Special Edition MICREX-NX

Transcription

Whole Number 211
Further evolution
protects customers’ assets
The MICREX-NX is a vertically and horizontally integrated system capable
of providing various solutions, from the field level to
the management level. With high scalability, the MIC
REX-NX can be applied effectively for small to largescale plants, redundant architecture and compliance
with international standards, the MICREX-NX realize
plant safety and security.
New Information and Control System
CONTENTS
Cover photo:
The business environment has
undergone a large transformation,
and production systems capable of
flexible and rapid responses to market changes are strongly demanded.
Accordingly, there is a need for vertically and horizontally integrated
solutions that organically link hierarchical levels from the production
site to production management and
operations, and that seamlessly integrate the various components and
solution packages required at the
production site.
In response to this situation,
Fuji Electric is advancing a total
solution by supplying industrial solution packages, supporting open
standards in control systems, increasing the efficiency and quality
of engineering, and supporting increasingly intelligent field devices.
The cover photo shows Fuji
Electric’s new information and control system MICREX-NX to illustrate the concept of a vertically and
horizontally integrated solution.
Trends and Prospects for Information and Control System
104
The New Information and Control System MICREX-NX
111
Advanced Information and Control Software Packages
for the MICREX-NX
116
Migration Strategy for the MICREX-NX
120
Engineering Support Tools for the MICREX-NX
125
Cabinet Mounting of the MICREX-NX
130
Head Office : No.11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan
http://www.fujielectric.co.jp/eng/company/tech/index.html
Trends and Prospects for
Information and Control System
Shin Hashimoto
Chihiro Nakajima
Junichi Kuroe
1. Introduction
In the more than ten years following the bursting
of Japan’s economic bubble, Japan has experienced an
unprecedented period of low growth. However, according to a business outlook survey for the period from
April to June of FY2004, capital investment for
FY2004 is expected to increase to 19.8 % compared to
the prior year. Although the future appears bright, the
business environment remains severe and there is a
need for corporate restructuring to enable companies
to survive even during periods of low growth. On the
other hand, against the backdrop of Japan’s deflationary market with falling prices for materials and
products, the trend toward globalization is continuing,
with manufacturing being shifted to China and other
Asian countries.
Under these circumstances, the Japanese manufacturing industry faces domestic challenges involving
the shift toward higher value-added products, construction of highly efficient manufacturing systems,
and adoption of energy-savings and other measures to
reduce the burden on the environment, while also
facing such overseas challenges as the stabilization of
materials procurement, construction of manufacturing
sites, establishment of distribution and sales networks,
and compliance with international standards for products and manufacturing processes. The industry is
working urgently to overcome these challenges.
In the past, mission critical business systems and
manufacturing execution systems (MES), supported by
technical advances in information technology (IT),
have aimed to optimize production management and
operations management. On the other hand, process
automation systems (PAS) have a successful track
record of optimizing manufacturing processes centering on monitoring and control. However, in an overall
production system, the role of an information and
control system is to manage these functions as an
intrinsically unified system and to create a mechanism
for optimizing the overall system.
In light of these circumstances, we believe that
information and control systems should be vertically
and horizontally integrated solutions, as shown in
104
Fig. 1, realizing both vertical integration that links the
field level to the production management and enterprise levels, and horizontal integration that seamlessly
connects upstream to downstream processes in a
manufacturing plant.
Based on the market trends of information and
control systems, analysis of user needs, and technical
trends, this paper describes Fuji Electric’s efforts in
developing an information and control system capable
of providing vertically and horizontally integrated
solutions.
2. Information and Control Systems: Market
Trends and User Needs
Figure 2 shows forecasts of the global, Asian and
Japanese markets for distributed control systems
(DCS) that are central to information and control
systems. Future average annual growth rates are
predicted to be 2.5 % for the global market, 6.4 % for
Asia (excluding Japan), and 0.5 % for Japan. Although
the Japanese market will remain essentially flat,
growing by only a small percentage, the Asian market
will continue to expand, with most market growth
occurring in China (1).
According to industry-specific market forecasts, in
the global, Asian and Japanese markets, the annual
growth rate of the materials production industry will
be less than average. Oppose to that the average
annual growth rates will be highest in the pharmaceutical, food and beverage industries, followed by the
electric power and water and sewage industries.
Under these market conditions, the steel and metal
industry, the industries of oil refining and chemicals as
well as cement and glass have little demand for new
plant facilities and the replacing of equipment is being
postponed to later dates. The greatest demands to
replace equipment is for maintaining those plants
which have previous received capital investment.
Within this market environment, user needs for
information and control systems have changed dramatically over the past several years. Namely, such
systems have improved their lifecycle cost efficiency by
enhancing conventional functions and performance
Vol. 51 No. 4 FUJI ELECTRIC REVIEW
Fig.1 Vertically and horizontally integrated solution
Vertical integration
Vertically and horizontally integrated solution
Fundamental technology
Management
know-how
Enterprise
Database
ERP/SCM
Supply
chain
Whole optimal
Fundamental
management system
Network
Production
management
Integrated production management
Energy
Knowledge
Automation
Process
control
Quality
Schedule
Facility
management
Traceability
Drive and
field
equipment
Sensor
Power
electronics
(drive equipment)
Process automation
Drive
PLC
DCS
Sensor
Control
technology
Actuator
Horizontal integration
Fig.2 Forecast of global, Asian and Japanese markets for
process automation
12,000
Market size (100 million yen)
10,000
Global market
8,000
6,000
4,000
Asian market
2,000
Japanese market
0
2002
2003
2004
2005
Year
2006
2007
Notes: 1) Asian market excluding Japan
2) Exchange rate calculated as 1 dollar = 110 yen
and by reducing costs at the time of initial investment.
Consequently, the lifecycle cost, i.e., the cumulative
cost incurred from system construction (planning,
design, manufacture and testing) to operation and
maintenance, equipment replacement and finally to
decommissioning, is reduced. In order to optimize the
lifecycle cost of plant equipment, it is not only
necessary to limit the initial investment, it is also
important to reduce maintenance and preservation
costs and equipment replacement costs as much as
possible.
Items of tremendous concern for today’s customers
are listed below.
(1) In the area of maintenance and preservation, in
addition to the presumed high level of reliability
ensured by the hardware and software platforms
which by definition should be elements of an
information and control system, the asset management can be systematized.
(2) In the area of equipment replacement, the latest
monitoring and control system technology and products can continue to evolve due to advances in IT.
These areas should work together and support the
partial replacement of existing equipment to the extent
to which user expertise with existing equipment can be
transferred to new equipment.
3. Technical Trends of Information and Control
System
In response to the user needs described above,
information and control systems are evolving while
incorporating the latest information and control technology. The main technical trends and future outlook
are described below.
3.1 Advances in production system integration
At present, a PAS cannot exist by itself, and
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interaction with ERP (enterprise resource planning),
SCM (supply chain management) and MES missioncritical systems, or in other words, expansion in the
vertical direction (vertical integration) is required.
Furthermore, expansion in the horizontal direction
(horizontal integration) to realize total process control
of the incoming materials transport, process control,
transport control, and outgoing package transport, as
well as utility management, is also required. With the
shift of manufacturing to overseas sites, these types of
integration, which include the local procurement of
materials, present significant challenges.
The following two items are regarded as important
in achieving vertical integration with an MES, which
is well suited for interaction with monitoring and
control systems.
(1) The original role of an MES is to perform process
management, in-process control, progress monitoring, record management, production facility management, quality control, etc. However, the MES
functionality of today does not stop there and the
MES is attracting attention as an enterprise
assessment tool for improving processes. It is also
analyzing those improvements, based on an evaluation of the process performance, and its role is
shifting to the analysis and visualization of record
data, which are additions to the conventional
management functions.
(2) In the past, it was common to construct an MES
using an order-made solution, for which software
was prepared individually. In the future, however, it is thought that an MES platform that
provides an execution environment and incorporates standard components will be promoted to
ensure higher efficiency and reliability of the
system design.
3.2 DCS technical trends
(1) Adoption of open technologies
The open technologies produced as a result of the
rapid expansion of IT have also rapidly spread to the
DCS field. Representative examples of open technologies whose adoption is becoming more widespread are
listed below.
q Personal computer and defacto standard OS
(Windows*1)
w Standard LAN technology (Ethernet*2, PROFI
BUS, Foundation Fieldbus*3, etc.)
e Standard interface protocols (TCP/IP, OPC,
etc.)
r Internet technology
*1: Windows is a registered trademark of Microsoft Corporation of the USA.
*2: Ethernet is a registered trademark of Xerox Corporation
of the USA.
*3: Foundation Fieldbus is registered trademark of the
Fieldbus Foundation.
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t Object oriented software technology
(2) Utilization of general-purpose products
There have previously been many instances in
which a specially developed and designed component
for a DCS has been replaced with a component made
from general-purpose products. Ensuring the functionality, performance, reliability and safety of system
products with software also has advantages in terms of
cost. Typical examples include the use of SCADA
(supervisory control and data acquisition) software for
the monitoring system and a PLC (programmable logic
controller) for the control system.
(3) Compliance with international standards
With the shift of manufacturing to overseas locations and the overseas exportation of plants, there has
been an increase in demand for equipment that
complies with international standards. Such compliance is essential for facilitating system construction
and the procurement of maintenance parts overseas,
and for example, in cases where compliance is required
by the overseas end user. Moreover, due to the trend
toward JIS (Japanese industrial standard) internationalization, the JIS is reflecting the content of IEC
standards, and plant equipment in Japan often incorporates technology and products that comply with
international standards.
4. Fuji Electric’s Efforts
With the emergence of DCSs in the 1970s, information and control systems have realized the advanced
functionality and higher performance that exists at
present. As can be seen in Fig. 3, Fuji Electric has
been supplying products to the market ever since the
early days of DCS development. Fuji Electric combined the individually developed E (electricity) and I
(instrumentation) functionality developed for its first
and second generations of information and control
systems in the first half of the 1980s with C (computer)
functionality developed for its third generation system
to achieve EIC integration. In the latter half of the
1990s, Fuji introduced its MICREX-AX (advanced
system), a fourth generation system based on the
concepts of open technology and evolution with inheritance. In 2004, Fuji developed and brought to market
the MICREX-NX (next generation system), a nextgeneration information and control system that adheres to prior concepts but also features vertical and
horizontal integration and integrated engineering.
Figure 4 shows a vertically and horizontally integrated
solution based on the MICREX-NX. Figure 5 shows the
positioning of Fuji Electric’s existing information and
control systems and the MICREX-NX.
The MICREX-NX next-generation information and
control system was jointly developed as part of a
collaborative effort between Fuji Electric and the PAS
business division of Siemens Corporation of Germany,
and is based on Siemens’ PCS7 DCS. Sales of the
Fig.3 Development of Fuji Electric’s information and control system
1975
1980
1985
Generation
1st
2nd
Series name
MICREX-PI
MICREX-PII
1995
3rd
MICREX-PIII
Distributed control system
Concept
1990
Analog-to-digital
5th
MICREX-AX
MICREX-NX
Advanced information
and control system
New information
and control system
Open architecture
Vertical &
horizontal integration
EIC integration
Total automation
1st, 2nd generation
Evolution with inheritance
3rd generation
4th generation
Architecture
Integrated
engineering
5th generation
Server client
HMI
HMI
HMI
LAN
DPCS-E
Computer
Controller
E
PC
Computer
DPCS-F
Controller
I
Single
Ethernet
Computer
Ethernet
Controller EI
Control
(controller)
(PIO)
(I/O network)
2005
4th
MICREX-IX
EIC integrated control system
2000
T-link
Controller EI
T-link
Industrial Ethernet
PLC based
controller
PROFIBUS DP
Sensor
Actuator
MICREX-NX began in September 2004.
Based on the MICREX-NX core, a next-generation
DCS founded on user needs, Fuji Electric’s information
and control systems has been strengthened as follows.
4.1 Advances in vertical and horizontal integration
(1) Vertically integrated system
Fuji Electric’s MES realizes flexible and highly
efficient production planning based on the manufacturing workflow, and enables seamless integration with a
PAS. Main features of this MES are listed below.
q Total optimization is realized through the
simultaneous real-time control of facilities and
equipment, quality inspection, operating instructions, and the operation record.
w Improved operation and ensured traceability of
the manufacturing process made possible by
the integration of information generated at the
manufacturing site and records analysis (process lot flow, correlation analysis, in-process
behavioral analysis, etc.)
e Use of an MES platform establishes an environment in which a system can be constructed
by combining standard components.
r Provides an engineering environment for integrating an MES and DCS
t Easy linking of data between the MES and
DCS by means of an interface based on TCP/
IP, OPC and other types of international
standards for data exchanges
(2) Horizontally integrated system
Advancing the conventional concept of EI integration, in addition to the integrated control of manufacturing processes and electrical machinery, all field
level processes from materials transport to distribution
and utility are also integrated.
Fuji Electric’s horizontally integrated systems
have the following features.
q The control component is based on a highperformance PLC. Coordinated operation of
electrical machinery control that requires highspeed response and process control that requires a fixed cycle can be accomplished via a
shared plant bus (IE: industrial Ethernet).
Moreover, integrated engineering tools enable
linked system design and testing.
w The field network is configured from a PROFI
BUS-DP and/or PROFIBUS-PA, which are international standards, and according to the
application, field level equipment from the
drive equipment to the measuring equipment
can be connected horizontally, enabling monitoring and control to be performed.
e The linkage between a vertically integrated
MES and DCS enables the flexible operation of
pre- and post-processes (materials transport,
distribution, utility, etc.) according to the operating status of the process line.
4.2 Provision of total solutions for the plant lifecycle
The MICREX-NX is provided with the following
mechanisms to reduce cost and ensure stable plant
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Fig.4 MICREX-NX based information and control system
Enterprise level
Office LAN
Ethernet
Plant information Plant maintenance
Production management level
OS client
OS single station
(multi VGA)
Batch client
ES
Batch server
(redundant)
OS server
(redundant)
Plant bus
Plant control level
AS414F/FH
AS417F/FH
ET200M
DP/PA-link
ET200M
DP/PA-link
Y-link
PROFIBUS-PA
PROFIBUS
-DP
AS414H
AS417H
PROFIBUS
-DP
PROFIBUS
-DP
AS414
AS416
AS417
PROFIBUS-PA
OS: Operator station
ES: Engineering station
AS: Automation station
ET200M failsafe
ET200M
DP/PA-link
Vertical integration
Service
Terminal bus
Process level
PROFIBUS-PA
Field level
Horizontal integration
operation during each phase of the plant lifecycle.
(1) System configuration phase (conception, design,
construction, testing)
(a) Scalable system configuration
Two series of products are available according
to the scale of the system, an entry system
BOX Series for small-scale plants, and a PRO
Series scalable from 150 to 60,000 tags for
medium and large-scale plants. Because these
series both have the same engineering environment, legacy equipment and expertise acquired
with minimal investment can continue to be
used when expanding the plant, thus enabling
the user to recover their investment.
(b) Compliance with international and industrywide standards
Each level of the plant naturally complies with
international LAN standards (such as Ethernet, industrial Ethernet, PROFIBUS-DP/PA,
HART, AS-i, MODBUS, etc.) and supports the
use of the international standard language IEC
61131-3. Additionally, the SIMATIC*4 BATCH
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control package (conforming to IEC61512 (ISA
S88)) for batch plant-use to enhance global
competitiveness, a system for electronic
records, electronic signatures, monitoring and
recording for food and pharmaceutical manufacturing processes that complies with regulations concerning electronic archives and electronic signatures (FDA 21 CFR Part 11) as
established by the United States’ Food and
Drug Administration (FDA), a safety instrumentation system (conforming to IEC61508),
and the like are available.
(c) Integrated engineering
q Integrated engineering is a key concept of
the MICREX-NX. An integrated engineering database enables high value-added
functions such as a monitoring and operating system, a control system, facility management, SIMATIC BATCH, a safety in*4: SIMATIC is a registered trademark of Siemens of
Germany.
Fig.5 Positioning of the MICREX-NX
Computer solution
IT linkage
MES linkage
MICREX-NX
MICREX-AX
Single user
system
Multi-client and
multi-server system
Client and
server system
Monitoring
and control
FOCUS
Jupiter
SIRIUS
Monitoring and control
Data logging
150 tags
5,000 tags
60,000 tags
Monitoring and control tags
strumentation system, and the like to be
configured in an integrated engineering
environment.
w A mechanism that enables software, which
is the intellectual property of the user, to
be stored in a library and reused accelerates the creation of software and the
application of expertise.
e A three-stage simulator of the controller,
PIO and plant can be used to implement
debugging without using an actual device,
thereby achieving more efficient design
and testing, and realizing higher quality.
(2) Operation and maintenance phase
(a) Improved utilization rate
The MICREX-NX realizes complete redundancy capable of handling multiple failures in the
various levels of the network, database server,
operator station, controller, PIO, and power
source. Moreover, with a rugged and highly
reliable design of the hardware, and the security measure that requires an operator to logon
before performing such tasks as plant operation, engineering, testing, software modification, and the like, a high utilization rate is
ensured.
(b) Simpler maintenance
In addition to improved capability for system
failure diagnosis and status display, the following characteristic mechanisms simplify daily
maintenance and shorten the recovery time
when a failure occurs.
q Diagnosis and preventative maintenance of
equipment and devices horizontally integrated by an integrated facility management system
w A system for managing the different versions of application software by means of a
revision history management function
e Rapid identification of the cause of a
failure by means of a 10ms minimum (1ms
resolution) time stamp function
r Online exchange of controllers and PIO
modules, and automatic backup after the
exchange
(3) Equipment replacement phase
Incremental migration enables a plant to be maintained or expanded flexibly in accordance with a user’s
plans for replacing equipment. Additionally, a hardware group that links an existing MICREX to a
MICREX-NX and a software converter that allows
reuse of a user’s legacy software assets make possible
the long-term inheritance of equipment and expertise
with minimal investment.
4.3 Inheritance and evolution of plant expertise and
control technology
The extent to which plant expertise and control
technology can be continuously utilized and the extent
to which it can evolve are important issues for users as
well as manufacturers. This content, including plant
operating expertise, control expertise, and the tool
environment in which this expertise is applied, is being
addressed by Fuji Electric as follows.
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(1) Control and monitoring-use software components
that have been accumulated over many years in
the fields of industrial, environmental, water
treatment and energy related applications are
converted into a shared library under the
MICREX-NX’s integrated engineering environment. In particular, the control library is packaged as a single object containing a controller
component, a human-machine interface (HMI),
and additional information such as control algorithms and the like, thereby enabling more efficient reuse of the library and facilitating the
inheritance of expertise.
A menu of the control content, from PID control to
advanced control and model predictive control, is
prepared to allow selection of the optimal usage
according to the intended application.
(2) Plant operation expertise exists mainly with the
user. The MICREX-NX has enriched its operation
support package to allow maximum use of the
user’s plant operation expertise. For example, the
route control package has a large effect on complex piping routes and tank yard operation in the
food, beverage, pharmaceutical and chemical
fields and the like.
5. Conclusion
trend toward technical standardization, information
and control systems have continued to evolve year
after year. The globalization of manufacturing, as
symbolized by the shift to overseas production, is well
known, and a more global perspective is adopted. This
also applies to the information and control systems
that provide plant support so that those systems can
continue to evolve while responding to user needs,
instead of being developed solely by one company. In
other words, the value added to information and
control systems depends not only on the hardware and
software platform, but also on the extent to which
expertise appropriate for a particular region and
industrial field can be consolidated and combined to
enable future inheritance and evolution. From this
perspective, Fuji Electric shares technology with Germany’s Siemens Corporation, and also pursues joint
development and shared manufacturing responsibility
to hasten the production of results and to advance
global product development.
Fuji Electric intends to continue to provide solutions based on user needs, and to develop and provide
systems that will continue to satisfy users in the
future.
Reference
(1) O’Brien, L. DCS Worldwide Outlook. ARC Advisory
Group. 2003.
Spurred on by rapid advances in IT and the global
110
The New Information and
Control System MICREX-NX
Satoshi Sakai
Kouichi Sakagami
Tetsuo Suzuki
1. Introduction
existing systems.
Over the past two decades or so, distributed control
systems (DCSs) have been widely used as plant
monitoring and control systems, and have become a
key component for supporting plant businesses centered on the fields of water treatment and measurement systems.
Until now, the most common type of DCS was a
high performance, highly reliable “heavy DCS” constructed using mainly specialized hardware and software for widest application across all fields.
However, with the long-term stagnating economy,
demand has increased in recent years for more efficient plant operation by sharing shop floor information
throughout an entire company and by applying that
information to production planning.
Additionally,
demand has also increased for a reduction in the costs
associated with maintenance and engineering, and a
“light DCS,” which is a highly flexible DCS that can be
applied selectively according to the application, and
that uses open technology and advanced software to
achieve vertical integration from the field level to the
manufacturing execution system (MES) level is requested. This light DCS can also be applied to fields
such as factory automation (FA) to develop horizontal
integrated business solutions.
In response to these requests, Fuji Electric has
developed a new information and control system,
which we call the MICREX-NX. This paper describes
the system configuration and presents an overview of
the MICREX-NX.
2.1 System configuration
2. MICREX-NX System Architecture
The MICREX-NX system is a highly reliable, highperformance system that is supported by the principles
and concepts of Siemens Corporation’s PCS7, based on
joint development by Fuji Electric and Siemens. The
concept of vertical and horizontal integration was
conceived so that a single system can use a unified
platform of hardware and software to process a wide
range of control objects. In addition, Fuji Electric also
plants to develop components capable of connecting to
The MICREX-NX system is configured from an
operator station (OS) that is an operating and monitoring component, an engineering station (ES) used for
setting various parameters, an automation system
(AS) that is a control component, and an ET200 series
that oversees process I/O. The OS uses an industrial
PC and realizes a Windows*1-based open interface.
The ES enables control programs and picture parts to
be converted easily into libraries in order to increase
manufacturability. The AS and the ET200 use a
highly reliable programmable controller (PLC) and I/O.
General versatility and high reliability are ensured by
connecting these components to an Ethernet*2-based
plant bus (industrial Ethernet) and a PROFIBUS as
the field network. Moreover, with a batch system
conforming to IEC61512 (ISA S88), compliance with
the regulations concerning electronic records and electronic signatures as established by the US Food and
Drug Administration (FDA) (FDA 21 CFR Part 11), the
realization of a safety instrumentation system
(IEC61508), and so on, the MICREX-NX complies with
the latest international regulations and industry standards. (See Fig. 1.)
2.2 Vertical integration and horizontal integration
The MICREX-NX system is provided with standardized data management and communication features. The MICREX-NX component is installed in the
main process, and many various specialized software
packages are used in auxiliary process and for managing warehouse loading/unloading so that the shop floor
is uniform with the same product architecture from
upstream to downstream. This feature contributes to
simplification of the work and to reduced cost in each
phase, including engineering, operation, training and
maintenance. Similarly, with this wide variety of
*2: Ethernet is a registered trademark of Xerox Corporation
of the USA.
111
Fig.1 Overview of MICREX-NX system
Information LAN
Ethernet
Office LAN
Internet, Intranet
Ethernet
Plant
information
Plant
maintenance
Existing MICREX
OS client
Batch client
Terminal bus
OS server
(redundant)
ICS-2500
ICS-2000
ACS-2000
Plant bus
FL-net
ACS-2000
AS414
AS416
AS417
P/PE link
ACS-250
T link
ASA-2000
SAS-55
SAS-300
Intelligent
CC
Serial
ET200M
DP/PA link
PROFIBUS-PA
AS414F/FH
AS417F/FH
ET200M
Fail safe
ET200M
DP/PA link
AS414H
AS417H
PROFIBUS-DP
PCS-500
OS server
(redundant)
PROFIBUS-DP
DPCS-F
Batch server
(redundant)
AOS-2000
ADS-2000
ADS-2000G
PROFIBUS-DP
DBS-1500
IDS-1500
ADS-2000
OS single station
Engineering station ES
(multi VGA)
Asset management package
Service
ET200M
DP/PA link
PROFIBUS-PA
PROFIBUS-PA
SAS-2500
MICREX-PIII
MICREX-IX
MICREX-AX
uniform components, products all having the same
architecture can be supplied to the fields of industrial
processing, machining, and the hybrid processing (field
in which continuous, batch and discrete processes are
mixed).
Moreover, integration of this data management
enables information from the enterprise resource planning (ERP) and MES levels to be shared as far
downstream as the field level.
2.3 High reliability
The MICREX-NX system is capable of complete
redundancy. All components from the operating and
monitoring component to the network, control system
and I/O can be made redundant to protect against
multiple errors in the system. Moreover, an event
management function, advanced time synchronization
and time stamp appending function, and an enhanced
self-diagnosis function enable a rapid response to
errors.
3. Engineering Station (ES)
3.1 Integrated engineering system
In conventional systems, the control and monitoring systems were engineered separately, and a considerable amount of time was required to define an
interface between these systems. With the MICREXNX, however, all engineering work – from field devices,
network, and control applications to the operator
112
station – is performed within an integrated environment. Control applications can be created using a
sequential function chart (SFC) or a continuance
function chart (CFC). A CFC block contains messages
and all data related to monitoring and operation, and a
block icon and faceplate for monitoring and operationuse can be generated automatically from a CFC-based
control application. Accordingly, the engineering work
in an operator station can be performed more efficiently, and because standardized picture parts can be used,
the work involved in unit testing is reduced.
Figure 2 shows the automatic generation of parts
for monitoring and operation.
3.2 More efficient engineering
(1) Extensive library
Standard components such as motors, valves and
PID controllers are provided in advance as software
objects in a library.
Because it is easy to create a user library, control
applications may be reused, thereby improving efficiency.
(2) Enhanced simulation environment
Using simulation software, a control application
generated from CFC or SFC can be tested on an
engineering system without the use of an actual
machine. As a result, errors can be detected and
eliminated at an early stage, thereby enabling early
shop floor commissioning and low-cost, high-quality
program production.
Fig.2 Automatic generation of parts for monitoring operation
Fig.3 Overview of operator station
Faceplate
Operator station
Archive server
(tag logging)
tagname
Block icon
L
M
M
S
OS client
(32 stations max.)
OS server
(redundant)
(12 pairs max.)
Automatic generation
Controller application
4. Operator Station (OS)
(3) Authorization settings for operator of monitoring
and operation in each area enable security to be
strengthened.
(4) With a loop-in alarm function, the plant screen for
a generated alarm can be displayed simply with
the press of a single button.
Also, two additional features are listed below.
(1) An SFC visualization function enables sequence
control described by the SFC to be displayed and
operated while the plant screen is being monitored.
(2) The display language can be switched online
between Japanese and English.
Figure 3 shows the configuration of the operator
station.
4.1 System configuration
4.3 Plant monitoring screen creation function
In contrast to the predetermined combinations of
component elements and the number of component
stations in the monitoring and operating component of
a conventional system, the configuration of the
MICREX-NX is scalable according to the size and
extension of the object to be monitored.
(1) Single user system
A single user system is configured with a single
operator station.
(2) Multi-user system with client server configuration
A multi-user system can be configured with a
maximum of 12 OS servers and a maximum of 32 OS
clients. Also, an optional archive server may be
installed to provide server redundancy and to store
large amounts of time-series data.
A special screen creation tool having the features
described below facilitates the creation of a plant
monitoring screen.
(1) A customized object function can create parts
(objects) for display.
(2) Operational settings can be specified easily with a
dynamic wizard and a configuration dialog.
(3) OLE components can be embedded easily.
(4) A parts library for various drawings is included as
a standard feature.
(5) An extensive standard library and a data processing function based on the two script languages of
VB script and C script are provided.
4.2 Features of the operator station
The MICREX-NX BOX is a system in which a PC
card equipped with a control function is installed in an
industrial PC. Functions of the engineering station,
operator station and automation station are realized
with this single component. The control function PC
card is connectable to remote I/O via the PROFIBUS,
and because the power supply system and control
signal system (reset signal and the like) are separate
from the PC body, control can continue unaffected by
errors generated due to such PC-side events as a crash
of the Windows operating system, interruption of the
power supply, or the like. Potential applications
CFC block
3.3 Multi-project engineering
So that a project can be constructed by several
teams working in parallel, the project can be divided
into sub-projects and engineering tasks can be performed individually. The individual sub-projects can
be inserted or deleted from the project at any time.
With a conventional system, the operation screen
for each asset was controlled from a menu, and much
engineering work was required to realize “intuitive
operation” adapted for the actual object. In contrast,
the MICREX-NX has the following characteristics.
(1) A standard function divides the entire plant into
asset units that can be controlled as “areas.”
(2) Intuitive monitoring and operation of the targeted
asset is achieved with a display capable of showing a maximum of five hierarchical structures
within an area.
5. MICREX-NX BOX
113
Fig.4 Configuration of MICREX-NX BOX system
MICREX-NX BOX
ES
Redundant
OS server
24 V DC
PDM
Simatic Net
Ethernet
on board
Fig.5 Redundant ring configuration
PCMCIA
card
CP5611
on board
OS
CPU416-2
PCI+PS
MPV
DP
DP
Optical switch
module
OSM
Dual redundant plant bus
(Industrial Ethernet)
DP/PA link
PROFIBUS-DP
PROFIBUS-MPVDP
OSM
OSM
OSM
PROFIBUS-PA
Redundant
AS
AS414H
AS417H
Equalization line
include small-scale plants, utility plants and systems
for testing, instruction, training and research. The
software and engineering data are shared with the OS
client server system, and the design facilitates linkage
to these systems and the expansion of their functions.
Figure 4 shows the configuration of the MICREXNX BOX system.
6. Network
6.1 Features
The plant bus is a powerful cell network based on
the IEEE 802.3 standard. An ISO protocol is used
instead of the usual TCP/ IP protocol.
Advantages of the plant bus are listed below.
(1) Capable of 100 Mbps transmission
(2) The plant bus is specially designed for industrial
use and has excellent ability to withstand adverse
environmental conditions.
(3) Redundancy can be achieved with an optical or
electronic ring configuration. When an error
occurs, changeover is implemented at a high speed
of 0.3 seconds.
(4) Total length: 5 km (electrical), 150 km (optical)
6.2 Component hardware
The following hardware components are provided
for the plant bus.
(1) Optical switch module (OSM)
An OSM is used in the case of a ring configuration
formed from optical fiber cables. With a ring configuration, switching from error detection to loop-back can
be implemented within 0.3 seconds. Up to 50 OSMs
may be connected per ring.
(2) Electronic switch module (ESM)
An ESM is used in the case of a ring configuration
formed from electronic cables. Other specifications are
the same as those of the OSM.
114
(3) Communication module
The communication processor module (CP443-1) is
a card for connecting an automation system to the
plant bus. By installing a communication processor
card (CP1613) in an operator station, that operator
station may be connected similarly to the plant bus.
(4) Cables
The following types of cables may be used: multimode and single-mode optical fiber cable, and twistedpair cable and electronically enhanced industrial-use
twisted-pair cable.
Figure 5 shows the redundant ring configuration.
7. Automation System (AS)
7.1 CPU duplex redundancy
Conventionally, controller redundancy has been
implemented with a warm standby redundancy method based on the equalization of partial data and the
like.
With the MICREX-NX, however, controller
redundancy is event-synchronous and is synchronized
to the access of a memory area resulting from an
external I/O data access or interrupt processing, or to
the timing at which processing is performed, thereby
enabling a changeover to the standby-side in less than
100 ms, instead of the approximate 1 s that had been
required in the past, and is applicable to plants in
which even a short interruption of operation not
permitted. Also, this mechanism eliminates the need
to consider system redundancy when creating an
application.
This redundant system is configured from two
redundant CPUs and sync cables connected between
the CPUs, two PROFIBUS systems, and a remote I/O
(ET200M) that is connected to both PROFIBUS systems.
The CPUs are synchronized with two sync cables
Fig.6 Appearance of the automation system
line redundancy can also be supported. I /O capable of
being made redundant is also available. Each type of
I/O has a self-diagnostic function, and therefore,
detailed I /O diagnostic information can be displayed at
an OS or ES. Of course, I /O modules may also be
added and parameters may be changed during operation.
9. Plant Control Package
A wide variety of plant control packages such as
batch control and pipe route control are provided for
the MICREX-NX. The batch system is described below
as a representative example of a batch control package.
(optical fiber cables) and four synchronization modules.
Two PROFIBUS slave interface modules (IM153-2)
are used in the remote I/O so that the interface is also
made redundant.
Figure 6 shows the appearance of the automation
system.
9.1 Overview of the batch system
The batch system is a package suitable for today’s
market needs and complies with IEC61512 (ISA S88),
the international standard for batch control, and with
FDA 21 CFR Part 11, for which there is strong demand
for compliance in the pharmaceutical industry.
7.2 Control language
Various languages have been developed to promote
the standardization and modularization of programs.
(1) Continuance function chart (CFC)
A CFC is an image of a process flowchart, and is
created by connecting the various function blocks with
lines on an editor.
(2) Sequential function chart (SFC)
Conforming to the SFC of IEC61131-3, this language aims for control that can easily divide a process
into phases.
(3) Standard control language (SCL)
This language conforms to the structured text (ST)
of IEC61131-3. This is an advanced language suitable
for sophisticated data processing.
8. Process I/O (PIO)
The MICREX-NX PIO is provided with remote I /O
and direct I/O functions. The remote I /O is capable of
realizing distributed control via the PROFIBUS. The
PROFIBUS is an excellent network for remote I/O and
is standardized in Europe, but is also becoming a
worldwide standard. With the production of many
varieties of components from Siemens Corporation or
third party manufacturers, the PROFIBUS can readily
be used in various types of plants. The transmission
speed of this PROFIBUS is selectable up to 12 Mbps
according to the intended use, and the cable length per
segment may be extended up to 100 m.
The ET200M remote I/O consists of a power supply
module, a PROFIBUS module, and up to eight mountable I/O module panels. Many types of I/O are
available for the ET200M, and this I/O module enables
the basic I/O range to be set according to the
measurement range software setting. Moreover, CPU
rack redundancy and PROFIBUS I/O transmission
9.2 Features of the batch system
(1) Plant hierarchy
The batch system enables a hierarchical structural
design that complies with ISA S88.01. A hierarchical
structural expression enables the clear identification of
which device is being used in which process, and the
flexible use of devices according to the product line.
(2) FDA 21 CFR Part 11 compliance
The batch system package satisfies the requirements for access management, electronic signature,
data storage, audit records and the like, as specified by
FDA 21 CFR Part 11. An access authorization setting
enables the plant to be protected from operation by an
unauthorized operator. The batch system can also
perform such tasks as recording the operating history
of an operator, and storing historical data of executed
production processes.
(3) Creation and modification of recipes
By using the batch system control center from
which monitoring and operation is usually performed,
the operator is able to create and modify recipes. The
operator can customize the production volume, devices
used, and all items used in batch processes up until the
production process.
10. Conclusion
The trend toward vertical and horizontal integration will continue in the future, and flexible system
configurations (open or multi-vendor configurations)
according to the individual plant will be required.
Under these circumstances, in order to continue to
satisfy user needs, Fuji Electric will continue to
manufacture DCS products that facilitate higher reliability, greater flexibility and long-term maintenance,
in order to realize optimal solutions.
115
Advanced Information and Control
Software Packages for the MICREX-NX
Takashi Ikeda
Masato Nakano
1. Introduction
With the development of information technology
(IT) recently, control systems have evolved toward
more advanced information integration and greater
networking capability. This evolution is supported by
trends toward higher system efficiency and integration, user requirements on plant safety, internet
security, and compliance with industrial standards and
various regulations.
The new information and control system MICREXNX is based on a concept of vertical and horizontal
integration, and has high scalability enable to apply to
small to large-scale plants. In an integrated engineering environment, the MICREX-NX supports the use of
highly intelligent field devices, integrates process and
discrete systems, and links up with upper-level manufacturing execution system (MES). These functions are
realized by combining the basic functions of the
MICREX-NX with various information control packages to built-in modeled (abstract) system elements
within a common engineering environment.
This paper introduces information and control
packages for MICREX-NX, the process device manager
(SIMATIC*1 PDM), the batch system (SIMATIC
Batch), and the route control system (SIMATIC Route
Control).
2. Process Device Manager
2.1 Overview of the process device manager
The process device manager (PDM) is a software
package that manages field devices connected with
MICREX-NX. This package facilitates the integration
of process data from process devices on the PROFIBUS
and also device diagnostic information and device
characteristic information, and as a result, enables the
acquisition of comprehensive diagnostic information
from each device, and basic information from diagnostic technology which is capable of detecting the diagnostic information of plants and machinery. Based on
*1: SIMATIC is a registered trademark of Siemens of
Germany.
116
this information, the efficiency of preventative maintenance such as periodic diagnosis and periodic overhauls of machinery can be improved greatly.
In addition, because the PDM package runs at an
integrated engineering environment of MICREX-NX
(SIMATIC Manager) so that, the field information and
operation management information also can be integrated. The trends toward more intelligent field
devices and standardized parameters facilitate the
greater use of information throughout the entire
lifecycle, from the process planning and engineering
through operation and maintenance, and facilitate
laborsaving.
The PDM package includes functions for the
system configuration, parameterization, self-diagnosis
and analysis of intelligent process devices; the PDM
can be run at an engineering station (ES), or also can
be used as a stand-alone architecture for verifying
operation at the time of commissioning. With an
electronic device description language (EDDL), the
PDM package can support field device characteristic
information for process devices connected to the
PROFIBUS-DP, as well as for devices connected to a
standardized network such as a HART or MOD bus.
This EDDL is supplied by the process device
manufacture and is a unified language that describes
characteristic parameters of process devices (the temperature, pressure and flow of various field devices).
Because the manufactures supply process control devices that contain application information, all the
processes that include design, implementation, acceptance testing and shipping can be improved greatly.
2.2 Features of the PDM
Functions and features of the PDM are described
below. Figure 1 shows the system configuration and
supported devices of the PDM.
(1) Functions for calibration, adjustment, and changing various parameters of field devices connected
to the PROFIBUS-DP/PA
(2) Self-diagnosis of the device status and communication status of field devices
(3) Function for comparing online device data with
offline device data
Fig.1 System configuration and supported devices of PDM
Engineering system
with SIMATIC PDM
Electronic device description language (EDDL)
Process value/status
Standardized parameters
(Diagnostic)
Stand-alone
SIMATIC PDM
Custom manufacture parameters
PROFIBUS-DP
ET200M
0/4 to 20 mA
+HART
Fig.2 Example of PDM image panel (device parameter view)
ET200iS
DP/PA link
PROFIBUS-PA
Fig.3 System configuration of batch system
Batch client
Terminal bus
OS, Batch
single station
ES
OS server
Batch server
Plant bus
Batch controller
(4) Function for assigning and configuring slave (network) addresses
(5) Function for managing, simulating and adjusting
test conditions for field devices
(6) Online monitoring of selected values, alarm and
status signals
(7) Live list for automatic detection of connection
status (communication status) of the installed
field devices
2.3 Monitor function of the PDM
The PDM displays the following online information
in an operator station (OS). Figure 2 shows an example
of a displayed image panel.
(1) Monitor of process device network
Displays the device information, including the
diagnostic status, and classifies that information according to the network configuration.
(2) Monitor of process device plant
Displays the device information, including the
diagnostic status of all devices in a network-based
system.
(3) Monitor of field device parameter
Displays the device parameter information in
tabular form and/or graphical form.
3. Batch System
3.1 Overview of the batch system
In recent years, quality management and observation of safety-related industrial standards and regulations have been strengthened for food, pharmaceutical
and chemical products, and a control system that
complies with these regulations is desired.
The
MICREX-NX batch system is a application software
package that complies with regulations related to
electronic records and electronic signatures as established by the batch control standard [IEC61512 (ISA
S88)] and the United States’ Food and Drug Administration (FDA). According to the plant size, the batch
system can be configured as an OS single-user system,
or a client and server system. The batch system can
also be applied to small to large-scale of batch process.
Moreover, safety can be enhanced through redundant
batch server and batch clients. Figure 3 shows the
system configuration.
Advanced Information and Control Software Packages for the MICREX-NX
117
The batch system is described based on three batch
structural models (a procedural model, a physical
model, and a process model) that complies with
IEC61512 (ISA S88). By introducing the concept of a
simple 4-layer structural model and by uniformly
describing the connection between models, the batch
system provides the capability for design and maintenance. In particular, by using a hierarchical recipes
(formula) that affect product quality, each process and
field device element in the batch plant is described
with a uniform method of expression. Figure 4 shows
the batch structural model.
The batch control center centralizes the control of a
batch based on system configuration information that
created with a MICREX-NX engineering station (ES)
and a master recipe created with a batch recipe editor.
The batch system provides the ability to register and
manage required functions as special libraries conforming to the ISA S88.01 structural model. These
libraries are described with a sequential function chart
(SFC) so that online monitoring and operation can be
performed on OS using MICREX-NX standard functions (SFC visualization function). Table 1 shows the
software configuration of the batch system. Batch
planning can be implemented independently within a
batch system using batch control center functions,
however, also can combine with upper-level MES
package (SIMATIC IT) that compliance with ISA
Fig.4 ISA S88-based model of batch system
Table 1 Batch system software packages
Process model
Procedure
Process
cell
Process
Unit
procedure
Unit
Process
stage
Operation
Unit
Process
operation
Unit
Process
action
Equipment
module
Process
action
Phase
Operates
with AS
Phase
Optional
packages
Operates
with
batch
server
Physical model
Basic software
Name of software
Procedural model
Main functions
Batch control Batch planning,
center
batch control
Comments
Batch client
Batch report
Recipe, batch data printing Batch client
Batch recipe
editor
Master recipe, library
creation, drawing changes
Batch client
Transmission of batch data
Batch control
(between controller and
Batch server
server
monitor)
Batch
planning
Configuration of batch
control center
Hierarchical
recipe
ISA S88.01 compliant
recipe
API interface
Interface with MES-related
software
Defined with ES
Fig.5 Compliance with FDA 21 CFR Part 11
Windows
User, group registration
MICREX-NX
Operator station, engineering station
Authority assigned according
to technical level
User 1
Administrator
User 2
Operator
Operator
User 3
Senior operator
Senior operator
User 4
Emergency operator
Emergency operator
Administrator
Unique user name, password
Electronic signature
Changing set point by senior operator
Logon with IC card
(user registration)
™Electronic signature in all operations
Audit trail in all
operations
Download to controller
™Input full name of signer, date and time of
signing, and content
118
Fig.6 Configuration of route control system
Table 2 System aspect of route control system
Item
Route control client
AS (automation system)
Size
32 systems (max.)
™1,024 motors, dampers,
valves, etc.
Terminal bus
Route control
server
™1,024 link elements, pipeline
Number of elements per AS
MICREX-NX
OS server
sections, etc.
™1,024 sensor elements,
process values
™1,024 parameter elements
Plant bus
Parallel transfer routes
64,000 partial routes (max.)
AS overlapping routes
32 overlapping routes (max.)
Number of elements per route
400 elements per AS (max.)
Number of modes per route
S95.01, enables to develop an information and control
system integrated from field level to the product
management level.
Additionally, compliance with FDA 21 CFR Part 11
realized high reliability for managing of access security, storage and retrieve manufacturing record data,
electronic signature, audit trail, and so on (See Fig. 5).
These functions are based on Windows*2 security
functions and an operator access management tool.
3.2 Features of the batch system
The batch system has the following features.
(1) Structural model and hierarchical recipe compliance with ISA S88.01
(2) Support from small to large-scale projects by using
distributed OS servers that able to access to all
control points or by accessing each OS servers.
(3) Support of FDA 21 CFR Part 11: user management, electronic certification, audit trail, revision
control
(4) High reliable system due to redundant OS servers
(5) Operating in integrated engineering environment
(6) OS faceplates for unit, phase and operation
4. Route Control System
The route control system is an software package
that monitors, controls and diagnoses systems that
transfer fluids through pipes or pipelines. Route
control system is mainly used in complex food, pharmaceutical and chemical plants and petrochemical
tank yards to realize efficient automatic transfer
control for the products.
Figure 6 shows the system configuration and
300 (max.)
Partial routes
32 modes (max.)
Table 2 lists the system aspect.
The standard engineering features of the MICREXNX and the main features of route control are listed
below.
(1) Monitoring and control of the transfer route and
related elements (such as valves)
(2) Diagnosis and alert of the transfer route and
related elements (such as valves)
(3) Dynamic linking of partial routes and the entire
route
(4) Engineering of complex route
Route control system can be implemented the
standard engineering function of the MICREX-NX
system and also can using special library. Moreover,
route control system can also be combined with upperlevel MES or batch system.
5. Conclusion
In this paper, we introduced advanced information
and control packages of MICREX-NX. Such as the
PDM package, batch system, and route control system.
In addition to these pakages the MICREX-NX provides
many packages for enhancing the safety and efficiency
of a plant, for example safety instrumentation system
and compliance with IEC61508 and IEC61511 adaptive control software packages, that are expected in
Japan. In the future, Fuji Electric intends to continue
its efforts to promote the advanced applications of
information and control systems.
Reference
(1) Theilmann, B.; Edmund, L. Online plant asset management integrated in process control systems. Automation Technology in Practice. 2004-01.
Advanced Information and Control Software Packages for the MICREX-NX
119
Takao Yamada
Fumihiko Fujita
1. Introduction
Fuji Electric first developed a distributed control
system (DCS) for application to plant systems in 1975,
and since that time, has applied DCSs to iron and steel
works and waste disposal plants in the private sector,
and then to various plant systems in the public sector,
such as water treatment facilities. Fuji Electric is
presently supplying its 4th generation DCS, the
MICREX-AX, to the market. The Japanese DCS
market shows signs of leveling-off, however, and Fuji
Electric is aiming to expand its process automation
system (PAS) business with the introduction of its
MICREX-NX, equipped with a new platform architecture suitable for application to new markets such as
food and pharmaceuticals, as well as to overseas
markets and the conventional fields of iron and steel
works, waste disposal, and water treatment. Figure 1
shows the changes over time in the MICREX systems
developed by Fuji Electric.
In the future, most of the MICREX-PIII and other
systems delivered by Fuji Electric will be due for
replacement. However, replacement of a plant all at
once will be financially difficult as customer budgets
have decreased, and this work must proceed with
consideration to minimizing the total cost of ownership
(TOC).
Fuji Electric provides its customers with a means
to improve manufacturing capability with the advanced capabilities of the MICREX-NX. Customers
can replace their existing systems with the MICREX-
NX sequentially, while inheriting some legacy hardware and software, and thereby prolonging the service
life of their existing systems.
This paper describes the process for migrating to
the MICREX-NX from an existing MICREX system,
while minimizing engineering labor and cost, and
efficiently inheriting assets of the existing system.
2. Scenarios for Migration from Existing Systems
Scenarios for migrating from a customer’s existing
MICREX system to the MICREX-NX system in order
to prolong the life of the existing system and to
increase manufacturing capability are described below
and illustrated in Fig. 2.
(1) Partial replacement of HMI only
Because the human machine interface (HMI) system uses general-use components such as a CRT and
hard disk, the HMI part will be the first to have its
production discontinued. Consequently, in this scenario, the existing HMI will be replaced with the latest
HMI version, and replacement of later-stage controllers will also be considered.
(2) Partial replacement, but retaining existing PIO
Due to such reasons as wiring complications or a
decrease in plant investment, the existing PIO part
will be retained, but the controller and HMI replaced.
(3) Plant replacement and expansion
To replace an aged plant and improve manufacturing capability, the controller, including the PIO, and
the HMI will be replaced all at once, or the plant
Fig.1 Changes in Fuji Electric’s MICREX systems
Generation
Series name
Concept
1975
1980
1st
MICREX-PI
2nd
MICREX-PII
Distributed control system
1985
3rd
1995
2000
2005
4th
MICREX-AX
5th
MICREX-NX
EIC integrated control system
Advanced information
control system
New information and
control system
EIC integration
Open architecture
Vertical and horizontal
integration
Evolution with inheritance
Integrated engineering
MICREX-PIII
Analog-to-digital
Total automation
120
1990
MICREX-IX
Fig.2 Migration scenarios
OCS/AOS
DBS/ADS
Replacement of
only HMI with
MICREX-NX
Partial replacement,
but retaining existing PIO
OS client
OS client
1
Ethernet*
OS server (GW)
Ethernet
OS server
Plant replacement and expansion
HMI, controller and PIO
replaced with MICREX-NX
Combined use with
former system
OS client
OS client
Ethernet
OS server
Ethernet
OS
server
OS
server
(GW)
DPCS-F, FL-net
DPCS-F, FL-net
DPCS-F, FL-net
Industrial Ethernet
PCS
ICS
ACS
AS
Industrial Ethernet
AS
AS
PROFIBUS-DP
T-link
P/PE-link
T-link
P/PE-link
Industrial Ethernet
PROFIBUS-DP
T-link
P/PE-link
PIO
ET200M
ET200M
Terminal
block
*1: Ethernet is a registered trademark of Xerox Corporation in the USA.
expanded.
3. Concept of the MICREX-NX Migration
The concept of the MICREX-NX migration is to
provide a mechanism that enables partial replacement
or expansion of an existing system by utilizing the
customer’s existing DCS assets to the maximum extent
while allowing the customer to enjoy the advantages of
the new MICREX-NX, such as the concept of plant
hierarchy and the automatic associations generated
among device modules in the controller and the HMI
faceplate.
The method for migrating to the provided MICR
EX-NX to partially replace or expand a plant while
inheriting legacy functions is described below. Figure 3
shows the overall migration process.
3.1 Easy connection of MICREX-NX to an existing system
The new MICREX-NX allows the partial replacement or expansion of an existing MICREX-PIII or later
system (MICREX-PIII, MICREX-IX, and MICREX-AX).
For this purpose, Fuji Electric provides a gateway
(GW) and link device as components for connecting the
existing system’s control network and remote I/O
network to the MICREX-NX.
(1) Gateway
The gateway connects Fuji Electric’s DPCS-F and
FL-net-compliant LAN backbone networks to the
MICREX-NX’s plant bus.
(2) Link device
The link device connects Fuji Electric’s P-link and
PE-link for connecting a remote I/O network or
general-purpose programmable controller (PLC) of an
existing system to the MICREX-NX’s controller.
3.2 Inheritance of existing system functions
(1) Migration of HMI objects and database (DB)
information
It is important that any changes to the customer’s
familiar display and operation of HMI objects, or any
inconsistencies of the HMI objects and operation
within the same control room are not conspicuous to
the user.
So that the migration can be implemented smoothly, a faceplate and diagnostic screen that are the same
as those of an existing MICREX system, and also a
database conversion tool are available.
(2) Inheritance of controller software assets
An application program converter is provided with
the new MICREX-NX. This converter converts controller application programs of the existing system, so that
121
Fig.3 Migration with MICREX-NX
MICREX-NX
OS client
ES
Existing MICREX
Migration of HMI
objects and DB
information
Terminal bus
Tag information
Alarm information
Trend information
Standard screen
Plant screen
Faceplate
OS server (GW)
AOS
AES
ADS
OS server
DPCS-F,
FL-net
Plant bus
AS
AS
Legacy software
assets
ACS
ACS
Link devices
T-link
Internal
instruments
EI wafer
Input processing
Common devices
Link device
P/PE-link
Link device
Ladder diagram
FB diagram
SFC
Loop diagram
Time chart
Other
PROFIBUS
replacement can be implemented smoothly without
having to develop new application programs for the
new MICREX-NX.
4. Migration Components
Fig.4 OS server (GW) functional structure
OS server (GW)
Relay
processing
Graphic
function
Alarm
function
Trend
function
4.1 OS server (GW)
Fuji Electric has two control level networks, its
original DPCS network and an FL-net-compliant LAN
that was developed based on the FL-net JIS specifications. A gateway based on the standard operator
station (OS) used with the MICREX-NX is provided in
order to connect these control level networks to the
plant bus that is the MICREX-NX network.
In
addition to the capability for performing data accesses
from the OS client to the existing controller, this
gateway also has the functionality described below.
(1) Converts alarm information generated by an existing system to the MICREX-NX’s message system
format, and performs client OS notification, display and acknowledgement operations, and the
like to integrate alarm information of an existing
system with the MICREX-NX method
(2) Notifies the OS client of existence information and
diagnostic information from controllers in an
existing system
(3) Integrates the redundancy of an existing system
with the MICREX-NX method
Figure 4 shows the basic architecture of an OS
server (GW) that realizes the above-described functions.
As shown in this drawing, the OS server (GW) is
equipped with a PCI interface card for physically
connecting a DPCS-F conventional network or an FLnet-compliant LAN to the standard OS server of a
122
Data manager
Existing MICREX
access function
NX driver
I/O driver
PCI board
Ethernet
Plant bus
Terminal bus
DPCS-F, LAN
compliant with FL-net
Existing MICREX
MICREX-NX
MICREX-NX. The data access operation of a standardconfiguration MICREX-NX (such as a graphic system
or trend system) is implemented via a data manager by
an existing MICREX access function that converts the
MICREX-NX information to a format for broadcast
transmission or message transmission on the DPCS-F
or FL-net-compliant LAN, or for file access (IJF
access), in order to accesses actual data in the existing
MICREX’s controller.
4.2 Link device for T-link
Fuji Electric’s original networks such as T-link,
open PIO and optical FFI are available for use as
remote I/O networks.
The T-link, in particular,
supports not only the I/O unit (IOU) that was used
widely with the MICREX-PIII, the I/O unit (IPU) which
achieved many good results with the MICREX-IX, and
MICREX-AX, as networks for connecting Fuji Electric’s
PIO, but also supports many varieties of PIOs. Examples are listed in Table 1.
A link device that links to the PROFIBUS-DP,
which is the MICREX-NX’s standard remote I/O
interface, is available as a component for connecting
the T-link to the MICREX-NX’s controller. This link
device enables an existing PIO and cable to be used
directly to connect to the MICREX-NX. Moreover, use
of the PROFIBUS-DP enables the advantageous configuration technique of the MICREX-NX and an integrated mode of engineering for implementing the
notification of failures, diagnostic information and the
like to the HMI, and also supports future system
growth. (Refer to Fig. 5.)
This link device, under the supervision of the
PROFIBUS interface, refreshes PIO data for the Tlink, and also integrates the following T-link functions.
(1) Diagnoses each PIO module connected to the T-
link, and issues notification of each diagnosis
(2) Sets parameters and transmits/receives data for
the communications module and other special
modules controlled by application programs, and
transmits messages for specified modules
(3) Realizes redundant functions of the existing system in the new redundant architecture of the
MICREX-NX
4.3 Link device for P/PE-link
Fuji Electric’s P/PE-link has been used not only for
the DCS controller, but also has been used in many
projects as a simple network for connecting to Fuji
Electric’s general-purpose PLC. As shown in Fig. 6, a
link device for connection to the MICREX-NX is also
Fig.6 P/PE link system configuration of MICREX-NX
OS
ES
Plant bus
Table 1 List of I/O supported by T-link
System
MICREX
-NX
I/O type
MICREX-PIII
PCS
-500
MICREX-IX
HDC MICREX-AX
-500
Single T
○
○
×
×
Redundant T
○
○
×
×
Single T
IOU
(HDC) Redundant T
○
×
○
○
○
×
○
×
TK capsule
○
○
○
○
CIO
○
×
○
○
FTL
○
×
○
○
IPU (including FFI)
○
×
×
○
IOU
(PCS)
AS
Redundant
AS
Ethernet
Link
device
Ethernet
Link
device
P/PE link
PLC
Link
device
P/PE link
PLC
PLC
PLC
Fig.5 T-link system configuration of MICREX-NX
OS
ES
Plant bus
AS
Redundant AS
PROFIBUS-DP
Link
device
T-link
Link
device
PROFIBUS-DP
Link
device
Link
device
T-link
Drag & drop
T-link I/O
123
Fig.7 Engineering resulting from DB information migration tool
OS client
Automatically generated block icon
Messages generated by
an existing system can
be displayed and
acknowledged
Automatically
generated picture
Automatic generation of linkage
between each I/O field and actual
data in controller
Existing HMI
Existing DB
OS server
(GW)
DB
DPCS-F
Existing controller
Prior
MICREX-NX
engineering data
provided for this P/PE-link. The link device enables
the handling of data between the general-purpose PLC
of a MICREX-F or MICREX-SX connected to an
existing system and the MICREX-NX’s controller.
Additionally, P/PE-link functions such as message
transmission, redundancy and the like are integrated
as standard features within the MICREX-NX architecture.
4.4 DB migration tool
So that the MICREX-NX system can use the same
data names as previously to access data on an existing
system, the engineering information (such as tag
definitions and alarm message definitions) contained
in the existing MICREX system must be loaded into
the MICREX-NX environment. This task is accomplished by using the DB migration tool. (Refer to
Fig. 7.)
The functions of the DB migration tool are listed
below.
(1) Registration of tags (user tags, module tags,
system tags)
(2) Registration of alarm messages
(3) Generation of plant hierarchy (picture tree)
(4) Generation of linkage between tags and block
icons and between tags and faceplates
This DB migration tool can be used to download
automatically the necessary engineering information
from the existing system, thereby eliminating the need
for one-by-one manual input. Also, when generating a
screen on the OS client, tag names and faceplates
corresponding to controller device modules on the
existing MICREX system can be used, and by simply
pasting the appropriate faceplate on the plant screen
124
Faceplate corresponding
to block icon
Registration of tags
Registration of alarm messages
Generation of plant hierarchy
Generation of linkage between tag and screen
DB information migration tool
(picture), linkage such as the display of device data,
parameter settings from the screen, and the like can be
realized.
4.5 Software converter
Controller applications for the third generation
MICREX-PIII and later are created with an engineering
tool called the FPROCES. Although there are some
restrictions, a converter is available for migrating
those applications to controller applications for the
MICREX-NX. By using this software converter, application programs created with various representational
systems such as ladder diagrams, FB diagrams, SFCs
and loop diagrams that have been generated by
FPROCES can be run as MICREX-NX programs.
5. Conclusion
The strategy for migrating an existing system to
the MICREX-NX has been described.
Based on Fuji Electric’s adopted motto of “evolution with inheritance,” we have continued to advance
new technology while inheriting the assets of our
customers’ existing systems. With the marketplace
introduction of the MICREX-NX, Fuji Electric’s new
DCS, we believe that the capability for smooth migration will appeal to our customers, and that this
capability will be a powerful advantage for our new
information and control systems in the future.
With the MICREX-NX positioned as a new DCS
platform, Fuji Electric intends to continue to provide
systems capable of contributing to the profit of our
customers.
Engineering Support Tools for
the MICREX-NX
Yoshitomo Takeuchi
Keisho Yamano
Takashige Mori
1. Introduction
The process automation system (PAS) market in
Japan has transitioned in recent years from a period of
growth, driven largely by new demand, to a mature
market where most of the demand comes from system
updating and renewal, and these conditions – under
which significant market growth is not expected – are
continuing. Meanwhile, PAS hardware components
such as human-machine interfaces (HMIs), controllers,
I/O devices, and the networks that connect them, have
continued to adopt open standards, and it is becoming
difficult to differentiate components made by different
companies. Under these market conditions, system
vendors are facing the difficult task of increasing the
added value of their application software, i.e., system
vendors must effectively utilize their accumulated
wealth of control-related expertise in order to differentiate their products from those of competitors while, at
the same time, realizing highly efficient and high
quality engineering capable of surviving in the severe
price competition of a mature market.
In other words, the importance of engineering will
only increase for system vendors, and in order to
succeed in the above-described task, a suitable platform for engineering support tools must be provided.
The engineering station (ES) engineering support
tool for the MICREX-NX meets market needs for the
above-described engineering support tools and also
provides various functions.
2. ES Functions and Features
2.1 ES functions
Figure 1 shows a functional overview of the ES.
Configured on a Windows*1 personal computer, the ES
is a common platform for a variety of support tools,
such as an HMIs and controllers. The ES is a
collection of multiple types of engineering software
programs, all of which are integrally controlled by the
manager. The manager calls the various engineering
support tools, and by means of data linked among
software programs and the use of a common platform,
provides a function for managing the support software.
2.2 ES features
(1) Integrated engineering data
Data from the various engineering support tools
called by the manager are integrally managed in a
database. Because input data is under centralized
control in the database, inputting data to one location
will cause a plurality of related data to be updated
automatically. As a result, the task of inputting data
is made more efficient, and data inconsistency due to
mistaken input or other human error is eliminated and
software quality is improved.
(2) Hierarchical engineering
In an ES, project data and library data for control
and monitoring software and the like is hierarchically
managed from a Windows Explorer-like screen. As a
result, an engineer is able to access desired data
intuitively and speedily, and copy-and-modify operations can be readily performed for each hierarchical
unit.
(3) View layout
The three views that form the core of MICREX-NX
engineering enable integrated engineering data to be
observed from different angles corresponding to each
view. The appropriate view can be selected according
to the situation and the phase. Figure 2 shows an
example of the view screen.
q Component view
The component view is used to set hardware
parameters relating to the automation system
(AS) of the control system, I/O devices that are
supplied to the AS, the operator station (OS),
the ES, and the network that connects these
hardware components. One special feature of
the component view is that it enables monitoring of the resource usage status of the AS.
Moreover, the hardware configuration (HW
Config) launched from this view can also be
used when migrating the existing I/O, and the
process device manager (PDM) is able to
perform centralized setting, failure diagnosis
125
Fig.1 ES functional overview
Batch system
BATCH
OS engineering
CFC templates for standard
applications
(e.g. motor, valve, controller)
User OS
faceplate
NX engineering
Engineering for
failsafe systems
Engineering for networks,
communication and hardware
Programming
for user function
blocks
PDM for field
device
management
Automation
engineering
Fig.2 View layout
and loop checks for intelligent field devices.
w Plant view
Plant view shows the hierarchical management architecture for the purpose of providing
an easy to understand overview of the plant to
which control will be applied. This hierarchical structure complies with IEC61512 (ISA
S88), the international standard for batch
control. Operation from a Windows Explorer-
126
like screen to create a hierarchy that matches
that hierarchical structure of the actual plant
enables efficient management of the controller
control program and the HMI screen. Moreover, the plant hierarchy defined here is automatically evolved to the OS screen hierarchy.
e Process object view
Though it is difficult to grasp the overall aspect
of scattered objects clearly by using hierarchical management of plant view, process object
view can provide an environment to manage
process objects intensively. The various parameters for process objects such as valves and
motors scattered throughout an individual control program or HMI screen can be set or
modified all at once by operation from an
Excel*2-like screen, without having to open
individual files. Integration with Office* 3
facilitates copy-and-paste operations from various lists such as an I /O list received from a
customer.
*2: Excel is a registered trademark of Microsoft Corporation
of the USA.
*3: Office is a registered trademark of Microsoft Corporation
of the USA.
(4) Library
The MICREX-NX contains a library for each
project, and libraries may be created easily by copying
and pasting control programs created by engineers.
Thus, control expertise can be accumulated and readily
utilized in future engineering tasks. Also provided are
library packages, equipped with many technical blocks
that contain a set of function blocks such as linearization, control blocks, and block icons and faceplates,
enabling the engineer to realize a high level of control.
3. Engineering Functions and Features
3.1 Overview of MICREX-NX engineering
Figure 3 shows the MICREX-NX engineering flow.
With the MICREX-NX, systems for performing controller engineering and HMI engineering are linked to one
another to increase the engineering efficiency.
3.2 Controller engineering functions and features
A control program is generated by combining the
following three languages in accordance with the
desired goal. Regardless of the language used to
generate a control program, the memory that stores
parameters used in each program is allocated automatically to permit use from only that program, and
therefore the engineer does not have to worry about
the problem of duplex writing in which multiple
control programs write to the same physical memory.
Moreover, this arrangement enables a library to be
operated easily. Compared to previous model types,
the functionality has been increased significantly at
this point.
Additionally, control program debugging is implemented by either connecting an AS to an ES, or by
running a PLCSIM control simulator on an ES to
enable online monitoring of each control program, and
thereby increasing the efficiency of control program
debugging.
Fig.3 MICREX-NX engineering flow
MICREX-NX
Engineering flow
Global configuration of manager
(1) Continuous function chart (CFC)
CFC that conforms to IEC61131 FBD is used to
generate a continuous control program in the
MICREX-NX. Figure 4 shows a screen shot of the CFC
editor. This screen shot shows an example of motor
operation control, and consists of a protection interlock
function, an operating function and a control function.
The control program can be created simply on a CFC
editor by dragging and dropping control blocks known
as function blocks (FBs) and function calls (FCs) and
then by linking the control blocks together with
connection lines. Many various control blocks are
available, including instrumental loop control, sequential control, numeric processing, logic processing, and
the like, and these program components can be
combined freely on the same chart according to the
desired control to generate a control program. The
result is a change from complex, vertically segmented
engineering for each control function, as seen in Fuji
Electric’s previous models, to sophisticated and horizontally structured engineering. Moreover, the computational sequence may be customized and unused pins
of control blocks may be hidden in order to support
various detailed needs. Additionally, a functionally
organized chart may be converted into control blocks to
provide an environment that enables the easy reuse of
control programs. The above features interact organically to enhance the engineering efficiency.
(2) Sequential function chart (SFC)
Conforming to IEC61131, an SFC is used to
generate a sequential control program. Figure 5 shows
an example screen shot of the SFC editor. The layout
of signals involved in the generation of steps and
transitions can be accomplished by simply selecting
the required signals from a control block parameter
list.
Moreover, the use of an SFC visualization
package enables online SFC status display and operation from an OS, without any special engineering.
(3) Structured control language (SCL)
SCL conforms to the structured text (ST) of
IEC61131. Since this programming language can
Fig.4 CFC editor screen shot
New function or
new project wizard
Hardware configuration
Customization of plant hierarchy
CFC programming
Controller engineering
Automatic generation
of block icons
SFC programming
OS compile
Block icon and faceplate
HMI engineering
OS engineering
Download to AS and OS
AS and OS runtime
127
Fig.5 SFC editor screen shot
provide a program with control structures, SCL is
mainly used when generating the FBs and FCs in a
CFC. SCL can be applied to generate more flexible
control programs since it enables a user to generate
required functions by him/herself and then to use those
functions.
Fig.6 Graphic designer screen shot
(4) User management
For the purpose of ensuring plant security and
traceability, all operators are given detailed authorization rights. Operation levels such as operational
authorization can be specified per plant.
3.3 HMI engineering functions and features
As has been described above, HMI engineering in a
MICREX-NX system is closely related to the controller’s control program. When a control block, for
example PID control, is created in the controller, two
HMI components are automatically generated. One is
a block icon that appears as a symbol on the HMI
screen. Another one is a faceplate window, is called
when a block icon is clicked and is used to implement
detailed status display, operation and settings. On the
other hand, a graphic designer is used to create an
HMI screen according to the process image, and then
automatically generated block icons are repositioned
according to that image to complete the HMI screen. A
faceplate designer may also be used to generate a
faceplate according to user needs.
(1) WinCC Explorer
The WinCC Explorer is a common platform for
HMI engineering. In addition to the abovementioned
graphic designer, various other functions such as a
global script and user manager are also provided.
(2) Graphic designer
Figure 6 shows a screen shot of the graphic
designer. The graphic designer is a software program
for creating HMI screens.
The graphic designer
supports HMI screen creation with the same operability and expressive ability as general-purpose image
processing software. Moreover, because users are able
to create their own libraries, previously created HMI
parts can be accumulated and reused, providing an
arrangement that leads to more efficient screen creation and to improved screen operability and the like.
(3) Global script
A script language conforming to C or visual basic
(VB) is provided, enabling general-purpose SCADAlike screens to be customized flexibly.
128
3.4 Support software
A group of tools that improve the efficiency and
quality of MICREX-NX engineering are introduced
below.
(1) Import /export assistant
The import /export assistant provides the capability
to generate multiple control programs all at once, and
all having the same functionality. A control program
template is created, and then the program destination,
I /O parameters, and other data that are unique for
each control program are specified in a single operation from an Excel-like screen and expanded to multiple programs. The expanded settings file can be stored
in an ES so that when a control program requires
modification, a pre-existing setting file can be used to
implement that change instantaneously in multiple
control programs. Figure 7 shows an overview of the
import /export assistant.
(2) Version cross checker
The version cross checker provides the capability
for version management of the generated control
programs. This software is provided with a function
that highlights the display of project contents that
have been added, deleted and/or changed before and
after modification, thereby enabling graphical verification of that modification. The version cross checker
can be used in a wide variety of applications such as
control program version control and failure analysis.
Figure 8 shows an example screen shot of comparative
results obtained by the version cross checker.
(3) Control simulator (PLCSIM)
With the MICREX-NX, an ES personal computer
can run a simulation of a controller. The simulation
environment is easily configured, and a single ES
personal computer can achieve the equivalent debug-
Fig.7 Import/export assistant
Fig.8 Version cross-checker screen shot
Template chart
Automatically
generated chart
Print
First, prior, next,
last difference
Filter
ON/OFF
Apply
filter
Different
attribute
Compare
Open
Program A
Program B
+
PH assign.
B17/Reac1
B17/Reac2
B17/Reac2
B17/Reac3
Import/Export
Assistant
Chart name PV_LR PV_LR
LIC1710
0
100
TIC2711
0
500
PIC2712
0
10
FIC3210
0
250
KP
1.7
1.25
2.0
1.5
TN
2.5
3.5
1.0
10
Measuring point list
TV
1.3
1.0
1.0
2.0
Automatically generated
plant hierarchy
ging performance as one OS and one AS connected to
each other. Accordingly, the debugging efficiency of a
controller and HMI screen is dramatically increased.
Moreover, an all-in-one personal computer enhances
portability and enables performance to be verified at
any location.
Symbol for SFC
Extra
object in B
Different
object
Extra
object in A
support tools, previously acquired control expertise can
be fully utilized to realize highly efficient and high
quality engineering that satisfies market needs. In the
future, Fuji Electric intends to continue to supply ideal
engineering platforms and to contribute to the development of process automation systems.
4. Conclusion
With the sophisticated MICREX-NX engineering
129
Hitoshi Ichinohe
Tetsuji Shio
Hiroyasu Ikedo
Control systems are often mounting in cabinets of
the customers’ desired dimensions in order to improve
environmental resistance and ensure proper functionality and management range. So that devices enclosed
within a limited volume can be configured and operated stably, the design of the cabinet must limit the rise
in internal temperature and must be equipped to
handle the assumed level of external noise at the site
of the installation. In addition to incorporating these
considerations, the cabinet for the MICREX-NX: new
information and control system is also designed to use
Euro terminal I /O modules to realize high-density
mounting. Moreover, external terminals are replaced
with the same ring terminal interface as in prior
products to realize the same mounting efficiency as in
the past. This paper presents an overview of the
MICREX-NX cabinet mounting technology.
2. Necessity of Cabinets
The main reasons for housing an industrial system
inside a cabinet are given below.
(1) Management, operation and security consideration
q To clarify the system’s responsibility of work
and range of the contract
w To enable maintenance with a 1-to-1 relationship between the power supply distribution
panel and the system
e To clearly identify the manager and clarify his/
her responsibility with lock and key management
(2) Environmental consideration
q Heat: To cool and/or heat the cabinet’s internal
ambient temperature to maintain the system
at a suitable temperature
w Atmosphere: To protect the interior from corrosive gas and/or dust
e Vibration: To protect the system from earthquakes and vibrations from large equipment
r EMC: To realize EMC (electromagnetic compatibility), shown in Fig. 1, comprising both an
130
Fig.1 EMC classification
Electrostatic discharge
EMC
EMS
(electromagnetic
compatibility)
(electromagnetic
susceptibility)
Radiated electromagnetic field
Conduction noise
1. Introduction
Conducted radio
frequency disturbance
Input terminal noise
Earth terminal noise
Surge voltage
Voltage dips, short
interruptions and voltage
fluctuation
Magnetic field
Conductor noise
(noise terminal voltage)
EMI
(electromagnetic
interference)
Radio noise (electric field intensity)
Harmonic current
EMS (electromagnetic susceptibility) level that
is immune to external interference and an EMI
(electromagnetic interference) level that does
not disturb other equipment.
(3) Safety consideration
q To protect against bodily harm by preventing
accidental contact with energized parts, heated
parts, and moveable parts such as fans
w To prevent workers from accidentally touching
the equipment (to prevent mistaken operation)
The MICREX-NX cabinet has been designed with
the above considerations. The cabinet is described
below with a focus on its thermal design, safety and
EMC environment design, and Euro-to-ring terminal
conversion.
3. Thermal Design
3.1 Cabinet cooling method
When mounted inside the enclosed space of a
cabinet, the system will be adversely affected by heat.
Thermal design is used to minimize this adverse effect.
The thermal design also considers other conditions
unrelated to heat and various cooling methods were
designed.
Conditions unrelated to heat include the efficiency
of mounting the system in the cabinet, protection
against EMC, dust, corrosive gas and other environmental factors, and the tradeoff relation between these
conditions and temperature rise.
The cooling methods shown in Fig. 2 are described
below.
(1) Air cooling without a fan
In this method, heat is exhausted by natural
convection through slits provided at the top and
bottom of the cabinet. This method does not require
any special equipment for cooling, and is advantageous
in terms of cost and mounting efficiency.
(2) Fan cooling
Forcible convection with a fan is used to exhaust
heat.
q Forced exhaust
This method uses filters through which air
passes at the cabinet bottom and a fan at the
top of the cabinet to exhaust heat. The cabinet
interior is negatively pressurized with respect
to the external atmosphere and because gaps
are also provided that allow the intake of small
particles, this method is disadvantageous in
providing protection from environmental factors such as dust and corrosive gas.
w Forced suction
This method uses filters through which air
passes at the cabinet bottom and fans at the
bottom of the cabinet to exhaust heat from the
cabinet top by means of convection. Because
the cabinet interior is positively pressurized
with respect to the external atmosphere and
the intake air must pass through a filter, this
method provides excellent protection against
the environment. However, because the filters
Fig.2 Cooling methods
(a) Air cooling
(without fan)
(d) Sealed structure
Gap
Filter
(b) Forced exhaust
(c) Forced suction
and fans are concentrated at the bottom of the
cabinet, the mounting efficiency is poor.
(3) Sealed structure
In this method, the cabinet is completely sealed.
Because no cooling fans or filters are used, and because
there is no convection, this method provides ideal
protection against dust and corrosive gas. However,
the cooling efficient is poor since heat is exhausted
solely by the radiation of heat from the cabinet surface.
Another drawback is that corrosive gas may enter the
cabinet when the door is opened and closed during
maintenance.
In the case of forced cooling, this problem does not
occur because external air that enters the cabinet is
eventually replaced with filtered air.
3.2 MICREX-NX cabinet mounting
The MICREX-NX has been designed to enable
mounting with any of the above cooling methods. The
thermal design must be implemented such that the
operating temperature of the mounted system does not
exceed 60°C.
Figure 3 shows a drawing of the MICREX-NX
controller cabinet mounting, and Fig. 4 shows the
external appearance of that controller cabinet.
A redundant controller, control LAN communications device, power supply, power receiving and distribution equipment, and an alarm unit are mounted in
the front panel. I/O devices for handling field signals
and Euro-ring terminal conversion cables that connect
to the field wiring are mounted in the back panel.
3.3 Actual thermal design
(1) Thermal balance
The mounting design basically organizes the system so that heat-generating devices are not arranged
consecutively. As a result, heat does not become
concentrated inside the cabinet and the temperature
can be averaged.
In the cabinet’s front panel, the controller and
power supply, which are heat-generating source, are
alternately mounted between low heat-generating
equipment. In the rear panel, each I/O device is
mounted so as to alternate with a Euro-ring terminal
conversion cable, which generates no heat at all.
(2) Heat shielding and ventilation route
In order to prevent a rise in temperature, it is
extremely important that the heat generated by equipment mounted in the cabinet does not affect any other
equipment in that same cabinet. With the MICREXNX cabinet mounting, a heat shield unit is used
between each piece of equipment.
This heat shield unit exhausts the self-generated
heat from the back top of the cabinet, without conveying that heat to upper stages, so that upper and lower
equipment are shielded in heat. The heat shield unit is
also provided with a function that supports the cables
connected to each piece of equipment.
131
Fig.3 Mounting of controller cabinet
(Front panel)
(Side panel)
(11)
(11)
(10)
(10)
Redundant
controller
(Back panel)
(11)
S7-400
(A)
(CPU)
Heat
shield unit
1
P
2
N
F1
(3.2A)
F2
(3.2A)
P1
P2
ET200M (I/O)-4
S7-400
(B)
(CPU)
Terminal unit
CONECTER UNIT
OUT
A
(9)
(9)
B
Heat shield unit
CPU
(A)
F1
(10A)
Heat shield unit
P1
CPU
(B)
(17)(19)
F2
(10A)
Communication
unit
P2
T1
1
P
2
N
F1
(3.2A)
F2
(3.2A)
P1
P2
P3
(16)(18)
P4
Heat shield unit
P5
HUB
(B)
(8)
P6
P8
OSM/
ESM
(B)
OLM(B)
OSM/
ESM
(A)
P7
FAN
/ALM
(16) (18)
(8)
Heat shield unit
F5
(10A)
(7)
Heat shield unit
P11
F12
1
2
3
4
5
ALM3
6
7
ALM4
8
Heat
shield unit
9
ALM5
10
Field
power
supply
(A)
(6)
(4)
Field
power
supply
(B)
Diode
unit
1
P
2
3
N
4
5
P
T1
1
P
2
N
F1
(3.2A)
F2
(3.2A)
P1
P2
(6)(4)
(5)
(3)
T1
OLM(A)
T2
ALM1
ALM2
2300
(7)
P9
P10
Power supply
(17) (19)
ET200M (I/O)-3
HUB
(A)
F3
(10A)
F4
(10A)
Heat
shield unit
I/O
T1
ET200M (I/O)-2
(5)(3)
Heat shield unit
Alarm unit
Heat shield unit
6
Heat shield unit
7
N
8
Front power supply
(B)
Power supply
(13)(15)
(2)
T1
(2)
Front power supply
(A)
(1)
(12)(14)
1
P
2
N
F1
(3.2A)
F2
(3.2A)
P1
P2
(13) (15)
ET200M (I/O)-1
(12) (14)
(1)
Power distribution unit
(A)
Ventilation route
(B)
700
Fig.4 Appearance of the controller cabinet
900
Fig.5 Temperature measurement results
35
Temperature rise ∆T (°C)
30
25
Forced exhaust
Air-cooled
Sealed
Forced suction
20
15
10
5
0
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)(11)(12)(13)(14)(15)(16)(17)(18)(19)
Measurement point
Front panel
Back panel
In addition, the cabinet is designed such that heat
exhausted from the rear passes through a chimney-like
ventilation route provided in the center of the cabinet,
to exhaust heat efficiently from the top of the cabinet.
(3) Actual measurement and evaluation of temperature distribution
For each of the cooling methods, the distribution of
temperature inside a cabinet of the above design was
measured and the suitability of the design was as-
132
(1) to (19) correspond to the measuring points of Fig. 3
sessed. The results are shown in Fig. 5.
The operating temperature for each system must
not exceed 60°C. Moreover, the maximum ambient
temperature of the cabinet is 40°C, and the temperature rise at an air intake vent for the equipment
mounted in the cabinet must not exceed 20°C.
A design tolerance of 5°C is maintained for these
conditions, i.e., the cabinet must be designed such that
the temperature rise at all air intake vents for a
system does not exceed 15°C. These results satisfy the
design condition because temperature rises in excess of
20°C occur only at the exhaust vents.
Accordingly, the thermal design of the MICREXNX cabinet enables mounting that is compatible with
the cooling methods of air cooling without a fan, fan
cooling with a fan, and sealed structure cooling, each of
which has advantages and disadvantages with respect
to mounting efficiency (cost) and resistance to the
environment, i.e., protection from EMC, dust and
corrosive gas.
5. High-density Design and Euro-to-ring Terminal Conversion
The miniaturization of equipment and reduction in
number of panels that accompany high-density mounting complies with requests for space savings and lower
cost. By using a Euro ring-type I/O module, thermal
design and a centralized power supply, MPU redundant systems with 1,536 (Euro terminals) and 1,024
(ring terminals) I/O points had been realized.
4. Safety and EMC Environmental Design
5.1 Euro terminal features and necessity for ring conversion
Measures against heat and EMC are vital in
ensuring the safe operation of the system. The layout
of the power supply input unit and the power supply
system is important because it forms a route along
which disturbances and noise can travel. To realize
the required specifications in a highly efficient manner, a front power supply method is adopted for the
cabinet power supply input unit and the power supply
system. The source power is received entirely at the
front power supply, where it is then converted into a
stable, low voltage of 24 V DC and delivered to each
devices.
Because this front power supply has a noiseresistant design, EMC protection and the required
cabinet specifications listed below are realized. Other
internal devices and the cabinet layout are important
because their design leads to better overall design
quality, since the designers can concentrate on functional design and thermal design, without distraction
from external requirements.
(1) Electrical shock prevention, insulation
100 V AC wiring is used only for connections
between the power-receiving terminal and the front
power supply. Insulation management is performed
along this interval only.
(2) Noise resistance
There is less wiring for electric power within the
cabinet and there is also less electromagnetic interference between electric power and signal wires.
(3) Harmonic current suppression function
Because the front power supply has functions for
correcting the power factor and suppressing the harmonic current, there is no need to configure active
filters for each devices.
(4) Input wide range power supply
Because the front power supply supports the input
specifications of 100 to 220 V AC and 110 to 220 V DC,
the internal devices can be standardized for an input of
24 V DC.
(5) Power supply line noise, surge voltage
The effective noise filter of the front power supply
provides effective shielding from line noise and surge
noise.
The characteristic feature of Euro terminals is that
the exposed copper core of wire whose sheathing has
been stripped off (or a cylinder-shaped pin attached to
the wire) is inserted into the terminal and tightened
with a screw to secure it. The two main advantages of
Euro terminals are listed below.
(1) The space occupied per wire is less than for
Japanese ring terminals, thus enabling higher
mounting density.
(2) Wiring work is simpler and results in labor
savings.
Direct application of the above advantages enables
high-density mounting to be realized with up to 1,536
points, with reduced labor. In Japan, however, ring
terminals are strongly requested and a mechanism for
converting Euro terminals to ring terminals is available.
5.2 Design of Euro-to-ring terminal conversion
The Euro-to-ring terminal conversion method was
designed in consideration of the I/O (IPU-II) of the
present MICREX-AX model, and in particular, a
revision of its structure was considered.
As the result of this study, the Euro-to-ringconversion cable, shown in Fig. 6, was developed. The
advantages of this method are described below.
(1) More compact structure
The wiring is soldered directly onto the lead of ring
terminal block. This results in a slimmer terminal
conversion part and ensures the withstand voltage.
As a result, the number of I/O points could be
increased from 768 to 1,024 in a single MPU redundant system cabinet.
(2) Improved workability
A two-piece construction terminal block was adopted. Because the terminal block can be replaced to
allow connection of the test equipment, the amount of
labor involved in the testing was reduced.
(3) Cable wire as a component
In the cabinet layout, an external wiring terminal
block is located directly beneath each I/O module, and
the length of the cable for Euro-ring conversion is
fixed. Thus, the wiring for the terminal is no longer
dependent on the customer’s specification. These parts
133
Fig.6 Conversion of Euro terminal to ring terminal
Euro terminal
is a type of
connector and
is inserted
into the I/O
module to
make a
connection.
Euro terminal
Ring terminal Internal
(2 piece type)
cable
The terminal
part can be
separated.
External
terminal
External
terminal
Lead pins are
soldered to attach the wiring.
are available as cable assembly components, which are
produced in advance and can be stocked.
6. Conclusion
The thermal design, safety and EMC environmental design, and the Euro-ring terminal conversion of
the MICREX-NX cabinet have been described. In
addition to these functions, there are also recent
requests for environmentally conscious design.
134
The Fuji Electric Group has declared its intention
to promote the reuse and recycling of constituent
materials for cabinets, and to design cabinets that
have low impact on the environment throughout their
entire product lifecycle, from material procurement to
structuring, transportation, usage, and finally, to disposal.
In terms of reuse and recycling, the design has
changed to adopt labeling of the raw materials in the
various components and to use rivets instead of angle
welding construction for easier disassembly.
To reduce environmental impact, the Fuji Electric
Group is working to improve technology for environmentally-conscious design and is involved in various
efforts to reduce environmental impact, such as acquiring a type III environmental label as established by
Japan Environmental Management Association for
Industry (JEMAI), for the first time in Japan in the
control system field. (Refer to the “Low-voltage motor
control center,” described on the JEMAI website (http:/
/www.jemai.or.jp/).)
In the future, Fuji Electric intends not only to
enhance system features and performance further, but
also to maintain the highest level of environmentally
conscious design and to continue to provide solutions to
the marketplace and contribute positively to society.
Global Network
: Representative Office
: Sales Bases
: Manufacturing Bases
AMERICA
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Tel : +1-510-651-0811 Fax : +1-510-651-9070
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Tel : +1-972-733-1700 Fax : +1-972-381-9991
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Tel : +1-540-387-5925 Fax : +1-540-387-8580
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MEXICO
Tel : +52-8-154-7000 Fax : +52-8-154-7007
EU
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Erlangen Representative Office
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Tel : +49-9131-729613 Fax : +49-9131-28831
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Tel : +49-69-6690290 Fax : +49-69-6661020
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U.K.
Tel : +44-1355-234111 Fax : +44-1355-238810
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FRANCE
Tel : +33-4-73-98-26-98 Fax : +33-4-73-98-26-99
ASIA
East Asia
China Representative Office (Shanghai)
CHINA
Tel : +86-21-6471-0897 Fax : +86-21-6471-4903
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CHINA
Tel : +86-411-8762-2000 Fax : +86-411-8762-2030
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Tel : +86-21-5718-5740 Fax : +86-21-5718-1448
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CHINA
Tel : +86-21-5718-5740 Fax : +86-21-5718-5745
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CHINA
Tel : +86-411-8730-5908 Fax : +86-411-8730-5911
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CHINA
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EQUIPMENT CO., LTD.
CHINA
Tel : +86-21-6921-1088 Fax : +86-21-6921-1066
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CHINA
Tel : +86-571-8821-1661 Fax : +86-571-8821-0550
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CHINA
Tel : +86-755-2734-2910 Fax : +86-755-2734-2912
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HONG KONG
Tel : +852-2664-8699 Fax : +852-2664-8040
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HONG KONG
Tel : +852-2311-8282 Fax : +852-2312-0566
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Taipei Representative Office
TAIWAN
Tel : +886-2-2561-1255 Fax : +886-2-2561-0528
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TAIWAN
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TAIWAN
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Tel : +886-3-321-3030 Fax : +886-3-321-7890
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Tel : +82-2-780-5011 Fax : +82-2-783-1707
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Bangkok Representative Office
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Tel : +66-2-308-2240, 2241 Fax : +66-2-308-2242
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Tel : +62-21-572-4281 Fax : +62-21-572-4283
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Tel : +63-2-844-6183 Fax : +63-2-844-6196
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Printed on recycled paper

Special Edition MICREX-NX

Transcription

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