TOP Server Maximizing Your Results

TOP ServerMaximizing Your Results Presenter: Kevin Rutherford, Senior Applications Engineer

Agenda • Overview of TOP Server • TOP Server System Tags • TOP Server Alias Map • Specific Driver Optimizations • ControlLogix Ethernet • Modbus Ethernet • Beckhoff TwinCAT • Case Study Success – SAB Alrode • Questions & Answers

What is TOP Server?

TOP Server Gets You Connected! NEW! 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 NEW! NEW! NEW! NEW!

Why TOP Server? • Top 4 Reasons • Broad Choice of Drivers • SINGLE Interface into your systems • Scalability • Support • Other Reasons • Functionality • Reliability • Flexibility • Diagnostics • Documentation • Customer Commitment • Standards Commitment • Saves You Money in Design & Startup

TOP ServerSystem Tags Overview • Informational and Functional Tags Accessible from the Client • Allow Runtime Changes to Many Channel and Device Parameters • Network Adapter • Device ID • Device Enable/Disable • Provide flexibility and ease of controlling communications parameters from the Client • Client Scripting functionality can also make use of access to System Tags.

System Tags: Different Levels • Three Different System Tag Levels • Application/Server Level • Channel Level • Device Level • Every Channel has a Group of System Tags • Every Device has a Group of System Tags

System Tags: Server Level • Informational, Read-Only Tags • Some of the More Useful System Level Tags • _ActiveTagCount • _ClientCount • _Time_Second • Browseable from any OPC Client • Suitelink/DDE Clients Use Topic “_ddedata” and a tag syntax of _System._TagName

System Tags: Channel Level For Ethernet Drivers • Channel Level Tags available depends on Serial or Ethernet • Most Useful System Tags for Ethernet Channel • _AvailableNetworkAdapters • _NetworkAdapter • Channel Level Suitelink / DDE • Topic = ChannelName__System • Tag Syntax = _TagName

System Tags: Channel Level For Serial Drivers • Channel Level Tags available depends on Serial or Ethernet • Most Useful System Tags for Serial Channel • Tags for COM Parameters (_BaudRate, etc.) • _ComID • Channel Level Suitelink / DDE • Topic = ChannelName__System • Tag Syntax = _TagName

System Tags: Device Level • Most Useful Device Level Tags • Timeout Based (_RequestTimeout, etc.) • _Error / _NoError Tags • _Enabled Tag • _DeviceID Tag • Device Level Suitelink / DDE • Topic = ChannelName_DeviceName__System • Tag Syntax = _TagName

System Tags: Siemens Ethernet • Special System Tags for Siemens S7 PLCs • Used for Controllers with Redundant CPUs • _Rack • _Slot • Device Level Suitelink / DDE • Topic = ChannelName_DeviceName • Tag Syntax = _TagName

TOP ServerAlias Map • Allows Creation of “Friendly” Topic Names • Eliminates Channel_Device Syntax • Useful for Creating Shorter Topic Names for Use in Clients • Can Map Multiple Aliases to the Same Channel/Device • Useful For Viewing Valid Topics • Scan Rate Override

AB ControlLogixAddressing • Special Considerations for ControlLogix Addressing • PLC addressing is not traditional “N7:0” style – it’s in tags - also called “Native Tag Addressing” – which are useful for PLC programming and save time there, but . . . • Traditional “blocking” of data in the PLC has little value • PLC communications protocol requires driver to put actual tagnames into packet • Packet request size limited to about 500 bytes • PLC “local program” tags add additional overhead to the request packet • Since each timer, counter, PID loop, Alarm Block is a structure with numerous sub-elements, and you can nest structures inside of structures and define your own strutures, the potential for explosion to thousands of tags is high

ControlLogix Connectivity – Ways to Optimize • Special Considerations for ControlLogix needed to ensure best performance with the new paradigm in programming and communications: • Arrays are highly efficient means of moving large blocks of data and circumventing request packet limits • Keep PLC tag names short • Use global tags wherever possible • If you don’t need it, don’t read it! • Be particularly careful to group your tags by required scan rate – don’t read it faster than you need it “just because its Ethernet” or “faster is better”! • Be careful of large numbers of Programs in a Logix project. Increased overhead on the processor can result in no time left for actual communications! • For Continuous Tasks, Communications Timeslice % >= 20%

AB Suite – ControlLogix Tips • Maximizing Performance • Use multiple channels on Ethernet • Put high frequency writes on a separate channel • Use symbolic & physical modes on ControlLogix where appropriate • Separate channels for each protocol mode • If > 1/3 of all tags in PLC requested, Physical Blocking faster than non-blocking • Using < 1/3 of items in a structure – Physical Non-Blocking • Using > 1/3 of items in a structure – Physical Blocking • Atomic tags – Physical Non-Blocking

TOP Server Modbus Ethernet • Key Performance Features • Configurable Protocol Settings • Zero/One Based Addressing & Bit Access • Reverse Bit/Byte/Word/Dword Ordering • Configurable Block Size (Registers & Coils) • 5 Device Models (For Non-Standard Implementations) • Configurable Socket Usage per Device • Maximizes throughput for devices supporting multiple socket connections • Can be restricted to single socket per channel for devices only supporting a single socket connection

OPC, Suitelink, DDE TOP Server OPC & I/O Server Beckhoff TwinCAT Ethernet TOP ServerBeckhoff TwinCAT Ethernet • Uses Beckhoff ADS API for best performance • Devices Supported • TwinCAT PLC • Bus Couplers (BC9xxx/BX9xxx) • Structured Tags/Symbolic Addressing • Automatic database generation • From device if available • From *tpy file for offline import • OPC Item Property Filtering • AMS Routing Support

Case Study – SAB Alrode-Quad Automation • Initial Test • Top Server • 50 000 items • CPU 22% • Original Solution • 50 000 items • CPU 50%+

Case Study – SAB Alrode-Quad Automation • TOP Server AB Suite • Quad-CPU PC • Load Spread! • 33% CPU • 128 106 tags! • Highly Scalable • Completed system has 350 000+ tags over 4 TOP Servers

Additional Resources • Lots of free help at http://www.toolboxopc.com • Quick Start Guide • Training Videos • Papers and Utilities – Trouble Shooting Guide • Contact Software Toolbox support@softwaretoolbox.com while you are in the planning stage, so we can help!

Contact Information & Other Learning Opportunities • Questions later? • Kevin Rutherford • krutherford@softwaretoolbox.com • 888-665-3678 or 704-849-2773 • support@softwaretoolbox.com • www.toolboxopc.com • www.softwaretoolbox.com • Other learning opportunities • Visit www.softwaretoolbox.com/webinars

TOP Server Maximizing Your Results