application note

Protein Purification Control Software

UNICORN iFix Integration

Introduction
Market requirements today are focused on solutions that deliver optimal performance in terms of:
Time to market Cost efficiency Reliability and high quality

Objective
This application note describes how UNICORN Run Time Data can be viewed and stored to a database by a third party application by using OPC as communication platform.

Products used
The following products were used for this application:
A. Intellution as a vendor for OPC Client. The software used is iFIX 3.0 and I/O Driver Ver 7.32c B. Windows 2000 or 2000 Server Operating System C. UNICORN 4.11

Large pharmaceutical production plants contain many components that must work smoothly together. One key element in plant architecture is the information management strategy. The problem of transferring the various components into an integrated plant becomes obvious when different components speak different languages. However, if a unified language is used translation becomes unnecessary and efficiency increases. OPC provides this kind of unified communication language among modules in a process plant. OPC is a standard specification that allows data management from any data source within a production environment. OPC defines a standard set of interfaces allowing the creation of a client/server model where any OPC client (any application interested in data) can communicate with any OPC server (any application providing data). UNICORN supports the following OPC standards:
Security Data Access (DA) Alarms & Events (A&E) Historical Data Access (HDA)

The OPC Client and OPC Server are located in separate PC's. Table 1. shows the setup used for this application note. The PC's communicate via TCP/IP. Table 1.
PC 1 iFIX 3.0 I/O driver ver. 7.32c WIN 2000 Server UNICORN 4.11 (Demo) PC 2 UNICORN 4.11 KTAFPLC WIN 2000

Implementation
In this example iFIX 3.0 is used for SCADA/HMI while I/O Driver Ver 7.32c is the OPC client driver. Table 1 shows where each component needs to be installed.
Note: Intellution I/O Driver Ver 7.323c supports the OPC Data Access Server only. Alarm & Events Server will be available in the future versions. The procedure in this application note assumes that user is familiar with Intellution products (iFIX 3.0 and I/O driver).

Any OPC client can communicate with any OPC server (local or remote) since the interfaces required for communication are guaranteed to be the same for all servers. A local OPC server is a server found on the same machine as the OPC client, a remote OPC server is a server found on a different machine than the OPC client.

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1 Configuring SCADA
This step provides iFIX with information about which tool to use and where to locate the UNICORN OPC Server.

Toolbox

Database Manager

SCU

Historical Trend Assign

Mission Control

Datalink Stamper

System Tree

Workspace

Fig 3.
1.6 In I/O Driver Server connection windows select Use Local OPC Client Driver Connect. 1.7 This will open the Power Tool window (Fig 4).

Fig 1.

1.1 Launch iFIX 3.0 program (Fig 1). 1.2 Click the SCU icon to open the configuration window.

2 Configuring Server, Groups and Items

This step instructs how to select an OPC server as well as how to create groups and OPC items.

Start

PLC

SCADA configuration

Add OPC Server

Add Group

Add Item

Fig 2. Fig 4.
1.3 Click the SCADA configuration icon (Fig 2). 1.4 Click ? (I/O Driver Name: ) OPC OPC Client v7.32c OK Add. OPC OPC Client v7.32c should appear in Configured I/O Drivers window. Click OK. 1.5 Double click OPC in the PLC symbol (Fig 1) and the text OPC will appear underneath SIM after step 1.4 is completed. 2.1 For this example we will use the following: Server name: Fplcf300. Group name: Event_Analog. Item name: Flow, Pressure, UV, etc. 2.2 Click Add OPC server icon. 2.3 Select OpcUNI0.opcDA2ServerS0.1 OK. 2.4 Type Server Name (Fplcf300), check the Enable box.
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2.5 Change server Location to Remote. 2.6 Click Browse Network, navigate to find STATION1 (name of PC where UNICORN resides) OK.
Note: The Add Group icon is now highlighted.

2.7 Click Add Group, type in the group name (Event_Analog), check the Enable box. The add item icon will now be highlighted. 2.8 Click Add Item, type in the item name (Flow), check the Enable box, and click Browse Server button. 2.9 Navigate to find the desired item, click OK. The item will now appear in the Item ID (Fig 5).
I/O Address Editor

Fig 6.

3.5 Description: enter the desired description. 3.6 Addressing: Driver: select OPC Client v7.32c. 3.7 I/O Address: Server;Group;ItemID[;AccessPath] Click the I/O address editor button and replace the following: Server with: Fplcf300. Group with: Event_Analog. ItemID with: Fplcf300.EVENT.ANALOG.Flow [;AccessPath] with ;; The information should be exactly the same as entered in steps: 2.4, 2.7, and 2.9 (Item ID). Click OK when finish.

Fig 5.
2.10 Repeat this action until all the desired groups created and all items are selected. 2.11 Press the Start button (Fig 4) to begin retrieving data from the OPC Server.

3.8 Engineering unit; enter the Low Limit, High Limit, and Units. 3.9 Click Save. 3.10 Click Yes at Place Block On/Off San? Screen. 3.11 Repeat steps 3.3 through 3.10 for other items. 3.12 When all items programmed, from main menu, View Refresh (Fig 7).

3 Creating Process Database

iFIX reads process information from the OPC Server and saves it in process databases. These databases are the primary source of process data for most iFIX applications. The main tool for creating and managing process databases is the Database Manager. In this step we will show how to create an Analog Input in the database. Use the same procedure for other types of data (Analog Output, Digital Input or Output, etc).
3.1 Click Database Manager icon (Fig 1). 3.2 Check Open Local Node OK. 3.3 From main menu Blocks Add select AI for the analog input block. This will open the Analog Input editor block (Fig 6). 3.4 Tag Name: FLOW.
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Fig 7.

Protein Purification Control Software

4 Storing Process Data in Database

In step 3 we created a process database. The data shown is the latest data received. In this step data will be stored until user manually stops the data recording.
4.1 From Main menu click Historical Trend Assign icon (Fig 1). This will open Historical Assign screen (Fig 8). Check the X Hour Files box to select the duration of file to be recorded. In this example we select 24 Hour Files.

4.9 When completed the Configuration screen should look like Figure 9. Click Save Changes to exit. 4.10 Save the file, File Save As. Type in the File name. 4.11 To begin storing data, click the Mission Control icon (Fig 1). 4.12 In the Mission Control screen, click HTC tab and click Start to begin storing data. 4.13 To stop data collection, repeat 4.11 and 4.12 above, but press Stop instead.

5 Displaying Animated Data (Flow Scheme)

This step describes how to display data in the animation screen (HMI), select predefined animated objects such as valves, pumps, etc. and link the object to the Process Database. Fig 8.
4.2 From the menu, select Group Add to open the configuration screen (Fig 9). 4.3 Click the ? in Tagname: field. 4.4 A window similar to Figure 11 will appear. Follow the same steps to select the tagnames (steps 5.4 to 5.7). 4.5 Click Add button. The item will appear in Tagname Window. 4.6 Repeat 4.3 to 4.5 until all Tags are selected. 4.7 Select the scan Rate. 4.8 Enter appropriate Limit. The limit in this case is similar to Hysterisis. 5.1 From System Tree (Fig 1) right click Pictures New Picture Finish. This will open a new Workspace. 5.2 From Toolbox, click Datalink Stamper icon (Fig 1), to open the Datalink windows (Fig 10).

Fig 10.

5.3 Click the button on the Source area to open Expression Builder screen (Fig 11). 5.4 Select FIX Database Tab. 5.5 Click on FIX in Node Names column. 5.6 Select the Tag from Tag Names column. 5.7 Click the F_* and select F_CV from Field Names column. Click OK. 5.8 Fill in the Whole Digits and Decimal boxes and click OK (Fig 10). 5.9 A stamp symbol will appear. Click the position on the Workspace where you want the data to be placed.

Fig 9.
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Fig 12.

6.3 Fill in the information in the General tab as shown (Fig 13).

Fig 11.

5.10 Hold down Ctrl key and press W to change the Workspace from Configure mode to Run mode. 5.11 The real data should be displayed. 5.12 Similarly, to animate a valves, pipes, pump, etc, select the predefine animated object from the Dynamo Sets folder in the System Tree (Fig 1). 5.13 Double click the category (e.g. ValveAnim ) to open the window that shows animated valve options. 5.14 Select the object and drop it onto the Workspace. 5.15 Select the source of data (the procedure is the same as steps 5.4 5.7). 5.16 See iFIX 3.0 manual for different ways of animate the valve.

6 Viewing Stored Data

This step describes how to display stored data in the form of TREND.
6.1 From System Tree (Fig 1) expand Dynamo Sets and double click Historical. 6.2 Click and drag the chart into workspace. A chart configuration dialog box will open (Fig 12).

Fig 13.

6.4 Click the Chart tab. Click the Hist.NODE.TAG.F_CV. 6.5 From drop down box, select Hist.FIX.FLOW.F_CV.

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6.6 Click the Add Pen icon (Fig 14).

6.8 Click on Time, X-Axis, etc, tab to configure the look of the chart. 6.9 Click OK (Fig 16).

Add Pen icon

Fig 14.

6.7 Repeat step 6.5 and 6.6 until all items are selected (Fig 15).

Fig 16.
6.10 To view data, hold down [Ctrl ] and press [W].

Fig 15.

For further information:

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