phoenix digital corporation: migration simplification- reduce technical, financial and operational...

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PUBLIC INFORMATION

Migration Simplification - Fiber Optics and Integrated Architecture Phoenix Digital

Fiber Optics and Integrated Architecture

Tom O’Connor, President

Who, What, Where, When, and Why

LEGACY PROCESS NETWORKS The Problem: Migration Sprawl and Operating Complexity)

IT SERVER

PLC PLC PLC PLC

PLC

Switch

PLCs

Ethernet

Plant

PLC GATEWAY DH+ / RIO

PLC PLC PLC PLC PLC

Many Networks with Different Media Types and Sizes.

Ethernet

Office

Ethernet

O C X

O C X

O C X

IS THERE A BETTER WAY?

Various Programming Problems

WHY ISN’T MIGRATION AN IMMEDIATE AND EASY DECISION?

• I am going to retire within two years. I do not want the management stress!

• I do not understand the new technology. It is WAY too complicated! • This will cost WAY too much upfront money! • If this new boat starts taking on water, explain the fix!

IT ALL COMES DOWN TO RISK

PHOENIX DIGITAL MIGRATION RISK MANAGEMENT

Types of Risk

• Financial Risk

•Technology Risk

•Operational Risk

Risk Result

•Career Risk

Risk Mitigation

• Do not spend it all at once

•Pick the simplest and best solution

•Keep retreat / regroup options open

THE PHOENIX DIGITAL APPROACH

• Develop a multi-year plan that is supported by a long lived, scalable architecture

• Use operating and maintenance funds wherever possible • Spell out the “retreat and regroup” plan • Go back and simplify it – who is going to live with this thing?

• How will we make sure it will work and, just in case, what is the fix?

NETWORK ARCHITECTURE FUNDAMENTALS

Technology • Transparency • Determinism • Capacity • Scalability • Connectivity • Simplicity

Performance • Redundancy • Fault Tolerance • Topology • Distance • Speed • Reliability

Life Cycle Costs • Migration or Conversion? • Installation • Commissioning • Testing • Diagnostics • Troubleshooting

SIMPLE, STATE OF THE ART DIAGNOSTICS ARE KEY

The Phoenix Digital Integrated Optical Architecture Solution

The OCX product architecture integrates existing, field proven, factory hardened Phoenix Digital technologies into a single fiber optic module, capable of transparent, multi-protocol communication on a real-time, redundant fiber network!!

• Unlimited Network Bandwidth

• One Hardware Module

• Common Field Wiring / Specifications

• Simultaneous, Multiple Independent Protocols

• Less than 1% “Bandwidth Creep”

• Redundant, Fault Tolerant, Self Diagnosing

• On-Board Intelligence for Customized Software for Application Development

• User-Controlled Node Prioritization

• Real-Time Diagnostics

• Lowest Lifecycle Cost

What Integrate Optical Advantage Does Phoenix Digital bring to Rockwell Automation

1. Fiber Optic Networking Expertise Deployed in RA Chassis 2. Redundant, Self-Healing, Intrinsically Safe, Long Distance, Noise Immune, Unlimited

Speed, Bandwidth, and Distance for Expanded Application Universe including non-RA Control Systems

3. Integrated Architecture approach insures any and every protocol can run on exactly the same cable plant

4. Specifically for Ethernet IP and all other Ethernet flavors… a) In-Chassis option for tighter Logix branding b) Linear, multi-drop wiring scheme option for control node deployment c) Real-time user diagnostics and perpetual configuration management d) Class I Div II UL rating

5. Specifically for ControlNet a) Unique, competitive ability to run fiber optic redundant ring b) Logix branding identity with in-chassis presentation c) Class I Div II UL rating

6. Specifically for Modbus a) Multi-Protocol transmission with all Ethernet protocols b) Automatic master multiplexing

7. Specifically for DH+ and R I/O a) Identical Network Wiring Scheme…no fiber cable changes required to upgrade to faster protocols.

IN CHASSIS SOLUTIONS FOR FAULT TOLERANT FIBER OPTIC NETWORKS

• Fastest Self-Healing Ring Switch Over Recovery Time in the Industry. • Continuous Network-Wide, Real-Time Diagnostic Monitoring. • Synchronous Fault Tracking. • On-Line Optical Power Metering. • Digital and Analog Diagnostic Outputs. • Identifies and Locates Network Faults and Impending Faults. • Rockwell Automation Backplane Connected Including RSLogix Profiles. • User Program Access To Diagnostics (Both On-Line and Backplane Resident). • Priority Queuing System - Faster Thru-Put for Critical Control Nodes.

SIMPLIFIED, REAL-TIME DIAGNOSTIC SOFTWARE FOR ETHERNET BASED

NETWORKS • Compatible with ALL Phoenix Digital OCX Series Ethernet fiber optic communication

modules. • Provides Fiber Optic Module Status for ALL Fiber Optic Modules on the Network

Status Information Including all Copper Connections • Provides Communication Port Status and Statistics for ALL 10/100 Mbps Ethernet

Ports, on ALL Fiber Optic Modules on the Network.

• Provides Communication Error Statistics for ALL 10/100 Mbps Ethernet Ports, on ALL Fiber Optic Modules on the Network.

• Provides Bandwidth Statistics Counters for ALL 10/100 Mpbs Ethernet Ports on ALL Fiber Optic Modules on the Network, Enabling the User to Monitor Network Loading, and Identify and Locate Communication “Bottlenecks” on the Network.

• Diagnostic Software Automatically Creates and Illustrates a Detailed, Custom Drawing of the Overall Network Installation, for ALL network topologies and Configurations. Perpetual Configuration Management!

• Report Generation and Documentation Capabilities Enable the User to View Network Drawings, Create Device/Location Tags, and Maintain a Permanent Record of the Network Design.

Phoenix Digital introduces a breakthrough in Ethernet network simplicity. Ethernet network installation, commissioning, testing, and troubleshooting have been far too complex for far too long. Busy operating personnel don’t want or need much of what other Ethernet products require to set up and operate. The solution --- new redundant, fiber optic Ethernet plug in modules take the time, cost and complexity out of the upgrade decision. SIMPLIFY! The new Phoenix Digital faceplate allows users to access the diagnostics via Rockwell Automation View 5000 or Windows-based PC to make the system integrators job easier or to leave the main control room free from interruption. Significant network information is user-defined and color coded providing continuous monitoring of all electrical and fiber connections. The Phoenix Digital Diagnostic Software offers easy access to network information, logs and maintains errors, offers three levels of security, and NO PROGRAMMING REQUIRED.

AWARD WINNING PHOENIX DIGITAL ETHERNET DIAGNOSTICS FOR STUDIO

5000

THE PHOENIX DIGITAL /ROCKWELL AUTOMATION INTEGRATED ARCHITECTURE

APPROACH (MADE EASY)

Customer Migration Profile Migrate DH+ and/or RIO to Ethernet

Need: 7 fiber patch panels 7 control panel patch cables (sets) 2500’ of 8 strand multimode fiber cable 7 Phoenix Digital fiber communication modules (redundant, plug & play, self healing, and fault tolerant)

Current System

Current Limitations: •Connectivity Distance •High noise areas •HMI update times •No Network Redundancy •Network Security issues



Multi-Year Budget Approach The client currently has some devices on the DH+ network, 2 on the RIO network, and some devices not currently connected to include a building 3000’ away. Both network cables are electrical (copper) based. Both networks are over 15 years old.

Estimated Infrastructure Cost Less Than $40K

•No changeover risk •Provide “retreat path” •Allow multi-year migration evolution

•Use operating / maintenance funds •More performance – less complexity •Scalable 20 year architecture

Let’s get started…..



•Independent installation and testing of the redundant, self healing, plug & play fiber optic network •Simple, real-time diagnostics •Retreat and regroup path •Legacy network stays up and running

•Robust remote testing does not interfere with plant operation •Additional connection to plant HMI optional at any / all times •Accelerate or regroup decision is virtually risk free •Intrinsic Network Security

•Unique, multi-drop topology due to ultra-high speed switching •Simultaneous fiber and copper network coexistence •Proprietary optical carrier permits total protocol transparency---plug & play---NO PROGRAMMING!



Now Simplify EVERYTHING!

•Minimize training and change over risk •Amazingly easy diagnostics for both RS View resident and remote PC access •Real-time monitor all copper and fiber connections simultaneously •No programming required •Familiar drop-and-add daisy chain cable topology •Multiple Levels of Network Security



• New Network Build Out Complete • Old Network Still Operational

• Maximum Flexibility – Minimum Risk



• MCCs • Drives • Motors • Pumps • Chlorinators • Filtration control • Valves • UPSs • Any Additional

Equipment

Wide Angle View Individual Logix Controller View

Ethernet Ethernet I/P Modbus TCP Profinet

• Most LAN applications don’t require fiber’s high level of performance.

• A copper-based LAN is more likely to experience slowdowns or downtime due to high error rates and bottlenecks during periods of high activity. Signal interference is also a major problem, especially in factory environments and other areas that have machinery, power lines or microwave sources that can create signal interference within a copper-based LAN.

• Fiber systems are more reliable. They can transmit data over greater distances without error and are less likely to have bottlenecks. Fiber optic cable is immune to signal interference and is more secure. Financial institutions, the military and other sensitive establishments have long recognized the benefit of fiber in that it is not subject to crosstalk or eavesdropping and is extremely difficult to tap. One of the biggest advantages to fiber is that its “excess” bandwidth capacity helps to “future proof” a network.

Myth Reality

FIBER OPTICS… THE COMPETITIVE ADVANTAGE

#1

• For new builds, fiber is more expensive than copper.

• Actually, fiber can be cheaper. That’s because of several factors including TSB-72 and new architectures based on common cabling. These architectures make good use of fiber’s inherent advantages, namely high bandwidth, low attenuation and its ability to carry signals at far greater distances than copper. Copper has become so expensive that people now steal it from building sites.

• With fiber, system designers don’t need to include as many active electronics in their networks, and telecommunications closets are not required on each floor. These closets take up valuable real estate and require expensive electronic, temperature control, and power management equipment.

Myth Reality


#2

• For existing networks, upgrading from copper is too costly.

• Many people consider fiber the logical choice for new installations, where there is no existing infrastructure to replace and the cost of the installation is budgeted as part of the overall building plan. However, in existing installations, the decision of whether to convert from copper to fiber can be a more difficult one. A company may not have the resources to get the job done all at once and may also feel that disposing of legacy systems is wasteful.

• An upgrade needn’t be cost prohibitive. One strategy is to upgrade the network gradually, over time. For example, a company could increase the speed and performance in a certain segment of their network where they are experiencing bottlenecks. That portion of the network could be upgraded to fiber at relatively little cost. Media converters would be installed to enable the fiber segment of the LAN to exchange data with the larger, copper network. Over a number of years, more segments of the network could be upgraded to fiber, allowing for a gradual migration from copper to fiber.

Myth Reality


#3

• Optical fiber is fragile.

• The glass used in fiber optic cable, which is made of ultra-pure silica, is actually stronger than steel!

• The glass fiber used in fiber optic cable has a tensile strength (pull resistance) that exceeds 600,000 pounds per square inch. Compared to copper or steel strand of the same size, glass is stronger.

• Also, the strength of fiber optic cable is further enhanced by a strong material that runs parallel to the fiber inside the cable jacket. This so-called “strength member” is typically made of aramid yarn, which is the same material used in bulletproof vests.

Myth Reality


#4

• Fiber is more difficult to install than copper.

• Even though fiber has become the accepted standard for datacom backbones, the belief still persists that fiber is more difficult to install than copper. It’s time to blast this myth, once and for all. Fiber is just as easy to install as copper, if not easier. Here’s why:

• Present high speed copper networks, comprised of Cat 5, 5e, and 6 UTP cable, require that installers adhere to installation procedures that are much more stringent and time consuming than fiber.

• Compared to fiber, there are more legal restrictions regarding how and where copper cabling can be installed and terminated.

• Also, installers must be careful not to route copper communications cable close to electrical power cables and other sources of EMI or RFI interference. Fiber optic cable is immune to this type of interference, and provides more options when trying to find the easiest, most direct way to run cable.

• Fiber optic cables are also stronger, thinner and lighter than their copper counterparts, so fiber is easier than copper to pull through small duct spaces.

Myth Reality


#5

• Fiber optic is more difficult to test than copper.

• One of the most common ‘myths’ about fiber is that it is more difficult to test than copper. Actually, fiber systems are far easier to test than modern copper networks. For example, to test a copper link, the technician must conduct tests that account for a multitude of variables including attenuation, crosstalk and cable length. Furthermore, the performance of copper systems differs at various frequencies, so the technician must conduct attenuation and near end crosstalk (NEXT) tests over a frequency range of 1 to 100 megahertz or more.

• Testing fiber is much easier. Fiber is immune to near end crosstalk (NEXT) and different frequencies do not affect operating performance. Pretty much all that’s required when testing fiber is to measure the attenuation and length of the fiber link.

• Also, upcoming 10 Gig copper Ethernet networks will require up to 15 different tests. In contrast, 10 Gig fiber Ethernet networks require testing only for attenuation and length.

Myth Reality


#6

FUTURE PROOF YOUR ARCHITECTURE! WITH FIBER OPTICS

Media Issue Copper Fiber

Bandwidth Limited Huge Distance Limited Up to 60 Miles (90 km) w/o Repeaters Noise Immunity No Total Isolation No Total Safety Varies Intrinsically Safe Cost Rising Steady-Falling Complexity Sizes, Distance Testing, etc. One Size Fits All Downtime Required to Move or Change Power OnDrop and Add Architecture Obsolescence 2-5 Years 20 Years+ Reliability Intrinsically Lower Higher

phoenix digital corporation: migration simplification- reduce technical, financial and operational...

Technology

redundant fiber network

fiber optic modules

network faults

fiber optic module status

network topologies

network loading

single fiber optic module

unlimited network bandwidth