APACS Architecture PDF
APACS Architecture PDF
PI39-1
Rev: 4
February 2001
APACS+ TM
ARCHITECTURE
The APACS+ process automation system incorporates unique able with APS systems are Direktor for batch control and the
architectural structures that offer unparalleled flexibility. PI historian.
These structures have been developed to cost-effectively meet Generic systems can be readily configured due to the open-
short-term needs and protect initial investment far into the ness of the APACS+ controller and communications systems.
future, all while maintaining architectural simplicity. Virtually any commercially available HMI can readily im-
APACS+ provides a complete control system that includes a port data from APACS+ controllers and create a powerful
controller and choice of client-server architectures that are working system.
either PC-based with Windows® 95/Windows NT® operating
software or workstation-based with UNIX operating software.
APACS+ ADVANCED CONTROLLER
The controller consists of a series of plug-in modules, each The APACS+ advanced controller makes significant contri-
dedicated to a particular task, such as control strategy execu- butions to the APACS+ system’s flexible architecture. It
tion, input/output functions, or communications functions. achieves this with a modular design, flexible communications
Operator stations can include one or more PCs running buses, and several options for redundancy.
APACS+ ProcessSuite software or one or more UNIX work-
Modular Design
stations running APACS+ Process Supervisor software.
The flexible APACS+ architecture starts with the controller’s
The APACS+ architecture brings together control system el-
modularity. Each module has a specific function and can be
ements in a scaleable and flexible manner. The modular con-
categorized into one of the following families:
troller hardware and operator interface variations allow the
system to start very small and grow incrementally at minimal Control Modules – A series of modules, each of which is able
cost. Expansion of the system or the adaptation of new tech- to execute any combination of four distinct control languages
nology into the system is achieved by simply adding mod- (function block, ladder logic, sequential function chart, and
ules. structured text).
APACS+ systems are classified by the type of high-level op- I/O Modules – A series of modules acting as interfaces be-
erator interface used. Three main types exist: APACS+ tween control modules and the field signals.
ProcessSuite-based systems, APACS+ Process Supervisor- Communications Modules – A series of modules providing
based systems, and APACS+ generic systems. APACS+ expansion of local communications functions, as well as in-
ProcessSuite systems include a rich selection of components terfaces to other devices and networks.
that run on PC platforms with Windows 95 or Windows NT.
Support Equipment
Included in ProcessSuite is the APACS+ Vision Human Ma-
chine Interface (HMI), Historian for historical data, Batch APACS+ includes a full complement of modular supporting
for batch control, as well as 4-mationTM and a variety of soft- equipment, including mounting racks, power supplies, ter-
ware tools to facilitate system engineering. mination strips, equipment enclosures, furniture, etc. All of
this equipment is designed to simplify the engineering and
APACS+ Process Supervisor systems are a UNIX-based APS
construction of a complete system.
package, which includes a powerful HMI system. Also avail-
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An APACS+ controller is created for a particular application applications, reducing engineering and installation costs and
by simply selecting functionality as individual modules and simplifying maintenance.
populating a ten-slot MODULRAC. In addition to the ten-
Controller Communication
slot MODULRAC, there is a six-slot SIXRAC and a single-
slot UNIRAC (I/O only) available. Generally (with some Within an APACS+ controller, there are two main bus struc-
consideration of I/O and power wiring), wherever a MODUL- tures: an IOBUS and a MODULBUS. A variant of
RAC is shown, a SIXRAC or UNIRAC could be used if MODULBUS known as MODULNET is available for added
desired. The ten-slot MODULRAC with modules is shown flexibility and longer distance applications. The IOBUS is
in Figure 1. used to communicate between a control module (master) and
multiple I/O modules (slaves). The MODULBUS (and
MODULNET) is a higher level peer-to-peer bus allowing
communication between control modules and with other com-
puter and communication modules.
IOBUS
M A S E H V S I O R
B C A A F I D D D T
The IOBUS provides a control module with dedicated, se-
X M M M M M M M M M cure access to I/O points, which are terminated at the I/O
modules. IOBUS is a redundant bus that has a data transmis-
sion rate of 1 mbps. The media access method is master/slave,
and the electrical specification is IEEE RS485.
FIGURE 1 MODULRAC Populated with Modules One control module (the master) and up to 39 slave I/O mod-
When a module is plugged into a MODULRAC, a connector ules can be distributed locally on an IOBUS. The IOBUS can
on the back of the module engages a receptacle on the be continued MODULRAC to MODULRAC using prefabri-
MODULRAC backplane. This connection provides the physi- cated cables, or can be run long distances up to 7500 ft. (2286
cal communications and power path. When the system is on- m) using Fiberoptic Extender (IFX) modules and duplex
line, communication takes effect as soon as the module is fiberoptic cables. It is also possible to have multiple control-
inserted. This “hot insert” feature allows on-line replacement ler modules in a single MODULRAC and by using Bus
of modules, minimizing process downtime for system main- Diverter Modules (BDM) extend an IOBUS from each con-
tenance. troller to one or more satellite MODULRACs containing I/O
In addition, all slots in MODULRAC are identical. This al- modules in a star configuration. Figure 2 shows an IOBUS
lows any module to be plugged into any slot, providing maxi- configured in a single branch across a maximum of four
mum flexibility in initial system design and for future expan- MODULRACs. Figure 3 shows several IOBUS arranged in
sion. It also allows the use of a single-rack version across all a star configuration with one branch using fiberoptic links.
A I I I I I I I I I I I I I I I
C / / / / / / / / / / / / / / /
M O O O O O O O O O O O O O O O
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A B A B A B
C D C D C D
M M M M ..... M M
I I I
/ / /
IFX O O O
1 2 ...... 39
IOBUS
Fiberoptic Link I I I
(shown in BDM branch, / / /
but can be used in any O O O
IOBUS expansion)
IFX 1 2 ...... 39
IOBUS
I I I
/ / /
O O O
1 2 ...... 39
IOBUS
MODULBUS MODULNET
The MODULBUS (M-BUS) provides deterministic, high- MODULNET (M-NET) provides the same secure 5 mbps
speed, secure communications between control, communi- communication as M-BUS, but allows expansion of the net-
cations, and computer modules. It is a redundant, token-pass- work to accommodate larger local areas of a plant. Using an
ing communication bus with a data transmission rate of 5 M-BUS Expander Module (MBX) inserted in a
mbps. Each M-BUS supports up to 32 drops for controllers, MODULRAC, the M-BUS transmissions are transformed into
communications modules, and computers. Figure a standard, modulated, carrierband IEEE 802.4 network called
4 shows a typical M-BUS configuration with its relationship M-NET. The M-NET network allows a greater geographic
to IOBUS. The maximum distance for M-BUS is 60 ft. (18.3 distribution, up to 2000 ft. (609.6 m), of the various network
m) inclusive of four MODULRACs. In Figure 4, there are 5 modules. M-NET also has 64 drops in a single network ver-
of 32 M-BUS drops. sus the 32 drops in M-BUS. Other than the distance and the
number of drops, M-NET is identical to M-BUS in that it is
redundant and uses deterministic token-passing for secure
Workstation Workstation
communications at a 5 mbps transmission rate.
RNI
MODULBUS MODULNET/MODULBUS
A I I I I I I I I I A I I I I I I I I I
C / / / / / / / / / C / / / / / / / / /
M O O O O O O O O O M O O O O O O O O O
M A I I I I I I I I M A I I I I I I I I
B C / / / / / / / / B C / / / / / / / /
X M O O O O O O O O X M O O O O O O O O
IOBUS
I I I I I I I I I I
/ / / / / / / / / /
O O O O O O O O O O
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MODULBUS/MODULNET Adapters
MODULAR/MODULNET Adapters are a series of ISA-
based or PCI-based adapter cards for connecting APACS+ to
a Personal Computer (PC). M I A I H V S I O R
B / C / F I D D D T
A MODULBUS Interface (MBI) ISA adapter can be installed X O M O M M M M M M
Redundancy
The APACS+ controller incorporates a standard level of re-
dundancy. In addition, the controller’s modularity supports
redundancy at an incremental level to economically accom- FIGURE 7 Rack-to-Rack Redundancy
modate different availability requirements.
In both redundancy configurations, the control modules op-
Built-in Redundancy erate in active/backup modes. The modules simultaneously
Features inherent to the controller provide a certain level of and synchronously execute the control scheme. If a serious
standard redundancy. For example, all of the controller’s com- failure occurs on the active control module system, an auto-
munication buses are redundant, and modules using them matic and bumpless switchover takes place and the backup
exercise both paths. If one side should have a problem, com- control module becomes the active unit. This tightly coupled
munications automatically continues on the other path. redundancy arrangement is made possible by the high-speed
In addition, MODULRAC’s backplane has three power sup- redundancy cable that connects the two control modules. Upon
ply buses (two on UNIRAC) to facilitate redundant and back- initialization (power up), the active module transfers its en-
up power connections. Each module connects to all power tire database to the backup module via the redundancy cable.
buses and uses the “best” power available. The power buses During operation, the active and backup maintain identical
can be fed by individual power modules or by connections to on-line information to be ready for switchover. While the re-
external bulk power supplies. dundancy configurations in Figures 6 and 7 are shown with
Optional Redundancy MODULNET communications, they also can be implemented
with MODULBUS communications within the 18 ft. (6 m)
Module redundancy is available either on a module-to-mod- distance limitation of the redundancy cable.
ule level for control modules or on a rack-to-rack level for
complete controller redundancy in control modules and I/O ProcessSuite-BASED SYSTEMS
modules. Module-to-module redundancy is easily and eco- ProcessSuite-based systems are process control systems in
nomically implemented by simply installing a twin module which the HMI (Human Machine Interface) and other super-
for control modules or communication modules adjacent to visory functions are provided by ProcessSuite components
the primary module and connecting them with a redundancy such as APACS+ Vision, Historian, and Batch. These sys-
cable. The redundant control modules share a common set of tems can be as small as a single controller with a single PC
I/O modules (as shown in Figure 6), providing redundant running the higher level functions. They can also be large
control, but common I/O as an economic tradeoff. Rack-to- systems consisting of many APACS+ controllers and network
rack redundancy completely duplicates a controller, includ- nodes for operations, maintenance, and engineering HMI,
ing the control module and all I/O modules, for maximum history collection, batch preparation, and scheduling.
dependability and only requires the redundancy cable con- ProcessSuite systems can be further classified in two catego-
necting the control modules of the two identical controller ries: continuous or batch. These categories are divided into
systems (as shown in Figure 7). entry-level, single server pair and multi-server pair continu-
ous architectures and stand alone, small system, medium sys-
tem and large system batch architectures.
Both continuous and batch architecture systems require cer-
tain ProcessSuite components to be installed within the sys-
M B A A H V S I O R tem for it to function. Components such as 4-mation, which
B C C C F I D D D T
X M M M M M M M M M is required for setup and maintenance of the APACS+ data-
base, and the APACS+ I/O server, to feed the Vision, Histo-
Redundancy
Cable rian, and Batch components with APACS+ data, must be in-
stalled.
FIGURE 6 Module-to-Module Redundancy
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APACS+ also contains a rich set of software tools to facili- Single-Server Cluster Architecture for
tate system implementation, such as 4-mation with four op- Continuous Systems
tional configuration languages, and the APACS+ Database
The single-server cluster architecture was developed for
Automation Utility. This utility easily uploads all HMI infor-
medium-size continuous applications that require an NT so-
mation from APACS+ controllers to ProcessSuite operator
lution. The single-server pair architecture was tested and vali-
stations to avoid entering this information multiple times.
dated for 2000 real I/O expanded to include up to 10 opera-
Entry-Level Architecture for tor nodes. A typical single-server pair architecture is shown
Continuous Systems in Figure 10.
The Entry-Level Architecture is a cost-effective NT solution ProcessSuite
Development Node
for small continuous applications. It has been tested and vali-
dated for 500 real I/O and up to four operator nodes. The
Entry-Level Architecture provides the flexibility necessary
for a system to grow into a single-server or multi-server pair.
Typical system layouts are shown in Figures 8 and 9. Figure OK
M-BUS
A I I I I I I I I I
9 shows the maximum four Client Nodes. C / / / / / / / / /
M O O O O O O O O O
OK OK OK
M-BUS/M-NET OK
M-BUS/M-NET A I I I I I I I I I
C / / / / / / / / /
Crossover M O O O O O O O O O
Cable
Hub A Hub B
OK OK OK
M-BUS/M-NET
RNI
UPS Crossover
Process Suite Cable Process Suite
Tag Server Tag Server M-BUS/M-NET
Node Node
A I I I I I I I I I
C / / / / / / / / /
M O O O O O O O O O
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ProcessSuite ProcessSuite
ProcessSuite ProcessSuite ProcessSuite Client Node Client Node
Client Node Client Node Development Node
OK OK
OK OK OK
Hub B
Hub A
ProcessSuite
Historian
Node
RNI
RNI Crossover
ProcessSuite Cable ProcessSuite
UPS Crossover Tag Server Tag Server
ProcessSuite Cable ProcessSuite M-BUS/M-NET
Tag Server Tag Server Node Node
Node Node M-BUS/M-NET
A I I I I I I I I I
A I I I I I I I I I C / / / / / / / / /
C / / / / / / / / / M O O O O O O O O O
M O O O O O O O O O
ProcessSuite
Client Node
ProcessSuite
Batch Server Node
OK
Hub A
M-BUS/M-NET
A I I I I I I I I I
C / / / / / / / / /
M O O O O O O O O O
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Batch System Architecture support two monitors directly and, through the display server,
The batch system architecture (see Figure 13) was developed it has the capability of providing multiple X-terminals with
for batch applications that require redundancy for the batch fully functional HMIs. Additional stations can be added to
process and over 15 operator displays. the network to provide higher availability, in the event of a
workstation failure, and also increases the number of X-ter-
Process Supervisor-Based Systems minals available for viewing the process.
In an APACS+ Process Supervisor-Based System, the HMI A Rack-mounted Network Interface (RNI) is required for con-
(Human Machine Interface) and other supervisory functions necting the APACS+ controller on MODULBUS/
are provided by APACS+ Process Supervisor (APS). It is a MODULNET to the plant-wide TCP/IP network, on which
UNIX-based workstation and is generally very cost-effec- the APACS+ Process Supervisor resides. Figures 14 and 15
tive in medium to larger systems, or in systems where spe- show single and dual network configurations for APACS+
cial functionality only available in UNIX systems is required. Process Supervisor Systems. Note that APACS+ Process Su-
Process Supervisor provides data scanning, database man- pervisor Systems use a package known as Direktor for batch
agement, and display server functions for an operator inter- control implementation, scheduling, and operation. Plant his-
face. Data scanning enables data exchange between the tory is collected via a PI plant historian.
database and the APACS+ control modules. The display server The ProcessSuite control node is a desktop PC running Win-
provides the operator with a window into the real-time data- dows NT and 4-mation. This node is used for the configura-
base via graphics and other tools. The single workstation can tion node of the APACS+ control system.
OK OK OK OK OK
Hub A Hub B
ProcessSuite
ProcessSuite Historian ProcessSuite
Batch Server Node Tagserver
Nodes Nodes
M-BUS/M-NET
Ethernet Crossover
Cable
A I I I I I I I I I
C / / / / / / / / /
M O O O O O O O O O
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OK OK OK OK OK
OK
Hub A
RNI
A I I I I I I I I I
C / / / / / / / / /
M O O O O O O O O O
OK OK OK OK OK
OK
Hub A Hub A
RNI RNI
A I I I I I I I I I
C / / / / / / / / /
M O O O O O O O O O
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COMMUNICATION WITH OTHER DEVICES The APACS+ system can include devices that support the
AND APPLICATIONS HART (Highway Addressable Remote Transducer) commu-
nication protocol through the HART Fieldbus Module (HFM).
Remote Capabilities HART devices manufactured by Siemens Moore include the
The previously discussed system architectures illustrate the XTC® transmitters, XTC transmitter-controllers, and Siemens
extensive flexibility that can be achieved using APACS+ com- Moore FIELDPAC® field-mounted controllers.
munication buses and networks. APACS+ takes this flexibil- The HFM supports a network of HART devices, providing
ity one step further by incorporating remote communication an effortless method of bringing field device data onto an
capabilities. Three communication methods are available, two APACS+ IOBUS, where it can be used by any APACS+ mod-
using telephone lines and a third using the Internet. The tele- ule or station.
phone line connections are best suited for troubleshooting or
monitoring, while the Internet approach is an entirely new API Toolkit
way of presenting on-line plant data for business purposes. APACS+ provides an open architecture that accommodates
PC ANYWHERE software runs in a remote PC and in the other applications to enhance its capabilities. Built-in provi-
host PC that is local to the APACS+ system. The remote PC sions for other applications include Application Programming
and the host PC are connected via modem and telephone lines. Interface (API) toolkits. The API toolkit provides software
Once the connection is established, the PC running PC ANY- developers with tools to create applications that can directly
WHERE remote mimics the monitor, the keyboard, and the exchange data with APACS+. To achieve this, the toolkit in-
mouse of the PC host to which it is connected. The use of PC cludes a library of predefined communications functions that
ANYWHERE with the APACS+ system is illustrated in Fig- are compatible with the MODULBUS format. One toolkit
ure 16. All of the keyboard and mouse actions normally per- option provides the ability to create applications that run a
formed on the host PC can be performed on the remote PC, PC directly connected to and communicating with
with all of the host displays being duplicated on the remote MODULBUS via an MBI Card or MODULNET via an MNI
PC. Card. Another toolkit option enables interaction with
APACS+ Process Supervisor’s real-time database.
MODBUS
Local Instrument Link (LIL)
An APACS+ ACM using its RS 232 serial port and the ACM
Serial Communications Function Block Library provides The existing Local Instrument Link (LIL) data can be inte-
MODBUS communication capability. The function blocks, grated into ProcessSuite Vision (HMI) through the Local In-
which are configured using 4-mation, allow the ACM to be a strument Link I/O Server (LIL I/O Server). The LIL I/O Server
MODBUS master or a MODBUS slave. As MODBUS mas- runs on a Windows NT machine that communicates to the
ter, an ACM can read and write data values from and to mul- LIL via an Independent Computer Interface (ICI) 320 and
tiple slave devices. When an ACM is acting as a MODBUS Vision via Ethernet. The LIL I/O Server can be integrated to
slave, it primarily provides APACS+ data in response to re- any of the preceding ProcessSuite architectures. A typical sys-
quests from a MODBUS master. The slave ACM can also tem architecture with LIL is illustrated in Figure 17 (on the
respond to commands from a MODBUS master to change next page). LIL data can also be integrated into the APACS+
APACS+ values. controllers through the LIL function blocks.
PC ANYWHERE PC ANYWHERE
Remote 4-mation Vision
OK OK
Modem Modem
A I I I I I I I I I
C / / / / / / / / /
M O O O O O O O O O
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ProcessSuite
HLL I/O Server Node
OK OK
RS232 ICI 2.5
OK OK
Hub A
RS232 or
RS422
Hi-Level
Link
3 3 3 3 3 3 3 3 3 3
5 5 5 5 5 5 5 5 5 5
3 3 3 3 3 3 3 3 3 3
Data from existing MYCRO satellites, such as Multi-Loop MYCRO Operator Stations
Controller (MLC) and Local Expansion Satellite (LES), can
be integrated into the HMI running ProcessSuite Vision
through the Hi-Level Link (HLL) I/O Server. The HLL I/O
Server runs on a Windows NT machine that communicates to
the HLL through an ICI 2.5 and Vision via Ethernet. The HLL
I/O Server can be integrated to any of the ProcessSuite archi-
tectures. Figure 18 illustrates a typical system architecture
with the HLL I/O Server.
APACS+ can also be integrated with existing MYCRO sys-
tem products using the Link Interface Module (LIM). Figure
19 shows an APACS+ system with the LIM as a station on Hi-Level Link
the HLL and in a MODULRAC where it is a drop on the
MODULBUS. The LIM appears on the MYCRO HLL just
as any other MYCRO satellite station does with respect to
L A I I I I I I I I
communication. It participates in the global database broad- I C / / / / / / / /
cast, sending APACS+ data across the HLL every 0.5 sec- M M O O O O O O O O
SPECIFICATIONS
Table 1 contains a list of specifications related to the APACS+
architecture.
APACS+, ProcessSuite, 4-mation, MYCRO, XTC, and Siemens Moore FIELDPAC are trademarks of
Siemens Moore Process Automation, Inc. All other trademarks are the property of their respective
owners.
Siemens Moore assumes no liability for errors or omissions in this document or for the application
and use of information included in this document. The information herein is subject to change without
notice.
Siemens Moore is not responsible for changes to product functionality after the publication of this
document. Customers are urged to consult with a Siemens Moore sales representative to confirm the
applicability of the information in this document to the product they purchased.
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