf

Pub.# 1756-RM094_-EN-P

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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

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Copyright © 2012 Rockwell Automation, Inc. All rights reserved. .

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 messagesRSLinx Data Handling - Storage of tag groups On-Line Edits - Storage of multiple edit rungsGraphical 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)

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PlantPAx Selection Guide and Reference Manual

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The PlantPAx Selection Guide is used to assist with equipment procurement after system requirements are defined.

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-SG001_-EN-P Pub. # PROCES-RM001_-EN-P


Factory Talk View SE System Design Recommendations - AID 32549

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 32549

Download the document that matches your version of the software Latest version available is:

FactoryTalk View SE v6.0 (CPR9 SR3) Design Considerations 2011 01b.chm

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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.

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.

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.

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.

Product Selection Toolbox Applications

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Integrated Architecture Builder - IAB

Quickly create a system configuration to visualize and quote the RA solution

Rules-based, Helps Insure Valid Configurations– Performs rule-based checking for controller, I/O, network,

including Ethernet capacityComprehensive 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 comparisonCreate 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

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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, WRC1717171717


How Do I Get IAB?

Product Selection Toolbox DVDPST-SG001G-EN-V (January 2011)

The Internet http://www.rockwellautomation.com/en/e-tools

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Rev 5058-CO900C 19

EtherNet/IP Capacity Tool

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copy20

EtherNet/IP Capacity Tool

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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 MemoryEstimate

Data / LogicEstimate

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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

487,544 – 513,520 = 25,976 byte difference

or 5.3% more memory consumed by RSLinx.

Memory is consumed when RSLinx is online and polling data.


System Performance Monitoring Tools


System Performance Monitoring Tools

Monitoring Controller Performance – Task Monitor tool provided with RSLogix5000 Aid 51737 - 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


RSLogix5000 – Controller / Module Properties

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Controller Properties• Fault Information• Memory Consumption• Redundancy Status

Module Properties• Connection Status• Fault Status• Module Specific Information


RSLogix5000 – Task and Program Properties

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Task Properties• Task Elapsed Time• Elapsed Time Between Triggers• Task Overlap Count

Program Properties• Program Execution Time


Logix5000 Task Monitor v3.0 Tool – User Tasks Tab

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Logix5000 Task Monitor Tool –Performance

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Sample Code, AOIs, AOPs, and Faceplates PlantPAx - L_CPU AOI and faceplates – Available from AID 62682 The Sample Code Library is also a great resource!

http://samplecode.rockwellautomation.com

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Sample Code, AOIs, AOPs, and Faceplates

Stratix Add On Profile (AOP) The AOP provides easy access to configuration and diagnostics

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System Maintenance Tools


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# 21928

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


System FerretSystem Ferret is used to gather information for all devices on an ENET/IP, CNET, or DeviceNetnetwork.

The tool generates an XML file which can be converted to excel report like below :

Download System Ferret from the Integrated Architecture Tool Page :http://www.rockwellautomation.com/solutions/integratedarchitecture/resources4.html#Ferret

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Ethernet Module Embedded Webpages Additional Ethernet/IP Information Available from AID 57174

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HTTrack

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

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Wireshark

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

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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 31073 – Tool for Collecting Event Log Files

FT Log File Viewer – Aid 37518 – Eventlog Export Tool


FactoryTalk Diagnostics Viewer

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

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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Copyright © 2011 Rockwell

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

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Predefined @Diagnostic Information Diagnostic items made available by ControlLogix to help

you evaluate controller memory and performance.

Useful to provide controller diagnostics on HMI screens

Also available on FT Live Data Test Client

Check FactoryTalk Help for more information!

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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!

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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Copy

Counter Monitor

Useful Counters Data Provider Version Data Items Optimized Packets Connections Open Connection Open (attempted, rejected, failed) Downloads Performed Invalid Items

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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 LinxClassic OPC Group Diagnostics

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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 31073 – Tool for Collecting Event Log Files Requires Tech Connect Contract

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Useful Logs

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• 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.


Configuring Logging

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Questions?

design, operate, and maintain your logix/factory talk … · considerations: i/o, logic, tag data,...

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