Rockwell Automation TechED 2018 - VZ03 - Architecting A Distributed HMI System

Architecting a Distributed HMI System
FactoryTalk® View SE System Overview, Limits, Redundancy, and Best Practices.
Paul Haikal
Instructional Developer
June 2018
PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2018 Rockwell Automation TechED™ Event #ROKTechED
Agenda
Your System Foundations Matter!
FactoryTalk® View SE System Overview
FactoryTalk® View SE Limits and Redundancy
Design Exercise - Design a Distributed Application
PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2018 Rockwell Automation TechED™ Event #ROKTechED 3
Before We Begin …
LAYING THE FOUNDATIONS
FOR A FACTORYTALK® VIEW SE DISRIBUTED SYSTEM
Technology Foundations and Hands-On Opportunities
 VZ07 – FactoryTalk® View SE Configuration and Maintenance
 VZ08 – FactoryTalk® View Site Edition Application: What’s New!
 VZ12 – Introductory Lab for Distributed HMI
 Extending FactoryTalk® View Site Edition with Thin and Zero Client Technologies
 SY21 - ThinManager®: Basic Lab
 SY20 - ThinManager®: Advanced Lab
 Ethernet Network
 NT05 – Building Converged Plantwide Ethernet Architectures
 Virtualization
 PR07 – Deploy and Manage a Virtualized PlantPAx® System
SYSTEM OVERVIEW
FACTORYTALK® VIEW SE DISTRIBUTED
FactoryTalk® View Site Edition
DISTRIBUTED
STATION
View Studio FactoryTalk® FactoryTalk® FactoryTalk® FactoryTalk®

FactoryTalk® View Studio provides Directory View SE Alarms and Events Linx™
a common development tool for
Station and Distributed Applications.
FactoryTalk® View SE Software Components
AD DS
SE
Client HMI Data DNS DHCP
Server Server
Alarm FactoryTalk®
Studio Server Directory ViewPoint
Enterprise (Optional)
 High Availability
FACTORYTALK® DIRECTORY
FactoryTalk® Services Platform
• Common • Common address • Common security • Common

software license lookup of authority for all diagnostic
management for resources that FactoryTalk messaging sub-
all FactoryTalk are shared among components in system across all
products FactoryTalk the system FactoryTalk
enabled products products
Activation Directory Security Diagnostics
• Comprehensive • Enterprise-wide • Enterprise-wide

record of any access to real- notification to
changes made to time real-time alarms
the manufacturing and events that
manufacturing data require action
system
Alarms and
Audit Live Data
Events
Why a Standalone FactoryTalk® Host?
 System Start-up
 Recommended that the FTD is the first FactoryTalk component to start, and the last to stop.
 Patching/Upgrading
 Dedicated host results in minimum system downtime with fewer components to patch and less affect upon reboot.
 Integrating with Info Software

 i.e. FactoryTalk® Historian and VantagePoint.
 Redundancy
 While redundant servers (e.g., HMI, Data, Alarm) can function properly in the absence of the FTD, the lowest risk
scenario is FTD uptime.
FactoryTalk® Directory
Internet
Firewall
Domain Controllers
•Server O/S
•DNS/DHCP/WINS
Managed Ethernet Switch for Control System Network (CSN) – HMI/Ctrl Communications
FactoryTalk® Directory Server

• FTD
• FactoryTalk® Activation Server
Flex Flex
ControlLogix® ControlLogix® SLC™ SLC™
ControlLogix® ControlLogix®
PLC-5® PLC-5®
CLIENTS
“Thick Client” Distributed System
 Traditional installation Clients
strategy
 Local installations and
licensing of all products
 Each computer has full
operating system install
FactoryTalk® View Site

Data
Directory Edition
Servers
Server Servers
“Thin Client” and “Zero Clients” Distributed System
 Traditional or virtualized Clients
installation strategy
 Remote Desktop Server
added with View Site Edition
Client Installation
 Desktop computers can be
replaced with thin client
computers or Zero clients FactoryTalk® View Site
Data
with a ThinManager® Directory
Server
Edition
Servers
Servers ThinManager®
deployment.
ThinManager® Integration with FactoryTalk® View SE 10.00
Overview
• Pass-through login from ThinManager® to
launched FT View SE clients
Device
s
Benefits
• Login once from ThinManager®, even if
User X multiple ViewSE clients are launched
Users
Group X
Role X
ThinManager® provides secure

configuration and delivery of content Location
“Web Client” or ViewPoint Clients
 Web client can be on any Clients
supported device
 FactoryTalk® ViewPoint is an
extension of View SE
FactoryTalk® View Site

Data FactoryTalk®
Directory Edition
Servers ViewPoint
Server Servers
When to use a web client?
 Use FactoryTalk® View Site Edition Client (thick or thin or
zero client) for:
 For onsite operators
 High availability and performance
 Rich and more complex application scope
 VBA custom code
 Use of ActiveX controls
 Full Trending capability
 Full Alarming capability
 Use FactoryTalk® ViewPoint Client (web client) for:

 Casual operators, managers, mobile users
 Non-critical performance
 Limited application scope
 Graphics displays
 Browser navigation
 Remote monitoring of trends and alarms
 Activation Required
 80 SE Clients (Starting with version 10)
 And 50 ViewPoint Web Clients **
 Workstation OS AD DS
SE
Server Server
Alarm FactoryTalk®
Studio
Server Directory ViewPoint
HMI Clients Internet
Firewall
Domain Controllers
•Server O/S
•DNS/DHCP/WINS
FactoryTalk® Directory Server 5 Clients

• FTD
FactoryTalk® View SE Clients
Flex Flex
ControlLogix®
PLC-5® PLC-5®
ControlLogix®
HMI SERVERS
HMI Server
 Graphic Displays
 Displays
 Objects
 Global Objects
 Parameter Files
 HMI Tags
 “Legacy” Alarms – Not supported
beyond version 10.
 Data Logs
 Event Detectors
 Derived Tag Files
 Up to 10 Servers
 High Availability AD DS
 Server OS
SE
Server Server
Alarm FactoryTalk®
Studio
When to Use Multiple HMI Servers
 Load balancing
 Large number of Datalogs.
 Large number of Event files and Derived Tag files.
 Large number of HMI “Legacy” Alarms (Not supported beyond version 10).
 Logical or Physical areas

 Ability to take down one HMI server for maintenance without affecting entire system.
 Expansion
 Grow an application by adding a new line, duplicating existing HMI server.
 Security
 Creating multiple servers allows security configuration at an area level.
 In production – The maximum number of FactoryTalk® View SE HMI servers that can be hosted on a
single computer is 1.
HMI Server Considerations
 In production – The maximum number of SE HMI servers that can be hosted on a single computer
is 1.
 Maximum number of HMI servers supported in an application is 10 for non-redundant and

redundant servers.
 Redundant servers are limited to 5 in versions earlier than v7.0 of View SE.
 How do licenses get served?

 From 1st to last, as projects load in the application
 FactoryTalk® View HMI Servers look for lowest key first
 This prevents the 25 display server from using a 100 display key
HMI Servers
Internet
Firewall
Domain Controllers SE Server

•Server O/S
•DNS/DHCP/WINS • (1) HMI Server

• FTD
Flex Flex
PLC-5® PLC-5®
DATA SERVERS
Introducing FactoryTalk® Linx
Enterprise
Data Server For Rockwell Automation Purchased For Third-party OPC® DA & UA
Control Hardware Software Access
Name changed to appropriately reflect FactoryTalk® Linx Revised name for FactoryTalk® Linx Gateway provides a
as the premier communications service included with closer tie between the communications service and
FactoryTalk® software portfolio purchased OPC® option.
RSLinx® Classic retains original name
FactoryTalk® Linx™
Data Server for Logix5000™
Linx™
Linx / Logix Integration Benefits / Advantages

• Designed for Logix • Reduced system processing
• Load tag lists into Logix Memory • Highest performance data access
• Optimized lists retained in Logix • Fastest request / screen load times
• Tracks Logix memory changes • Refresh active tags & browsing
• Push unsolicited Messages • Reduced Logix / Network impact
• Access Extended Tag Properties • Faster development
Data Server Options
 **Preferred**
 Live Data Server for FactoryTalk® View SE and other FactoryTalk® applications (FactoryTalk® Transaction Manager, FactoryTalk® Historian, etc.)
 Optimized performance via TCP/IP, not DCOM
 Offline browsing of Logix based controller projects
 Unsolicited Messages
 Alias Topic Functionality (New)
 Can be used with Studio 5000 Logix Designer (New)
 OPC® UA support - Activation required (New)
 Preferred Data Server for ALL Rockwell Automation® controllers
 Complex communication routing. Protocol changing (ex. Ethernet to DH+™)

 Offline browsing of PLC/SLC RSLogix™ files
 KEPServer Enterprise and 3rd Party OPC® Servers

 KEPServer Enterprise is preferred for connecting to Non-AB controllers.
Data Servers - Complex Paths
Data Server
EtherNet/IP
DH+™
ControlNet
SLC™ ControlLogix®
SLC™
PLC PLC
• RSLinx® Classic Required • FactoryTalk® Linx™ Supported

– DH+™ protocol = PCCC – ControlNet protocol = CIP
– Ethernet protocol = CIP – Ethernet protocol = CIP
 No Activation**
 High Availability AD DS
 Server OS
SE
Server Server
Alarm FactoryTalk®
Studio
FactoryTalk® Linx™ Data Server
FactoryTalk® Live Data clients
(FactoryTalk® View, FactoryTalk® Historian, FactoryTalk® VantagePoint®, FactoryTalk® Transaction Manager)
Data Network Data Network
FactoryTalk® Live Data servers FactoryTalk® Live Data servers

(FactoryTalk® Linx™) (FactoryTalk® Linx™)
Control Networks Control Networks
CompactLogix™ PLC-5® ControlLogix® CompactLogix™ PLC-5® SLC™ 500

ControlLogix® SLC™ 500
FactoryTalk® Linx Sizing Variables
Number of
FactoryTalk System testing
Controllers
(Shortcuts)
Digital and Tags defined
Total tags
•750,000
Analog within each
Instruction
based
controller
(Namespace on scan per
Alarms )
application
FactoryTalk®
Linx Resource
Impact Total tags
Tag Types
(Scalar,
Array, UDT)
Number of
FactoryTalk®
Clients
on scan per
data server
•100,000
Number of
Number of
Tag
Tags on
Scan
References
by Clients
Distribute the load across multiple
FactoryTalk® Linx Data Servers.
Data Servers
Internet
Firewall
SE Server
Domain Controllers
•Server O/S • (1) HMI Server
•DNS/DHCP/WINS
Data Server
• (1) FactoryTalk® Linx™

• FTD
• FactoryTalk® Activation Server FactoryTalk® View SE Clients
Flex Flex
PLC-5® PLC-5®
ALARM SERVERS
Alarming
 HMI/Legacy Alarms (Not supported beyond version 10)
 Alarm configuration and status are located in the HMI server.
 Uses legacy alarm objects (Banner, Summary.)
 A single update rate for all HMI alarms.
 Server Tag-Based Alarms

 Alarm configuration and status are located in the FactoryTalk® Alarm server.
 Uses new alarm objects (Banner, Summary, etc.)
 Can use FactoryTalk® Linx™, Classic, or 3rd party OPC
 Logix Alarms
 Alarm configuration and status are located in the Logix 5000 device.
 Uses new alarm objects (Banner, Summary, etc.)
 Utilizes FactoryTalk® Linx™ for alarm communications
FactoryTalk® Alarms & Events - Two Alarm Sources
• Alarm instructions available in the Logix family of • Software-based alarm servers poll data tags for
controllers with FRN 16 thru 20 and 24 or higher. alarm conditions.
• Logix Tag-Based Alarms supported in 5580, 5480 • The Alarm server detects alarm conditions and
and 5380 controllers with FRN 31 or higher. triggers alarm events
• The controller detects alarm conditions and • The FactoryTalk® Alarms and Events service
triggers alarm events. captures all of the controller events and sends
notification to connected clients
• The FactoryTalk® Alarms and Events service
captures all of the controller events and sends • Information is displayed in the A&E Alarm
notification to connected clients. Management components on the clients
• Information is displayed in the A&E Alarm • Supports all controllers - PLC-5®, SLC™ 500, or
Management components on the clients any third-party device through OPC.
Logix Alarms Server Alarms

Logix Alarms
Reduction in network traffic

through “publishing” technology
Improved time stamp accuracy
No alarm information loss in the

event of HMI outage
No HMI tag duplication required,

alarm instruction or tags directly
A single, consistent shared alarm

generation and response
mechanism
On the fly changes to alarming

tags are automatically updated in
HMI
Logix Alarm Instructions with v20
Controllers with revision 20 or earlier - System performance and tested limits
Controller specifications
Specification Value
Tested number of “subscribers” (FactoryTalk® Linx™ Servers) per 3

controller
Controller memory used for buffering by each subscriber 100k
Typical number of alarm state transitions per subscriber 1000
Recommended maximum number of alarms per controller 2000
Approximate controller memory used for each alarm 1k (digital), 2.2k (analog)*
Supported languages for alarm messages All languages supported by

FactoryTalk® View SE
Logix Alarm Instructions with v24
Controllers with revision 24 - System performance and tested limits
Controller specifications
Specification Value
Tested number of “subscribers” (FactoryTalk® Linx™ Servers) per 3

controller
Typical number of alarm state transitions per subscriber 1000
Recommended maximum number of alarms per controller 3000
Approximate controller memory used for each alarm 1k (digital), 2.5k (analog)*
Supported languages for alarm messages All languages supported by

FactoryTalk® View SE
Logix Tag Based Alarms
Factory Talk Alarms & Events
Benefits
• No need to add an instruction; simplified design workflows
inside Studio 5000 Logix Designer
• No addition programming required. Alarms automatically
sent to FactoryTalk® Alarms and Events
• New alarm manager provides a single place to configure
• Small memory footprint; great for applications that have high
alarm counts
• Alarm definitions allow for increased modularity
• Supports bulk generation of alarms via XML import/export
• Every structure instance will now have an alarm. Alarm
instances can be customized
New
Supported in 5580, 5480 and 5380 Only Logix

Tag-Based Alarms
AD DS
SE
Server Server
Alarm FactoryTalk®
Studio
 No Activation
 Server OS
 20,000 Alarms per A&E Server (View SE 10.0)  High Availability
 7,500 Logix Alarms max per Logix Controller
(Supported in 5580, 5480 and 5380 Only)
Internet
Alarm Servers
Firewall
SE Server
Domain Controllers
• (1) HMI Server
•Server O/S Data Server
•DNS/DHCP/WINS
• (1) FactoryTalk® Linx™
Alarm Server
• (1) A&E Tag-based Server

• FTD
• FactoryTalk® Activation Server FactoryTalk® View SE Clients
Flex Flex
PLC-5® PLC-5®
FACTORYTALK® VIEW STUDIO ENTERPRISE
AD DS
SE
Server Server
Alarm FactoryTalk®
Studio
 Multi-user development
 Up to 5 simultaneous
development stations  High Availability
 Workstation OS
View Studio Enterprise
Internet
Firewall
Domain Controllers Application Server

•Server O/S • (1) HMI Server
•DNS/DHCP/WINS • (1) Data Servers
• FactoryTalk® Linx™
w/Alarms and Events
• (1) Tag-based Alarm Server

• FTD
Flex Flex
ControlLogix®
ControlLogix® PLC-5® PLC-5® Engineering Workstation
• RSLogix™
5/500/5000
• RSLinx® Classic
• View Studio
HIGH AVAILABILITY
Sample Redundant System
Internet
Firewall
Domain Controllers Primary Server Secondary Server

•For the Cel Sys Domain • (1) HMI Server • (1) HMI Server
•Server O/S • (1) Data Servers Redundant • (1) Data Servers
•DNS/DHCP/WINS • FactoryTalk® Linx™ Pair • FactoryTalk® Linx™
w/Alarms and Events w/Alarms and Events
• (1) Tag-based Alarm Server • (1) Tag-based Alarm Server

• FTD
Flex Flex
ControlLogix®
PLC-5® PLC-5® Engineering Workstation
ControlLogix®
• RSLogix™
5/500/5000
• RSLinx® Classic
• View Studio
High Availability Considerations
 Only one host should be designated as the “Primary” with the

responsibility of the Primary HMI and Primary Data servers.
 Redundancy is not a mechanism for load balancing.
Good Bad
Server #1 Server #2 Server #1 Server #2
• HMI Server Primary • HMI Server Secondary • HMI Server Primary • HMI Server Secondary
• Data Server Primary • Data Server Secondary • Data Server Secondary • Data Server Primary
Redundant Redundant
Pair Pair
ARCHITECTING EXERCISE
Design a Distributed Application
Design a FactoryTalk® View SE System
Design a FactoryTalk® View SE Network Distributed application for a customer with the following
criteria.
 The plant is divided into 2 areas.
 The first consists of Production Line 1 and Production Line 2.
 This area of the plant runs from 8 AM to 5 PM and power is turned off outside these hours to conserve energy.
 There is a need for 140 screens and about 10,000 alarms.
 Customer is requesting redundancy for their alarms only in this area.
 The second is made up of Production Line 3. This area runs 24/7.
 In this area, there is a need for 240 screens and 15,000 alarms.
 Customer is requesting full redundancy (HMI, Alarms, and Data Servers) for this area.
 There is a need for 1 Engineering Workstation, 10 Read/Write thick clients

 The customer has provided 5 servers, 1 Engineering Workstation and 10 operator workstations.
 Some displays have to be made available to the plant manager laptop without installing any
Rockwell Software® on it.
Design Exercise
Engineering Workstation Control Room with 10 Clients
 FactoryTalk® View Studio Enterprise  10 View SE Clients

 Studio 5000® / RSLogix 5000®
 RSLogix™ 5
 FactoryTalk® Linx™
 RSLinx® Classic
Design Exercise
(Solution 1 - Preferred)
SERVER 1 SERVER 2 SERVER 3 SERVER 4 SERVER 5

Design Exercise
(Solution 1 – Using View SE 10.0 - Preferred)
250 250 250
1 Client

Design Exercise
(Solution 2 - Using View SE 10.0 )
Unlimited Unlimited
1 Client

Design Exercise
(Solution 3 - Using View SE 10.0 and Bundled Catalog Numbers)
Unlimited Unlimited Unlimited
3 Clients

FactoryTalk View SE Distributed
New Part Numbers
View SE unlimited displays server,

9701-VWSS000CW10LENE ESD
10 R/W clients, 1 ViewPoint client

9701-VWSS000CW10LENM Media

9701-VWSS000CW25LENE ESD

9701-VWSS000CW25LENM Media
We have added four new part numbers in the system.

Answering the Call for Larger Systems – Where We Are!
Servers View 7.00 View 8.10 View 10.00
FactoryTalk® Alarms & Events Servers (non-redundant) 10 Servers
FactoryTalk® A&E Servers (redundant) 10 Server Pairs
FactoryTalk® View Servers (non-redundant) 10 Servers
FactoryTalk® View Servers (Redundant) 10 Server Pairs
Clients View 7.00 View 8.10 View 10.00

FactoryTalk® A&E Clients 50 Clients 50 Clients 80 Clients
FactoryTalk® View Clients 50 SE Clients 50 SE Clients 80 SE Clients
FactoryTalk® ViewPoint Clients Or 50 Web Clients And 50 Web Clients And 50 Web Clients
Max Number of Clients 50 100 130
Scalability
Overview
View SE HMI Clients ViewPoint Clients • Support for 80 View SE clients
(Web/Mobile)
• Support for 50 ViewPoint web clients
• Validated system of 1,000,000 tags across
10 redundant HMI servers.
= 80 = 50 Benefits
• More clients with a smaller system footprint
View SE HMI Servers ViewPoint Server
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Thank You!
#ROKTechED
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PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2018 Rockwell Automation TechED™ Event #ROKTechED

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Architecting a Distributed HMI System

FactoryTalk® View SE System Overview, Limits, Redundancy, and Best Practices.

Your System Foundations Matter!

FactoryTalk® View SE System Overview

FactoryTalk® View SE Limits and Redundancy

Design Exercise - Design a Distributed Application

View Studio FactoryTalk® FactoryTalk® FactoryTalk® FactoryTalk®

• Common • Common address • Common security • Common

Activation Directory Security Diagnostics

• Comprehensive • Enterprise-wide • Enterprise-wide

 Integrating with Info Software

FactoryTalk® Directory Server

FactoryTalk® View Site

ThinManager® provides secure

FactoryTalk® View Site

 Use FactoryTalk® ViewPoint Client (web client) for:

FactoryTalk® Directory Server 5 Clients

 Logical or Physical areas

 Maximum number of HMI servers supported in an application is 10 for non-redundant and

 How do licenses get served?

Domain Controllers SE Server

FactoryTalk® Directory Server 5 Clients

RSLinx® Classic retains original name

Linx / Logix Integration Benefits / Advantages

 Complex communication routing. Protocol changing (ex. Ethernet to DH+™)

 KEPServer Enterprise and 3rd Party OPC® Servers

• RSLinx® Classic Required • FactoryTalk® Linx™ Supported

Data Network Data Network

FactoryTalk® Live Data servers FactoryTalk® Live Data servers

Control Networks Control Networks

CompactLogix™ PLC-5® ControlLogix® CompactLogix™ PLC-5® SLC™ 500

FactoryTalk® Directory Server 5 Clients

 Server Tag-Based Alarms

Logix Alarms Server Alarms

Reduction in network traffic

Improved time stamp accuracy

No alarm information loss in the

No HMI tag duplication required,

A single, consistent shared alarm

On the fly changes to alarming

Tested number of “subscribers” (FactoryTalk® Linx™ Servers) per 3

Typical number of alarm state transitions per subscriber 1000

Recommended maximum number of alarms per controller 2000

Supported languages for alarm messages All languages supported by

Tested number of “subscribers” (FactoryTalk® Linx™ Servers) per 3

Recommended maximum number of alarms per controller 3000

Supported languages for alarm messages All languages supported by

Supported in 5580, 5480 and 5380 Only Logix

FactoryTalk® Directory Server 5 Clients

Domain Controllers Application Server

FactoryTalk® Directory Server 5 Clients

Domain Controllers Primary Server Secondary Server

FactoryTalk® Directory Server 5 Clients

 Only one host should be designated as the “Primary” with the

 There is a need for 1 Engineering Workstation, 10 Read/Write thick clients

Engineering Workstation Control Room with 10 Clients

 FactoryTalk® View Studio Enterprise  10 View SE Clients

SERVER 1 SERVER 2 SERVER 3 SERVER 4 SERVER 5

250 250 250

SERVER 1 SERVER 2 SERVER 3 SERVER 4 SERVER 5

SERVER 1 SERVER 2 SERVER 3 SERVER 4 SERVER 5

Unlimited Unlimited Unlimited

SERVER 1 SERVER 2 SERVER 3 SERVER 4 SERVER 5