Special Edition MICREX-NX. Whole Number 211

Transcription

1 Special Edition MICREX-NX Whole Number 211

2 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

3 Special Edition MICREX-NX CONTENTS Trends and Prospects for Information and Control System 104 The New Information and Control System MICREX-NX 111 Advanced Information and Control Software Packages 116 for the MICREX-NX 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. 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 , Japan

4 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 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 104 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

5 Fig.1 Vertically and horizontally integrated solution Vertical integration Vertically and horizontally integrated solution Fundamental technology Enterprise Management know-how Supply chain Production management Knowledge Whole optimal ERP/SCM Integrated production management Quality Fundamental management system Schedule Energy Database Network Control technology Automation Process control Facility management Traceability Sensor Drive and field equipment Process automation Power electronics (drive equipment) Drive PLC DCS Sensor Actuator Horizontal integration Fig.2 Market size (100 million yen) Forecast of global, Asian and Japanese markets for process automation 12,000 10,000 8,000 6,000 4,000 2,000 0 Global market Asian market Japanese market Year 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 Trends and Prospects for Information and Control System 105

6 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. 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 106 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

7 Fig.3 Development of Fuji Electric s information and control system Generation Series name 1st 2nd 3rd 4th 5th MICREX-PI MICREX-PII MICREX-PIII MICREX-IX MICREX-AX MICREX-NX Concept Distributed control system EIC integrated control system Advanced information and control system Analog-to-digital EIC integration Open architecture Total automation Evolution with inheritance New information and control system Vertical & horizontal integration Integrated engineering 1st, 2nd generation 3rd generation 4th generation 5th generation Architecture HMI Computer PC Computer Server client Single HMI HMI Computer Ethernet LAN DPCS-E DPCS-F Ethernet Industrial Ethernet Control (controller) (PIO) (I/O network) Controller E Controller I Controller EI T-link Controller EI T-link PLC based controller PROFIBUS DP Sensor Actuator MICREX-NX began in September 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 Trends and Prospects for Information and Control System 107

8 Fig.4 MICREX-NX based information and control system Enterprise level Office LAN Plant information Ethernet Plant maintenance Production management level OS single station (multi VGA) OS client Terminal bus Batch client ES Service PROFIBUS -DP AS414 AS416 AS417 OS server (redundant) ET200M DP/PA-link PROFIBUS -DP Plant bus AS414H AS417H ET200M DP/PA-link Y-link Batch server (redundant) PROFIBUS -DP Plant control level AS414F/FH AS417F/FH ET200M failsafe ET200M DP/PA-link Process level Vertical integration PROFIBUS-PA PROFIBUS-PA PROFIBUS-PA OS: Operator station ES: Engineering station AS: Automation station 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 Additionally, the SIMATIC* 4 BATCH 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. 108 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

9 Fig.5 Positioning of the MICREX-NX Computer solution MES linkage IT linkage Monitoring and control MICREX-NX Single user system MICREX-AX Client and server system Multi-client and multi-server system 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. Trends and Prospects for Information and Control System 109

10 (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 Spurred on by rapid advances in IT and the global 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 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

11 The New Information and Control System MICREX-NX Satoshi Sakai Kouichi Sakagami Tetsuo Suzuki 1. Introduction 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. 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 existing systems. 2.1 System configuration 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 *1: Windows is a registered trademark of Microsoft Corporation of the USA. *2: Ethernet is a registered trademark of Xerox Corporation of the USA. The New Information and Control System MICREX-NX 111

12 Fig.1 Overview of MICREX-NX system Existing MICREX Information LAN Ethernet Office LAN Ethernet Internet, Intranet Plant information Plant maintenance Batch client OS client Terminal bus OS single station Engineering station ES (multi VGA) Asset management package Service DBS-1500 IDS-1500 ADS-2000 OS server (redundant) AOS-2000 ADS-2000 ADS-2000G Batch server (redundant) OS server (redundant) PCS-500 ICS-2500 ICS-2000 DPCS-F ACS-2000 SAS-300 SAS-2500 FL-net ACS-2000 ACS-250 ASA-2000 SAS-55 P/PE link T link Intelligent CC Serial PROFIBUS-DP AS414 AS416 AS417 ET200M DP/PA link PROFIBUS-PA Plant bus AS414F/FH AS417F/FH ET200M Fail safe ET200M PROFIBUS-DP DP/PA link PROFIBUS-PA PROFIBUS-DP AS414H AS417H ET200M DP/PA link PROFIBUS-PA 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 MICREX- NX, however, all engineering work from field devices, network, and control applications to the operator 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. 112 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

13 Fig.2 Automatic generation of parts for monitoring operation Fig.3 Overview of operator station Faceplate Operator station Block icon L M tagname M S Archive server (tag logging) OS client (32 stations max.) Automatic generation OS server (redundant) (12 pairs max.) Controller application 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. 4. Operator Station (OS) CFC block 4.1 System configuration 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. 4.2 Features of the operator station 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. (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. 4.3 Plant monitoring screen creation function 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. 5. MICREX-NX BOX 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 The New Information and Control System MICREX-NX 113

14 Fig.4 Configuration of MICREX-NX BOX system Fig.5 Redundant ring configuration MICREX-NX BOX ES PDM OS 24 V DC Redundant OS server Ethernet on board Simatic Net PCMCIA card CP5611 on board CPU416-2 PCI+PS MPV DP DP Optical switch module OSM DP/PA link PROFIBUS-DP PROFIBUS-MPVDP Dual redundant plant bus (Industrial Ethernet) 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 MICREX- NX BOX system. 6. Network 6.1 Features The plant bus is a powerful cell network based on the IEEE 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. (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 114 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

15 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 (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. 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 IEC , 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 IEC 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 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. 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. 9.2 Features of the batch system (1) Plant hierarchy The batch system enables a hierarchical structural design that complies with ISA S 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. The New Information and Control System MICREX-NX 115

16 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 MICREX- NX 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. 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 116 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

17 Fig.1 System configuration and supported devices of PDM Engineering system with SIMATIC PDM Electronic device description language (EDDL) Stand-alone SIMATIC PDM PROFIBUS-DP Process value/status Standardized parameters (Diagnostic) Custom manufacture parameters ET200M DP/PA link 0/4 to 20 ma +HART PROFIBUS-PA ET200iS Fig.2 Example of PDM image panel (device parameter view) 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

18 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 Name of software Main functions Comments Operates with batch server Operates with AS Procedural model Procedure Unit procedure Operation Phase Phase Physical model Process cell Unit Unit Unit Equipment module Defined with ES Process model Process Process stage Process operation Process action Process action Basic software Optional packages Batch control center Batch report Batch recipe editor Batch control server Batch planning Hierarchical recipe API interface Batch planning, Batch client batch control Recipe, batch data printing Batch client Master recipe, library creation, drawing changes Transmission of batch data (between controller and monitor) Configuration of batch control center ISA S88.01 compliant recipe Interface with MES-related software Batch client Batch server Fig.5 Compliance with FDA 21 CFR Part 11 User 1 Windows User, group registration Administrator Authority assigned according to technical level Administrator MICREX-NX Operator station, engineering station User 2 Operator Operator Unique user name, password User 3 Senior operator Senior operator User 4 Emergency operator Emergency operator Electronic signature Changing set point by senior operator Logon with IC card (user registration) Electronic signature in all operations Download to controller Audit trail in all operations Input full name of signer, date and time of signing, and content 118 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

19 Fig.6 Configuration of route control system Table 2 System aspect of route control system Route control client Route control server MICREX-NX OS server Terminal bus Plant bus Item AS (automation system) Number of elements per AS Parallel transfer routes Partial routes AS overlapping routes Number of elements per route Number of modes per route Size 32 systems (max.) 1,024 motors, dampers, valves, etc. 1,024 link elements, pipeline sections, etc. 1,024 sensor elements, process values 1,024 parameter elements 300 (max.) 64,000 partial routes (max.) 32 overlapping routes (max.) 400 elements per AS (max.) 32 modes (max.) 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 *2: Windows is a registered trademark of Microsoft Corporation of the USA. Table 2 lists the system aspect. The standard engineering features of the MICREX- NX 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 Advanced Information and Control Software Packages for the MICREX-NX 119

20 Migration Strategy for the MICREX-NX 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 st MICREX-PI nd 3rd 4th 5th MICREX-PII MICREX-PIII MICREX-IX MICREX-AX MICREX-NX Concept Distributed control system EIC integrated control system Advanced information control system Analog-to-digital Total automation EIC integration Open architecture Evolution with inheritance New information and control system Vertical and horizontal integration Integrated engineering 120 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

21 Fig.2 Migration scenarios OCS/AOS DBS/ADS Replacement of only HMI with MICREX-NX Partial replacement, but retaining existing PIO Plant replacement and expansion HMI, controller and PIO replaced with MICREX-NX Combined use with former system OS client OS client OS client OS client Ethernet *1 Ethernet Ethernet Ethernet OS server (GW) OS server OS server OS server OS server (GW) DPCS-F, FL-net DPCS-F, FL-net DPCS-F, FL-net Industrial Ethernet Industrial Ethernet Industrial Ethernet PCS ICS ACS T-link P/PE-link T-link P/PE-link T-link P/PE-link AS AS AS PROFIBUS-DP PROFIBUS-DP 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 Migration Strategy for the MICREX-NX 121

22 Fig.3 Migration with MICREX-NX ES OS client MICREX-NX Terminal bus Migration of HMI objects and DB information OS server (GW) Tag information Alarm information Trend information ADS Existing MICREX AOS Standard screen Plant screen Faceplate AES OS server Plant bus DPCS-F, FL-net AS AS Legacy software assets Link devices T-link Link device P/PE-link Link device ACS ACS Internal instruments EI wafer Input processing Common devices 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 Existing MICREX Existing MICREX access function I/O driver PCI board DPCS-F, LAN compliant with FL-net Data manager NX driver Ethernet Plant bus Terminal bus 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 122 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

23 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 T- link, 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 Table 1 List of I/O supported by T-link Plant bus I/O type IOU (PCS) IOU (HDC) TK capsule CIO FTL Single T System Redundant T Single T Redundant T IPU (including FFI) MICREX -NX MICREX-PIII PCS -500 HDC -500 MICREX-IX MICREX-AX AS P/PE link PLC Link device Ethernet PLC Redundant AS Link device PLC P/PE link Ethernet Link device PLC Fig.5 T-link system configuration of MICREX-NX OS ES Plant bus AS Redundant AS PROFIBUS-DP PROFIBUS-DP Link device Link device Link device Link device T-link T-link Drag & drop T-link I/O Migration Strategy for the MICREX-NX 123

24 Fig.7 Engineering resulting from DB information migration tool OS client Automatically generated block icon Automatically generated picture Messages generated by an existing system can be displayed and acknowledged Automatic generation of linkage between each I/O field and actual data in controller Faceplate corresponding to block icon DPCS-F Existing HMI Existing DB DB OS server (GW) Registration of tags Registration of alarm messages Generation of plant hierarchy Generation of linkage between tag and screen Existing controller Prior MICREX-NX engineering data DB information migration tool 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 (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. 124 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

25 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 *1: Windows is a registered trademark of Microsoft Corporation of the USA. 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 Engineering Support Tools for the MICREX-NX 125

26 Fig.1 ES functional overview CFC templates for standard applications (e.g. motor, valve, controller) OS engineering User OS faceplate Batch system BATCH NX engineering Engineering for failsafe systems Engineering for networks, communication and hardware Automation engineering Programming for user function blocks PDM for field device management Fig.2 View layout e 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 Explorerlike 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. 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. 126 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

27 (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 (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 IEC Since this programming language can Global configuration of manager New function or new project wizard MICREX-NX Engineering flow Fig.4 CFC editor screen shot Hardware configuration Customization of plant hierarchy CFC programming Controller engineering Automatic generation of block icons OS compile SFC programming Block icon and faceplate HMI engineering OS engineering Download to AS and OS AS and OS runtime Engineering Support Tools for the MICREX-NX 127

28 Fig.5 SFC editor screen shot Fig.6 Graphic designer 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. 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. (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. 3.4 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- 128 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

29 Fig.7 Import/export assistant Fig.8 Version cross-checker screen shot Template chart Automatically generated chart Print Compare Open First, prior, next, last difference Filter ON/OFF Apply filter Different attribute Program A Program B Symbol for SFC + Import/Export Assistant Extra object in B PH assign. Chart name PV_LR PV_LR KP TN TV B17/Reac1 LIC B17/Reac2 TIC B17/Reac2 PIC B17/Reac3 FIC Measuring point list Automatically generated plant hierarchy Different object Extra object in A 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. 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 Engineering Support Tools for the MICREX-NX 129

30 Cabinet Mounting of the MICREX-NX Hitoshi Ichinohe Tetsuji Shio Hiroyasu Ikedo 1. Introduction Fig.1 EMC classification 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 EMC (electromagnetic compatibility) EMS (electromagnetic susceptibility) EMI (electromagnetic interference) 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 Electrostatic discharge Radiated electromagnetic field 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. Conduction noise Magnetic field Conductor noise (noise terminal voltage) Radio noise (electric field intensity) Harmonic current Conducted radio frequency disturbance Input terminal noise Earth terminal noise Surge voltage Voltage dips, short interruptions and voltage fluctuation 130 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

31 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 Fig.2 w 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. 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 Cooling methods (a) Air cooling (without fan) (b) Forced exhaust Gap Filter (d) Sealed structure (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 MICREX- NX 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. Cabinet Mounting of the MICREX-NX 131

32 CONECTER UNIT OUT A B CPU (A) F1 (10A) P1 CPU (B) F2 (10A) P2 HUB (A) F3 (10A) P3 P4 P5 HUB (B) F4 (10A) P6 P7 P8 FAN /ALM F5 (10A) P9 P10 P11 F12 T2 ALM1 ALM2 ALM3 ALM4 ALM5 T1 P N P N T1 1 2 F1 (3.2A) T1 1 2 F1 (3.2A) T1 1 2 F1 (3.2A) T1 1 2 P1 P1 P1 F1 (3.2A) P1 F2 (3.2A) P2 F2 (3.2A) P2 F2 (3.2A) P2 F2 (3.2A) P2 P N P N P N P N Fig.3 Mounting of controller cabinet (Front panel) (Side panel) (Back panel) Redundant controller Heat shield unit Communication unit Heat shield unit Power supply Heat shield unit Power supply S7-400 (A) (CPU) OSM/ ESM (A) Field power supply (A) (11) (11) (11) (10) (10) Field power supply (B) S7-400 (B) (CPU) Heat shield unit Heat shield unit (8) (9) (7) OSM/ ESM (B) Heat shield unit Diode unit Heat shield unit Alarm unit Heat shield unit Front power supply (B) Front power supply (A) Power distribution unit (A) (B) OLM(B) OLM(A) 2300 (4) (6) (6)(4) (3) (2) (1) (5) (1) (5)(3) (2) (9) (8) (7) Ventilation route ET200M (I/O)-4 Heat shield unit (17) (19) (17) (19) ET200M (I/O)-3 (16)(18) (16) (18) Heat shield unit ET200M (I/O)-2 Heat shield unit (13)(15) (13) (15) ET200M (I/O)-1 (12)(14) (12) (14) I/O Terminal unit Fig.4 Appearance of the controller cabinet Fig.5 Temperature measurement results Temperature rise T ( C) Forced exhaust Air-cooled Sealed Forced suction Front panel Back panel 0 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)(11)(12)(13)(14)(15)(16)(17)(18)(19) Measurement point (1) to (19) correspond to the measuring points of Fig. 3 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 assessed. 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 132 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

33 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 MICREX- NX 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. 4. Safety and EMC Environmental Design 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. 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. 5.1 Euro terminal features and necessity for ring conversion 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 Cabinet Mounting of the MICREX-NX 133

34 Fig.6 Conversion of Euro terminal to ring terminal The Fuji Electric Group has declared its intention to promote the reuse and recycling of constituent Euro terminal is a type of connector and is inserted into the I/O module to make a connection. are available as cable assembly components, which are produced in advance and can be stocked. 6. Conclusion Euro terminal Ring terminal (2 piece type) External terminal Internal cable The terminal part can be separated. Lead pins are soldered to attach the wiring. External terminal 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. 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 ( / 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. 134 Vol. 51 No. 4 FUJI ELECTRIC REVIEW

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