Devices, Field Communication

Key Concepts and Terminology

Protocols

Protocols are the rules governing the communication between devices. FactoryStudio supports a variety of communication protocols, both native and OPC-based.

Channels

The Device Module uses Channels to establish connections with field devices. Each channel is defined by a specific protocol driver and connection type, such as RS-232 or TCP/IP. Channels allow the module to access multiple devices (such as PLCs) using the defined protocol and interface.

Nodes

Each device connected to the system through channels is called a Node. Nodes can be individual devices or groups of devices. Each node contains one or more Points.

Points

Points are individual items that can be read or written from/to nodes. They can be registers, I/O values or variables residing in field devices (nodes). Each Point is bound to a specific Tag in the Project configuration.

AccessType

Each Point is associated with an AccessType, which defines the rules for reading and writing values for that Point, such as the polling rate, whether a read is performed on startup, and whether you write values to that Point. The AccessType allows users to configure how clients can access data points in the system.

Overall, the Device Module simplifies architecture by removing the need for additional communication products like Kepware/Matrikon and provides an easy-to-use communications hub that supports comms and logic between practically any device, database or historian anywhere.

How the Device Module Works

The typical configuration workflow for the Device Module has the following sequence:

Features Highlights

• Simplify your architecture by removing the needing for additional communication products (e.g. Kepware / Matrikon)

• Easily setup a communications hub to support comms and logic between practically any device, any database, any historian, anywhere.

• On-Premise, Edge or enterprise level, and to/from the cloud – we have you covered!

• MQTT Broker and OPC Server are both built-in!

• MQTT SparkPlug B and OPC-UA simulators expedite demos and prototyping.

• Driver Toolkit allows our team, or any third-party, to easily add new interfaces.

Managing Channels and Nodes

Channels are responsible for managing communication protocols and drivers, while Nodes handle multiple threads pointing to the configured Channels. Understanding the relationship between Channels and Nodes is essential for efficient data exchange.

• Channels: Execute processes based on communication protocols and drivers, configuring the required protocol or driver for a specific device.
• Nodes: Perform multiple threads pointing to the Channels, ensuring efficient data exchange and minimizing latency.

Channels are created and configured to handle specific communication protocols and drivers. Nodes, in turn, manage threads and multiple threads pointing to these Channels. This multi-threaded approach ensures efficient data exchange and reduces latency, allowing the system to scale and handle numerous devices simultaneously.

To create channels:

• Go to Edit → Devices → Channels.
• Click Create New.
• The Create New Channel window displays.
• Enter or select information, as needed.
• Click OK. The channel is added as a new row in the table

To edit device channels:

• Go to Edit → Devices → Channels.
• To add or remove a column, right-click the column heading area and select or deselect columns.
• Edit the fields on the row corresponding to the channel you want to modify.

Creating Nodes

Nodes are the devices or PLCs on the network that you communicate with. You can enter the settings for your nodes as usual through the Engineering Workspace. You can also import settings from an OPC server or from another data source. See "Importing PLC Addresses" below.To configure nodes:

• Go to Edit → Devices → Nodes.

• Enter or select information, as needed.

• To add or remove a column, right-click the column heading area and select or deselect columns.

Organizing the Points with Acess Types

Points are groups that point to Nodes and are responsible for transferring information between configured devices and FactoryStudio. AccessTypes define specific methods for reading and writing data point values using polling. The number of data points you can configure is related to both the ProductModel that is configured for the project and your software license. 

• Points: Groups pointing to Nodes, responsible for transferring information between configured devices and FactoryStudio.
• AccessTypes: Define specific methods for reading and writing data point values at specific moments using polling.

Points are organized into groups that point to Nodes, handling the transfer of information between configured devices and FactoryStudio. AccessTypes are used to define the specific methods for reading and writing data point values at specific moments using polling. This approach allows for optimized data exchange and minimizes latency.

To configure data points:

• Go to Devices → Points.

• You can copy and paste tags from the Tag → Objects.

• Enter or select information, as needed.

• To add or remove a column, right-click the column heading area and select or deselect columns.

Access Types Configuration

Access types define the specific methods for reading and writing the values of each data point. This could be the polling rate, whether or not a read is performed on startup, and whether or not unsolicited input is accepted. FactoryStudio comes with a few predefined access types that you can use, or you can create your own.

To configure access types:

• Go to Devices → AccessTypes.

• Do one of the following:

• To edit an existing access type, double-click a field.

• To create a new access type, click Create New.

• Enter or select information, as needed.

One very efficient AcceesType is to read data when it is being used by the application. Go to the section OnDisplayOrServer for more information.

Handling Read and Write events

In a SCADA system, handling read and write events is crucial for the efficient exchange of data between the HMI, PLCs, and other devices. FactoryStudio facilitates these events by allowing users to configure access types, which define the specific methods for reading and writing the values of each data point. The access types can be configured to determine the polling rate, specify whether a read is performed on startup, and decide whether unsolicited input is accepted.

Configuring the Device Module

The Device Module in FactoryStudio plays a central role in managing communication between the HMI and devices in an industrial automation system. To ensure seamless integration and optimal performance, it is essential to properly configure the Device Module. This includes selecting the appropriate communication protocol, creating and managing device channels, and defining device nodes and points.

Selecting a Communication Protocols

FactoryStudio supports a wide range of communication protocols to facilitate interaction between the HMI and various industrial devices. To select the appropriate protocol for your system, consider factors such as compatibility with the devices in your network, data transfer speed, reliability, and security requirements. Once you have determined the most suitable protocol, configure it within the Device Module to establish communication between the HMI and devices.

Protocol Comparison: Native vs OPC

What are the benefits of supplying native protocols interfaces to PLCs, instead of just use OPC client and rely on external OPC server to get the date?

Some PLCs are using OPC UA as their native built-in protocol, certainly this question does apply to them, but to other equipments using proprietary protocols. 

There are many scenarios when the native driver is more beneficial. Let us explore some of them:

Higher Performance

Instead of a direct connection, invariably adding one more application in the middle cause additional lag time. Further, the AccessTypes and the ability of parles execution (multi-threading) available in the Device Module allows optimized configuration not available in most OPC servers.

Cost Reduction

Most of the native drivers are included at no charge. The exceptions when there is a cost, it is typically quite smaller than the OPC server cost.

The OPC server still needs to use the Native Protocol Addresses

One misleading argument to use OPC is to hide the PLC address from the configuration. The reason it is misleading is that you need to use the native PLC address to setup the configuration of the OPC server anyway; you just duplicated the work load.  

The exception here is if the OPC Server is already installed and serving multiple applications. In this case, the connection using the OPC Client to the centralized OPC server is recommended.

Another good option is to leverage the OPC Server included in the Module device for the Edge application. In this case, the project connects with the field device with the native protocol, still enabling its OPC Server functionality, so other applications can use the built OPC Server in the FrameworX to access the data. 

Easier Field Maintenance and Deployment 

As explained on the previous item, if the OPC Server was not in its place, adding one more "middle-man" is just stressing the deployment and maintenance procedures.

Improved technical support  

Two points for potential failure or misconfigurations, and two independent suppliers, typically do not compare with a single environment and centralized support.

Available Communication drivers

The up-to-date list of Communication drivers is publics at docs.tasoft.com at the Communication Drivers section.

Additional driver can be created using the Drivers Toolkit.

Creating and Managing Device Channels

Device channels in FactoryStudio are the pathways for communication between the HMI and the devices in the system. To create and manage channels, follow these steps:

To create channels:

• Go to Edit → Devices → Channels.

• Click Create New.

• The Create New Channel window displays.

• Enter or select information, as needed.

• Click OK. The channel is added as a new row in the table

To edit device channels:

• Go to Edit → Devices → Channels.

• To add or remove a column, right-click the column heading area and select or deselect columns.

• Edit the fields on the row corresponding to the channel you want to modify.

By properly configuring the Device Module, selecting the right communication protocol, and effectively managing device channels, you can ensure a robust and efficient industrial automation system using FactoryStudio as your HMI/SCADA solution.

To learn more about how to create and edit channels within the device module, please refer to: Device Configuration - v10 - Tatsoft LLC

Defining Device Nodes

Creating Nodes

Nodes are the devices or PLCs on the network that you communicate with. You can enter the settings for your nodes as usual through the Engineering Workspace. You can also import settings from an OPC server or from another data source. See "Importing PLC Addresses" below.To configure nodes:

• Go to Edit → Devices → Nodes.

• Enter or select information, as needed.

• To add or remove a column, right-click the column heading area and select or deselect columns.

To learn more about how to create and edit Nodes within the device module, please refer to: Device Configuration - v10 - Tatsoft LLC

Adding and Editing Device Points

Device points define specific values for each node that can be accessed using tags. Configuring data points is crucial for monitoring and controlling various aspects of the industrial automation system. The number of data points you can configure is related to both the ProductModel that is configured for the project and your software license. To add and edit device points, follow these steps:

To configure data points:

• Go to Devices → Points.

• You can copy and paste tags from the Tag → Objects.

• Enter or select information, as needed.

• To add or remove a column, right-click the column heading area and select or deselect columns.

To learn more about creating and editing Points within the device module, along with various methods for importing PLC addresses, pleaserefer to: Device Configuration - v10 - Tatsoft LLC

Importing PLC Addresses

When creating communication nodes and data points, you can import them if they are defined in another data source in the following ways:

• You can copy and paste the contents of a table from Excel. The tables can have different columns or order, as long you include the title of the column in the copy and paste operations. The system will put the data in the expected columns, even if the order is different in the source and target tables.

• You can import the data from csv files.

• For Rockwell ControlLogix devices, you can import from L5k definition files.

• You can use various Import Wizards from many data sources

• For OSIsoft® PI database, there is a FactoryStudio version to share definitions.

• A programming API is available that can populate the tables from code, even from runtime execution when it is necessary.

Customizing the Pre-defined AccessTypes

FactoryStudio comes with several pre-defined access types that define the specific methods for reading and writing the values of each data point. To further optimize data exchange, users can customize these access types as needed. To customize pre-defined access types:

To configure access types:

• Go to Devices → AccessTypes.

• Do one of the following:

• To edit an existing access type, double-click a field.

• To create a new access type, click Create New.

• Enter or select information, as needed.

To learn more about the device module's accesstype tab, see: Device Configuration - v10 - Tatsoft LLC

One very efficient AcceesType is to read data when it is being used by the application. Go to the section OnDisplayOrServer for more information.

Working with the Device Module

The Device Module in FactoryStudio is an essential component that enables seamless communication between the HMI and various devices in the industrial automation system, such as PLCs and other equipment. To maximize the potential of this module, it is crucial to understand its features and capabilities in-depth.

Runtime Execution

During runtime execution, the Device Module manages all aspects of communication between the HMI and the devices in the industrial automation system. This includes establishing and maintaining connections, handling read and write requests, and processing data quality and device status information. Proper configuration and optimization of the Device Module are critical for ensuring seamless data exchange, minimal latency, and optimal system performance. The Device Module supports a wide range of communication protocols, making it adaptable to diverse devices and systems.

Integration with Other Modules

FactoryStudio's modular architecture allows the Device Module to easily integrate with other modules like Alarms, Historian, and Scripts. This integration enhances system functionality and simplifies data management, fostering a unified approach to industrial automation. This seamless integration between modules promotes efficient workflows, reduces development time, and enables the creation of sophisticated and powerful HMI/SCADA solutions.

Distinctions between Devices and TagProviders

In FactoryStudio, devices represent the physical equipment in the system, while TagProviders are the logical entities that store and manage tag information. Understanding the distinction between these two components is essential for effective system configuration and management. By clearly separating the responsibilities of these components, FactoryStudio promotes modularity, simplifies configuration, and enables users to build scalable and maintainable solutions.

Using Data Quality on Displays

Data quality is a critical aspect of any HMI/SCADA system, as it ensures that operators receive reliable and accurate information about the process. FactoryStudio allows users to incorporate data quality on displays to provide a visual representation of data reliability, enabling operators to make well-informed decisions. This allows operators to identify potential issues and take appropriate action to maintain system performance and safety.

Advanced Features and Options

FactoryStudio offers various advanced features and options to further enhance the capabilities of the industrial automation system. These features include support for importing PLC addresses, integration with third-party systems, and an API for programming custom functionality. Leveraging these features can help create a tailored and efficient HMI/SCADA solution that meets the specific requirements of your industrial automation system.

Troubleshooting and Best Pratices

Troubleshooting and implementing best practices are essential for ensuring the smooth operation of your industrial automation system using FactoryStudio. By addressing common issues and following recommended guidelines, you can enhance system performance, maintain reliability, and minimize downtime.

In the PLC Address Import section under Devices > Points, it is important to ensure that the correct protocol option is selected when connecting ControlLogix PLCs. In some cases, the default option "Model OTHERS" may not work correctly, and it may be necessary to select a specific model, such as "Model 1756-L8X". If you encounter issues with a ControlLogix Channel not sending or receiving values, try changing the protocol option to the specific model and test the communication.

In the PLC Address Import section under Devices > Points, it is important to ensure that the path and file name are correct when importing L5K files using the "From Filename" or "From Device" options. In some cases, the "From Device" option may fail, and it may be necessary to use the "From Filename" option with the L5K file to make it work correctly.

Common Issues and Solutions

Communication Failures: If your system experiences communication failures between the HMI and devices, check the configuration of channels, nodes, and points. Ensure that device settings, such as IP addresses and communication protocols, are correct. Additionally, verify that the Device Module is running and that there are no errors in the communication logs.

Data Quality Issues: When encountering data quality issues, such as stale data or inaccurate values, review the configuration of access types and polling rates. Adjusting these settings may improve data quality and ensure reliable information is displayed on the HMI.

Importing PLC Addresses: If you experience issues importing PLC addresses, verify that the source file format and contents are correct. Also, ensure that the appropriate import method is selected in FactoryStudio, such as importing from Excel spreadsheets, CSV files, or L5K definition files.

Best Practices and Recommendations

System Design: Plan and design your industrial automation system with scalability and maintainability in mind. Use a modular approach, separating responsibilities between devices, TagProviders, and other modules. This promotes efficient workflows and simplifies system management.

Documentation: Keep thorough documentation of your system, including device configurations, communication settings, and customizations. This will help with troubleshooting, maintenance, and future system upgrades.

Training: Ensure that operators and maintenance personnel are well-trained in using FactoryStudio and understand the specific configurations of your system. This will enable them to identify and resolve issues efficiently, minimizing system downtime.

Regular Maintenance and Updates: Schedule regular maintenance for your system, including software updates, hardware inspections, and performance assessments. This proactive approach will help to identify potential issues before they escalate, ensuring the reliability and performance of your industrial automation system.

Device Module Runtime Attributes

Using Diagnostic Tools

After you start the project in the Startup window, select the diagnostic tools. These are: PropertyWatch (Watch), TraceWindow (Trace), and ModuleInformation (Info). 

You can also start the diagnostic tools on the Run → Test and Run → Startup pages by left-clicking the desired tool's icon. If menus are enabled for the display, you can also access the tools menu. 

Module Information

The Module Information tool provides information about the operation of the modules. If you choose the devices module and a specific channel, you will see information regarding the function of the communication channel. 

The "Read Groups Information" is important because it provides information about the virtual reading groups, the run time of each item, the quantity of the readings, and the readings that have failed. It also reports on the code and date/time of the last error. 

These are the typical steps to use the Module Information tool:

• Go to Read Groups Information to look at the number of successful and failed communication events and in order to quickly identify the communication blocks.

• If you have systematic errors in all of the blocks or status codes with negative values, it typically means you cannot access the remote device. Check if the node address is right.

• If you have specific blocks with systematic errors, verify the tags and addresses that are connected to the blocks. Use the TraceWindow with the Device information to collect information about the communication errors.

• For some protocols, like OPC, the discarded items will show as a wrong addresses in the configuration.

Keep in mind that you can only READ from a field device when an Enterprise application is running in test mode. This makes it useful to run the application with ONLINE CONFIGURATION enabled because you do not need to start and stop the driver when modifying the configuration. You can modify PLC addresses, AccessTypes, and most of the application, and you can see the results in real-time on your running application. You can use the Startup window or the PropertyWatch tool to start and stop only one module, instead of restarting the entire runtime system. 

Property Watch

Property Watch is a diagnostic tool used to access the tags and internal properties of the system for reading or writing. Type the name of the property in the Object column, and its value will be found in the Value column.

For example, in the screen shown above, select Tag.Coils or Device.Channel.modbus.Status . The value of these objects will be shown. To the right side, additional properties are displayed for the selected object. 

Trace Window

The Trace Window tool displays system messages in a data grid interface. If you enable the module devices in the settings, information will be available about the status of reads, writes, unsolicited input, TX frames (sent), and RX frames (received).

When checking the devices CheckBox in the Settings, enable only the ERROR, INFO, and Warning information. Do not enable the Debug information, or you will create too much data. For ControlLogix devices, it is very important to use this tool, as the system will present here the invalid addresses on the configuration.

If you click the settings button in the configuration dialog, you can select which message types and modules to display. You can see the data in the data grid or save it to a file. It is also possible to configure a tag in ObjectName, and click the Add button to display a menu to select that object and include it in the monitoring.

The Device Namespace

The Device namespace is the entry point for all objects related to the device module.

The Device.Channel object lists all of the configured channels and their runtime properties.

The Device.Node object lists all of the configured nodes and their runtime properties.

The Device.AccessType object lists the defined access types and has options to execute synchronous calls on reading and writing to the device. 

The following tag properties are updated based on the device module: