special edition micrex-nxefasco.co.kr/eng/product/catalog/f02 special edition... · 2016-10-07 ·...

Whole Number 211

Special Edition MICREX-NX

New Information and Control System

Further evolutionprotects customers’ assets


The MICREX-NX is a verti-

cally and horizontally integrated system capable

of providing various solutions, from the field level to

the management level. With high scalability, the MIC

REX-NX can be applied effectively for small to large-

scale plants, redundant architecture and compliance

with international standards, the MICREX-NX realize

plant safety and security.

Cover photo:The business environment has

undergone a large transformation,and production systems capable offlexible and rapid responses to mar-ket changes are strongly demanded.Accordingly, there is a need for ver-tically and horizontally integratedsolutions that organically link hier-archical levels from the productionsite to production management andoperations, and that seamlessly in-tegrate the various components andsolution packages required at theproduction site.

In response to this situation,Fuji Electric is advancing a totalsolution by supplying industrial so-lution packages, supporting openstandards in control systems, in-creasing the efficiency and qualityof engineering, and supporting in-creasingly intelligent field devices.

The cover photo shows FujiElectric’s new information and con-trol system MICREX-NX to illus-trate the concept of a vertically andhorizontally integrated solution.

Special Edition MICREX-NX

CONTENTS

Trends and Prospects for Information and Control System 104

The New Information and Control System MICREX-NX 111

Advanced Information and Control Software Packages 116for the MICREX-NX

Migration Strategy for the MICREX-NX 120

Engineering Support Tools for the MICREX-NX 125

Cabinet Mounting of the MICREX-NX 130

Head Office : No.11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan

http://www.fujielectric.co.jp/eng/company/tech/index.html

Vol. 51 No. 4 FUJI ELECTRIC REVIEW104

Shin HashimotoChihiro NakajimaJunichi Kuroe

Trends and Prospects forInformation and Control System

1. Introduction

In the more than ten years following the burstingof Japan’s economic bubble, Japan has experienced anunprecedented period of low growth. However, accord-ing to a business outlook survey for the period fromApril to June of FY2004, capital investment forFY2004 is expected to increase to 19.8 % compared tothe prior year. Although the future appears bright, thebusiness environment remains severe and there is aneed for corporate restructuring to enable companiesto survive even during periods of low growth. On theother hand, against the backdrop of Japan’s deflation-ary market with falling prices for materials andproducts, the trend toward globalization is continuing,with manufacturing being shifted to China and otherAsian countries.

Under these circumstances, the Japanese manu-facturing industry faces domestic challenges involvingthe shift toward higher value-added products, con-struction of highly efficient manufacturing systems,and adoption of energy-savings and other measures toreduce the burden on the environment, while alsofacing such overseas challenges as the stabilization ofmaterials procurement, construction of manufacturingsites, establishment of distribution and sales networks,and compliance with international standards for prod-ucts and manufacturing processes. The industry isworking urgently to overcome these challenges.

In the past, mission critical business systems andmanufacturing execution systems (MES), supported bytechnical advances in information technology (IT),have aimed to optimize production management andoperations management. On the other hand, processautomation systems (PAS) have a successful trackrecord of optimizing manufacturing processes center-ing on monitoring and control. However, in an overallproduction system, the role of an information andcontrol system is to manage these functions as anintrinsically unified system and to create a mechanismfor optimizing the overall system.

In light of these circumstances, we believe thatinformation and control systems should be verticallyand horizontally integrated solutions, as shown in

Fig. 1, realizing both vertical integration that links thefield level to the production management and enter-prise levels, and horizontal integration that seamlesslyconnects upstream to downstream processes in amanufacturing plant.

Based on the market trends of information andcontrol systems, analysis of user needs, and technicaltrends, this paper describes Fuji Electric’s efforts indeveloping an information and control system capableof providing vertically and horizontally integratedsolutions.

2. Information and Control Systems: MarketTrends and User Needs

Figure 2 shows forecasts of the global, Asian andJapanese markets for distributed control systems(DCS) that are central to information and controlsystems. Future average annual growth rates arepredicted to be 2.5 % for the global market, 6.4 % forAsia (excluding Japan), and 0.5 % for Japan. Althoughthe Japanese market will remain essentially flat,growing by only a small percentage, the Asian marketwill continue to expand, with most market growthoccurring in China (1).

According to industry-specific market forecasts, inthe global, Asian and Japanese markets, the annualgrowth rate of the materials production industry willbe less than average. Oppose to that the averageannual growth rates will be highest in the pharmaceu-tical, food and beverage industries, followed by theelectric power and water and sewage industries.

Under these market conditions, the steel and metalindustry, the industries of oil refining and chemicals aswell as cement and glass have little demand for newplant facilities and the replacing of equipment is beingpostponed to later dates. The greatest demands toreplace equipment is for maintaining those plantswhich have previous received capital investment.

Within this market environment, user needs forinformation and control systems have changed dramat-ically over the past several years. Namely, suchsystems have improved their lifecycle cost efficiency byenhancing conventional functions and performance


Fig.2 Forecast of global, Asian and Japanese markets forprocess automation

Fig.1 Vertically and horizontally integrated solution

Vertically and horizontally integrated solution

ERP/SCM

Whole optimal

Vertical integration Fundamental technology

Horizontal integration

Integrated production management

Process automation

Facility management

Process control

KnowledgeQuality Schedule

Energy

Fundamental management system

Enterprise

Supply chain

Production management

Automation

Drive and field

equipment

Sensor

Power electronics

(drive equipment)

Control technology

Network

Database

Management know-how

Drive ActuatorPLC SensorDCS

Traceability

2002 2003 2004 2005 2006 2007

2,000

4,000

6,000

8,000

10,000

12,000

0

Mar

ket

size

(10

0 m

illi

on y

en)

Year

Global market

Asian market

Japanese market

Notes: 1) Asian market excluding Japan2) Exchange rate calculated as 1 dollar = 110 yen

and by reducing costs at the time of initial investment.Consequently, the lifecycle cost, i.e., the cumulativecost incurred from system construction (planning,design, manufacture and testing) to operation andmaintenance, equipment replacement and finally todecommissioning, is reduced. In order to optimize thelifecycle cost of plant equipment, it is not onlynecessary to limit the initial investment, it is also

important to reduce maintenance and preservationcosts and equipment replacement costs as much aspossible.

Items of tremendous concern for today’s customersare listed below.(1) In the area of maintenance and preservation, in

addition to the presumed high level of reliabilityensured by the hardware and software platformswhich by definition should be elements of aninformation and control system, the asset manage-ment can be systematized.

(2) In the area of equipment replacement, the latestmonitoring and control system technology and prod-ucts can continue to evolve due to advances in IT.

These areas should work together and support thepartial replacement of existing equipment to the extentto which user expertise with existing equipment can betransferred to new equipment.

3. Technical Trends of Information and ControlSystem

In response to the user needs described above,information and control systems are evolving whileincorporating the latest information and control tech-nology. The main technical trends and future outlookare described below.

3.1 Advances in production system integrationAt present, a PAS cannot exist by itself, and


interaction with ERP (enterprise resource planning),SCM (supply chain management) and MES mission-critical systems, or in other words, expansion in thevertical direction (vertical integration) is required.Furthermore, expansion in the horizontal direction(horizontal integration) to realize total process controlof the incoming materials transport, process control,transport control, and outgoing package transport, aswell as utility management, is also required. With theshift of manufacturing to overseas sites, these types ofintegration, which include the local procurement ofmaterials, present significant challenges.

The following two items are regarded as importantin achieving vertical integration with an MES, whichis well suited for interaction with monitoring andcontrol systems.(1) The original role of an MES is to perform process

management, in-process control, progress monitor-ing, record management, production facility man-agement, quality control, etc. However, the MESfunctionality of today does not stop there and theMES is attracting attention as an enterpriseassessment tool for improving processes. It is alsoanalyzing those improvements, based on an evalu-ation of the process performance, and its role isshifting to the analysis and visualization of recorddata, which are additions to the conventionalmanagement functions.

(2) In the past, it was common to construct an MESusing an order-made solution, for which softwarewas prepared individually. In the future, howev-er, it is thought that an MES platform thatprovides an execution environment and incorpo-rates standard components will be promoted toensure higher efficiency and reliability of thesystem design.

3.2 DCS technical trends(1) Adoption of open technologies

The open technologies produced as a result of therapid expansion of IT have also rapidly spread to theDCS field. Representative examples of open technolo-gies whose adoption is becoming more widespread arelisted below.

q Personal computer and defacto standard OS(Windows*1)

w Standard LAN technology (Ethernet*2, PROFIBUS, Foundation Fieldbus*3, etc.)

e Standard interface protocols (TCP/IP, OPC,etc.)

r Internet technology

t Object oriented software technology(2) Utilization of general-purpose products

There have previously been many instances inwhich a specially developed and designed componentfor a DCS has been replaced with a component madefrom general-purpose products. Ensuring the function-ality, performance, reliability and safety of systemproducts with software also has advantages in terms ofcost. Typical examples include the use of SCADA(supervisory control and data acquisition) software forthe monitoring system and a PLC (programmable logiccontroller) for the control system.(3) Compliance with international standards

With the shift of manufacturing to overseas loca-tions and the overseas exportation of plants, there hasbeen an increase in demand for equipment thatcomplies with international standards. Such compli-ance is essential for facilitating system constructionand the procurement of maintenance parts overseas,and for example, in cases where compliance is requiredby the overseas end user. Moreover, due to the trendtoward JIS (Japanese industrial standard) internation-alization, the JIS is reflecting the content of IECstandards, and plant equipment in Japan often incor-porates technology and products that comply withinternational standards.

4. Fuji Electric’s Efforts

With the emergence of DCSs in the 1970s, informa-tion and control systems have realized the advancedfunctionality and higher performance that exists atpresent. As can be seen in Fig. 3, Fuji Electric hasbeen supplying products to the market ever since theearly days of DCS development. Fuji Electric com-bined the individually developed E (electricity) and I(instrumentation) functionality developed for its firstand second generations of information and controlsystems in the first half of the 1980s with C (computer)functionality developed for its third generation systemto achieve EIC integration. In the latter half of the1990s, Fuji introduced its MICREX-AX (advancedsystem), a fourth generation system based on theconcepts of open technology and evolution with inherit-ance. In 2004, Fuji developed and brought to marketthe MICREX-NX (next generation system), a next-generation information and control system that ad-heres to prior concepts but also features vertical andhorizontal integration and integrated engineering.Figure 4 shows a vertically and horizontally integratedsolution based on the MICREX-NX. Figure 5 shows thepositioning of Fuji Electric’s existing information andcontrol systems and the MICREX-NX.

The MICREX-NX next-generation information andcontrol system was jointly developed as part of acollaborative effort between Fuji Electric and the PASbusiness division of Siemens Corporation of Germany,and is based on Siemens’ PCS7 DCS. Sales of the

*1: Windows is a registered trademark of Microsoft Corpora-tion of the USA.

*2: Ethernet is a registered trademark of Xerox Corporationof the USA.

*3: Foundation Fieldbus is registered trademark of theFieldbus Foundation.


Fig.3 Development of Fuji Electric’s information and control system

HMI

HMI Computer PC

Computer

DPCS-E DPCS-F

Controller E

Controller I

Controller EI

T-link

Server client

Single

1stGeneration

Series name

Concept

Sensor Actuator

Architecture

HMI

LAN

Control (controller)

(PIO) (I/O network)

2nd 3rd 4th 5th

MICREX-PI MICREX-PII MICREX-PIII MICREX-IX MICREX-AX MICREX-NX

Distributed control system EIC integrated control system Advanced information and control system

New information and control system

Analog-to-digital EIC integration Open architecture

1st, 2nd generation

1975 1980 1985 1990 1995 2000 2005

Total automation Evolution with inheritance

Vertical & horizontal integration

Integrated engineering

3rd generation 4th generation 5th generation

Ethernet

Controller EI

T-link

PLC based controller

PROFIBUS DP

Computer

Industrial Ethernet

Ethernet

MICREX-NX began in September 2004.Based on the MICREX-NX core, a next-generation

DCS founded on user needs, Fuji Electric’s informationand control systems has been strengthened as follows.

4.1 Advances in vertical and horizontal integration(1) Vertically integrated system

Fuji Electric’s MES realizes flexible and highlyefficient production planning based on the manufactur-ing workflow, and enables seamless integration with aPAS. Main features of this MES are listed below.

q Total optimization is realized through thesimultaneous real-time control of facilities andequipment, quality inspection, operating in-structions, and the operation record.

w Improved operation and ensured traceability ofthe manufacturing process made possible bythe integration of information generated at themanufacturing site and records analysis (pro-cess lot flow, correlation analysis, in-processbehavioral analysis, etc.)

e Use of an MES platform establishes an envi-ronment in which a system can be constructedby combining standard components.

r Provides an engineering environment for inte-grating an MES and DCS

t Easy linking of data between the MES andDCS by means of an interface based on TCP/IP, OPC and other types of internationalstandards for data exchanges

(2) Horizontally integrated system

Advancing the conventional concept of EI integra-tion, in addition to the integrated control of manufac-turing processes and electrical machinery, all fieldlevel processes from materials transport to distributionand utility are also integrated.

Fuji Electric’s horizontally integrated systemshave the following features.

q The control component is based on a high-performance PLC. Coordinated operation ofelectrical machinery control that requires high-speed response and process control that re-quires a fixed cycle can be accomplished via ashared plant bus (IE: industrial Ethernet).Moreover, integrated engineering tools enablelinked system design and testing.

w The field network is configured from a PROFIBUS-DP and/or PROFIBUS-PA, which are in-ternational standards, and according to theapplication, field level equipment from thedrive equipment to the measuring equipmentcan be connected horizontally, enabling moni-toring and control to be performed.

e The linkage between a vertically integratedMES and DCS enables the flexible operation ofpre- and post-processes (materials transport,distribution, utility, etc.) according to the oper-ating status of the process line.

4.2 Provision of total solutions for the plant lifecycleThe MICREX-NX is provided with the following

mechanisms to reduce cost and ensure stable plant


operation during each phase of the plant lifecycle.(1) System configuration phase (conception, design,

construction, testing)(a) Scalable system configuration

Two series of products are available accordingto the scale of the system, an entry systemBOX Series for small-scale plants, and a PROSeries scalable from 150 to 60,000 tags formedium and large-scale plants. Because theseseries both have the same engineering environ-ment, legacy equipment and expertise acquiredwith minimal investment can continue to beused when expanding the plant, thus enablingthe user to recover their investment.

(b) Compliance with international and industry-wide standardsEach level of the plant naturally complies withinternational LAN standards (such as Ether-net, industrial Ethernet, PROFIBUS-DP/PA,HART, AS-i, MODBUS, etc.) and supports theuse of the international standard language IEC61131-3. Additionally, the SIMATIC*4 BATCH

control package (conforming to IEC61512 (ISAS88)) for batch plant-use to enhance globalcompetitiveness, a system for electronicrecords, electronic signatures, monitoring andrecording for food and pharmaceutical manu-facturing processes that complies with regula-tions concerning electronic archives and elec-tronic signatures (FDA 21 CFR Part 11) asestablished by the United States’ Food andDrug Administration (FDA), a safety instru-mentation system (conforming to IEC61508),and the like are available.

(c) Integrated engineeringq Integrated engineering is a key concept of

the MICREX-NX. An integrated engineer-ing database enables high value-addedfunctions such as a monitoring and operat-ing system, a control system, facility man-agement, SIMATIC BATCH, a safety in-

Fig.4 MICREX-NX based information and control system

Office LAN EthernetPlant information

OS single station(multi VGA)

OS client Batch client

Terminal bus

Plant bus

PR

OF

IBU

S- D

P

PR

OF

IBU

S- D

P

PROFIBUS-PA

OS: Operator stationES: Engineering stationAS: Automation station

Enterprise level

AS414HAS417H

ET200M

DP/PA-link

AS414AS416AS417

OS server(redundant)

Batch server(redundant)

Plant maintenance

Production management level

Plant control level

Process level

Field level

ServiceES

DP/PA-link

Y-link PR

OF

IBU

S- D

P

AS414F/FHAS417F/FH

ET200M failsafe

DP/PA-link

ET200M

ET200M

PROFIBUS-PA PROFIBUS-PA

Horizontal integration

Ver

tica

l in

tegr

atio

n

*4: SIMATIC is a registered trademark of Siemens ofGermany.


strumentation system, and the like to beconfigured in an integrated engineeringenvironment.

w A mechanism that enables software, whichis the intellectual property of the user, tobe stored in a library and reused acceler-ates the creation of software and theapplication of expertise.

e A three-stage simulator of the controller,PIO and plant can be used to implementdebugging without using an actual device,thereby achieving more efficient designand testing, and realizing higher quality.

(2) Operation and maintenance phase(a) Improved utilization rate

The MICREX-NX realizes complete redundan-cy capable of handling multiple failures in thevarious levels of the network, database server,operator station, controller, PIO, and powersource. Moreover, with a rugged and highlyreliable design of the hardware, and the securi-ty measure that requires an operator to logonbefore performing such tasks as plant opera-tion, engineering, testing, software modifica-tion, and the like, a high utilization rate isensured.

(b) Simpler maintenanceIn addition to improved capability for systemfailure diagnosis and status display, the follow-ing characteristic mechanisms simplify dailymaintenance and shorten the recovery timewhen a failure occurs.

q Diagnosis and preventative maintenance ofequipment and devices horizontally inte-grated by an integrated facility manage-ment system

w A system for managing the different ver-sions of application software by means of arevision history management function

e Rapid identification of the cause of afailure by means of a 10ms minimum (1msresolution) time stamp function

r Online exchange of controllers and PIOmodules, and automatic backup after theexchange

(3) Equipment replacement phaseIncremental migration enables a plant to be main-

tained or expanded flexibly in accordance with a user’splans for replacing equipment. Additionally, a hard-ware group that links an existing MICREX to aMICREX-NX and a software converter that allowsreuse of a user’s legacy software assets make possiblethe long-term inheritance of equipment and expertisewith minimal investment.

4.3 Inheritance and evolution of plant expertise andcontrol technologyThe extent to which plant expertise and control

technology can be continuously utilized and the extentto which it can evolve are important issues for users aswell as manufacturers. This content, including plantoperating expertise, control expertise, and the toolenvironment in which this expertise is applied, is beingaddressed by Fuji Electric as follows.

Fig.5 Positioning of the MICREX-NX

MES linkage

MICREX-NX

Single user system

FOCUSJupiter

150 tags 5,000 tags 60,000 tags

Monitoring and control tags

IT linkage

MICREX-AX

Client and server system

Multi-client and multi-server system

SIRIUS

Computer solution

Monitoring and controlData logging

Monitoring and control


(1) Control and monitoring-use software componentsthat have been accumulated over many years inthe fields of industrial, environmental, watertreatment and energy related applications areconverted into a shared library under theMICREX-NX’s integrated engineering environ-ment. In particular, the control library is pack-aged as a single object containing a controllercomponent, a human-machine interface (HMI),and additional information such as control algo-rithms and the like, thereby enabling more effi-cient reuse of the library and facilitating theinheritance of expertise.A menu of the control content, from PID control toadvanced control and model predictive control, isprepared to allow selection of the optimal usageaccording to the intended application.

(2) Plant operation expertise exists mainly with theuser. The MICREX-NX has enriched its operationsupport package to allow maximum use of theuser’s plant operation expertise. For example, theroute control package has a large effect on com-plex piping routes and tank yard operation in thefood, beverage, pharmaceutical and chemicalfields and the like.

5. Conclusion

Spurred on by rapid advances in IT and the global

trend toward technical standardization, informationand control systems have continued to evolve yearafter year. The globalization of manufacturing, assymbolized by the shift to overseas production, is wellknown, and a more global perspective is adopted. Thisalso applies to the information and control systemsthat provide plant support so that those systems cancontinue to evolve while responding to user needs,instead of being developed solely by one company. Inother words, the value added to information andcontrol systems depends not only on the hardware andsoftware platform, but also on the extent to whichexpertise appropriate for a particular region andindustrial field can be consolidated and combined toenable future inheritance and evolution. From thisperspective, Fuji Electric shares technology with Ger-many’s Siemens Corporation, and also pursues jointdevelopment and shared manufacturing responsibilityto hasten the production of results and to advanceglobal product development.

Fuji Electric intends to continue to provide solu-tions based on user needs, and to develop and providesystems that will continue to satisfy users in thefuture.

Reference(1) O’Brien, L. DCS Worldwide Outlook. ARC Advisory

Group. 2003.


Satoshi SakaiKouichi SakagamiTetsuo Suzuki

The New Information andControl System MICREX-NX

1. Introduction

Over the past two decades or so, distributed controlsystems (DCSs) have been widely used as plantmonitoring and control systems, and have become akey component for supporting plant businesses cen-tered on the fields of water treatment and measure-ment systems.

Until now, the most common type of DCS was ahigh performance, highly reliable “heavy DCS” con-structed using mainly specialized hardware and soft-ware for widest application across all fields.

However, with the long-term stagnating economy,demand has increased in recent years for more effi-cient plant operation by sharing shop floor informationthroughout an entire company and by applying thatinformation to production planning. Additionally,demand has also increased for a reduction in the costsassociated with maintenance and engineering, and a“light DCS,” which is a highly flexible DCS that can beapplied selectively according to the application, andthat uses open technology and advanced software toachieve vertical integration from the field level to themanufacturing execution system (MES) level is re-quested. This light DCS can also be applied to fieldssuch as factory automation (FA) to develop horizontalintegrated business solutions.

In response to these requests, Fuji Electric hasdeveloped a new information and control system,which we call the MICREX-NX. This paper describesthe system configuration and presents an overview ofthe MICREX-NX.

2. MICREX-NX System Architecture

The MICREX-NX system is a highly reliable, high-performance system that is supported by the principlesand concepts of Siemens Corporation’s PCS7, based onjoint development by Fuji Electric and Siemens. Theconcept of vertical and horizontal integration wasconceived so that a single system can use a unifiedplatform of hardware and software to process a widerange of control objects. In addition, Fuji Electric alsoplants to develop components capable of connecting to

existing systems.

2.1 System configurationThe MICREX-NX system is configured from an

operator station (OS) that is an operating and monitor-ing component, an engineering station (ES) used forsetting various parameters, an automation system(AS) that is a control component, and an ET200 seriesthat oversees process I/O. The OS uses an industrialPC and realizes a Windows*1-based open interface.The ES enables control programs and picture parts tobe converted easily into libraries in order to increasemanufacturability. The AS and the ET200 use ahighly reliable programmable controller (PLC) and I/O.General versatility and high reliability are ensured byconnecting these components to an Ethernet*2-basedplant bus (industrial Ethernet) and a PROFIBUS asthe field network. Moreover, with a batch systemconforming to IEC61512 (ISA S88), compliance withthe regulations concerning electronic records and elec-tronic signatures as established by the US Food andDrug Administration (FDA) (FDA 21 CFR Part 11), therealization of a safety instrumentation system(IEC61508), and so on, the MICREX-NX complies withthe latest international regulations and industry stan-dards. (See Fig. 1.)

2.2 Vertical integration and horizontal integrationThe MICREX-NX system is provided with stan-

dardized data management and communication fea-tures. The MICREX-NX component is installed in themain process, and many various specialized softwarepackages are used in auxiliary process and for manag-ing warehouse loading/unloading so that the shop flooris uniform with the same product architecture fromupstream to downstream. This feature contributes tosimplification of the work and to reduced cost in eachphase, including engineering, operation, training andmaintenance. Similarly, with this wide variety of


*2: Ethernet is a registered trademark of Xerox Corporationof the USA.


Fig.1 Overview of MICREX-NX system

uniform components, products all having the samearchitecture can be supplied to the fields of industrialprocessing, machining, and the hybrid processing (fieldin which continuous, batch and discrete processes aremixed).

Moreover, integration of this data managementenables information from the enterprise resource plan-ning (ERP) and MES levels to be shared as fardownstream as the field level.

2.3 High reliabilityThe MICREX-NX system is capable of complete

redundancy. All components from the operating andmonitoring component to the network, control systemand I/O can be made redundant to protect againstmultiple errors in the system. Moreover, an eventmanagement function, advanced time synchronizationand time stamp appending function, and an enhancedself-diagnosis function enable a rapid response toerrors.

3. Engineering Station (ES)

3.1 Integrated engineering systemIn conventional systems, the control and monitor-

ing systems were engineered separately, and a consid-erable amount of time was required to define aninterface between these systems. With the MICREX-NX, however, all engineering work – from field devices,network, and control applications to the operator

station – is performed within an integrated environ-ment. Control applications can be created using asequential function chart (SFC) or a continuancefunction chart (CFC). A CFC block contains messagesand all data related to monitoring and operation, and ablock icon and faceplate for monitoring and operation-use can be generated automatically from a CFC-basedcontrol application. Accordingly, the engineering workin an operator station can be performed more efficient-ly, and because standardized picture parts can be used,the work involved in unit testing is reduced.

Figure 2 shows the automatic generation of partsfor monitoring and operation.

3.2 More efficient engineering(1) Extensive library

Standard components such as motors, valves andPID controllers are provided in advance as softwareobjects in a library.

Because it is easy to create a user library, controlapplications may be reused, thereby improving effi-ciency.(2) Enhanced simulation environment

Using simulation software, a control applicationgenerated from CFC or SFC can be tested on anengineering system without the use of an actualmachine. As a result, errors can be detected andeliminated at an early stage, thereby enabling earlyshop floor commissioning and low-cost, high-qualityprogram production.

OS single station (multi VGA)

Plant bus

ET200M

ET200M

Existing MICREX



Batch server(redundant)

AS414HAS417H

FL-net

MICREX-AX

AOS-2000ADS-2000ADS-2000G

DP/PA link

PROFIBUS-PA

PROFIBUS-PA

PR

OF

IBU

S-D

P

P/PE link

T link

Intelligent CC

Information LAN Ethernet EthernetOffice LAN

Internet, Intranet

Batch client

Service

OS client

Engineering station ESAsset management package

Terminal bus

Plant information

Plant maintenance

MICREX-PIIIMICREX-IX

ET200MFail safe

AS414F/FHAS417F/FH

DP/PA link

PR

OF

IBU

S-D

P

ET200M

AS414AS416AS417

DP/PA link

PROFIBUS-PA

PR

OF

IBU

S-D

P

Serial

DBS-1500IDS-1500ADS-2000

ASA-2000

SAS-55

SAS-2500

SAS-300

ACS-2000

ACS-250

ACS-2000

ICS-2000

ICS-2500

PCS-500

DPCS-F


3.3 Multi-project engineeringSo that a project can be constructed by several

teams working in parallel, the project can be dividedinto sub-projects and engineering tasks can be per-formed individually. The individual sub-projects canbe inserted or deleted from the project at any time.

4. Operator Station (OS)

4.1 System configurationIn contrast to the predetermined combinations of

component elements and the number of componentstations in the monitoring and operating component ofa conventional system, the configuration of theMICREX-NX is scalable according to the size andextension of the object to be monitored.(1) Single user system

A single user system is configured with a singleoperator station.(2) Multi-user system with client server configuration

A multi-user system can be configured with amaximum of 12 OS servers and a maximum of 32 OSclients. Also, an optional archive server may beinstalled to provide server redundancy and to storelarge amounts of time-series data.

4.2 Features of the operator stationWith a conventional system, the operation screen

for each asset was controlled from a menu, and muchengineering work was required to realize “intuitiveoperation” adapted for the actual object. In contrast,the MICREX-NX has the following characteristics.(1) A standard function divides the entire plant into

asset units that can be controlled as “areas.”(2) Intuitive monitoring and operation of the targeted

asset is achieved with a display capable of show-ing a maximum of five hierarchical structureswithin an area.

(3) Authorization settings for operator of monitoringand operation in each area enable security to bestrengthened.

(4) With a loop-in alarm function, the plant screen fora generated alarm can be displayed simply withthe press of a single button.

Also, two additional features are listed below.(1) An SFC visualization function enables sequence

control described by the SFC to be displayed andoperated while the plant screen is being moni-tored.

(2) The display language can be switched onlinebetween Japanese and English.

Figure 3 shows the configuration of the operatorstation.

4.3 Plant monitoring screen creation functionA special screen creation tool having the features

described below facilitates the creation of a plantmonitoring screen.(1) A customized object function can create parts

(objects) for display.(2) Operational settings can be specified easily with a

dynamic wizard and a configuration dialog.(3) OLE components can be embedded easily.(4) A parts library for various drawings is included as

a standard feature.(5) An extensive standard library and a data process-

ing function based on the two script languages ofVB script and C script are provided.

5. MICREX-NX BOX

The MICREX-NX BOX is a system in which a PCcard equipped with a control function is installed in anindustrial PC. Functions of the engineering station,operator station and automation station are realizedwith this single component. The control function PCcard is connectable to remote I/O via the PROFIBUS,and because the power supply system and controlsignal system (reset signal and the like) are separatefrom the PC body, control can continue unaffected byerrors generated due to such PC-side events as a crashof the Windows operating system, interruption of thepower supply, or the like. Potential applications

Fig.2 Automatic generation of parts for monitoring operation Fig.3 Overview of operator station

L

M SM

tagname

Operator station

Controller application

Block icon

Faceplate

CFC block

Automatic generation

Archive server (tag logging)

OS client (32 stations max.)

OS server (redundant)(12 pairs max.)


(3) Communication moduleThe communication processor module (CP443-1) is

a card for connecting an automation system to theplant bus. By installing a communication processorcard (CP1613) in an operator station, that operatorstation may be connected similarly to the plant bus.(4) Cables

The following types of cables may be used: multi-mode and single-mode optical fiber cable, and twisted-pair cable and electronically enhanced industrial-usetwisted-pair cable.

Figure 5 shows the redundant ring configuration.

7. Automation System (AS)

7.1 CPU duplex redundancyConventionally, controller redundancy has been

implemented with a warm standby redundancy meth-od based on the equalization of partial data and thelike. With the MICREX-NX, however, controllerredundancy is event-synchronous and is synchronizedto the access of a memory area resulting from anexternal I/O data access or interrupt processing, or tothe timing at which processing is performed, therebyenabling a changeover to the standby-side in less than100 ms, instead of the approximate 1 s that had beenrequired in the past, and is applicable to plants inwhich even a short interruption of operation notpermitted. Also, this mechanism eliminates the needto consider system redundancy when creating anapplication.

This redundant system is configured from tworedundant CPUs and sync cables connected betweenthe CPUs, two PROFIBUS systems, and a remote I/O(ET200M) that is connected to both PROFIBUS sys-tems.

The CPUs are synchronized with two sync cables

Fig.5 Redundant ring configurationFig.4 Configuration of MICREX-NX BOX system

include small-scale plants, utility plants and systemsfor testing, instruction, training and research. Thesoftware and engineering data are shared with the OSclient server system, and the design facilitates linkageto these systems and the expansion of their functions.

Figure 4 shows the configuration of the MICREX-NX BOX system.

6. Network

6.1 FeaturesThe plant bus is a powerful cell network based on

the IEEE 802.3 standard. An ISO protocol is usedinstead of the usual TCP/IP protocol.

Advantages of the plant bus are listed below.(1) Capable of 100 Mbps transmission(2) The plant bus is specially designed for industrial

use and has excellent ability to withstand adverseenvironmental conditions.

(3) Redundancy can be achieved with an optical orelectronic ring configuration. When an erroroccurs, changeover is implemented at a high speedof 0.3 seconds.

(4) Total length: 5 km (electrical), 150 km (optical)

6.2 Component hardwareThe following hardware components are provided

for the plant bus.(1) Optical switch module (OSM)

An OSM is used in the case of a ring configurationformed from optical fiber cables. With a ring configu-ration, switching from error detection to loop-back canbe implemented within 0.3 seconds. Up to 50 OSMsmay be connected per ring.(2) Electronic switch module (ESM)

An ESM is used in the case of a ring configurationformed from electronic cables. Other specifications arethe same as those of the OSM.

MICREX-NX BOX

ES

24 V DC

DP/PA linkPROFIBUS-DP

PROFIBUS-PA

PROFIBUS-MPVDP

Etherneton board

PCMCIAcard

CP5611on board

PDM OS

Simatic Net CPU416-2PCI+PS

MPVDPDP

Redundant OS server

Optical switch module

Dual redundant plant bus(Industrial Ethernet)

OSMOSM

OSM

OSM

Redundant ASAS414HAS417H

Equalization line


Fig.6 Appearance of the automation system

(optical fiber cables) and four synchronization modules.Two PROFIBUS slave interface modules (IM153-2)

are used in the remote I/O so that the interface is alsomade redundant.

Figure 6 shows the appearance of the automationsystem.

7.2 Control languageVarious languages have been developed to promote

the standardization and modularization of programs.(1) Continuance function chart (CFC)

A CFC is an image of a process flowchart, and iscreated by connecting the various function blocks withlines on an editor.(2) Sequential function chart (SFC)

Conforming to the SFC of IEC61131-3, this lan-guage aims for control that can easily divide a processinto phases.(3) Standard control language (SCL)

This language conforms to the structured text (ST)of IEC61131-3. This is an advanced language suitablefor sophisticated data processing.

8. Process I/O (PIO)

The MICREX-NX PIO is provided with remote I /Oand direct I/O functions. The remote I /O is capable ofrealizing distributed control via the PROFIBUS. ThePROFIBUS is an excellent network for remote I/O andis standardized in Europe, but is also becoming aworldwide standard. With the production of manyvarieties of components from Siemens Corporation orthird party manufacturers, the PROFIBUS can readilybe used in various types of plants. The transmissionspeed of this PROFIBUS is selectable up to 12 Mbpsaccording to the intended use, and the cable length persegment may be extended up to 100 m.

The ET200M remote I/O consists of a power supplymodule, a PROFIBUS module, and up to eight mount-able I/O module panels. Many types of I/O areavailable for the ET200M, and this I/O module enablesthe basic I/O range to be set according to themeasurement range software setting. Moreover, CPUrack redundancy and PROFIBUS I/O transmission

line redundancy can also be supported. I /O capable ofbeing made redundant is also available. Each type ofI/O has a self-diagnostic function, and therefore,detailed I /O diagnostic information can be displayed atan OS or ES. Of course, I /O modules may also beadded and parameters may be changed during opera-tion.

9. Plant Control Package

A wide variety of plant control packages such asbatch control and pipe route control are provided forthe MICREX-NX. The batch system is described belowas a representative example of a batch control package.

9.1 Overview of the batch systemThe batch system is a package suitable for today’s

market needs and complies with IEC61512 (ISA S88),the international standard for batch control, and withFDA 21 CFR Part 11, for which there is strong demandfor compliance in the pharmaceutical industry.

9.2 Features of the batch system(1) Plant hierarchy

The batch system enables a hierarchical structuraldesign that complies with ISA S88.01. A hierarchicalstructural expression enables the clear identification ofwhich device is being used in which process, and theflexible use of devices according to the product line.(2) FDA 21 CFR Part 11 compliance

The batch system package satisfies the require-ments for access management, electronic signature,data storage, audit records and the like, as specified byFDA 21 CFR Part 11. An access authorization settingenables the plant to be protected from operation by anunauthorized operator. The batch system can alsoperform such tasks as recording the operating historyof an operator, and storing historical data of executedproduction processes.(3) Creation and modification of recipes

By using the batch system control center fromwhich monitoring and operation is usually performed,the operator is able to create and modify recipes. Theoperator can customize the production volume, devicesused, and all items used in batch processes up until theproduction process.

10. Conclusion

The trend toward vertical and horizontal integra-tion will continue in the future, and flexible systemconfigurations (open or multi-vendor configurations)according to the individual plant will be required.

Under these circumstances, in order to continue tosatisfy user needs, Fuji Electric will continue tomanufacture DCS products that facilitate higher reli-ability, greater flexibility and long-term maintenance,in order to realize optimal solutions.


Takashi IkedaMasato Nakano

Advanced Information and ControlSoftware Packages for the MICREX-NX

1. Introduction

With the development of information technology(IT) recently, control systems have evolved towardmore advanced information integration and greaternetworking capability. This evolution is supported bytrends toward higher system efficiency and integra-tion, user requirements on plant safety, internetsecurity, and compliance with industrial standards andvarious regulations.

The new information and control system MICREX-NX is based on a concept of vertical and horizontalintegration, and has high scalability enable to apply tosmall to large-scale plants. In an integrated engineer-ing environment, the MICREX-NX supports the use ofhighly intelligent field devices, integrates process anddiscrete systems, and links up with upper-level manu-facturing execution system (MES). These functions arerealized by combining the basic functions of theMICREX-NX with various information control packag-es to built-in modeled (abstract) system elementswithin a common engineering environment.

This paper introduces information and controlpackages for MICREX-NX, the process device manager(SIMATIC*1 PDM), the batch system (SIMATICBatch), and the route control system (SIMATIC RouteControl).

2. Process Device Manager

2.1 Overview of the process device managerThe process device manager (PDM) is a software

package that manages field devices connected withMICREX-NX. This package facilitates the integrationof process data from process devices on the PROFIBUSand also device diagnostic information and devicecharacteristic information, and as a result, enables theacquisition of comprehensive diagnostic informationfrom each device, and basic information from diagnos-tic technology which is capable of detecting the diag-nostic information of plants and machinery. Based on

this information, the efficiency of preventative mainte-nance such as periodic diagnosis and periodic over-hauls of machinery can be improved greatly.

In addition, because the PDM package runs at anintegrated engineering environment of MICREX-NX(SIMATIC Manager) so that, the field information andoperation management information also can be inte-grated. The trends toward more intelligent fielddevices and standardized parameters facilitate thegreater use of information throughout the entirelifecycle, from the process planning and engineeringthrough operation and maintenance, and facilitatelaborsaving.

The PDM package includes functions for thesystem configuration, parameterization, self-diagnosisand analysis of intelligent process devices; the PDMcan be run at an engineering station (ES), or also canbe used as a stand-alone architecture for verifyingoperation at the time of commissioning. With anelectronic device description language (EDDL), thePDM package can support field device characteristicinformation for process devices connected to thePROFIBUS-DP, as well as for devices connected to astandardized network such as a HART or MOD bus.

This EDDL is supplied by the process devicemanufacture and is a unified language that describescharacteristic parameters of process devices (the tem-perature, pressure and flow of various field devices).Because the manufactures supply process control de-vices that contain application information, all theprocesses that include design, implementation, accep-tance testing and shipping can be improved greatly.

2.2 Features of the PDMFunctions and features of the PDM are described

below. Figure 1 shows the system configuration andsupported devices of the PDM.(1) Functions for calibration, adjustment, and chang-

ing various parameters of field devices connectedto the PROFIBUS-DP/PA

(2) Self-diagnosis of the device status and communi-cation status of field devices

(3) Function for comparing online device data withoffline device data

*1: SIMATIC is a registered trademark of Siemens ofGermany.

Advanced Information and Control Software Packages for the MICREX-NX 117

Displays the device parameter information intabular form and/or graphical form.

3. Batch System

3.1 Overview of the batch systemIn recent years, quality management and observa-

tion of safety-related industrial standards and regula-tions have been strengthened for food, pharmaceuticaland chemical products, and a control system thatcomplies with these regulations is desired. TheMICREX-NX batch system is a application softwarepackage that complies with regulations related toelectronic records and electronic signatures as estab-lished by the batch control standard [IEC61512 (ISAS88)] and the United States’ Food and Drug Adminis-tration (FDA). According to the plant size, the batchsystem can be configured as an OS single-user system,or a client and server system. The batch system canalso be applied to small to large-scale of batch process.Moreover, safety can be enhanced through redundantbatch server and batch clients. Figure 3 shows thesystem configuration.

Fig.2 Example of PDM image panel (device parameter view)

Fig.1 System configuration and supported devices of PDM

(4) Function for assigning and configuring slave (net-work) addresses

(5) Function for managing, simulating and adjustingtest conditions for field devices

(6) Online monitoring of selected values, alarm andstatus signals

(7) Live list for automatic detection of connectionstatus (communication status) of the installedfield devices

2.3 Monitor function of the PDMThe PDM displays the following online information

in an operator station (OS). Figure 2 shows an exampleof a displayed image panel.(1) Monitor of process device network

Displays the device information, including thediagnostic status, and classifies that information ac-cording to the network configuration.(2) Monitor of process device plant

Displays the device information, including thediagnostic status of all devices in a network-basedsystem.(3) Monitor of field device parameter

Fig.3 System configuration of batch system

Engineering systemwith SIMATIC PDM Electronic device description language (EDDL)

Stand-alone SIMATIC PDM

Standardized parameters(Diagnostic)

Custom manufacture parameters

Process value/status

ET200M DP/PA linkET200iS

0/4 to 20 mA+HART

PROFIBUS-DP

PROFIBUS-PA

Batch client

Terminal bus

ES OS server Batch server

Plant bus

Batch controller

OS, Batch single station


created with a MICREX-NX engineering station (ES)and a master recipe created with a batch recipe editor.The batch system provides the ability to register andmanage required functions as special libraries con-forming to the ISA S88.01 structural model. Theselibraries are described with a sequential function chart(SFC) so that online monitoring and operation can beperformed on OS using MICREX-NX standard func-tions (SFC visualization function). Table 1 shows thesoftware configuration of the batch system. Batchplanning can be implemented independently within abatch system using batch control center functions,however, also can combine with upper-level MESpackage (SIMATIC IT) that compliance with ISA

The batch system is described based on three batchstructural models (a procedural model, a physicalmodel, and a process model) that complies withIEC61512 (ISA S88). By introducing the concept of asimple 4-layer structural model and by uniformlydescribing the connection between models, the batchsystem provides the capability for design and mainte-nance. In particular, by using a hierarchical recipes(formula) that affect product quality, each process andfield device element in the batch plant is describedwith a uniform method of expression. Figure 4 showsthe batch structural model.

The batch control center centralizes the control of abatch based on system configuration information that

Fig.5 Compliance with FDA 21 CFR Part 11

Fig.4 ISA S88-based model of batch system Table 1 Batch system software packages

Operates with batch server

Operates with AS

Defined with ES

Procedural model

Procedure

Unit

Process

Unit

UnitPhase

Phase

Unit procedure

Process cell

Process stage

Process operation

Process action

Process action

Equipment module

Operation

Physical model Process model

Name of software Main functions Comments

Batch control center

Batch planning, batch control Batch client

Batch report Recipe, batch data printing Batch client

Batch recipe editor

Master recipe, library creation, drawing changes Batch client

Batch control server

Transmission of batch data (between controller and monitor)

Batch server

Batch planning

Configuration of batch control center

Hierarchical recipe

ISA S88.01 compliant recipe

API interface Interface with MES-related software

Bas

ic s

oftw

are

Opt

ion

al

pack

ages

User 1

Unique user name, password

Changing set point by senior operator

™Electronic signature in all operations

Audit trail in all operations

Logon with IC card (user registration)

MICREX-NXOperator station, engineering station

WindowsUser, group registration

User 2

User 3

User 4 Emergency operator

Senior operator

Operator

Administrator

Emergency operator

Senior operator

Operator

Administrator

Authority assigned according to technical level

Electronic signature

Download to controller

™Input full name of signer, date and time of signing, and content

Advanced Information and Control Software Packages for the MICREX-NX 119

Fig.6 Configuration of route control system Table 2 System aspect of route control system

S95.01, enables to develop an information and controlsystem integrated from field level to the productmanagement level.

Additionally, compliance with FDA 21 CFR Part 11realized high reliability for managing of access securi-ty, storage and retrieve manufacturing record data,electronic signature, audit trail, and so on (See Fig. 5).

These functions are based on Windows*2 securityfunctions and an operator access management tool.

3.2 Features of the batch systemThe batch system has the following features.

(1) Structural model and hierarchical recipe compli-ance with ISA S88.01

(2) Support from small to large-scale projects by usingdistributed OS servers that able to access to allcontrol points or by accessing each OS servers.

(3) Support of FDA 21 CFR Part 11: user manage-ment, electronic certification, audit trail, revisioncontrol

(4) High reliable system due to redundant OS servers(5) Operating in integrated engineering environment(6) OS faceplates for unit, phase and operation

4. Route Control System

The route control system is an software packagethat monitors, controls and diagnoses systems thattransfer fluids through pipes or pipelines. Routecontrol system is mainly used in complex food, phar-maceutical and chemical plants and petrochemicaltank yards to realize efficient automatic transfercontrol for the products.

Figure 6 shows the system configuration and

Table 2 lists the system aspect.The standard engineering features of the MICREX-

NX and the main features of route control are listedbelow.(1) Monitoring and control of the transfer route and

related elements (such as valves)(2) Diagnosis and alert of the transfer route and

related elements (such as valves)(3) Dynamic linking of partial routes and the entire

route(4) Engineering of complex route

Route control system can be implemented thestandard engineering function of the MICREX-NXsystem and also can using special library. Moreover,route control system can also be combined with upper-level MES or batch system.

5. Conclusion

In this paper, we introduced advanced informationand control packages of MICREX-NX. Such as thePDM package, batch system, and route control system.In addition to these pakages the MICREX-NX providesmany packages for enhancing the safety and efficiencyof a plant, for example safety instrumentation systemand compliance with IEC61508 and IEC61511 adap-tive control software packages, that are expected inJapan. In the future, Fuji Electric intends to continueits efforts to promote the advanced applications ofinformation and control systems.

Reference(1) Theilmann, B.; Edmund, L. Online plant asset man-

agement integrated in process control systems. Auto-mation Technology in Practice. 2004-01.*2: Windows is a registered trademark of Microsoft Corpora-

tion of the USA.

Route control client

Terminal bus

Route control server

MICREX-NX OS server

Plant bus

Item Size

AS (automation system) 32 systems (max.)

Number of elements per AS

™1,024 motors, dampers, valves, etc.

™1,024 link elements, pipeline sections, etc.

™1,024 sensor elements, process values

™1,024 parameter elements

Parallel transfer routes 300 (max.)

Partial routes 64,000 partial routes (max.)

AS overlapping routes 32 overlapping routes (max.)

Number of elements per route 400 elements per AS (max.)

Number of modes per route 32 modes (max.)


Takao YamadaFumihiko Fujita

Migration Strategy for the MICREX-NX

1. Introduction

Fuji Electric first developed a distributed controlsystem (DCS) for application to plant systems in 1975,and since that time, has applied DCSs to iron and steelworks and waste disposal plants in the private sector,and then to various plant systems in the public sector,such as water treatment facilities. Fuji Electric ispresently supplying its 4th generation DCS, theMICREX-AX, to the market. The Japanese DCSmarket shows signs of leveling-off, however, and FujiElectric is aiming to expand its process automationsystem (PAS) business with the introduction of itsMICREX-NX, equipped with a new platform architec-ture suitable for application to new markets such asfood and pharmaceuticals, as well as to overseasmarkets and the conventional fields of iron and steelworks, waste disposal, and water treatment. Figure 1shows the changes over time in the MICREX systemsdeveloped by Fuji Electric.

In the future, most of the MICREX-PIII and othersystems delivered by Fuji Electric will be due forreplacement. However, replacement of a plant all atonce will be financially difficult as customer budgetshave decreased, and this work must proceed withconsideration to minimizing the total cost of ownership(TOC).

Fuji Electric provides its customers with a meansto improve manufacturing capability with the ad-vanced capabilities of the MICREX-NX. Customerscan replace their existing systems with the MICREX-

NX sequentially, while inheriting some legacy hard-ware and software, and thereby prolonging the servicelife of their existing systems.

This paper describes the process for migrating tothe MICREX-NX from an existing MICREX system,while minimizing engineering labor and cost, andefficiently inheriting assets of the existing system.

2. Scenarios for Migration from Existing Systems

Scenarios for migrating from a customer’s existingMICREX system to the MICREX-NX system in orderto prolong the life of the existing system and toincrease manufacturing capability are described belowand illustrated in Fig. 2.(1) Partial replacement of HMI only

Because the human machine interface (HMI) sys-tem uses general-use components such as a CRT andhard disk, the HMI part will be the first to have itsproduction discontinued. Consequently, in this scenar-io, the existing HMI will be replaced with the latestHMI version, and replacement of later-stage control-lers will also be considered.(2) Partial replacement, but retaining existing PIO

Due to such reasons as wiring complications or adecrease in plant investment, the existing PIO partwill be retained, but the controller and HMI replaced.(3) Plant replacement and expansion

To replace an aged plant and improve manufactur-ing capability, the controller, including the PIO, andthe HMI will be replaced all at once, or the plant

Fig.1 Changes in Fuji Electric’s MICREX systems

1975

Total automation

EIC integration Open architecture

Evolution with inheritance

Vertical and horizontal integration

Integrated engineering

1980 1985 1990 1995 2000 2005

1stMICREX-PI

Distributed control system EIC integrated control system Advanced information control system

New information and control system

MICREX-PII MICREX-PIII MICREX-IX MICREX-AX MICREX-NX2nd 3rd 4th 5th

Analog-to-digital

GenerationSeries name

Concept


expanded.

3. Concept of the MICREX-NX Migration

The concept of the MICREX-NX migration is toprovide a mechanism that enables partial replacementor expansion of an existing system by utilizing thecustomer’s existing DCS assets to the maximum extentwhile allowing the customer to enjoy the advantages ofthe new MICREX-NX, such as the concept of planthierarchy and the automatic associations generatedamong device modules in the controller and the HMIfaceplate.

The method for migrating to the provided MICREX-NX to partially replace or expand a plant whileinheriting legacy functions is described below. Figure 3shows the overall migration process.

3.1 Easy connection of MICREX-NX to an existing systemThe new MICREX-NX allows the partial replace-

ment or expansion of an existing MICREX-PIII or latersystem (MICREX-PIII, MICREX-IX, and MICREX-AX).For this purpose, Fuji Electric provides a gateway(GW) and link device as components for connecting theexisting system’s control network and remote I/Onetwork to the MICREX-NX.

(1) GatewayThe gateway connects Fuji Electric’s DPCS-F and

FL-net-compliant LAN backbone networks to theMICREX-NX’s plant bus.(2) Link device

The link device connects Fuji Electric’s P-link andPE-link for connecting a remote I/O network orgeneral-purpose programmable controller (PLC) of anexisting system to the MICREX-NX’s controller.

3.2 Inheritance of existing system functions(1) Migration of HMI objects and database (DB)

informationIt is important that any changes to the customer’s

familiar display and operation of HMI objects, or anyinconsistencies of the HMI objects and operationwithin the same control room are not conspicuous tothe user.

So that the migration can be implemented smooth-ly, a faceplate and diagnostic screen that are the sameas those of an existing MICREX system, and also adatabase conversion tool are available.(2) Inheritance of controller software assets

An application program converter is provided withthe new MICREX-NX. This converter converts control-ler application programs of the existing system, so that

Fig.2 Migration scenarios

DPCS-F, FL-net DPCS-F, FL-net Industrial EthernetIndustrial EthernetIndustrial Ethernet

OS client OS client OS client OS client

DPCS-F, FL-net

Ethernet*1

Ethernet Ethernet Ethernet

OS server OS serverOS server

OS server (GW)OS server (GW)

OCS/AOSDBS/ADS

PCSICSACS

AS AS AS

PIO

Terminal block

T-linkP/PE-link

T-linkP/PE-link

T-linkP/PE-link

PROFIBUS-DP PROFIBUS-DP

ET200M ET200M

*1: Ethernet is a registered trademark of Xerox Corporation in the USA.

Replacement of only HMI with MICREX-NX

Partial replacement, but retaining existing PIO HMI, controller and PIO

replaced with MICREX-NXCombined use with

former system

Plant replacement and expansion


replacement can be implemented smoothly withouthaving to develop new application programs for thenew MICREX-NX.

4. Migration Components

4.1 OS server (GW)Fuji Electric has two control level networks, its

original DPCS network and an FL-net-compliant LANthat was developed based on the FL-net JIS specifica-tions. A gateway based on the standard operatorstation (OS) used with the MICREX-NX is provided inorder to connect these control level networks to theplant bus that is the MICREX-NX network. Inaddition to the capability for performing data accessesfrom the OS client to the existing controller, thisgateway also has the functionality described below.(1) Converts alarm information generated by an exist-

ing system to the MICREX-NX’s message systemformat, and performs client OS notification, dis-play and acknowledgement operations, and thelike to integrate alarm information of an existingsystem with the MICREX-NX method

(2) Notifies the OS client of existence information anddiagnostic information from controllers in anexisting system

(3) Integrates the redundancy of an existing systemwith the MICREX-NX method

Figure 4 shows the basic architecture of an OSserver (GW) that realizes the above-described func-tions.

As shown in this drawing, the OS server (GW) isequipped with a PCI interface card for physicallyconnecting a DPCS-F conventional network or an FL-net-compliant LAN to the standard OS server of a

MICREX-NX. The data access operation of a standard-configuration MICREX-NX (such as a graphic systemor trend system) is implemented via a data manager byan existing MICREX access function that converts theMICREX-NX information to a format for broadcasttransmission or message transmission on the DPCS-For FL-net-compliant LAN, or for file access (IJFaccess), in order to accesses actual data in the existingMICREX’s controller.

4.2 Link device for T-linkFuji Electric’s original networks such as T-link,

open PIO and optical FFI are available for use asremote I/O networks. The T-link, in particular,supports not only the I/O unit (IOU) that was used

Fig.4 OS server (GW) functional structure

Fig.3 Migration with MICREX-NX

OS client

Terminal bus

Plant bus

PROFIBUS

ES

AS AS

ADSAOS AES

ACS ACS

OS server

Legacy software assets

Link devices

OS server (GW)

MICREX-NX Existing MICREX

Tag informationAlarm informationTrend information

Standard screenPlant screenFaceplate

Ladder diagramFB diagramSFCLoop diagramTime chartOther

Internal instrumentsEI waferInput processingCommon devicesLink device

Link device

P/PE-link

T-link

DPCS-F,FL-net

Migration of HMI objects and DB

information

MICREX-NXExisting MICREX

OS server (GW)

Plant busTerminal bus

DPCS-F, LAN compliant with FL-net

Data manager

NX driverExisting MICREX

access function

I/O driverPCI board Ethernet

Alarm function

Trend function

Graphic function

Relay processing


Table 1 List of I/O supported by T-link

Fig.5 T-link system configuration of MICREX-NX

Fig.6 P/PE link system configuration of MICREX-NX

I/O typePCS-500

SystemMICREX

-NX

○

MICREX-IXMICREX-AX

×

MICREX-PIII

○ IOU(PCS)

Single T

HDC-500

×

○ × ○ Redundant T ×

○ ○ × IOU(HDC)

Single T ○

○ × × Redundant T ○

○ ○ ○ TK capsule ○

○ ○ × CIO ○

○ ○ × FTL ○

○ ○ × IPU (including FFI) ×

widely with the MICREX-PIII, the I/O unit (IPU) whichachieved many good results with the MICREX-IX, andMICREX-AX, as networks for connecting Fuji Electric’sPIO, but also supports many varieties of PIOs. Exam-ples are listed in Table 1.

A link device that links to the PROFIBUS-DP,which is the MICREX-NX’s standard remote I/Ointerface, is available as a component for connectingthe T-link to the MICREX-NX’s controller. This linkdevice enables an existing PIO and cable to be useddirectly to connect to the MICREX-NX. Moreover, useof the PROFIBUS-DP enables the advantageous con-figuration technique of the MICREX-NX and an inte-grated mode of engineering for implementing thenotification of failures, diagnostic information and thelike to the HMI, and also supports future systemgrowth. (Refer to Fig. 5.)

This link device, under the supervision of thePROFIBUS interface, refreshes PIO data for the T-link, and also integrates the following T-link functions.(1) Diagnoses each PIO module connected to the T-

link, and issues notification of each diagnosis(2) Sets parameters and transmits/receives data for

the communications module and other specialmodules controlled by application programs, andtransmits messages for specified modules

(3) Realizes redundant functions of the existing sys-tem in the new redundant architecture of theMICREX-NX

4.3 Link device for P/PE-linkFuji Electric’s P/PE-link has been used not only for

the DCS controller, but also has been used in manyprojects as a simple network for connecting to FujiElectric’s general-purpose PLC. As shown in Fig. 6, alink device for connection to the MICREX-NX is also

OS

AS

Plant bus

ES

Redundant AS

PROFIBUS-DPPROFIBUS-DP

Link device

Link device

Drag & drop T-link I/O

Link device

Link device

T-linkT-link

PLC PLC

OS

AS

Ethernet

Plant bus

P/PE link

PLC PLC

ES

Redundant AS

Ethernet

Link device

Link device

Link device

P/PE link


Fig.7 Engineering resulting from DB information migration tool

(picture), linkage such as the display of device data,parameter settings from the screen, and the like can berealized.

4.5 Software converterController applications for the third generation

MICREX-PIII and later are created with an engineeringtool called the FPROCES. Although there are somerestrictions, a converter is available for migratingthose applications to controller applications for theMICREX-NX. By using this software converter, appli-cation programs created with various representationalsystems such as ladder diagrams, FB diagrams, SFCsand loop diagrams that have been generated byFPROCES can be run as MICREX-NX programs.

5. Conclusion

The strategy for migrating an existing system tothe MICREX-NX has been described.

Based on Fuji Electric’s adopted motto of “evolu-tion with inheritance,” we have continued to advancenew technology while inheriting the assets of ourcustomers’ existing systems. With the marketplaceintroduction of the MICREX-NX, Fuji Electric’s newDCS, we believe that the capability for smooth migra-tion will appeal to our customers, and that thiscapability will be a powerful advantage for our newinformation and control systems in the future.

With the MICREX-NX positioned as a new DCSplatform, Fuji Electric intends to continue to providesystems capable of contributing to the profit of ourcustomers.

provided for this P/PE-link. The link device enablesthe handling of data between the general-purpose PLCof a MICREX-F or MICREX-SX connected to anexisting system and the MICREX-NX’s controller.Additionally, P/PE-link functions such as messagetransmission, redundancy and the like are integratedas standard features within the MICREX-NX architec-ture.

4.4 DB migration toolSo that the MICREX-NX system can use the same

data names as previously to access data on an existingsystem, the engineering information (such as tagdefinitions and alarm message definitions) containedin the existing MICREX system must be loaded intothe MICREX-NX environment. This task is accom-plished by using the DB migration tool. (Refer toFig. 7.)

The functions of the DB migration tool are listedbelow.(1) Registration of tags (user tags, module tags,

system tags)(2) Registration of alarm messages(3) Generation of plant hierarchy (picture tree)(4) Generation of linkage between tags and block

icons and between tags and faceplatesThis DB migration tool can be used to download

automatically the necessary engineering informationfrom the existing system, thereby eliminating the needfor one-by-one manual input. Also, when generating ascreen on the OS client, tag names and faceplatescorresponding to controller device modules on theexisting MICREX system can be used, and by simplypasting the appropriate faceplate on the plant screen

DB

OS server (GW)

Messages generated by an existing system can be displayed and acknowledged

Automatic generation of linkage between each I/O field and actual data in controller

Existing HMI

Existing controller

Existing DB

DPCS-F

DB information migration tool

Automatically generated picture

Automatically generated block icon

Faceplate corresponding to block icon

OS client

Registration of tagsRegistration of alarm messagesGeneration of plant hierarchyGeneration of linkage between tag and screen

Prior MICREX-NX engineering data


Yoshitomo TakeuchiKeisho YamanoTakashige Mori

Engineering Support Tools forthe MICREX-NX

1. Introduction

The process automation system (PAS) market inJapan has transitioned in recent years from a period ofgrowth, driven largely by new demand, to a maturemarket where most of the demand comes from systemupdating and renewal, and these conditions – underwhich significant market growth is not expected – arecontinuing. Meanwhile, PAS hardware componentssuch as human-machine interfaces (HMIs), controllers,I/O devices, and the networks that connect them, havecontinued to adopt open standards, and it is becomingdifficult to differentiate components made by differentcompanies. Under these market conditions, systemvendors are facing the difficult task of increasing theadded value of their application software, i.e., systemvendors must effectively utilize their accumulatedwealth of control-related expertise in order to differen-tiate their products from those of competitors while, atthe same time, realizing highly efficient and highquality engineering capable of surviving in the severeprice competition of a mature market.

In other words, the importance of engineering willonly increase for system vendors, and in order tosucceed in the above-described task, a suitable plat-form for engineering support tools must be provided.

The engineering station (ES) engineering supporttool for the MICREX-NX meets market needs for theabove-described engineering support tools and alsoprovides various functions.

2. ES Functions and Features

2.1 ES functionsFigure 1 shows a functional overview of the ES.

Configured on a Windows*1 personal computer, the ESis a common platform for a variety of support tools,such as an HMIs and controllers. The ES is acollection of multiple types of engineering softwareprograms, all of which are integrally controlled by themanager. The manager calls the various engineering

support tools, and by means of data linked amongsoftware programs and the use of a common platform,provides a function for managing the support software.

2.2 ES features(1) Integrated engineering data

Data from the various engineering support toolscalled by the manager are integrally managed in adatabase. Because input data is under centralizedcontrol in the database, inputting data to one locationwill cause a plurality of related data to be updatedautomatically. As a result, the task of inputting datais made more efficient, and data inconsistency due tomistaken input or other human error is eliminated andsoftware quality is improved.(2) Hierarchical engineering

In an ES, project data and library data for controland monitoring software and the like is hierarchicallymanaged from a Windows Explorer-like screen. As aresult, an engineer is able to access desired dataintuitively and speedily, and copy-and-modify opera-tions can be readily performed for each hierarchicalunit.(3) View layout

The three views that form the core of MICREX-NXengineering enable integrated engineering data to beobserved from different angles corresponding to eachview. The appropriate view can be selected accordingto the situation and the phase. Figure 2 shows anexample of the view screen.

q Component viewThe component view is used to set hardwareparameters relating to the automation system(AS) of the control system, I/O devices that aresupplied to the AS, the operator station (OS),the ES, and the network that connects thesehardware components. One special feature ofthe component view is that it enables monitor-ing of the resource usage status of the AS.Moreover, the hardware configuration (HWConfig) launched from this view can also beused when migrating the existing I/O, and theprocess device manager (PDM) is able toperform centralized setting, failure diagnosis



Fig.1 ES functional overview

and loop checks for intelligent field devices.w Plant view

Plant view shows the hierarchical manage-ment architecture for the purpose of providingan easy to understand overview of the plant towhich control will be applied. This hierarchi-cal structure complies with IEC61512 (ISAS88), the international standard for batchcontrol. Operation from a Windows Explorer-

like screen to create a hierarchy that matchesthat hierarchical structure of the actual plantenables efficient management of the controllercontrol program and the HMI screen. More-over, the plant hierarchy defined here is auto-matically evolved to the OS screen hierarchy.

e Process object viewThough it is difficult to grasp the overall aspectof scattered objects clearly by using hierarchi-cal management of plant view, process objectview can provide an environment to manageprocess objects intensively. The various pa-rameters for process objects such as valves andmotors scattered throughout an individual con-trol program or HMI screen can be set ormodified all at once by operation from anExcel*2-like screen, without having to openindividual files. Integration with Office*3

facilitates copy-and-paste operations from vari-ous lists such as an I /O list received from acustomer.

Fig.2 View layout

*2: Excel is a registered trademark of Microsoft Corporationof the USA.

*3: Office is a registered trademark of Microsoft Corporationof the USA.

CFC templates for standard applications

(e.g. motor, valve, controller)

OS engineering

User OS faceplate

Batch systemBATCH

Engineering for failsafe systems Engineering for networks,

communication and hardware

Automation engineering

Programming for user function

blocks

PDM for field device

management

NX engineering


Fig.3 MICREX-NX engineering flow

(4) LibraryThe MICREX-NX contains a library for each

project, and libraries may be created easily by copyingand pasting control programs created by engineers.Thus, control expertise can be accumulated and readilyutilized in future engineering tasks. Also provided arelibrary packages, equipped with many technical blocksthat contain a set of function blocks such as lineariza-tion, control blocks, and block icons and faceplates,enabling the engineer to realize a high level of control.

3. Engineering Functions and Features

3.1 Overview of MICREX-NX engineeringFigure 3 shows the MICREX-NX engineering flow.

With the MICREX-NX, systems for performing control-ler engineering and HMI engineering are linked to oneanother to increase the engineering efficiency.

3.2 Controller engineering functions and featuresA control program is generated by combining the

following three languages in accordance with thedesired goal. Regardless of the language used togenerate a control program, the memory that storesparameters used in each program is allocated automat-ically to permit use from only that program, andtherefore the engineer does not have to worry aboutthe problem of duplex writing in which multiplecontrol programs write to the same physical memory.Moreover, this arrangement enables a library to beoperated easily. Compared to previous model types,the functionality has been increased significantly atthis point.

Additionally, control program debugging is imple-mented by either connecting an AS to an ES, or byrunning a PLCSIM control simulator on an ES toenable online monitoring of each control program, andthereby increasing the efficiency of control programdebugging.

(1) Continuous function chart (CFC)CFC that conforms to IEC61131 FBD is used to

generate a continuous control program in theMICREX-NX. Figure 4 shows a screen shot of the CFCeditor. This screen shot shows an example of motoroperation control, and consists of a protection interlockfunction, an operating function and a control function.The control program can be created simply on a CFCeditor by dragging and dropping control blocks knownas function blocks (FBs) and function calls (FCs) andthen by linking the control blocks together withconnection lines. Many various control blocks areavailable, including instrumental loop control, sequen-tial control, numeric processing, logic processing, andthe like, and these program components can becombined freely on the same chart according to thedesired control to generate a control program. Theresult is a change from complex, vertically segmentedengineering for each control function, as seen in FujiElectric’s previous models, to sophisticated and hori-zontally structured engineering. Moreover, the compu-tational sequence may be customized and unused pinsof control blocks may be hidden in order to supportvarious detailed needs. Additionally, a functionallyorganized chart may be converted into control blocks toprovide an environment that enables the easy reuse ofcontrol programs. The above features interact organi-cally to enhance the engineering efficiency.(2) Sequential function chart (SFC)

Conforming to IEC61131, an SFC is used togenerate a sequential control program. Figure 5 showsan example screen shot of the SFC editor. The layoutof signals involved in the generation of steps andtransitions can be accomplished by simply selectingthe required signals from a control block parameterlist. Moreover, the use of an SFC visualizationpackage enables online SFC status display and opera-tion from an OS, without any special engineering.(3) Structured control language (SCL)

SCL conforms to the structured text (ST) ofIEC61131. Since this programming language can

Fig.4 CFC editor screen shotGlobal configuration of manager

New function or new project wizard

Hardware configuration

Customization of plant hierarchy

CFC programming

SFC programmingController engineering

OS compileAutomatic generation of block icons

Block icon and faceplate HMI engineering

OS engineering

Download to AS and OS

AS and OS runtime

MICREX-NX Engineering flow


provide a program with control structures, SCL ismainly used when generating the FBs and FCs in aCFC. SCL can be applied to generate more flexiblecontrol programs since it enables a user to generaterequired functions by him/herself and then to use thosefunctions.

3.3 HMI engineering functions and featuresAs has been described above, HMI engineering in a

MICREX-NX system is closely related to the control-ler’s control program. When a control block, forexample PID control, is created in the controller, twoHMI components are automatically generated. One isa block icon that appears as a symbol on the HMIscreen. Another one is a faceplate window, is calledwhen a block icon is clicked and is used to implementdetailed status display, operation and settings. On theother hand, a graphic designer is used to create anHMI screen according to the process image, and thenautomatically generated block icons are repositionedaccording to that image to complete the HMI screen. Afaceplate designer may also be used to generate afaceplate according to user needs.(1) WinCC Explorer

The WinCC Explorer is a common platform forHMI engineering. In addition to the abovementionedgraphic designer, various other functions such as aglobal script and user manager are also provided.(2) Graphic designer

Figure 6 shows a screen shot of the graphicdesigner. The graphic designer is a software programfor creating HMI screens. The graphic designersupports HMI screen creation with the same operabili-ty and expressive ability as general-purpose imageprocessing software. Moreover, because users are ableto create their own libraries, previously created HMIparts can be accumulated and reused, providing anarrangement that leads to more efficient screen cre-ation and to improved screen operability and the like.(3) Global script

A script language conforming to C or visual basic(VB) is provided, enabling general-purpose SCADA-like screens to be customized flexibly.

(4) User managementFor the purpose of ensuring plant security and

traceability, all operators are given detailed authoriza-tion rights. Operation levels such as operationalauthorization can be specified per plant.

3.4 Support softwareA group of tools that improve the efficiency and

quality of MICREX-NX engineering are introducedbelow.(1) Import/export assistant

The import/export assistant provides the capabilityto generate multiple control programs all at once, andall having the same functionality. A control programtemplate is created, and then the program destination,I /O parameters, and other data that are unique foreach control program are specified in a single opera-tion from an Excel-like screen and expanded to multi-ple programs. The expanded settings file can be storedin an ES so that when a control program requiresmodification, a pre-existing setting file can be used toimplement that change instantaneously in multiplecontrol programs. Figure 7 shows an overview of theimport/export assistant.(2) Version cross checker

The version cross checker provides the capabilityfor version management of the generated controlprograms. This software is provided with a functionthat highlights the display of project contents thathave been added, deleted and/or changed before andafter modification, thereby enabling graphical verifica-tion of that modification. The version cross checkercan be used in a wide variety of applications such ascontrol program version control and failure analysis.Figure 8 shows an example screen shot of comparativeresults obtained by the version cross checker.(3) Control simulator (PLCSIM)

With the MICREX-NX, an ES personal computercan run a simulation of a controller. The simulationenvironment is easily configured, and a single ESpersonal computer can achieve the equivalent debug-

Fig.5 SFC editor screen shot Fig.6 Graphic designer screen shot


Fig.8 Version cross-checker screen shot

ging performance as one OS and one AS connected toeach other. Accordingly, the debugging efficiency of acontroller and HMI screen is dramatically increased.Moreover, an all-in-one personal computer enhancesportability and enables performance to be verified atany location.

4. Conclusion

With the sophisticated MICREX-NX engineering

Fig.7 Import/export assistant

PH assign. Chart name PV_LR PV_LR KP TN TVB17/Reac1 LIC1710 0 100 1.7 2.5 1.3B17/Reac2 TIC2711 0 500 1.25 3.5 1.0B17/Reac2 PIC2712 0 10 2.0 1.0 1.0B17/Reac3 FIC3210 0 250 1.5 10 2.0

Template chartAutomatically generated chart

Automatically generated plant hierarchy

Measuring point list

+Import/Export

Assistant

Print First, prior, next, last difference

Filter ON/OFF

Apply filter

Symbol for SFC

Different attribute

Compare

Open

Program A

Program B

Extra object in B

Extra object in A

Different object

support tools, previously acquired control expertise canbe fully utilized to realize highly efficient and highquality engineering that satisfies market needs. In thefuture, Fuji Electric intends to continue to supply idealengineering platforms and to contribute to the develop-ment of process automation systems.


Fig.1 EMC classification

Hitoshi IchinoheTetsuji ShioHiroyasu Ikedo

Cabinet Mounting of the MICREX-NX

1. Introduction

Control systems are often mounting in cabinets ofthe customers’ desired dimensions in order to improveenvironmental resistance and ensure proper function-ality and management range. So that devices enclosedwithin a limited volume can be configured and operat-ed stably, the design of the cabinet must limit the risein internal temperature and must be equipped tohandle the assumed level of external noise at the siteof the installation. In addition to incorporating theseconsiderations, the cabinet for the MICREX-NX: newinformation and control system is also designed to useEuro terminal I /O modules to realize high-densitymounting. Moreover, external terminals are replacedwith the same ring terminal interface as in priorproducts to realize the same mounting efficiency as inthe past. This paper presents an overview of theMICREX-NX cabinet mounting technology.

2. Necessity of Cabinets

The main reasons for housing an industrial systeminside a cabinet are given below.(1) Management, operation and security consider-

ationq To clarify the system’s responsibility of work

and range of the contractw To enable maintenance with a 1-to-1 relation-

ship between the power supply distributionpanel and the system

e To clearly identify the manager and clarify his/her responsibility with lock and key manage-ment

(2) Environmental considerationq Heat: To cool and/or heat the cabinet’s internal

ambient temperature to maintain the systemat a suitable temperature

w Atmosphere: To protect the interior from corro-sive gas and/or dust

e Vibration: To protect the system from earth-quakes and vibrations from large equipment

r EMC: To realize EMC (electromagnetic com-patibility), shown in Fig. 1, comprising both an

EMS (electromagnetic susceptibility) level thatis immune to external interference and an EMI(electromagnetic interference) level that doesnot disturb other equipment.

(3) Safety considerationq To protect against bodily harm by preventing

accidental contact with energized parts, heatedparts, and moveable parts such as fans

w To prevent workers from accidentally touchingthe equipment (to prevent mistaken operation)

The MICREX-NX cabinet has been designed withthe above considerations. The cabinet is describedbelow with a focus on its thermal design, safety andEMC environment design, and Euro-to-ring terminalconversion.

3. Thermal Design

3.1 Cabinet cooling methodWhen mounted inside the enclosed space of a

cabinet, the system will be adversely affected by heat.Thermal design is used to minimize this adverse effect.The thermal design also considers other conditionsunrelated to heat and various cooling methods weredesigned.

EMC

(electro-magnetic

compatibility)

EMS

(electro-magnetic

susceptibility)

(electro-magnetic

interference)

EMI

Electrostatic discharge

Magnetic field

Conductor noise (noise terminal voltage)

Radio noise (electric field intensity)

Harmonic current

Radiated electromagnetic field

Conducted radio frequency disturbance

Input terminal noise

Earth terminal noise

Surge voltage

Voltage dips, short interruptions and voltage fluctuation

Con

duct

ion

noi

se


Conditions unrelated to heat include the efficiencyof mounting the system in the cabinet, protectionagainst EMC, dust, corrosive gas and other environ-mental factors, and the tradeoff relation between theseconditions and temperature rise.

The cooling methods shown in Fig. 2 are describedbelow.(1) Air cooling without a fan

In this method, heat is exhausted by naturalconvection through slits provided at the top andbottom of the cabinet. This method does not requireany special equipment for cooling, and is advantageousin terms of cost and mounting efficiency.(2) Fan cooling

Forcible convection with a fan is used to exhaustheat.

q Forced exhaustThis method uses filters through which airpasses at the cabinet bottom and a fan at thetop of the cabinet to exhaust heat. The cabinetinterior is negatively pressurized with respectto the external atmosphere and because gapsare also provided that allow the intake of smallparticles, this method is disadvantageous inproviding protection from environmental fac-tors such as dust and corrosive gas.

w Forced suctionThis method uses filters through which airpasses at the cabinet bottom and fans at thebottom of the cabinet to exhaust heat from thecabinet top by means of convection. Becausethe cabinet interior is positively pressurizedwith respect to the external atmosphere andthe intake air must pass through a filter, thismethod provides excellent protection againstthe environment. However, because the filters

and fans are concentrated at the bottom of thecabinet, the mounting efficiency is poor.

(3) Sealed structureIn this method, the cabinet is completely sealed.

Because no cooling fans or filters are used, and becausethere is no convection, this method provides idealprotection against dust and corrosive gas. However,the cooling efficient is poor since heat is exhaustedsolely by the radiation of heat from the cabinet surface.Another drawback is that corrosive gas may enter thecabinet when the door is opened and closed duringmaintenance.

In the case of forced cooling, this problem does notoccur because external air that enters the cabinet iseventually replaced with filtered air.

3.2 MICREX-NX cabinet mountingThe MICREX-NX has been designed to enable

mounting with any of the above cooling methods. Thethermal design must be implemented such that theoperating temperature of the mounted system does notexceed 60°C.

Figure 3 shows a drawing of the MICREX-NXcontroller cabinet mounting, and Fig. 4 shows theexternal appearance of that controller cabinet.

A redundant controller, control LAN communica-tions device, power supply, power receiving and distri-bution equipment, and an alarm unit are mounted inthe front panel. I /O devices for handling field signalsand Euro-ring terminal conversion cables that connectto the field wiring are mounted in the back panel.

3.3 Actual thermal design(1) Thermal balance

The mounting design basically organizes the sys-tem so that heat-generating devices are not arrangedconsecutively. As a result, heat does not becomeconcentrated inside the cabinet and the temperaturecan be averaged.

In the cabinet’s front panel, the controller andpower supply, which are heat-generating source, arealternately mounted between low heat-generatingequipment. In the rear panel, each I/O device ismounted so as to alternate with a Euro-ring terminalconversion cable, which generates no heat at all.(2) Heat shielding and ventilation route

In order to prevent a rise in temperature, it isextremely important that the heat generated by equip-ment mounted in the cabinet does not affect any otherequipment in that same cabinet. With the MICREX-NX cabinet mounting, a heat shield unit is usedbetween each piece of equipment.

This heat shield unit exhausts the self-generatedheat from the back top of the cabinet, without convey-ing that heat to upper stages, so that upper and lowerequipment are shielded in heat. The heat shield unit isalso provided with a function that supports the cablesconnected to each piece of equipment.

Fig.2 Cooling methods

(d) Sealed structure(a) Air cooling (without fan)

Gap

(b) Forced exhaust (c) Forced suction

Filter


Fig.3 Mounting of controller cabinet

Fig.4 Appearance of the controller cabinet

In addition, the cabinet is designed such that heatexhausted from the rear passes through a chimney-likeventilation route provided in the center of the cabinet,to exhaust heat efficiently from the top of the cabinet.(3) Actual measurement and evaluation of tempera-

ture distributionFor each of the cooling methods, the distribution of

temperature inside a cabinet of the above design wasmeasured and the suitability of the design was as-

sessed. The results are shown in Fig. 5.The operating temperature for each system must

not exceed 60°C. Moreover, the maximum ambienttemperature of the cabinet is 40°C, and the tempera-ture rise at an air intake vent for the equipmentmounted in the cabinet must not exceed 20°C.

A design tolerance of 5°C is maintained for theseconditions, i.e., the cabinet must be designed such thatthe temperature rise at all air intake vents for a

Fig.5 Temperature measurement results

T1

1

2

P

N

(3.2A)F1

P1

(3.2A)F2

P2

(3.2A)F2

P2

P

N

(3.2A)F1

P1

T1

1

2

P2P1

(3.2A)F2

P

N

(3.2A)F1

T1

1

2

T1

(3.2A)F2

P2

P

N

(3.2A)F1

P1

1

2

10

T1

N

P

N

P

ALM1

ALM2

ALM3

ALM4

ALM5

8

7

6

5

4

3

2

1

9

8

7

6

5

4

3

2

P11

P10

P9

F12

T2

P8

(10A)

P7

P6

/ALM

F5(10A)

FAN

1

P3

P4

(10A)F3

(A)HUB

P5

HUB(B)

F4

P1

F1(10A)

(A)CPU

(10A)F2

(B)CPU

P2

CONECTER UNIT

OUT

B

A

OSM/ESM(A)

OSM/ESM(B)

Field power supply

(A)

Field power supply

(B)

Diode unit

Alarm unitHeat shield unit

Heat shield unit

S7-400(A)

(CPU)

S7-400(B)

(CPU)

Heat shield unit

Heat shield unit

OL

M(B

)O

LM

(A)

(Side panel)(Front panel)

ET200M (I/O)-4

ET200M (I/O)-3

ET200M (I/O)-2

ET200M (I/O)-1

Heat shield unit

Heat shield unit

Heat shield unit

(Back panel)

Front power supply (B)

(A) (B)

Front power supply (A)

Power distribution unit

Heat shield unit

Redundant controller

Power supply

I/O

Ventilation route

Terminal unit

700

2300

900

(1)(1)

(2)(2)

(3)(3)

(6) (4)

(5) (5)

(4) (6)

(7)(7)

(8)(8)

(9)(9)

(10) (10)(11) (11) (11)

(12)

(13)

(14) (12) (14)

(15) (13) (15)

(16)(18) (16) (18)

(17)(19) (17) (19)Communication

unit

Heat shield unit

Heat shield unit

Heat shield unit

Power supply

Front panel Back panelMeasurement point

(1) to (19) correspond to the measuring points of Fig. 3

Tem

pera

ture

ris

e ∆T

(°C

)

5

10

15

20

25

30

35

0(2)(1) (3) (4) (5) (6) (7) (8) (9) (10)(11)(12)(13)(14)(15)(16)(17)(18)(19)

Forced exhaustAir-cooledSealedForced suction


system does not exceed 15°C. These results satisfy thedesign condition because temperature rises in excess of20°C occur only at the exhaust vents.

Accordingly, the thermal design of the MICREX-NX cabinet enables mounting that is compatible withthe cooling methods of air cooling without a fan, fancooling with a fan, and sealed structure cooling, each ofwhich has advantages and disadvantages with respectto mounting efficiency (cost) and resistance to theenvironment, i.e., protection from EMC, dust andcorrosive gas.

4. Safety and EMC Environmental Design

Measures against heat and EMC are vital inensuring the safe operation of the system. The layoutof the power supply input unit and the power supplysystem is important because it forms a route alongwhich disturbances and noise can travel. To realizethe required specifications in a highly efficient man-ner, a front power supply method is adopted for thecabinet power supply input unit and the power supplysystem. The source power is received entirely at thefront power supply, where it is then converted into astable, low voltage of 24 V DC and delivered to eachdevices.

Because this front power supply has a noise-resistant design, EMC protection and the requiredcabinet specifications listed below are realized. Otherinternal devices and the cabinet layout are importantbecause their design leads to better overall designquality, since the designers can concentrate on func-tional design and thermal design, without distractionfrom external requirements.(1) Electrical shock prevention, insulation

100 V AC wiring is used only for connectionsbetween the power-receiving terminal and the frontpower supply. Insulation management is performedalong this interval only.(2) Noise resistance

There is less wiring for electric power within thecabinet and there is also less electromagnetic interfer-ence between electric power and signal wires.(3) Harmonic current suppression function

Because the front power supply has functions forcorrecting the power factor and suppressing the har-monic current, there is no need to configure activefilters for each devices.(4) Input wide range power supply

Because the front power supply supports the inputspecifications of 100 to 220 V AC and 110 to 220 V DC,the internal devices can be standardized for an input of24 V DC.(5) Power supply line noise, surge voltage

The effective noise filter of the front power supplyprovides effective shielding from line noise and surgenoise.

5. High-density Design and Euro-to-ring Termi-nal Conversion

The miniaturization of equipment and reduction innumber of panels that accompany high-density mount-ing complies with requests for space savings and lowercost. By using a Euro ring-type I/O module, thermaldesign and a centralized power supply, MPU redun-dant systems with 1,536 (Euro terminals) and 1,024(ring terminals) I/O points had been realized.

5.1 Euro terminal features and necessity for ring conver-sionThe characteristic feature of Euro terminals is that

the exposed copper core of wire whose sheathing hasbeen stripped off (or a cylinder-shaped pin attached tothe wire) is inserted into the terminal and tightenedwith a screw to secure it. The two main advantages ofEuro terminals are listed below.(1) The space occupied per wire is less than for

Japanese ring terminals, thus enabling highermounting density.

(2) Wiring work is simpler and results in laborsavings.

Direct application of the above advantages enableshigh-density mounting to be realized with up to 1,536points, with reduced labor. In Japan, however, ringterminals are strongly requested and a mechanism forconverting Euro terminals to ring terminals is avail-able.

5.2 Design of Euro-to-ring terminal conversionThe Euro-to-ring terminal conversion method was

designed in consideration of the I/O (IPU-II) of thepresent MICREX-AX model, and in particular, arevision of its structure was considered.

As the result of this study, the Euro-to-ring-conversion cable, shown in Fig. 6, was developed. Theadvantages of this method are described below.(1) More compact structure

The wiring is soldered directly onto the lead of ringterminal block. This results in a slimmer terminalconversion part and ensures the withstand voltage.

As a result, the number of I/O points could beincreased from 768 to 1,024 in a single MPU redun-dant system cabinet.(2) Improved workability

A two-piece construction terminal block was adopt-ed. Because the terminal block can be replaced toallow connection of the test equipment, the amount oflabor involved in the testing was reduced.(3) Cable wire as a component

In the cabinet layout, an external wiring terminalblock is located directly beneath each I/O module, andthe length of the cable for Euro-ring conversion isfixed. Thus, the wiring for the terminal is no longerdependent on the customer’s specification. These parts


are available as cable assembly components, which areproduced in advance and can be stocked.

6. Conclusion

The thermal design, safety and EMC environmen-tal design, and the Euro-ring terminal conversion ofthe MICREX-NX cabinet have been described. Inaddition to these functions, there are also recentrequests for environmentally conscious design.

Fig.6 Conversion of Euro terminal to ring terminal The Fuji Electric Group has declared its intentionto promote the reuse and recycling of constituentmaterials for cabinets, and to design cabinets thathave low impact on the environment throughout theirentire product lifecycle, from material procurement tostructuring, transportation, usage, and finally, to dis-posal.

In terms of reuse and recycling, the design haschanged to adopt labeling of the raw materials in thevarious components and to use rivets instead of anglewelding construction for easier disassembly.

To reduce environmental impact, the Fuji ElectricGroup is working to improve technology for environ-mentally-conscious design and is involved in variousefforts to reduce environmental impact, such as acquir-ing a type III environmental label as established byJapan Environmental Management Association forIndustry (JEMAI), for the first time in Japan in thecontrol system field. (Refer to the “Low-voltage motorcontrol center,” described on the JEMAI website (http://www.jemai.or.jp/).)

In the future, Fuji Electric intends not only toenhance system features and performance further, butalso to maintain the highest level of environmentallyconscious design and to continue to provide solutions tothe marketplace and contribute positively to society.

Euro terminal

Ring terminal (2 piece type)

External terminal

External terminal

Internal cable

Lead pins are soldered to attach the wiring.

The terminal part can be separated.

Euro terminal is a type of connector and is inserted into the I/O module to make a connection.


: Representative Office : Sales Bases : Manufacturing Bases

Global Network

AMERICA

EU

FUJI ELECTRIC CORP. OF AMERICAUSATel : +1-201-712-0555 Fax : +1-201-368-8258U.S. FUJI ELECTRIC INC.USATel : +1-732-560-9410 Fax : +1-732-457-0042FUJI HI-TECH, INC.USATel : +1-510-651-0811 Fax : +1-510-651-9070FUJI SEMICONDUCTOR, INC.USATel : +1-972-733-1700 Fax : +1-972-381-9991GE FUJI DRIVES, USA INC.USATel : +1-540-387-5925 Fax : +1-540-387-8580GE FUJI DRIVES AMERICA S.A. de C.V.MEXICOTel : +52-8-154-7000 Fax : +52-8-154-7007

FUJI ELECTRIC HOLDINGS CO., LTD.Erlangen Representative OfficeGERMANYTel : +49-9131-729613 Fax : +49-9131-28831FUJI ELECTRIC FA EUROPE GmbHGERMANYTel : +49-69-6690290 Fax : +49-69-6661020FUJI ELECTRIC (SCOTLAND) LTD.U.K.Tel : +44-1355-234111 Fax : +44-1355-238810FUJI ELECTRIC FRANCE S.A.FRANCETel : +33-4-73-98-26-98 Fax : +33-4-73-98-26-99

ASIA

FUJI ELECTRIC HOLDINGS CO., LTD.China Representative Office (Shanghai)CHINATel : +86-21-6471-0897 Fax : +86-21-6471-4903FUJI ELECTRIC HOLDINGS CO., LTD.China Representative Office (Beijing)CHINATel : +86-10-6505-1263 Fax : +86-10-6505-1851FUJI ELECTRIC FA (SHANGHAI) CO., LTD.CHINATel : +86-21-6466-2810 Fax : +86-21-6473-3292FUJI ELECTRIC (CHANGSHU) CO., LTD.CHINATel : +86-512-5284-5629 Fax : +86-512-5284-5640FUJI GE DRIVES (WUXI) CO., LTD.CHINATel : +86-510-528-1932 Fax : +86-510-528-2052FUJI ELECTRIC DALIAN CO., LTD.CHINATel : +86-411-8762-2000 Fax : +86-411-8762-2030SHANGHAI FUJI ELECTRIC SWITCHGEAR CO., LTD.CHINATel : +86-21-5718-5740 Fax : +86-21-5718-1448

SHANGHAI FUJI ELECTRIC TRANSFORMER CO., LTD.CHINATel : +86-21-5718-5740 Fax : +86-21-5718-5745DALIAN FUJI BINGSHAN VENDING MACHINE CO., LTD.CHINATel : +86-411-8730-5908 Fax : +86-411-8730-5911DALIAN JIALE VENDING MACHINE OPERATION CO., LTD.CHINATel : +86-411-8596-2721 Fax : +86-411-8596-2732SHANGHAI GENERAL FUJI REFRIGERATION EQUIPMENT CO., LTD.CHINATel : +86-21-6921-1088 Fax : +86-21-6921-1066HANGZHOU FUJI REFRIGERATING MACHINE CO., LTD.CHINATel : +86-571-8821-1661 Fax : +86-571-8821-0550FUJI ELECTRIC (SHENZHEN) CO., LTD.CHINATel : +86-755-2734-2910 Fax : +86-755-2734-2912HONG KONG FUJIDENKI CO., LTD.HONG KONGTel : +852-2664-8699 Fax : +852-2664-8040FUJI ELECTRIC FA (ASIA) CO., LTD.HONG KONGTel : +852-2311-8282 Fax : +852-2312-0566FUJI ELECTRIC SYSTEMS CO., LTD.Taipei Representative OfficeTAIWANTel : +886-2-2561-1255 Fax : +886-2-2561-0528FUJI ELECTRIC TAIWAN CO., LTD.TAIWANTel : +886-2-2515-1850 Fax : +886-2-2515-1860FUJI/GE TAIWAN CO., LTD.TAIWANTel : +886-2-2556-0716 Fax : +886-2-2556-0717ATAI FUJI ELECTRIC CO., LTD.TAIWANTel : +886-3-321-3030 Fax : +886-3-321-7890FUJI ELECTRIC KOREA CO., LTD.KOREATel : +82-2-780-5011 Fax : +82-2-783-1707

East Asia

Southeast Asia

FUJI ELECTRIC SYSTEMS CO., LTD.Bangkok Representative OfficeTHAILANDTel : +66-2-308-2240, 2241 Fax : +66-2-308-2242FUJI ELECTRIC SYSTEMS CO., LTD.Jakarta Representative OfficeINDONESIATel : +62-21-572-4281 Fax : +62-21-572-4283FUJI ELECTRIC (MALAYSIA) SDN. BHD.MALAYSIATel : +60-4-403-1111 Fax : +60-4-403-1496FUJI ELECTRIC PHILIPPINES, INC.PHILIPPINESTel : +63-2-844-6183 Fax : +63-2-844-6196FUJI ELECTRIC SINGAPORE PRIVATE LTD.SINGAPORETel : +65-6535-8998 Fax : +65-6532-6866FUJI/GE PRIVATE LTD.SINGAPORETel : +65-6533-0010 Fax : +65-6533-0021

Printed on recycled paper

special edition micrex-nxefasco.co.kr/eng/product/catalog/f02 special edition... · 2016-10-07 ·...

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