OVEN PLC110[M02]-MS4, HMI, OPC, and SCADA, or how much chamomile tea a person needs. Part 2

Good day, friends. This is the second part of the review that follows the first, and today I am writing a review on the upper level of the system indicated in the title.

The group of upper-level tools includes all the software and hardware that stands above the PLC network (IDE for PLCs, HMI, utilities for frequency converters, modules, etc. are not included here).

I will attach the structure of the system from the first part again to make it easier to understand what I am talking about.

So, the upper level includes:

• PC gateway, routing traffic between two networks (PLC network and enterprise LAN)
• OPC server — software that collects data from the Modbus TCP network and interprets it for processing in SCADA and databases.
• SCADA — A software complex that includes a server and clients. Our graphical interface for monitoring and managing processes.
• DBMS — Software that allows us to archive data coming into SCADA and, if necessary, extract it for viewing graphs, logs, and generating reports.

I will not touch on the enterprise corporate network (CN), as it falls under the responsibility of our system administrator, but I will describe how I interacted with him, what tasks I set when I describe the implementation of the system rather than the overview.

So, let's get started

First of all, we will physically implement the hardware that will operate. Hardware-wise, for functioning in two different networks, the computer needs two network adapters. The first one is an on-motherboard adapter (for operation in the CN), and the second one (for operation in Modbus-TCP) I inserted into the PCI-E port and connected a patch cord to the router (just to avoid spreading cables from the PLC cabinets to the PC across the office. On the PLC side, we also install a router, of course).

In fact, this is enough for the computer to function in each network, but by default, the networks will not see each other; you will need to press some buttons.

Important aspects of network connection configuration:

1. Connection in the CN should not be performed by obtaining an address from the DHCP server; the adapter settings need to be configured manually (the address must not fall within the DHCP address range) with mandatory specification of the network gateway. This is very important later for organizing remote access.
2. Do not attempt to create a network bridge between the adapters; all routing is performed when the corresponding Windows service is enabled.
3. If you want to access the PLC network from any HMI computer, you need to configure routing for the primary gateway of the network.
4. For remote access, I recommend using non-standard free ports to immediately deter potential hackers.
5. No additional software installation is required; everything is accomplished with standard Windows tools.

Software

I wanted to choose products that meet certain criteria:

• Domestic manufacturer — while I can reach English-speaking technical support through all available channels, not all my colleagues can boast the same. System maintenance should be accessible to everyone so that I am not disturbed while on vacation.
  Additionally, I note that the cost of domestic software is more aligned with our realities and acceptable for clients.
• Relatively new, yet partly tested, simply because I want to keep up with the times.
• A pleasant, aesthetic interface — not all SCADA systems can boast this. Unfortunately, design in automation tools will take a long time, and I would like to see the consumer qualities of the final product at a high level.
• Easy integration of OPC, SCADA, and DBMS (without complicated configurations and minimal button presses), so that a simple automation technician can be sent to Kamchatka (in the literal sense, we have client factories there), rather than a system architect.

OPC server

During my introduction to MasterSCADA 4D, while testing the PLC, I actively visited the manufacturer's website and saw that they offer custom OPC servers for virtually any data transmission protocol. A separate option is suggested for the Modbus protocol. Master OPC Universal Modbus Server, meaning it can only communicate via Modbus.

Below is a screenshot of the interface: quite concise, in my opinion, with nothing unnecessary, but perhaps an experienced user might find something lacking.

The limitation of the free version is 32 tags., but I put boolean variables in the registers and sent it as a single LONG INT tag, and in the SCADA, I then 'parsed' it into bits, a little trick, I hope no one comes after me. By the way, not all SCADAs can access individual bits of a word, so the recipe isn't universal.

It took me about a minute to receive the first REAL type tag after installing OPC, so I didn't look any further; I was satisfied with the simplicity. However, it is fair to note that this software even allows for the execution of user scripts for data reception, which can significantly expand functionality in skilled hands.

SCADA system

In this matter, I mean not only creating a beautiful and functional environment for the user but also convenience for the developer, as a programmer who spends at least 15 minutes an hour flipping through documentation to find the necessary information loses up to 2 hours a day (just mathematically), which is 25% of the working day. I would like to point out that I do not consider my choice absolutely objective; as they say, it's a matter of taste.

The domestic SCADA market offers us:

• Simple SCADA
• SimpLight
• MasterSCADA 4D
• OVEN Telemechanics LIGHT
• KASKAD

I confess I didn’t look any further; there might be something else. Given that I made my choice, it means the operation was successful. Let's consider these systems, keeping in mind the criteria described above:

1. KASKAD — immediately received the lowest rating for visualization; I didn't even download the distribution. The controls that broke free from Win95 put a fat period on this software for me.
   No rating
2. OVEN Telemechanics LIGHT — I also didn't download it, but the reasons here are not only due to the interface, although I also think it leaves much to be desired. Firstly, OVEN products cause me legitimate concerns regarding reliability and flexibility after a month and a half of testing and debugging PLCs with modules. Secondly, this SCADA is positioned primarily as a monitoring and management system in energy distribution networks. It doesn't quite suit my tasks in the food industry (even if it can do everything, the marketers still narrowed the target audience themselves). So, I’ll pass.
   No rating
3. MasterSCADA 4D — at first glance, this seems to be the most obvious and straightforward option. Let me explain:
   • Does not require a separate installation of an OPC server when working with OVEN PLC, as the drivers are already built-in.
   • Overall, a quite pleasant and attractive interface, control elements also get a solid 4/5.
   • Convenient design environment.

   Everything seemed fine, and I considered this system without alternatives when I picked up the controller. BUT:

   One fine day I opened a project in RunTime mode (simulation), and I had 4 blank windows hanging, rubbing my eyes, closing, checking the project manager, restarting — same thing. Then I went through a series of standard manipulations like analyzing the changes made, rebooting the PC, and so on, which yielded no results. Conclusion: I’m putting the distribution away for better days, no desire to troubleshoot, it's unreliable.

   Rating: 3.5/5 Good packaging, but the contents aren't great.

4. Simplight — I must admit, I was charmed by the value/price ratio from the technical bulletin on the manufacturer's site. It includes Web server and SMS, Email, many clients, and a lot of connectable OPC, all of this costs about 5000 rubles at the time of writing — a trifle. And if you are a developer and make a separate request in the online form on the site, they will send you a version of the distribution with 200 tags without any limitations, which I think is very cool. This is definitely a plus.

   Now for the downsides:

   Mainly: the IDE consists of several standalone utilities that have limited functionality, meaning when working on a single project, you will be forced to keep 3-4 windows + help + documentation open, which is not convenient even on a multi-monitor system.

   • Appearance is below average, as if drawn in Paint.
   • Help is very sparse.
   • Highly compressed functionality, clearly visible when setting trends and graphs.
   • Script editor is pixelated, which is hard on the eyes.
   • Setting up software tags is quite an ordeal.
   • If you want to simply bring a project on a flash drive for editing on another PC, it's quite difficult. The file structure of projects is confusing.
   • Sales representatives invade your life, which gets annoying.

   In the image: Simplight script editor.

   
   
   Rating: 3.0/5 The insides are good, but the packaging is nonexistent.

5. Simple SCADA This is my choice; I am likely to be biased here, but still. The manufacturer offers two types of DEMO: one limited to 64 external tags with slightly reduced functionality, and a fully functional version with a Runtime limit of 1 hour (after which the SCADA server needs to be restarted). The cost of the distribution in the simplest configuration starts at 6900 rubles as of the time of writing this article.

   
   
   Pros:

   • Very beautiful, both in terms of the IDE and control elements.
   • Rich documentation, everything is detailed from start to finish.
   • Simple integration of the OPC server data.
   • Very straightforward interface, even intuitively understandable.
   • Simple integration with the database management system.
   • To run the remote client. is not required. the presence of a project.
   • Great report generator.
   • For all objects, there are events like OnClick, OnMouseEnter, etc. Overall, the IDE resembles a simplified version of the Delphi Embarcadero editor, and the script editor has autocompletion.

   Cons:

   • There aren't many control elements available for use (there's an option to create custom ones).
   • Since SCADA is practically Plug and Play, I think there are functional limitations, but I haven't encountered them.
   • Trends with a full control panel (scaling, pause, scrolling) are displayed only in a separate window.
   • For fully functional the license will cost a good amount (from 38000 rubles and up).

   Rating: 4.5/5. Contents - good, packaging - good.

Database

Here the choice was much simpler; Simple SCADA offers two products for use: MS SQL Server and MySQL. The latter was closer to me since I had worked with it before, so I settled on that.

I can note that all archiving settings come down to installing a package from Oracle and its simple configuration, followed by one-click connection in SCADA.

Next, we choose in the tag manager what to archive and what not to, and enjoy.

Thank you all for your attention.

Next is a series of articles sequentially describing the solutions to the problems I encountered, leading to the creation of a Step-by-Step system.

Source: habr.com