IFPAC 2002 John Mosher Honeywell Industrial Process Control

IFPAC 2002 John Mosher Honeywell Industrial Process Control Machine Automation & Safety Smart Distributed System

Smart Distributed System Description Smart Distributed System is: • Open • CAN-based • Event-driven • Highly reliable • “Smart” device-level network For real-time communication of Process, Configuration, and Diagnostic information Smart Distributed System

Smart Distributed System History 1988 Initial investigations 1990 Protocol Stack work started 1991 Initial Specification finished 1992 / 1993 Beta System test January 94 Official Launch 1995 PC based Control 1995 Protocol enhancements (SDS ALP 2. 0) 1996 Distributed Control / Auto-configuration 1997 Product portfolio development finished 1997 SEMI Int’l Std E 54. 5 -0997 (Sensor/Actuator Network) 1998 Smart Solution Provider Group 2000 IEC / CENELEC Standard 62026 -5 Smart Distributed System

Smart Distributed System Development • CAN technology provides a robust architecture and high volume production to drive component costs down. • The SDS Application Layer Protocol was developed by Honeywell to define and optimize event-driven CAN for industrial control applications in a Microsoft Windows-based control environment. • The SDS Application Layer Protocol is optimized for “Smart Sensors and Actuators”, where Configuration, Diagnostic, and Process information can be embedded cost-effectively in a very small footprint. SDS was Developed to Improve I/O System Reliability and Deliver More (and Better) Process Information. Smart Distributed System

Smart Distributed System Network Architecture Software OS Think & Do QNX Steeplechase UNIX Wonderware NT Intellution DOS Nemasoft C Code & Others PC Interface Honeywell Softing Holjeron I+ME Gmb. H DIP Inc Micro. Smith Synergetic Microsystems Advantech Activator Honeywell Termiflex Protocol Converters SDS<>Lonworks SDS<>RS-232/485 SDS<>Profibus Color Sensors MULTIPORT-SENSOR ITS-ACTUATOR Auxilary Devices & Compnoents Daniel Woodhead Molex Motorola Phillips Brand Rex Beldon 977 PROX HONEYWELL Products unless noted Smart Distributed System MOTOR STARTERS GE ED&C Square D PROXIMITY MULTIPORT ACTUATOR PRESSURE HDLS VALVES and VALVE MANIFOLDS SMC MAC Festo Burkert Parker-Hannifan Numatics OPERATOR INTERFACES EXOR Holjeron Xycom Barcode/RFID Microscan Accusort PROXIMITY ITS-SENSOR DIRECT PLC INTERFACE GE ED&C Q-Term Advantech Western Reserve Opto-22 HDMP Photoelectric Other PLCs Micro Switch (VME) Honeywell IAC Yamatake Siemens GE Fanuc Modicon PLC Direct Industrial I/O Annunciators Nematron Exor Q-Term Holjeron CONTACTORS MINI BASE Prox or Photo 12 mm Prox Mini High Performance Fiber Optic Photos DRIVES GE Fanuc Magnatek Pacific Scientific Infranor ANALOG I/O Opto-22 SNAP Holjeron AQUA Series PLC Direct

Smart Distributed System Network Architecture • Communication rates of 125, 250, 500, and 1, 000 k. Baud • 1500 ft maximum distance at 125 k. Baud (longer with Bridge) • 64 maximum electrical loads (Nodes) per network. 126 with repeater • 12 -24 VDC, 2 power wires + 2 communication wires + shield • Multiple physical layers topologies • 126 logical addresses - not related to physical location on the network • Proven event driven architecture for maximum throughput (<1 ms) • Event-Driven, Master-Slave, Multicast and Peer to Peer Services • Network heartbeat to insure device health every 2. 5 seconds • Robust Network Management capabilities (Microsoft architecture) HONEYWELL PROPRIETARY Smart Distributed System

SDS Network Stack Ü SDS Process Data Services Diagnostic Data Services Configuration Data Services ÜCAN Event driven Polled Cyclical Single Master Multi Master Peer to Peer Multicast ISO OSI 7 Layer Model Application Layer Presentation Layer Session Layer Transport Layer Network Layer Data Link Layer Physical Layer Smart Distributed System

SDS Object Model / Address Mechanism Up to 126 Logical Devices Logical device 32 Objects Data Variables 255 Attributes 255 Actions 255 Events Smart Distributed System Function Calls Event Reports

SDS System Architecture - Object Models SDS Minimum Behavior I/O Devices 1 Digital IN Analog IN Digital OUT Analog OUT Serial String 1. 1 1. 2 1. 3 Smart Distributed System

SDS System Architecture - Application Layer Protocol • SDS Supports Master/Slave, Multicast, and Peer-to-Peer Architectures. • Allows for a wide variety of control implementations • SDS supports Event-Driven, Polled, and Cyclical Reporting Structures. • Multiple structures can be used on the same network. For example, sensors may report ‘Change Of State’ in the Event-Driven mode while analog values are reported every 50 ms. in the Cyclical Reporting mode • SDS has 2 Special APDU (Application Layer Protocol Data Unit) Forms: • Short Form APDU - Shortens the CAN message for single-bit commands such as COS, Write, and Acknowledgement. This allows for greater throughput and improved system response time. • Fragmented APDU - Allows for data messages longer than the standard 6 data byte format. Up to 256 bytes of data may be sent. This allows complex data such as ASCII strings to be sent across the network. SDS Application Layer meets Industrial Needs Smart Distributed System

SDS System Architecture - Embedded Functions • Network Health Diagnostics: Examples: Power, CRC Error, Message Overrun, Missing Device, ISA Board and/or Channel Failure • Device Diagnostics: Examples: Misaligned/dirty photo, prox target too close/far, mechanical switch operation limit, valve return too slow, motor overload tripped, disconnect opened, barcode good/bad read, VFD faults, and overtemp, pressure range alarm, analog calibration error, etc. • Device Embedded Control Functions: Examples: NO/NC, light/dark operate, on delay, off delay, one shot, batch count, motion detection, jam detection, barcode format, temperature setpoint, analog high/low alarm, etc. • Devices can be changed/installed with power on: - Only the address must be set - Automatic readdressing is available - Other functionality is optional and can be auto-configured • Universal Data Communication: Any digital, analog, or serial data may be embedded in a device or connected via a wide selection of remote I/O nodes. SDS Embedded Diagnostics and Network Management features Smart Distributed System

SDS Network Advantages - for Developers • Well-defined, stable, open, and free Application Layer Protocol Download all necessary specifications for free • Solid acceptance in many markets Semiconductor, Electronics Assembly, Automotive, Food & Beverage, Machine Tool, Parcel & Package Distribution, etc • Quick and cost-effective implementation Low cost, small footprint integrated microprocessors (6805 X 4, PIC - <<$10) No approval process is required • Wide variety of developer tools, devices, and services are available. Preloaded chipsets, C - code libraries, NT. dll, UNIX and QNX software toolkits, device conformance tester software, high-end bus analyzer software, developer support, etc. • Well-developed infrastructure • Smart Solution Providers Network comprised of mutually supportive vendors dedicated to providing the ‘whole product’ solution. • UL Testing to insure interoperability and conformance SDS Offers Significant Advantages to Developers Smart Distributed System

SDS Automatic Config/Replace Device SDS Configuration File Checks for Device Health and Verifies/Corrects Attributes at Startup. Replacement of Bad Devices can be Automatic. ******************* * CFG FILE * ******************* * Date: 03/19/01 Time: 17: 20: 29 Board PCI 1 Channel 1 Baud: 125 Address: 1 Input: 1 Replacement_Address = 126 Attr 6 (Byte) = 1 Attr 10 (Byte) = 0 Attr 61 (Byte) = 3 Attr 62 (Word) = 0 Attr 63 (Word) = 0 Attr 64 (Word) = 0 Attr 65 (Byte) = 0 Attr 73 (Byte) = 0 Smart Distributed System Hierarchy = 1. 1. 1 Address: 2 Input: 1 Replacement_Address = 126 Attr 6 (Byte) = 1 Attr 10 (Byte) = 0 Attr 57 (Long) = 0 Attr 58 (Byte) = 0 Attr 60 (Byte) = 0 Attr 61 (Byte) = 3 Attr 62 (Word) = 0 Attr 63 (Word) = 0 Attr 64 (Word) = 0 Attr 65 (Byte) = 0 Hierarchy = 1. 1. 1 Easily editable text file saves all device settings and lets maintenance personnel replace devices without powerdown or configuration tools.

SDS Automatic Error Log SDS automatically creates a time and date stamped error log file in an easily manipulated text file: Feb/21/2001 06: 55: 04 SDS Diagnostic Log Initialized ---> Feb/21/2001 06: 55: 12 Device Diagnostic Bit Values Have Changed for Bus: 2 Address: 10 : Rom. Ck. Sm 0, Wtch. Dog 0, Bus. Off 0, Fatal. Err 0, Missing. Node 0, Dupl. Node 0, EEProm 0, Write. Error 0, Dev. Err. Code 0, Mismatch 0 Device Diagnostic Bytes 0 -3 (in Hex) : 00, 02, 00, Bus Diagnostics : 00, 10 ---> Feb/21/2001 06: 56: 22 Device Diagnostic Bit Values Have Changed for Bus: 3 Address: 31 : Rom. Ck. Sm 0, Wtch. Dog 0, Bus. Off 0, Fatal. Err 0, Missing. Node 0, Dupl. Node 0, EEProm 0, Write. Error 0, Dev. Err. Code 0, Mismatch 0 Device Diagnostic Bytes 0 -3 (in Hex) : 00, 40, 00, Bus Diagnostics : 00, 10 ---> Feb/21/2001 06: 53 Device Diagnostic Bit Values Have Changed for Bus: 2 Address: 10 : Rom. Ck. Sm 0, Wtch. Dog 0, Bus. Off 0, Fatal. Err 0, Missing. Node 0, Dupl. Node 0, EEProm 0, Write. Error 0, Dev. Err. Code 0, Mismatch 0 Device Diagnostic Bytes 0 -3 (in Hex) : 00, 06, 00, Bus Diagnostics : 00, 10 ---> Feb/21/2001 07: 47 Device Diagnostic Bit Values Have Changed for Bus: 3 Address: 10 : Rom. Ck. Sm 0, Wtch. Dog 0, Bus. Off 0, Fatal. Err 0, Missing. Node 0, Dupl. Node 0, EEProm 0, Write. Error 0, Dev. Err. Code 0, Mismatch 0 Device Diagnostic Bytes 0 -3 (in Hex) : 00, C 0, 00, Bus Diagnostics : 00, 10 ---> Feb/21/2001 07: 50: 33 Device Diagnostic Bit Values Have Changed for Bus: 2 Address: 17 : Rom. Ck. Sm 0, Wtch. Dog 0, Bus. Off 0, Fatal. Err 0, Missing. Node 0, Dupl. Node 0, EEProm 0, Write. Error 0, Dev. Err. Code 0, Mismatch 0 Device Diagnostic Bytes 0 -3 (in Hex) : 00, 08, 00, Bus Diagnostics : 00, 10 ---> Feb/21/2001 07: 52: 01 Device Diagnostic Bit Values Have Changed for Bus: 3 Address: 8 : Rom. Ck. Sm 0, Wtch. Dog 0, Bus. Off 0, Fatal. Err 0, Missing. Node 0, Dupl. Node 0, EEProm 0, Write. Error 0, Dev. Err. Code 0, Mismatch 0 Device Diagnostic Bytes 0 -3 (in Hex) : 00, 21, 00, Bus Diagnostics : 00, 10 Smart Distributed System

Typical Attribute Capabilities for Analog Devices Device-Specific Diagnostics (Below) and Representative Input Scaling of Analog Input Device (Right) show range of data settings available to user. Smart Distributed System

SDS Network Advantages - for Customers • Fast, Reliable, Open, and Proven Device Network • Internationally-approved industrial network protocol • Field-proven reliability in system critical applications • Flexibility to Expand, Reconfigure, adapt to new applications • Built to handle Process, Configuration, and Diagnostic data • Optimized for Microsoft Distributed i. Nternet Architecture (DNA) • Backed by Global Service and Support from Honeywell SDS Offers Significant Advantages to Users Smart Distributed System

Scalability - SDS and Windows CE Distributed Control User Computer Or Analyzer Supervising one or more “SAM” Powered By “SAM” - Win. CE-based Think & Do with SDS Master and optional Local I/O and Bluetooth To Next Win. CE Ethernet Controller Available Now! SDS Network - All Device Types Supported Smart Distributed System

Product Development Example High precision temperature monitoring and control development continues forward utilizing an internal temperature sensor connected to a third terminal on the header of Honeywell's TS 700 high reliability bimetallic thermal switches. The temperature sensor is thermally mounted to the internal surface of thermal switch and is contained within the clean, dry, hermetic, He/N 2 filled enclosure. This protects the temperature sensor and eliminates the need to provide separate packaging and wiring of sensors, providing the ultimate in savings and reliability for installations requiring thermal regulation, protection and monitoring. Smart Distributed System Temperature Sensor with Overtemp Switch

Product Development Example Typical Ne. SSI Device would combine state-of-the-art sensor technology with small, SDS Interface in appropriate packaging and use off-the-shelf connections. RJ 45 SDS A/D Temp. Press. Substrate Smart Distributed System Substrate

SDS Customers - (partial listing) Electronics and Semiconductor: • Dell Computer ** • Compaq • IBM • Tektronix • Hewlett-Packard • Silicon Graphics/Cray • Motorola • Gateway Computer • Lucent Technologies • Xerox • OKI • Samsung • QSC Audio ** • SCI Systems Other Markets: • General Motors • Ford • Honda • Boeing • Halliburton Energy Services • U. S. Postal Service • Proctor & Gamble • Coca-Cola • Hunt-Wesson • Fastenal Company • Target Stores • Eagle Logistics • UPS • DHL Worldwide • TNT Courier ** Modern Material Handling Manufacturing Site of the Year Award Smart Distributed System

SDS Market Share - Microsoft-based Control Applications Smart Distributed System

Major SDS Installations - U. S. Smart Distributed System

Smart Distributed System - Contact Information SDS Web Site: (with Links to other manufacturers and developers) http: //www. honeywell. com/sensing/prodinfo/sds - SDS Application Layer Protocol - SDS Physical Layer Specification - Component Modeling Specification - Component Interface Specification - Control Interface Specification - Conformance Test Procedure Specification - Product Information and Developer’s Training Conformance Testing: Underwriter’s Laboratories (UL) Chuck Goetz 847 -272 -8800 ext. 43163 or E-Mail: goetzc@ul. com Application and Technical Support: Honeywell Sensing & Control Bob Nickels 815 -235 -5735 or E-Mail: bob. nickels@honeywell. com Smart Solutions Providers Organization (formerly Partner’s Program) Contact Paul Jensen at 503 -675 -1667 or E-Mail: pjensen@holjeron. com http: //www. simpleaswire. com SEMI SAN committee representative for SDS - John Mosher (209)339 -4004 or E-mail: john. mosher@honeywell. com Smart Distributed System