Device Servers - Networking & Communications

Device Servers andCommunication ControllersPaul WackerProduct Sales Manager (eA(US)2009 WPC • Product Training

Session Objectives• Increase your product knowledge• Understand key product features and benefits• Recognize new sales opportunities• Learn about competitors and product positioning

Serial Device Connectivity

The Ubiquitous Serial Connection …• Asynchronous serial connections are still the mostcommon industrial device interface• Interface types– RS-232– RS-422– RS-485• Common uses– Configuration and setup– Programming or download– HMI interface– Production monitoring– Troubleshooting and diagnosticsRS-232

Some Industrial Devices with Serial PortsPLCRTUHMIMarquee DisplayTemperatureControllerVisionSystemsScaleAC PowerMonitorBarcodeScannerPanel / LabelPrinterRFIDScannerCleanroomParticle Counter

The Limitations of Serial Ports• Dedicated connections only– Typically one PC/host per serial device– One protocol for all devices• Very limited distance– RS-232: 50 Ft. (15 m)– RS-422/485: 4000 Ft. (1200 m)• Poor performance– Typical speeds of 9,600bps to 115,200 bps (not Mbps)• Installation cost– Separate and dedicated cable per serial device

What if You Could …• Quickly and easily replace limited distance serialconnections with an anywhere/anytime access– Leverage existing Ethernet and IP networking infrastructure– Access anywhere there’s a network connection– No distance limitations!LAN / WANRS-232DeviceServerRS-232RS-232

Configuration and Setup• Windows utility functions– Discover units on network– Configure network settings– Configure serial port settings– Select operating mode• Other interfaces– Web browser– Telnet– Local RS-232 console• Other Windows utility information– Also supports ADAM-457x and EDG-45xx series– Included on the product CD and available on advantech.com

Mode: Pair Configuration (Peer-to-Peer)• Connection is initiated by either Device Server• Applications: an RS-232 extension cord,interconnecting devices over a LAN/WANEthernetDeviceServerDeviceServerRS-232RS-232

Mode: TCP Server w/ Redirection• Comport redirection software is installed on computer• Remote devices are addressed as a virtual COM ports• Applications: legacy PC-based software applicationsHostComputerWindowsLegacy Application SoftwareNative COMPort DriverRS-232Virtual COMPortEthernetEthernetDeviceServerRS-232

Example: ManufacturingRemote PLC programming/diagnosticsHost Computerwith COM PortRedirectionEthernetBenefits• Time Savings – remote access fromyour desktop or laptop (via VPN)• Increased Flexibility – access anydevice from any desktop/laptop• Reduced Cost – leverage existing IPLAN/WAN infrastructure instead ofinstalling dedicated cablingRS-232EKI-1521Device Server

Example: Warehousing/LogisticsNetwork Enabled Barcode ScannersHost Computerwith COM PortRedirectionEthernetBenefits• Rapid Integration – Quickly andeasily connect disparate devices• Increased Flexibility – overcomedistance limitations of serial devicesRS-232EKI-1521Device ServerRS-232EKI-1521Device Server

Wireless Connectivity• Enables real-time untethered access• Most compelling use is where wiredconnections simply can’t be used– Handheld computing devices and tools– Moveable or reconfigurable equipment– Rotating equipment and machinery– Mobile equipment (forklifts, AGVs, trucks, etc.)• Installations where wiring is cost prohibitive

802.11 Wireless (WiFi) Basics• Wireless adaptation of Ethernet• Key advantages– Low power, license-free operation– Untethered network and device access– Very cost effective due to commercial success• Versions– 802.11b: 2.4 GHz, 11 Mbps, 115 ft. (35 m) indoor range– 802.11a: 5 GHz band, 54 Mbps, 115 ft. (35 m) indoor range– 802.11g: 2.4 GHz band, 54 Mbps, 115 ft. (35 m) range– 802.11n: 5 GHz/2.4 GHz band, 248 Mbps, 230 ft. (70 m) range** Range can be extended with directional antennas

EKI-135x Hardware Overview802.11b/gWireless• Dual Power Inputs (12 to 48 VDC)• Reverse Power Polarity Protection• Fault Relay for external PLC/Controller• IP30 Metal Chassis• Operating Temp (0 to 50°C)Serial PortsRS-232/422/485EKI-1351 : 1-portEKI-1352 : 2-port• Serial ESD Protection: 15KV• Power Input Protection:1KV Burst (EFT), 0.5 KV Surge

EKI-6311G OverviewDiversityAntennasKey Features• 802.11b/g Operation, 80mW max.• Wireless AP, Client, Repeater• WEP, WPA, and WPA2 Support• 802.1x/RADIUS Remote Authentication• IP65 Rated for Outdoor Use• Power over Ethernet (PoE)• Weatherproof Plastic Chassis• IP65 ratedWall or MastMounting• 10/100 Ethernet Port w/ conduit fitting• Power over Etherent (PoE)

Application: Remote LED DisplayHost Computerwith COM PortRedirection802.11b/gAccess PointEthernetBenefits• Transparency – No changes requiredto RS-232 based display or software• Cost Savings – Rapid installationwithout the need to pull or burycommunications cableRS-232EKI-1351Device Server

Modbus Gateways

Modbus Overview• Communications protocol introducedin the mid 1970’s by Modicon• Now an open standard with broad vendor support• Most popular industrial protocol world-wide• Implementation is master/slave (client/server)– Modbus ASCII• Asynchronous serial (RS-232/422/485)• Oldest of implementations– Modbus RTU• Asynchronous serial (RS-232/422/485)• Most efficient (binary), and most popular– Modbus TCP• Ethernet and TCP/IP networks onlyhttp://www.modbus.orgModbusMasterModbus RTURS-485ModbusSlave

How Do You Bridge the Modbus Gap?• Most new equipment is Modbus/TCP• Modbus serial and Ethernet versionsnot designed to work with each other• Large installed bases of Modbus serial► How do you preserve current investments?► Is there a way to bridge the old and new?► What about serial only Modbus devices?

EKI-112x Modbus Gateway• Integrated hardware/software solutionto connect serial and Ethernet devices– Modbus/TCP to Modbus ASCII or RTU– Modbus ASCII or RTU to Modbus/TCP• Transparent – no changes required toattached devices/equipment• Preserve installed equipment investments• Integrate devices without EthernetEKI-1121L: 1-portEKI-1122L: 2-portEKI-1124L: 4-portModbus RTURS-485Modbus/TCPEthernetModbusGateway

Product Selectionand Overview

Easy Selection• How many serial devices to connect?• If more than 1 device, how far apart are they?• Serial tunneling or Modbus Gateway?• Wired or wireless?• Panel (DIN-rail) or rackmount configuration?

Device Servers & Modbus GatewaysWireless802.11b/g802.11b/g WLAN1x RS-232/422/485802.11b/g WLAN2x RS-232/422/485802.11b/gWireless AP& Client BridgeEKI-1351EKI-1352Modbus Gateway Modbus Gateway1x RS-232/422/485 2x RS-232/422/485Modbus Gateway4x RS-232/422/485EKI-6311GDual 10/100 LAN8x RS-232/422/485Wired10/100MEKI-1221Dual 10/100 LAN1x RS-232/422/485EKI-1222Dual 10/100 LAN2x RS-232/422/485EKI-1224Dual 10/100 LAN4x RS-232/422/485EKI-1528Dual 10/100 LAN16x RS-232/422/485EKI-1521EKI-1522EKI-1524EKI-15261 Port 2 Port 4 Port 8 Port16 Port

Market Outlook andDeveloping Opportunities

Market Outlook• Growing demand for Ethernet– Projected 3.6M shipments in 2012– Open standards, easy integration– Multiple protocols on same cableWorldwide Market for IndustrialEthernet (Thousands of Nodes)• Key IndustriesSource: ARC Advisory Group– Chemical – Water & Wastewater– Oil & Gas – Automotive– Food & Beverage – Aerospace & Defense– Pharmaceutical – Machinery– Pulp & Paper – Fabricated Metals– Mining & Metals – Electrical– Electric Power – Electronics & Semiconductor

Competitors: Device ServersComtrolMinneapolis , MNPerle SystemsNashville, TNDigi InternationalMinnetonka ,MNPrecidia TechnologiesOntario, CanadaFieldServer TechnologiesMilpitas, CAProsoft TechnologyBakersfield, CAKorenixTaipei, TaiwanQuatechHudson, OHLantronix, Inc.Irvine, CASealevel SystemsLiberty, SCMoxa GroupTaipei, TaiwanSixnetClifton Park, NY

Sample Qualifying Questions …• IPPCs, TPCs, UNO and ADAM-5000/6000– Are you using RS-232 devices/peripherals?– Are RS-232 distance limitations a problem?– Do you need– What if you could have more than 2 or 3 serial ports?– What if you could reducing the number of cables used?• General– How do you troubleshoot/diagnose your machine orequipment when there is a problem?– How much time could you save if you could connect to yourequipment from your office or laptop?– What if you could access your machine/equipment fromanywhere on your network?– What if you could have wireless access to your equipment?

The Device Server Value PropositionRemotely monitor, manage and controlserial devices over IP networks …• Easy Integration – connect both newand legacy serial devices to Ethernet• Increased Flexibility – break the1-host to 1-device constraints and quicklyintegrate disparate devices• Cost Savings – leverage existing IP-based LAN/WANinfrastructure, eliminating the need for dedicated cabling• Save Time – quickly and easily connect to remotedevices wherever there is network access

Communication ControllerPreview

Beyond Device Servers …• Growing need to connect remote assets– Unlock information contained within– Not all devices “talk” the same protocol– Local control and processing often needed– Data storage for averaging/totalizing readings• Emerging computing category– Gateway for remote (serial) devices– Protocol conversion (serial-Ethernet)– Data logging (pre-process, store, forward)

Industrial Box PCs not Always a Good Fit• More CPU capacity than necessary• Display port (VGA) not needed• No need for a keyboard/mouse• High power consumption (25+W)• Too large for available space• Cost prohibitive

EKI-112xL Embedded Comm. Controller• Small form-factor, user-programmable,low-power controller• Derivative of EKI-152x Device Server• ARM versus x86– Low power consumption– Easy thermal management• Embedded Linux powered (uClinux)• User programmable in C, tools included• Extremely low cost ( Under $300)– EKI-1121L: 1-port RS-232/422/485– EKI-1122L: 2-port RS-232/422/485– EKI-1124L: 4-port RS-232/422/485µC

Example: PV Solar Panel MonitoringMonitoring Service Provider• Revenue-grade metering• Performance-based incentives• “Green” marketing by clientsApplied Solutions• Communications gateway– EKI-112xL: Emb. Comm. Controller• PV current/voltage monitoring– ADAM-4017+/4019+: Analog Input Mod.

Energy Asset ManagementRemote Power Monitoring• Data collection and consolidation• Informed management decisions• Improved reliability & efficiencyApplied Solutions• Web-based Communications Gateway– EKI-112xL: Embedded Communications Controller• Remote sensor integration– ADAM-4017/4052: Remote I/O Modules

Key Application Considerations• Price sensitivity• Limited interfaces– Ethernet (2)– Serial (1, 2 or 4 RS-232/422/485)• Familiarity with C and Linux• Modest available resources– Flash: 8 MB (4MB available)– RAM: 16MB (8 MB available)• Low power consumption (under 4W)• Ideal applications– Communications protocol conversion– Data logging with “push” to central server– Gateway (web interface) for serial devices

Product Launch Plans• Launch preparations in process– Sales Kit– AE training• Sample quantities are availablePart NumberEKI-1121L-AEEKI-1122L-AEEKI-1124L-AEDescriptionEmbedded Communications Controller; 80 MHz ARM7, 16 MB DRAM,8 MB Flash, Dual 10/100 LAN, 1-port RS-232/422/485Embedded Communications Controller; 80 MHz ARM7, 16 MB DRAM,8 MB Flash, Dual 10/100 LAN, 2-port RS-232/422/485Embedded Communications Controller; 80 MHz ARM7, 16 MB DRAM,8 MB Flash, Dual 10/100 LAN, 4-port RS-232/422/485• Start thinking about potential opportunities• Look for coming product announcementµC

Q u e s t i o n s ?

Device Networking Opportunities• Established marketplace, growing brand recognition• Unique position as a PC-based automation supplier• Advantech is well positioned to grow market share• Easy to quote: how many ports? wired or wireless?• Solution selling with IPC/TPC/UNO/ADAM• True incremental sales opportunity… follow the Ethernet cable!

Industrial Communication Solutions