zenon Book EN

additional information

equipping machines

zenon in operation

engineering with zenon

2

Preface

engineering with zenon

3

At COPA-DATA, we develop software that supports you efficiently and flexibly in overcoming the challenges you face. With over 30 years of experience, we are adept at engineering out the pitfalls hidden in the details while always ensuring that the big picture is reflected in our product. Trendsetting technologies are harnessed through up-to-date product development and by the dynamic team behind zenon.

Our commitment to continuously develop relevant technology at the forefront of our industry provides you with the guarantee of long-term investment security.

Our innovation enables you to benefit from a competitive advantage.

This book provides you with an overview of zenon – the software system for industrial automation and the energy sector. We invite you to be inspired by zenon and all the opportunities it offers for you to conquer your challenges and stay one step ahead of your global competition.

equipping machines

Industry 4.0 and the Industrial IoT have introduced a great deal of change to the industry. These developments affect many company stakeholders – from machine operators to the CEO.

zenon in operation

In order to compete on a global scale, we are all required to continually become more efficient and more flexible. This includes working carefully with raw materials, integrating the “human resource” both sustainably and intelligently, and being able to adapt to individual customer requirements quickly and flexibly.

additional information

Phillip Werr CMO/COO COPA-DATA

4

Contents Engineering with zenon zenon provides an engineering environment in which all projects are created, expanded, and maintained. Start with fast, uncomplicated, and error-free project creation. Then you can efficiently maintain and expand your projects over the entire life cycle.

Setting Parameters Instead of Programming......................................................................9 Object Orientation............................................................................................................11 Central Project Engineering Environment........................................................................13 Automated Engineering....................................................................................................15 Efficient Project Validation...............................................................................................17 Out-of-the-box Usability..................................................................................................19 Efficient Project Maintenance..........................................................................................21 Collaborative Engineering.................................................................................................23 Multi-Project Administration: Decentralized and Flexible Intelligence ..........................25 Creating Smart System Architecture.................................................................................27 Heterogeneous Production Landscapes............................................................................29 Built-in Soft Logic.............................................................................................................31 Native Drivers for Added Freedom...................................................................................33 Redundancy – Simple and Effective.................................................................................35 zenon Network Technology..............................................................................................37 Compatibility for Future-Proof Projects...........................................................................39 Fit for Big Data..................................................................................................................41 Secure Data Archives........................................................................................................43 Sophisticated Alarm Administration.................................................................................45 À la Carte Reporting.........................................................................................................47 Validated Security under IEC 62443.................................................................................49

zenon in operation zenon supports various user groups – ranging from machine operators to the CEO – in a universal system. Tailor-made applications contribute to greater flexibility and efficiency. With connectivity and transparency, zenon combines different disciplines in one system and creates an ergonomic environment for every user.

Modernize Developed Structures with Ease.....................................................................53 Batch Size of One: Production and Business Processes Perfectly Integrated.................................................55 A Tailored User Experience...............................................................................................57

Operation: User-Defined and Context-Sensitive..............................................................59

engineering with zenon

5

Safe Operation with Touch and Multi-Touch ...................................................................61 Overview with the zenon Worldview...............................................................................63 zenon Batch Control..........................................................................................................65 Manage Recipes Intelligently............................................................................................67 Rapid Reporting, Clear Analysis.......................................................................................71 Big Data and the Cloud.....................................................................................................73 Reporting across Locations with Cloud Technology.........................................................75 Always up to Speed..........................................................................................................77 The Smart Factory Requires Security...............................................................................79 Cut Down on Distances Traveled through Decentralization.............................................81 High Scalability.................................................................................................................83

zenon in operation

Secure Data Archiving......................................................................................................69

Future-Proof Projects with Seamless Updates.................................................................85 Redundancy and Secure Data Flow..................................................................................87

Equipping machines Machines and equipment are controlled and monitored with zenon. zenon supports flexible machine configuration, secure connectivity, and optimum usability for operators. With zenon, machines and equipment can be seamlessly integrated in smart environments.

Optimum Usability – Efficiently Executed.......................................................................93 Modular Systems via Automated Engineering ................................................................95

equipping machines

Manage Alarms Intelligently.............................................................................................89

Access Reporting at the Machine.....................................................................................97 Flexibly Configure Recipes...............................................................................................99 Stay Compatible – across Generations of Machines.......................................................101 Effective Production Requires Robust Software............................................................103 The Secure Route to the Smart Factory..........................................................................107

Additional Information Index...............................................................................................................................110 Contact Details................................................................................................................113

additional information

When Machines Communicate with Machines..............................................................105

engineering with zenon zenon in operation

zenon provides an engineering environment in which all projects are created, expanded, and maintained. Start with fast, uncomplicated, and error-free project creation. Then you can efficiently maintain and expand your projects over the entire life cycle. This helps you to keep the total cost of ownership low and maintain maximum flexibility.

equipping machines

with zenon

additional information

Engineering

engineering with zenon

8

2

30,000 lines of code

Programming

clicks

vs

Setting parameters

Assuming a redundant network is being created, an engineer would ordinarily need to write around 30,000 lines of code. With zenon, that same engineer can achieve the same outcome with just two clicks.

The engineering team has expanded, but the new team member has no programming experience – and not much time to get trained up. But this doesn’t stop them from getting a quick handle on the first project tasks they are assigned or completing even complex challenges quickly. How? Because all they have to do is set parameters, with none of the arduous work involved in programming.

Create your first project with just a few clicks zenon requires absolutely no prior knowledge of programming. All it involves is setting parameters for the properties and functions you need. Predefined static and dynamic elements and symbols make working with zenon even easier. Just a few clicks are all it takes to create functions – and that includes complex ones such as redundant networks. Thanks to the configurable nature of the software, there is also a significant reduction in the

validation work required for strictly regulated industries such as pharmaceuticals and food & beverage. Despite all this, zenon remains a flexible system. Not only can it be expanded using wizards, but those who would rather follow the programming route can also access it via an open Application Programming Interface.

`` Flexible allocation of resources `` Shorter project orientation time

engineering with zenon

`` Faster engineering `` Higher margins in projects with a fixed price

additional information

Setting parameters instead of programming – the zenon philosophy The product philosophy of “setting parameters instead of programming” makes it possible to complete even complex projects with minimum fuss. Creating visualization projects is simply a matter of setting parameters – no additional programming work is necessary. This principle is played out throughout the entire zenon software system. It allows new team members to get to grips with the tasks they are assigned in hardly any time at all – and what’s more, provides a reliable basis for maintaining projects of all sizes, even if the team‘s makeup changes or someone with specialist knowledge leaves the project.

zenon in operation

Setting Parameters Instead of Programming

equipping machines

9

global project

Editing properties

Object

A

-

Colors Variables Symbols Functions

dific

ca

ti

on

s

project a

m od ns io at ific

project c

difi

ations

mo

mo

engineering with zenon

10

project b

In zenon, objects are created and maintained centrally. Properties are assigned to objects with just a few clicks. Changes affecting aspects such as color can be made at a central point and are then distributed throughout the project automatically.

Integrating the filler of a filling line into five different projects for the same customer? Easy! Grouping and filtering production data? No problem. Want to change the color of a valve symbol from green to red across the board before commissioning – even though it’s been used 100 times in the project? All it takes is a click.

How object orientation works Properties of objects such as screens, symbols, and variables are configured only once. The properties are easily distributed throughout the project with just a click or by using Styles. After the one-off process of defining them, objects can then be reused in several different ways – a real advantage. Any changes only have to be

made at one central point, and are then automatically transferred to wherever they apply.

Let’s say you want to change the shape or color of a symbol. You simply make the change in a global symbol library – and the change is automatically carried over to the individual project screens. This ensures projects are easy to maintain, and you can rest easy in the knowledge that errors won’t creep in even if you do make a large amount of subsequent changes to a project.

Even complex projects are given a clear structure, consistency is ensured, and you save time and money on engineering.

engineering with zenon

`` Projects are quick to create and maintain `` Consistency is ensured `` Rapid corrections and changes at a moment’s notice, even if several symbols are involved `` Time savings and faster commissioning – resulting in lower project costs

additional information

Object orientation: a key principle of zenon Object orientation has been a part of the zenon product philosophy from the very beginning. Objects are created and maintained at a single point – but they can be used in multiple places and even across projects. However, they can also be adapted locally at any time.

Object orientation is applied universally throughout zenon, primarily to prevent duplicate copies of data being stored. This enables objects to be reused consistently, so engineering processes are streamlined and amendments can be made quickly and easily – while also avoiding careless mistakes. As a result, the entire project remains a consistent whole. Even change requests right before go live are no problem – because they can be actioned so quickly.

zenon in operation

Object Orientation

equipping machines

11

engineering with zenon

12

Reports

Trends

Alarms

Apps

Batch Control

Web applications

Drivers

Variable administration

Programming in accordance with IEC 61131-3

and much more!

Engineering environment in zenon

The zenon Editor is the central engineering environment in the software system and enables all applications to be created, edited, maintained, and shared.

Once zenon has been used to implement machine operation, users consider line management and reporting to be a natural extension to their systems. But they still wonder “Do I need an additional tool for this?” or “Will reporting work on my smartphone?”

An engineering tool with countless possibilities The zenon Editor offers a complete engineering tool for all product categories and approaches to solutions.

Its consistent object orientation makes it incredibly simple to use and maintain variables universally for all application cases, for instance. No matter whether the task involves control programming in accordance with

IEC 61131-3, energy distribution in redundant networks, HTML5 web applications, or sophisticated energy data management – everything can be managed conveniently and reliably with the zenon Editor.

`` Flexibility for every project stage and every project size `` Future-proof: growing projects can be expanded

engineering with zenon

`` Efficiency thanks to consistent project engineering `` Less time and effort spent on training and faster development of expertise

additional information

zenon Editor: Start small and aim for targeted growth The zenon system only requires one Editor to carry out all engineering tasks. This Editor can also be used to implement an extremely wide range of project requirements – no matter how large or small the project is or whether it is intended to work on mobile devices or web applications. Projects remain scalable and can evolve along with the requirements of the customer. You only need a single central engineering environment in order to create, edit, share, and maintain a whole host of different applications.

This also means a better overview, faster familiarization, a high level of compatibility, and less time and effort spent on training. What‘s more, you will be able to respond extremely quickly to new project requirements and continue to develop your expertise.

zenon in operation

Central Project Engineering Environment

equipping machines

13

engineering with zenon

14

Time

Added value Time for creating a wizard

x

If the same tasks need to be performed for lots of projects or in very large projects, it is worthwhile creating a wizard that will automate them. Achieve time savings and prevent errors – freeing you to create added value.

Quantity of installed projects

Creating variables can be an arduous task – performing the same steps and the same mouse clicks again and again can cause the engineer to lose concentration and errors to start creeping in. It also leaves hardly any time for more stimulating and challenging tasks, especially when resources are calculated with very little leeway. Can‘t these monotonous steps be outsourced?

`` Automating monotonous tasks `` Prevents errors in project engineering

equipping machines

Automated engineering in zenon zenon offers a wide range of options for automating project engineering. The wizards it includes perform a variety of standardized and recurring tasks relating to creating a project. The API interface of the zenon Editor means that it is also possible to access the Editor externally and create custom wizards. This enables you to generate sub-projects automatically, for example. zenon‘s openness allows every user to automate the processes they require and adapt them to specific projects.

One example of automated project creation is the zenon Automotive Generator (zag), which can be used to create recurring symbols and link variables automatically. It has applications mainly in the automotive industry.

`` Time and cost savings

additional information

More time for the important things zenon enables easy and secure automation of basic and recurring tasks. It replaces monotonous work, completing tasks quickly and reliably. zenon allows you to automate not only the creation of variables, but also the import of screens and formulas. This significantly reduces the risk of incorrect engineering. And project creators will see a noticeable increase in the time available to them for the more challenging and interesting tasks.

engineering with zenon

Automated Engineering

zenon in operation

15

engineering with zenon

16

man days

for programmed application

Engineering

man days

Validation

for gamp 5 software category 4

Engineering

Validation

When it comes to programmed applications, validation often takes twice as long as the engineering itself.

When you use a category 4 GAMP 5 software instead, validation is reduced to just half the time needed for engineering.

Industries that are subject to strict regulations, such as the pharmaceutical and life sciences sectors, often encounter the same problem: project validation usually takes twice as long and uses double the resources when compared to the engineering phase itself. A large portion of the costs stem not from the project but from the validation. And the same applies for every single change. Thanks to zenon, things are changing.

Speedier engineering, speedier validation zenon meets the ISPE GAMP 5 Guidelines for software category 4. In practice, that means significantly speedier system validation. What’s more, zenon also meets the requirements of GMP (Good Manufacturing Practice) and FDA 21 Part 11 for strictly validated production environments, such as the pharmaceutical industry.

In zenon, projects don’t require extensive programming. Instead, pre-prepared components are on hand to support engineers for quick, error-free results. zenon also comes with templates for various screens to allow for speedy implementation. The reduction in engineering work and the accelerated validation process for projects keep project engineering phases short while ensuring speedy setups.

The comprehensive user administration function – including Active Directory integration – provides your system with the security it deserves and is also available out-of-the-box.

If you were to program all of these functions, you would have to validate every single line of code. And every time you changed the code, you would have to validate it all over again. zenon’s out-of-the-box functions only need to be validated once and then can be used again at any time without any revalidation being required.

engineering with zenon zenon in operation

Efficient Project Validation

equipping machines

17

`` Save time and money during the validation phase

`` Minimize risks by eliminating sources of error `` Out-of-the-box: GAMP 5 software category 4 and FDA 21 Part 11

additional information

`` Shorter setup times Complex functions out-of-the-box zenon allows for quick and efficient validation by providing complex functions and key components straight out-of-the-box. Extensive reports (Audit-Trail, alarm statistics, etc.) are created at the touch of a button.

Templates for Alarm Message Lists or redundant systems and complex network architecture are configured in a matter of minutes without any tedious programming.

engineering with zenon

18

WPF elements

Styles

Templates

Color palettes

Transparency

usability

Forms

Multi-Touch

zenon contains a number of useful functions to help you make sure your projects meet the latest usability standards.

The working environment of a production line should be as efficient and ergonomic as possible in order to support optimum performance while also significantly reducing errors. After all, users in an industrial environment expect the same high level of usability in their interfaces as that provided by standard tablets and smartphones. In other words, they want Multi-Touch functionality, operating safety, and an appealing screen design. And what provides all of this?

engineering with zenon

Out-of-the-box Usability

zenon in operation

19

Outstanding usability with zenon “What you see is what you get” starts in zenon Editor.

Objects that you generate in the Editor appear exactly as they would in the finished project. Thanks to the practical zenon Styles, you only need to define object properties once before then transferring them throughout the project with just a single click of the mouse. You can adjust your designs from a central location, making it easy to apply consistent rendering throughout the entire project and beyond.

Symbols have already been prepared for many industries and are ready to use straight away. WPF

elements and templates in line with the latest usability standards can be added to your project at just the touch of a button. You can also create, import, and export your own templates tailored precisely to the end users’ requirements. zenon projects are easily adapted for Touch and Multi-Touch environments. For instance, zenon already contains native Multi-Touch gestures that you can add through simple configuration and without any extra programming.

`` Design flexibility for project engineering `` Simple application of intuitive operating concepts `` A high degree of user satisfaction

additional information

User friendliness as a central component of ergonomics An automation project not only needs to be functional, it is also expected to provide users with the optimum level of support for their job. For project engineers, this means implementing usability standards and incorporating the latest findings regarding user ergonomics. Luckily, zenon is here to help – making user-friendly design an integral part of any customer project. zenon does all of this with full flexibility and without any programming, and can even incorporate corporate branding specifications.

equipping machines

zenon.

engineering with zenon

20

Current project status in zenon Runtime

reload

munich

Modification in zenon Editor

salzburg

Remote Transport zenon Runtime

munich reload

Hot Reload

New project status available immediately!

reload

munich

Changes and updates to the project take place in a central location or remotely using zenon Remote Desktop. Changes can then be transferred using Remote Transport. The Hot Reload function ensures that changes can be imported during live operation.

An extra tank is added to the production line at a drinks manufacturer. This tank also needs to be added to the visualization project. To do this, the project manager simply expands the project with symbols and functions, remotely imports the updates, and reloads the project. The display in the control room now shows the new tank and its current values. What’s more, operations didn’t have to be stopped once during the update.

Smooth, simple project updates with zenon zenon provides you with an easy way to maintain, modify, and update your projects. Seamless project versioning ensures that any modifications to the project can be traced. Because projects are configured and not programmed, they don’t generate huge quantities of obscure code. All properties can be configured in a clear

overview. The project remains easy to maintain, even when a key developer leaves the team.

Projects can expand, no matter which version they were created in. With every new version, project engineers benefit from the latest zenon technology, while still being able to maintain projects created using older versions of the software.

`` Thanks to compatibility, projects can be maintained over the long term

engineering with zenon

`` Transparency in engineering `` No more downtime during updates

additional information

Project updates without any downtime With zenon, you can maintain, modify, and update your projects with ease. Most importantly, your users don‘t have to experience a single minute of downtime.

Projects are edited and updated from a central location and can even be tested using simulations before they go live. You can also engineer your projects remotely, meaning that service technicians don’t need to get called out anymore. Instead, they can enjoy speedy, secure access at any time thanks to zenon Remote Desktop.

Any modifications to the project are transferred to the Runtime computer using Remote Transport. Meanwhile, the Hot Reload function allows updates to be imported during operations – without a single interruption or second of downtime.

zenon in operation

Efficient Project Maintenance

equipping machines

21

engineering with zenon

22

Project A

ab c SQL

a

b

c

With multi-user projects, several users can work on one project at the same time without getting in each other’s way. A central SQL Server hosts the projects.

Everything is better in a team – especially when your tools are in on the act. Let’s look at visualization as an example: a user experience expert is creating the user interface.

At the same time, another employee is defining the variables and dealing with reports. The start-up date is edging ever closer and, because time is getting tight, you decide to add a few members to the team. As a result, even the language tables for translating the project and the measurement unit switches are ready on time.

Multi-user projects in zenon With zenon’s distributed engineering functions, you can distribute duties within your team and make efficient use of the time you have. The projects are managed on a central SQL Server, enabling several people to work on one project at the same time. However, the solution always ensures that objects can only ever be modified by one user. Whenever a person is working on an object, it is checked out and locked for everyone else. This helps to eliminate overlapping or double configuration. Once

the object has been checked back in, all other users have immediate access to the latest version of the project.

Standalone projects can also be converted into multiuser projects at any time at just the touch of a button – and vice versa. Your projects, your choice.

` Speedier project completion ` Flexible project coordination based on team members’ expertise and availability

engineering with zenon

` Optimum organization for large-scale projects

additional information

Efficient scheduling for your project team With its multi-user project feature, zenon enables several users to work on the same project at the same time – all without getting in each other’s way. This approach significantly reduces engineering time and speeds everything up, particularly in large-scale projects. When you’re working in project teams, you can split up tasks according to your team members’ specialist expertise.

Driver experts, user experience specialists, and other experts can work together in parallel. Teams can be added to at any time and reorganized. Even employees from different sites can access the same project, allowing for simple project planning and control.

zenon in operation

Collaborative Engineering

equipping machines

23

engineering with zenon

24

The control room brings together displays for selected machines from different production lines.

Bottle cleaner

Filler

Labeler

Packer

Bottle cleaner

Filler

Labeler

Packer

Bottle cleaner

Filler

Labeler

Packer

Bottle cleaner

Filler

Labeler

Packer

With Multi-Project Administration, you can also access information (e.g. alarms) from one machine on the display of another.

Picture the scene: your production line is made up of four machines in a row. Their panels are already running on zenon but you don’t have an overview that brings together the information from all four panels on a single screen. The solution is simple: a zenon integration project. All you have to do is add your existing projects to an integration project using drag&drop and you‘re done!

Decentralized project administration zenon Multi-Project Administration goes beyond traditional client-server structures. Instead of using a central solution, it follows the principle of decentralization. This means that you can split a large project into several smaller projects in a package.

This makes enhancements and project maintenance even easier, particularly in combination with zenon’s object orientation. With this solution it is possible to edit and update individual parts of the project, leaving

any unaffected parts alone. This is particularly useful in industries with strict regulations because it ensures efficient and affordable validation and revalidation.

Security is at the forefront of everything we do. In just a few clicks of the mouse, you can create failureproof redundant network architecture. And, because the definition of server and client are not related to specific computers but are instead defined on a project basis, you can guarantee data consistency with less hardware than normal.

engineering with zenon

`` Increased transparency and improved overviews `` High performance `` Simple maintenance `` A high level of data consistency and less additional hardware requirements thanks to zenon’s redundancy concepts

additional information

Project division improves your overview and performance The journey to creating a successful Smart Factory involves decentralized intelligence and a high degree of flexibility. In zenon, you can engineer smart structures without any hassle thanks to Multi-Project Administration. You can consolidate large projects into logical units and then put them wherever you want.

You can even spread your projects over several different computers, which helps to improve performance and increase flexibility. This gives you a quick way to create complete control room projects and consolidate all of your sub-projects into a single integration project.

zenon in operation

Multi-Project Administration: Decentralized and Flexible Intelligence

equipping machines

25

engineering with zenon

26

databases

mobile applications

cloud

redundancy control

network

interfaces

Smart system architecture with zenon: perfect connections from the sensor to the cloud. A secure and robust solution for complex systems with outstanding connectivity.

The architecture for your project calls for various systems to communicate with one another. You need to link hardware components built by a range of different manufacturers, while also making sure the network has a redundant design.

Plus, you need database connections, cloud connections, and mobile access to production. And when you are trying to plan more efficient material flows and streamline your order processing, your production line and supply chain need to be

engineering with zenon

Creating Smart System Architecture

zenon in operation

27

Simple and secure handling for complex system architecture zenon can bring together a huge range of hardware components and enable them to communicate with one another. The open interfaces in zenon guarantee data consistency from the sensor to the ERP system and then up to the cloud. Meanwhile, zenon also blends seamlessly into your existing infrastructure and database systems.

As a result, you can build a full universal system with very little effort, easily bringing together information from various levels. All of this can be configured from a single Editor – even when integrating mobile devices.

With zenon, you can securely configure even the most complicated of network structures with ease.

processing. Even a variety of cloud solutions are easy to implement with zenon – for example, using Microsoft Azure. And, of course, you can also run parts of your system architecture in a virtual environment.

Open programming interfaces and the option to program your own project solutions using Visual Studio open up even more opportunities. And with over 300 native drivers and communication protocols, nothing will stop you from connecting a wide array of devices and machines in the Industrial Internet of Things (IIoT).

equipping machines

coordinated via your ERP system.

`` Development of complex systems with very little effort

Perfect networking with zenon The increasing convergence of information technology (IT) and operational technology (OT) calls for open and secure automation systems. zenon connects production with the business world thanks to outstanding connectivity, including with ERP systems such as SAP and Microsoft Dynamics.

Thanks to a free selection of databases, you can enjoy ultimate flexibility for data archiving and data

`` Easy configuration for secure, robust, and redundant networks `` Open programming interfaces

additional information

`` Open and cutting-edge system architecture

engineering with zenon

28

siemens

mitsubishi

opc ua

zenon offers hardware independence at field level. With over 300 native drivers and communication protocols, you can connect the majority of machines and sensors available on the market. zenon Logic, the built-in IEC 61131-3 solution, can be used as a soft PLC – enabling you to control your devices.

zenon logic plc

Capacities are expected to rise, existing systems need to become more efficient, and new software is brought in to increase flexibility. In structures that have developed over time, old and new production systems from a range of different manufacturers often run in parallel. So how do you seamlessly and effectively incorporate your heterogeneous production landscape into your new projects? And how do you get your hands on process data from your patchwork of production systems?

Free choice of hardware and incorporation into existing systems zenon can provide over 300 native drivers and communication protocols, allowing you to directly connect the majority of equipment currently available on the market. zenon Logic – the zenon software system’s built-in IEC 61131-3 solution – can also be used as a soft PLC for controlling equipment.

With zenon, you get to decide which hardware you add to your systems. Simply select the best technology for the application at hand.

` Hardware independence at field level ` Find the best technology for the application in question ` Reduce costs

engineering with zenon

` Efficiently integrate your existing equipment

additional information

Full communication with zenon Using lots of different machines and system components can often be beneficial – after all, it helps you to consolidate strengths while minimizing weaknesses. The benefits are particularly high if your automation software gets in on the act. zenon effortlessly brings together data from your heterogeneous production landscape.

Thanks to its open interfaces and array of ready-made communication protocols, zenon can bring together a huge range of production equipment – connecting existing machines and sensors with ease. Ideally, you should use zenon “on top” of the system where all of your process data flows together.

zenon in operation

Heterogeneous Production Landscapes

equipping machines

29

engineering with zenon

30

visualization

visualization

soft logic IEC 61131-3 Runtime

soft logic IEC 61131-3 Runtime

zenon Logic – zenon’s built-in PLC programming environment – can be used as soft logic for project simulation or complex KPI calculations.

visualization

soft plc

IEC 61131-3 Runtime I/Os

visualization

soft plc

IEC 61131-3 Runtime I/Os

For machine control applications, zenon Logic can be used as a soft PLC.

Equipment Effectiveness (OEE) calculation. When it comes to OEE, availability, performance, and quality have to be calculated on an ongoing basis. With zenon, you can use precise data taken directly from the production line – perfectly supported by zenon’s built-in zenon Logic.

The zenon Logic programming environment zenon comes with a built-in IEC 61131-3 programming environment as standard: zenon Logic. Thanks to consistent integration throughout the zenon software system, zenon and zenon Logic use just one shared database. Engineers therefore only have to generate objects such as variables once and can maintain them from a central location. What‘s more, zenon Logic also serves as a soft PLC for controlling machines and systems, enabling you to streamline hardware costs.

Simulation, calculation, and control built in zenon’s built-in soft logic combines the HMI/SCADA world with the PLC world through a shared database.

This not only helps to prevent errors but also expedites and simplifies engineering and maintenance. With zenon Logic, you can also perform calculations and logical checks, for example, for complex KPI calculations. zenon Logic can also be used in the field of project simulation. Here, zenon Logic simulates the target PLC and provides realistic values during tests in the engineering phase. You will therefore be able to see straight away how the project will work so that you can eliminate errors and risks before you go live.

zenon Logic is a versatile calculation tool, a sophisticated soft PLC, and a tool for simulating realistic control operations.

`` Central database thanks to universal integration `` No more repeat data maintenance `` Offline simulation

engineering with zenon zenon in operation

The project specifications for a drink-filling machine call for real-time Overall

equipping machines

Built-in Soft Logic

additional information

31

engineering with zenon

32

Allen-Bradley RSLinx

Mitsubishi MELSEC-FX

Allen-Bradley ODVA

Modbus Energy

Azure

Modbus RTU and Open Modbus TCP

B&R-PVI

Moeller PSUNI

BACnet

OMRON

Beckhoff TwinCat

OPC Client V2-0

Codesys ARTI

OPC UA Client

Codesys V3

Phoenix Contact

DNP3

PILZ-PSS

EIB-KNX

Siemens Controls Generation S5

Euchner Ident

Siemens Controls Generation S7

Festo EasyIP Multiprog

Siemens Controls Generation S7 TIA

Hilscher MPI

Saia Directly

HMI Adapter

SAIA2ND32

IEC 60870-5-101_104

Siclimat X Decos

IEC 60870-5-103

Sigmatek LASAL

IEC 61850

Simotion

IEC-62056-21

SNMP

LON/i-LON 100

SQL ODBC

Mitsubishi MELSEC A, Q

...

This list shows a selection of the 300+ native drivers and communication protocols available through zenon.

You want to make your company’s new building smart. Linking the control units for its heating system, sun blinds, air conditioning system, etc., would allow you to run a comprehensive energy management system. You also want to be able to incorporate production and building data into your evaluations. However, your production landscape has grown over time, meaning that is heterogeneous. Quite the challenge!

Is there any system out there that can get to grips with “exotic” equipment as well?

In-house driver development The communication functions offered by zenon guarantee ultimate connectivity in heterogeneous systems. zenon has access to over 300 in-house drivers and communication protocols. All of our drivers meet the highest standards for data consistency, performance,

stability, and security, and are checked on an ongoing basis.

COPA-DATA also takes part in a number of standardization committees, meaning that we contribute to the development of standards to ensure our customers always have early access to important communication protocols in line with the latest standards. As a result, zenon can communicate perfectly and reliably with many different devices, either using a standardized approach or individually programmed – it’s up to you.

engineering with zenon

`` Independent native drivers and communication protocols `` Easily expandable and with optimum maintenance `` High level of connectivity `` Stable communication

additional information

Independence brings more flexibility The Industrial Internet of Things (IIoT) requires open systems that allow for flexible enhancement without forgetting about security. Heterogeneous systems, on the other hand, require software systems that can speak lots of different languages. That’s where zenon comes in. Its array of native drivers, which we are constantly enhancing and extending, provide you with the support you need to connect your equipment and machines – from the sensor to a segmented system. System integrators not only benefit from a wide selection of existing drivers but also from the tailor-made development of new native drivers.

COPA-DATA develops its own communication stacks, allowing for the speedy expansion and optimum maintenance of drivers.

zenon in operation

Native Drivers for Added Freedom

equipping machines

33

engineering with zenon

34

Seamless Redundancy Server

Rated Redundancy

Standby

Server

Standby

Standby

Server

Standby

Server

Standby

Server

PLC

Server failure

PLC

Server recovered = Standby

PLC

The seamless redundancy in zenon guarantees maximum data consistency. You won’t even have to deal with gaps when you switch to a standby server because the standby server also remains connected to the PLC (provided the PLC allows this).

Rated redundancy uses the quality of the data transmission as a criterion.

If the quality parameters are not met, a standby server with a better data connection steps in.

Your project team is impressed: you have just engineered a redundant system within a matter of minutes – and it works perfectly. All it took was just a few clicks of the mouse and it did not require you to program a single line of code. All the functions you needed to create a redundant network were available in an out-of-the-box solution. All you needed to do was select the server and standby server and configure the redundancy type.

Tailor-made redundancy, out-of-the-box zenon provides a range of ready-made redundancy modes to suit a wide range of requirements. For instance, you can easily configure dominant and non-dominant redundancy, while benefiting from secure and robust performance.

One of the most unique aspects of zenon is its rated redundancy, which uses the quality of the data transmission as a criterion. To do this, you define the various parameters relating to the quality of data which

must be met within the data flow to enable the server to do its job. If these parameters are not met, a standby server with a better data connection steps in.

All possible forms of redundancy can be configured without any additional programming work.

`` Maximum data consistency `` Robust and secure `` Seamless redundancy, out-of-the-box

engineering with zenon

`` Minimized sources of error and risk

additional information

Data security and seamless redundancy at the touch of a button The seamless redundancy offered by zenon guarantees you maximum data consistency. zenon’s intelligent redundancy system offers a lot more than just switching to a standby server should your original server fail. It also ensures that none of your data gets lost during the switch. As a result, you are able to configure seamless data transmission without a single second of programming.

You select and configure all your properties straight from zenon Editor, saving you lots of time and avoiding any potential sources of error right from the start of engineering.

zenon in operation

Redundancy – Simple and Effective

equipping machines

35

engineering with zenon

36

Web clients

cloud Smartphone

HTML5

Tablet

Comprehensive reporting

App / SMS

SQL server

Engineering environment

Server

SCADA client

Internet / web server

Redundant server

HMI panel

HMI panel

PLC

PLC

PLC

PLC

Fieldbus, CAN, Profibus ‌

With zenon, you can configure secure network architectures with ease, even for the most complex models. Redundant systems can be implemented straight out-of-the-box.

ERP

Networks can be a troublesome issue for many project managers. Unstable systems and problems with the network configuration can be costly. However, there is one easy way to create a stable, functioning network – with zenon. What‘s more, you can do it without any programming and in a very short space of time. Simply tick the network, enter the computer, and – if you want – select your redundancy configuration.

Secure configuration for complex network architectures zenon networks are always easy to configure, no matter how complex they are. It takes just a few clicks to assign the roles of server, standby server, and client to your computers – allowing you to create both conventional client-server structures and secure complex multihierarchical models. zenon monitors all network conditions to guarantee effective performance and provide reliable protection against unwanted data loss. High-quality encryption and client authentication in the network provide secure communication. Thanks to the built-in user administration function, you can prevent unauthorized

access and unauthorized user actions. And, of course, you can integrate with your existing Active Directory services for this purpose.

All zenon modules work automatically with your configured network solution.

`` Speedy and secure network configuration `` Server-client configuration at the touch of a button

engineering with zenon

`` Exceptionally stable network performance `` Flexible network architectures

additional information

Flexible and robust With zenon, creating a network for your automation project is easy and secure. Even the most complex of topologies can be configured in a clear and effective manner. You won’t need to program a single line of code. zenon networks are stable, secure, and robust right from the outset. A wide array of properties allow the network to be configured carefully to meet the demands of the project and environment in question.

zenon in operation

zenon Network Technology

equipping machines

37

engineering with zenon

38

engineer pc zenon Editor

7.60

Project

zenon Runtime zenon

7.60

zenon

7.20

zenon

6.20

compile for:

zenon Project Backup in version 7.20

In this example, a zenon project with version 7.20 is opened and processed in a version 7.60 zenon Editor. Runtime environments with versions 6.20 to 7.60 can be compiled with this Editor.

Upgrading to a new version? Who knows whether everything will still work again afterwards? Even though the new version comes with a whole host of new options and will make your life easier – it’s even got a new module – the risk seems too great.

Projects for clients are too delicate for anything to go wrong. Compatibility? Ok, we’ll take a look. Once the upgrade is finished, one thing becomes clear: all that worry was for nothing, everything is working perfectly.

Added security with compatibility If you are using a brand new version of zenon for engineering, you can still import projects from older versions and edit them easily in zenon Editor. Simply select the version you need for the Runtime environment in the Editor at the touch of a button. You can then rest

assured that you are only engineering features that will actually work. And, of course, you can use several different versions of zenon Runtime in a single network at the same time. It’s up to you to decide which version of the Editor and Runtime environment you use.

Universal compatibility not only applies for version upgrades but also to small and larger-scale product updates.

`` Minimized risk for updates and upgrades

engineering with zenon

`` Always up to date with technology `` No expensive machine downtime `` Simple servicing and maintenance `` Use of the latest operating systems and security standards

additional information

Always up to date Compatibility is a core feature in zenon and this helps to ensure your projects remain fit for the future. COPADATA takes this issue very seriously; after all, only functional compatibility minimizes the risk during upgrades, helping you to keep your systems up to date at all times.

With zenon, projects remain compatible over a number of different product versions. They keep on running without any interruptions and can also be maintained with ease. Even when you’re using the latest version of zenon Editor, you can still use it to securely service older versions of zenon Runtime. Project managers will always benefit from the latest features without having to worry about older projects.

What’s more, with zenon you can perform upgrades without any expensive machine downtime.

zenon in operation

Compatibility for FutureProof Projects

equipping machines

39

engineering with zenon

40

Third party

Database

File-based

microsoft azure

Database

File-based

plc

Real-time data processing

Data Generation

sensors Up to n sensors

zenon offers you a flexible way to save and evaluate data. You can use zenon to work with very large amounts of data, making it an effective way to guarantee secure long-term archiving and read-back capability. With zenon, realtime reporting and predictive maintenance applications are made easy.

A customer has to comply with stringent regulatory requirements. He still collects his carefully archived data on magnetic tape, a solution that is anything but future-proof.

The alternative is a lot easier and a lot more secure: zenon projects are well equipped to tackle large quantities of data and can process them effectively. They are also easy to configure and can be enhanced with affordable limitless add-ons – including cloud connections. Making it affordable to swap your magnetic tape for big data in the cloud.

Performance optimization and scalability In zenon, you don’t need a separate tool for archiving as it’s already part of the Editor. Its native archive server, the zenon Historian, can tackle even the largest quantity of data. zenon’s archive aggregation function ensures your projects remain effective, even in the realm

of big data. And if you’re exporting data for long-term archives or for collaboration between various sites, you will find an array of different options in zenon – all the way through to easy connection with cloud services, such as Microsoft Azure. zenon therefore provides you with a convenient, affordable, and secure way to scale databases.

`` Simple archiving, extraction, and onward processing

engineering with zenon

`` Real-time reporting and predictive maintenance applications `` Problem-free project work for big data applications `` No additional engineering tool required for big data applications `` Highly scalable

additional information

Expanding your horizon with the cloud These days, so many companies are legally required to collect, archive, and read back data in accordance with certain rules. This can generate huge amounts of data. What’s more, big data is an important foundation for Smart Factories, whether you need it for the realtime reporting of important statistics or predictive maintenance applications that help you to plan impending work. zenon is perfectly equipped to archive and evaluate large quantities of data and then make this data available again. A special wizard helps you to decide which data should be archived in which period within just a short space of time. As a result, you will be ready to meet each and every regulatory requirement. What’s more, you can also draw up reports and analyses for huge amounts of data without any hassle.

zenon in operation

Fit for Big Data

equipping machines

41

engineering with zenon

42

flexibility

Native Native

SQL SQL

Cloud-based Cloud-based Historian Historian

Historian Historian in in the the network network Native Native

SQL SQL

zenon zenon

Local Local Historian Historian Native Native

SQL SQL

Field Field level level

zenon offers a range of flexible options for archive systems. You have options in terms of architecture and in choosing between native archiving or archiving to SQL Server.

archiving method Event-triggered Event-triggered

Cyclical Cyclical

On On change change in in value value

zenon facilitates the ideal form of archive for any application.

When you’re archiving large quantities of data, a clear arrangement is just as important as powerful performance. Complex systems and archiving models can quickly become an issue when you’ve got a lot of data. zenon supports project managers using triedand-tested functions: data can be recorded directly on the production system, stored in the database, and reliably extracted – with read-back capability and top performance guaranteed by data aggregation. And each and every step is easily adjusted.

Universal, configurable, and innovative The zenon Historian is fully integrated into the software system. This means you can easily link data from a variety of different areas of production. For instance, you can compare production data directly against energy consumption values. Or have immediate access to reports from batch production for your batch approval processes.

The Historian is an out-of-the-box solution and is easy to engineer thanks to the special wizard. Your data

archive is always redundancy-ready without any extra engineering. You have three different options for your archive: cyclical, upon value changes, or event-triggered.

Depending on the purpose and goal of your archive, you decide when data should be archived and when and how it should be exported. This means, for example, that you can protect and store data for the long term, process it in another tool, or read it back if necessary.

`` Affordable architecture for universal archive systems

engineering with zenon

`` Redundancy-ready archive helps protect against data loss `` Powerful enough to handle big data applications `` Simple export options

additional information

High data security with low project costs In zenon, archive engineering is quick and easy thanks to zenon Historian, zenon’s archive server. Our engineers’ priority was setting parameters instead of complicated programming. As a result, you can set up and maintain archives with a high level of data consistency with ease. zenon network technology with redundancy also helps to protect against data losses. The powerful performance of zenon Historian is further enhanced by the automatically configurable aggregated archive. Now nothing will stand in the way of you recording even the largest amounts of data for comprehensive reporting and big data applications.

zenon in operation

Secure Data Archives

equipping machines

43

engineering with zenon

44

hysteresis Upper threshold

hysteresis

Lower threshold Upper threshold

The individual specification of thresholds prevents an alarm flood in the event ofthreshold oscillating values.

Lower

delay period delay period Limit value

x seconds

x seconds

Limit value

x seconds

x seconds

Defining individual delay periods means that alarms aren’t generated until the limit value is broken for a certain period of time (x) (figure on the left). If the value falls back below the limit value before the delay period has expired, no alarm is generated (figure on the right).

Production systems cannot be efficient or successful without effective alarm administration. However, managing alarm administration systems is often complex and tends to take up a lot of time. Configuring and fine-tuning them requires experience and professional tools. Without these things, problems such as alarm floods caused by oscillating values, repeat work by various departments, or poor coordination can creep in. zenon‘s alarm administration enables the delivery of clear

engineering with zenon

Sophisticated Alarm Administration

zenon in operation

45

Setting up alarm administration with zenon zenon’s object-oriented approach helps to make sure that alarm configuration can take place in just a few minutes – even on large-scale projects. You define the limit values at a central location, using the variable or data type directly. Using your own thresholds helps to stop an unnecessary flood of alarms caused by oscillating values. And for larger-scale projects, you can use the assortment of options offered by the Reaction Matrix to define global alarm conditions and then reapply them for several different variables. Even zenon Runtime users are able to adjust thresholds. Any changes are then recorded in the Chronological Event List.

The logical classification of alarms into classes, groups, and areas helps you to maintain a clear overview. When it comes to displaying and filtering alarms in the Alarm Message List, you can access our pre-prepared views at the touch of a button. Various filter settings make it easier for you to adjust the alarm administration concept to your specific needs. If you wish to import changes to limit values while production is underway, you can use the simple Remote Transport function to transfer values and the Hot Reload function to adopt new ones without stopping your system.

`` Reduction of engineering time and costs `` Simple maintenance `` Effective alarm administration, even for the most complex requirements `` Out-of-the-box alarm administration that can be adjusted to your needs

additional information

Effective alarm configuration In order to apply clear, functional, and user-friendly alarm administration in zenon, you can simply use the pre-prepared screen types, functions, and properties that can be configured at the touch of a button. This allows you to define, for example, how limit violations should be displayed, who should be automatically informed, and which reports should contain information on this issue. Thanks to the simple engineering, you can save time, minimize the potential for errors, and cut costs.

equipping machines

information and effective warnings.

of metadata

Overarching reports and BI from an array of sources (zenon and third parties)

Consistent use

engineering with zenon

46

Realistic production reports

zenon offers flexible and powerful opportunities for reporting and business intelligence (BI).

The specifications are clear: energy consumption data from recent months needs to be compared in relation to production data. Energy costs for a specific batch need to be checked. And then the reports need to be sent automatically straight to the energy manager as a PDF in an e-mail. What’s more, you want to be able to access real-time consumption data straight from your smartphone. Let’s have a look …

Reporting the way you want it For reports used for documentation, evaluation, or chart-based or table-based presentation of process data, zenon allows you to use both live data and data from the archive. You can also integrate your reports directly into your zenon project, a process which is made even easier by the default templates provided for common reports.

These templates are available out-of-the-box and are really easy to use. And if you require full data archiving, zenon can offer seamless redundancy.

No matter how many reports you need or how complex they are, zenon makes sure all data is available

universally. As a result, you can avoid repeat work and repeat archiving, reducing potential sources of error and cutting costs.

Keen to use all the opportunities provided by a high-end reporting solution? Then enhance your zenon Supervisor with the specially developed zenon Analyzer, which can also access data in other systems and comes with plenty of pre-configured reports.

`` Out-of-the-box configurable templates

engineering with zenon

`` Universal data archiving over all levels `` Historical reports and real-time dashboards `` Simple distribution of information in an array of formats

additional information

From simple figures to complex trends zenon offers a wide assortment of reporting options: from simple KPIs through dashboards all the way to complex calculations using comparisons with historical data. It can do all of this without needing any additional software. Because zenon is designed to be a universal system, you can use valid data straight from production across any level. For instance, zenon Batch Control allows you to incorporate data from batch production into your production reports in real time and at just the touch of a button.

zenon in operation

À la Carte Reporting

equipping machines

47

engineering with zenon

48

physical

perimeter

application

data

 Runtime as a service  Integrated / domain users

 Binary data storage  Password protection for projects

internal network  Network encryption  Client authentication  Distributed systems

host  Latest operating systems and tools  Signed files and setups

policies, procedures, awareness  Cooperation with IT experts  100% in-house development

 = zenon security precautions

Various levels of security measures protect your automation system against unauthorized access. COPA-DATA develops the security features used in zenon in line with the standard IEC 62443 on “Security for industrial process measurement and control. Network and system security”.

The IIoT and Smart Factories require increasingly large networks. Apps are used in a variety of areas; project managers want to access production data online while devices need to be able to communicate with one another automatically. All of these requirements to open up systems to the outside world also create new risks. These days, engineers are often faced with the questions: what are the risks we need to think about and how can we counteract these threats?

Protection against unauthorized access Systems are only ever as secure as their weakest point. zenon undergoes ongoing security tests and is adapted accordingly. A large number of security issues can be solved right at the start of the project brief. Secure password protection, protection against unauthorized access, and encrypted data transfer are built in as standard in zenon – allowing for consistent security via simple engineering. zenon also allows project updates to be imported during the course of operations, enabling you to update system security without any downtime.

easy-to-configure user levels for individual authorization of user actions further reinforce access security.

The wide array of security measures include configurable communication ports and powerful 128-bit encryption for network communication. zenon Editor also comes with file signatures and a seamless history of changes. To give you the latest and unpublished insights into how we are tackling this issue, we are always happy to provide further information in a face-to-face meeting.

Built-in security for zenon COPA-DATA develops zenon in line with the standard IEC 62443 on “IT Security for Industrial Control Systems – Industrial Network and System Security”. zenon is also certified on an ongoing basis for the latest version of Windows. You can therefore rest assured that we comply with all the latest Microsoft security standards. zenon’s architecture and design meet all current security requirements. For simple and consistent user administration, zenon also supports Windows’ user administration concept with Active Directory and Active Directory Lightweight Directory Services. The

` Built-in configurable security functions save time and reduce risk

engineering with zenon zenon in operation

Validated Security under IEC 62443

equipping machines

49

` Convenient updates help you to keep up with the latest security standards ` Features provide support for the development of secure automation projects

additional information

` Secure system architecture

– in a universal system. Tailor-made applications contribute to greater flexibility and efficiency. With connectivity and transparency, zenon combines different disciplines in one system and creates an ergonomic environment for every user. Make zenon the core element of your digital strategy and secure a sustainable competitive advantage.

zenon in operation

zenon supports various user groups – ranging from machine operators to the CEO

equipping machines

operation

additional information

zenon in

zenon in operation

52

New facility

Future facility Old facility

Thanks to the openness of zenon, nothing stands in the way of business growth. Production landscapes that are heterogeneous and have been added over time can be visualized and controlled using zenon.

New facilities and components can be integrated without any problems.

53

production structures. Machines from various manufacturers, perhaps even specialized custom machines, now need to work together seamlessly. The next investments have already been planned. But which PLCs are to be considered?

Ultimately, the solution has to communicate with every piece of the puzzle. So which protocols does it support? And how complex is the necessary engineering work?

zenon speaks your language zenon offers over 300 drivers and communication protocols, allowing it to connect to a wide range of different hardware options and to incorporate new machines as seamlessly as existing hardware. No matter whether you have the latest standard or an outdated proprietary protocol, zenon speaks the right language.

Its flexible network solutions enable zenon to link new

and existing equipment and be integrated into older production environments with ease.

All zenon drivers and protocols are developed and maintained by COPA-DATA in-house – and can also be expanded and enhanced on request. This doesn‘t just produce many advantages with respect to security and performance – it also increases flexibility. Customer requests can be fulfilled quickly and purposefully, leaving users free to use whichever hardware they want.

`` Freely select the most suitable hardware `` Existing hardware can be integrated `` Link together equipment in heterogeneous environments `` Flexible integration of different plant areas `` Overview of the entire production environment

additional information

Invest in established structures PLCs, RTUs, energy meters, intelligent sensors – a whole host of hardware components are used at field level.

Often, they communicate in proprietary protocols and therefore have to cooperate with each other perfectly.

With zenon, you are free to choose which hardware you use. You create your plants to your requirements and zenon ensures reliable connectivity. This means that even heterogeneous production environments can be visualized and controlled in line with the latest standards. No device or machine needs to be replaced. zenon communicates with all components, provides you with an overview and control, and gives you a high level of investment security.

equipping machines

The company has grown considerably in recent years – and, in turn, so have its

zenon in operation

Modernize Developed Structures with Ease

zenon in operation

54

Logistics

Business processes

Production

zenon can be easily integrated into an existing IT and automation infrastructure. Direct communication between production and business processes enables the networking of all stages of production – from customer specifications to the finished product.

55

becoming more closely integrated in the value chain as a whole. From the customer request to the finished product, every single step should be linked together and, ideally, be able to communicate with each other independently. This then enables products with a batch size of just one to be customized. The first step towards achieving this is to seamlessly integrate production and business processes.

Consistency across all levels To ensure that the management level receives valid data in real time whenever possible, zenon offers comprehensive KPIs and reports as well as native interfaces for third-party systems such as SAP ERP or Microsoft Dynamics. Naturally, communication also functions in the opposite direction, allowing production orders to be processed and monitored more efficiently.

The direct communication between the production level

and planning level increases flexibility and productivity.

Unnecessary intermediate steps are left out, enabling you to pick up the pace and reduce the possibility of errors occurring.

The openness of zenon means that it can be integrated simply and seamlessly into the existing IT infrastructure. And the various ways in which it can be incorporated into cloud architectures provide you with more options and guarantee the optimal scalability of the entire system.

`` Identify potential for enhancing efficiency `` Efficient material flows and order processing `` Rapid response and well-founded decisions `` Traceability for complete quality assurance `` Consistent documentation

additional information

Link management and production When the optimal coordination of order management and production matters, zenon has the strengths to provide you with all the assistance you need. Above all else, it is able to communicate smoothly with IT systems. For example, production and process data can be transferred to the ERP system in real time, and information from the ERP is passed on just as quickly to production.

This integration with higher-level systems is a fundamental step towards a consistent value chain. When the information flow functions seamlessly, material flows and order processing can be tracked and planned more efficiently and decisions can be made faster and more confidently, based on well-founded information.

equipping machines

Industry 4.0 and the Industrial Internet of Things (IIoT) are resulting in production

zenon in operation

Batch Size of One: Production and Business Processes Perfectly Integrated

56

°C zenon in operation

Deutsch

°F English

°C 한국어

User interfaces can be adapted during operation to suit various user requirements. Languages, measuring units, and color palettes can be configured individually for each user.

57

and logs on to the machine with his details. All the text is displayed in his native language and the color combinations are adapted precisely to his needs. Individual settings that are offered automatically allow him to work comfortably and stress-free. And the fact that he suffers from red-green color blindness is no longer a challenge for him to overcome.

Switch languages, units, and color palettes online With its language tables, zenon makes it really easy for you to translate a project into as many languages as you like. While you are using it, all you have to do is click a button and the language will switch without having to restart the system. The same also applies to measuring units and color palettes. One click turns Celsius into Fahrenheit or adapts the colors to individual needs. zenon Chameleon Technology allows color palettes to be predefined for different applications and activated

with one click. This allows you to implement different day and night views or special views for people with redgreen color blindness, for example, with ultimate ease.

Settings for colors, measuring units, and languages can be saved individually for each user and automatically applied when they log in. Just as simple is the procedure for assigning color profiles to specific groups and situations, such as a separate profile for administrators or processes in simulation mode.

`` Ergonomic work environment `` Error prevention thanks to optimal usability `` Enhanced performance thanks to intuitive user interfaces `` Simple configuration of individual user profiles

additional information

Ergonomic user interfaces zenon provides you with exceptional flexibility when it comes to customizing languages, measuring units, and colors. Every project can therefore be flexibly adapted to various user requirements while it is under way and each user‘s personal settings are active as soon as they log in. This improves the ergonomics and usability of the user interface – and ensures that projects are easier to roll out and maintain across all areas and internationally.

For example, you could create the project in English, run it in Korean, and make it available to the German maintenance technician in his native language. All you have to do is create and maintain a central project.

equipping machines

Time to change shift. The colleague who is taking over the night shift arrives

zenon in operation

A Tailored User Experience

58

om t n iz a atio miz custo

cus tom izatio n

cust

zenon in operation

zenon project

io

n

ceo

Dashboards used across multiple locations

machine operator

All data relating to a machine

production manager

Overview of the entire facility at location A

Data can be filtered and displayed in accordance with user requirements. Information can also be tailored to the context and situation at hand so that only the necessary information is displayed.

59

And the production manager has completely different requirements to the operations manager when it comes to the level of detail needed to monitor KPIs. The CEO, on the other hand, wants to have an immediate overview of all locations. Satisfying all of these requests can seem to be a huge challenge – especially when the tasks and requirements are constantly changing.

Adapt information to the user and the situation Information based on the production data can be processed in zenon so that users only see the data that they actually need. For example, in a zenon Worldview, it is possible to zoom in from the entire plant to the individual parts of a machine. Depending on the zoom level, data is displayed with a different granularity. This allows critical alarms to be seen and located promptly.

In the overview screen, flashing can signal where the alarm is occurring, for example. The operator zooms into

the area concerned and immediately receives detailed information about the alarm and can therefore respond quickly and expertly to the unexpected events.

When it comes to reporting and trends, there are a whole host of options for the customized filtering and presentation of data. Depending on which information the user currently needs, the screen displays a different level of detail or presents the data with a different focus.

Reports can also be created and sent automatically.

`` Faster response times `` Positive development of performance and availability `` Focused and situation-based provision of key information

additional information

Only provide the information that the user really needs In zenon, you can precisely specify who receives which information and how. Depending on the role of the user, screens can be customized, personal filters defined in event lists, or different KPIs displayed, for example.

Each operator can also individually adapt the views they see to gain a better overview. zenon makes it possible to adapt information to a specific situation based on the context. This increases the ability to respond, for example in the event of an alarm, when requirements change temporarily and have to be dealt with quickly.

equipping machines

The machine operator requires different information to the production manager.

zenon in operation

Operation: User-Defined and Context-Sensitive

zenon in operation

60

Two-handed operation via Multi-Touch provides machine operators with support for safety-critical inputs.

The operator must activate a release with one hand so that the corresponding action can be carried out by the other hand.

61

working in this new area of the company for a short time but has found operating the machines no trouble at all. In the same way as he does on his smartphone, he can switch between views with swipe gestures and zoom into sections using two fingers. The tables and buttons are easy to use – even when wearing gloves.

Deploy touch and Multi-Touch with purpose Familiar gestures such as swiping, panning, zooming, scrolling, etc., are built into zenon. The individual configuration options in zenon make it extremely easy to optimize user interfaces for touch and Multi-Touch operation. For example, the size of a button can be selected so that it can be used without any problems when wearing safety gloves. Or enable two-hand operation via Multi-Touch. This feature is particularly helpful during machine operation when making safetyrelated entries as it prevents unwanted actions. For

example, when performing safety-critical actions, the operator can be first required to activate an unlocking mechanism with one hand in order to then be able to perform the operation with the other hand.

Even 3D views of plants can be displayed with ultimate clarity and be operated easily and intuitively.

`` Shorten training time `` Reduce error rates `` Maximize operating safety `` Optimize user-friendliness

additional information

User-friendliness and operating safetymade perfect User interfaces that have been created with zenon can be operated intuitively and ergonomically without a keyboard or mouse. This is because the gestures familiar to us all from our smartphones and tablets can also be used in the same way in an industrial environment.

There is no need for failure-prone peripheral equipment such as mouses and keyboards, as all entries can be made quickly and directly on the screen. This enables you to increase the user-friendliness and safe operation of your plants. Training time is also shortened thanks to the intuitive touch operation feature.

equipping machines

The machine operator has learned the ropes quickly. He has only been

zenon in operation

Safe Operation with Touch and Multi-Touch

62

5204 Pasteurizer

zenon in operation

Inspector

11138

Filler

12121

Depalletizer

5302

11330

BottleWasher

Palletizer

17298

Unpacker

25927

7563

Crate Washer

Labeller

Packer

7412

Depalletizer

5302

Palletizer

17298

The zenon Worldview includes an overview of the entire facility, but may also, if required, automatically include detailed information when the zoom level is increased.

63

important to maintain an overview, whereas on the other, keeping track of the details is essential. It can be very difficult to marry the two. But if you’re able to quickly find your feet and zoom in from the big picture right down to the specific details with ease you can respond promptly and correctly. The zenon Worldview offers this: an overview of the entire production plant and – on the same screen – in-depth information.

Optimal overview with the zenon Worldview No matter how big the screens you are using are, the zenon Worldview provides you with an optimal overview of the entire production plant. zenon makes it possible to adapt the displayed information to the current zoom level and the required level of detail automatically.

Individual plant parts or production locations can be selected directly in order to obtain specific information.

For example, an alarm is easily identified in the zenon Worldview screen because it is flashing. The user then knows immediately what has generated the alarm, can access detailed information and instructions for

resolving it within seconds and can, therefore, respond quickly and confidently.

Tip: by incorporating GIS data or geographical information, the zenon Worldview can also be displayed as a map.

`` Overview of the entire production environment `` Level of detail based on information requirements `` Versatile: for large production plants, various locations, etc. `` Faster response times

additional information

Keep an eye on the entire production environment With the zenon Worldview, you can retain an overview of your entire production plant on one screen. Even vast plants can be visualized on a single screen. Users have the entire plant in view – and can zoom in on the details on the same screen when required. This helps to locate alarms in an instant and receive detailed information on individual machines or locations at any time. And when combined with Multi-Touch, the zenon Worldview provides you with a simple, reliable, and user-friendly tool to ease the stress of your working day.

equipping machines

Keeping an eye on a vast production plant can be very challenging. On the one hand, it is

zenon in operation

Overview with the zenon Worldview

zenon in operation

64

zenon Batch Control offers an integrated reporting tool which allows you to obtain reports on completed batches at the touch of a button.

The graphical user interface enables user-friendly recipe creation without any need for programming.

PLC 1

PLC 2

PLC 3

zenon Batch Control is independent of hardware and can operate with various PLCs.

65

a need that can easily be met when configurations can be changed quickly and directly at the plant in batch-based production. Flexibility and productivity increase when the shift manager is able to check and adapt recipes without any programming knowledge. This is true whether in the food & beverage, pharmaceutical, or chemical industries.

Simple handling and seamless integration The graphical interface in zenon Batch Control guarantees intuitive operation. Batch processes are easy to create, modify, and launch without any programming.

And while the processes are under way, the operator can see the current status of the recipe at any time. Batch documentation and reports can be called up at the touch of a button and batch releases can be issued promptly after completion.

As zenon is designed to be independent of any hardware, zenon Batch Control can also be used flexibly and irrespective of the control hardware that has been selected. Integrated seamlessly into zenon, the Alarm Management, Audit-Trail, Trends, and Reporting features are available for batch processes. In addition, there is a comprehensive user administration function, which can be controlled with fine granularity and meets the stringent FDA requirements.

With its ease of operation, high security, and the option to access recipes via API, zenon Batch Control enables you to adapt to changing market requirements quickly. `` Increase flexibility and diversity `` Respond to rapidly changing market requirements `` Create or modify batch recipes without programming knowledge `` Validation efficiency and cost savings thanks to faster validation

additional information

Flexibility brings efficiency in validation processes zenon Batch Control makes flexibility possible even for companies operating in strictly regulated environments such as the pharmaceutical industry. zenon Batch Control was developed based on the standard ISA-88. Accordingly, the process for a batch recipe and the execution of the technological function on the machine are separated.

This provides maximum flexibility and minimizes the amount of validation work required. Naturally, zenon Batch Control also meets the numerous requirements of ISA-88 with respect to quality assurance. As a result, zenon supports continuous improvement, enhances efficiency, and assures the quality of the products.

equipping machines

There is market demand for individual products, often in small batches. This is

zenon in operation

zenon Batch Control

zenon in operation

66

zenon allows you to flexibly and quickly modify recipes in the Runtime. This means that you can adjust parameters quickly, e.g. when changing over to a different product.

67

The product to be produced changes constantly – and so too do the associated manufacturing parameters. Equipment has to be converted on a daily basis.

However, this doesn‘t pose all too great a challenge to the machine operator when parameters such as bottle size, filling level, etc., are supplied at the touch of a button, meaning that machines can be converted in an instant.

Have everything under control with the Recipegroup Manager The Recipegroup Manager is flexible in terms of its design and can be incorporated into different production environments with ease. Reading and writing recipes are two central functions in the Recipegroup Manager.

Writing a recipe causes it to be transferred from the management system to the controller. zenon then receives feedback from the PLC stating whether the recipe has arrived. When values are read from the controller – known as teaching – they are loaded into the recipe directly. Defined minimum and maximum values are taken into account. Recipes can also be exported and imported.

The operator can view the status of a recipe – for example, “Development”, “Released”, or “Locked” – at any time. The creation, execution, and modification of recipes is linked to the integrated user administration function. Corresponding actions can therefore only be performed by authorized personnel. The integrated versioning of recipes ensures an excellent overview and precise traceability. The strict requirements for safety and reproducibility in industries such as pharmaceutical, food & beverage, and chemical can therefore be satisfied with an out-of-the-box solution.

`` Reliable operation `` Clear and transparent `` Considerable time savings

additional information

Configure recipes in zenon Runtime zenon offers a Recipegroup Manager that can be custom-configured and requires no programming work.

The Recipegroup Manager is easy to operate, saving training time for employees who are responsible for the process. And the integrated user authorization function combined with the user-friendly, intuitive design ensures maximum operating safety.

equipping machines

Subcontractors in the pharmaceutical industry need to be fast and flexible.

zenon in operation

Manage Recipes Intelligently

68

zenon in operation

KPIs

Processing

Filtering

Historian

Pre-processing

Data input

With zenon Historian, data is recorded and preprocessed without interruption so, even when data volumes are high, zenon delivers high-performance reporting. The data can be used to generate informative reports and highlight trends.

69

the current production data, collated in production and visualized in real time. Plus the energy consumption data from the last week as well as the OEE values. The user can track all data precisely, as well as create reports when required and make them available to other users. Everything is therefore provided in one system, creating a complete database of all operational information.

Complete data recording The zenon Historian is integrated in the software system and carries out archiving in zenon. It offers a whole host of connection options to various archive stores and databases, including the cloud. With functions such as archive compression, it is able to process even large amounts of data with a high level of performance.

Archiving takes place flexibly and in real time, depending

on requirements. Values can be written to archives cyclically, based on events, or upon a change.

In order to eliminate the risk of data loss, archiving in zenon is also designed with full redundancy. The complete data record forms the basis for displaying live data, such as current KPIs, or the basis for informative historical reports. Trends enable values to be displayed in detail in relation to the time at which they were recorded. zenon ensures that all key data is permanently stored and is available for certification and reports at all times.

`` One interface for both historical and live data `` High performance, even with large amounts of data `` Guaranteed data consistency without loss

additional information

Call up real-time data and historical data at the same time Complete and effective data archiving is an important concern for many production areas. An important advantage of archiving with the zenon Historian is that it is seamlessly integrated in the software system.

Therefore it is extremely easy to call up real-time data and access historical data at the same time. zenon ensures that batches and production stages, shift results, and processes remain replicable and meet stringent requirements, such as those of the FDA. zenon is able to access archived data quickly and reliably and impresses users with its high performance, even when handling large amounts of data.

equipping machines

The user has all the important data prepared in view on one screen. For example,

zenon in operation

Secure Data Archiving

70

zenon in operation

Energy usage

Production output

â‚Ź per unit produced

Energy costs

zenon allows you to shed light on the relationship between energy usage data and production output.

When used in conjunction with energy tariffs, you can analyze the data against informative KPIs, such as energy costs per unit produced.

"Golden batch"

OEE "Golden batch" Current usage

OEE Current batch trends can be compared with those of previously recorded optimal batches.

71

machines deliver their data automatically and many sensors still have to be read manually. Notepads and spreadsheets rule rather than automated processes. However, all this could be done at the touch of a button – including the automatic sending of reports. Or, at least, it could be if you have the right automation software in place.

Comprehensive reporting tool The comprehensive report function in zenon impresses with its wide variety of options. When it comes to displaying online values and historical data, the Report Generator and Report Viewer come into play. The presentation of two historical time periods provides direct ways of comparing KPIs. You can even evaluate alarms, events, batch data, shifts, and many other aspects directly in zenon using the reporting tools.

Reports can be presented graphically in real time or as historical analysis, displayed online, or even sent automatically via e-mail. zenon Faceplates enable you to bring together different evaluations and perspectives in a single screen, resulting in numerous comparison

options, dashboards with tailored KPIs, and much more besides.

The reporting options are enhanced perfectly with the zenon Analyzer, which processes, distributes, and archives data from different sources in a targeted manner.

`` Informative reports prepared in graphical form `` Direct export and send option `` Integration with the overall production process `` Report creation directly from production `` Simultaneous evaluation of historical data and live data

additional information

Generate informative KPIs Many key performance indicators (KPIs) only deliver strategically valuable information when they are linked sensibly with other parameters, such as production figures. Integrating zenon into the overall process enables links like this to be established easily, and therefore relative KPIs to be calculated. For instance, with zenon, you can track the energy costs that are incurred for each production unit.

equipping machines

Reporting on energy consumption is often demanding and tedious. Not all

zenon in operation

Rapid Reporting, Clear Analysis

zenon in operation

72

zenon can be used to secure large volumes of data cost-effectively and safely in a public or private cloud.

The data can then be retrieved from the cloud, as required.

73

In many companies, production data needs to be recorded, saved, and archived for the long term at regular very short intervals. To do this, a wide variety of media, ranging from network drives and external hard drives to magnetic tapes, are used.

The disadvantages of these methods are well documented: storage space can be expensive, access isn‘t immediate, and copies must be made before the media fails.

Plus, whether the production data that has been saved can be read back again is often

zenon in operation

Big Data and the Cloud

Archive large amounts of data securely Numerous functions in the archiving in zenon provide assistance when handling very large amounts of data.

The high level of connectivity that zenon offers enables data to be obtained from a large number and wide variety

of sources, to be saved as required, and to be used for the purposes of comprehensive reporting at any time.

Big data applications are characterized by high performance in zenon. Its archives can reliably manage and read back even large amounts of data. The large volumes collected can be used as a database for further evaluations, such as Predictive Analytics.

`` Sustainable data archiving that can quickly be read back `` Option for Predictive Analytics applications `` Cloud integration negates the need for a local archive for large data collections `` Flexible use of public and private cloud

additional information

Where should the masses of data go?

Numerous industries need to ensure they have a detailed archiving process in place due to legal or regulatory requirements. This often produces large amounts of data and the problem of physically storing the data archives.

CDs, external hard drives, magnetic tapes, or paper are no longer suitable from a technical perspective. zenon profits from the advantages of a public or private cloud to ensure high-performance and clear archiving, enabling you to move away from dusty archives, large storage rooms, and the risks of having media that can no longer be read.

Archiving with zenon in the cloud means that all data can be read out quickly and can be used by other applications. It doesn‘t matter whether it is from the last production shift or several years old – with its consistent user interface, zenon ensures maximum usability and ergonomics.

equipping machines

unclear. So what‘s the alternative?

zenon in operation

74

SITE A

SITE B B

SITE C

SITE D B

SITE A

SITE B B

SITE C B

B

B

SITE D B

A connection to the cloud allows you to create dashboards which cover multiple locations and which include real-time energy usage data from various production sites.

B

75

anywhere – or compare two locations in real time. The data is stored directly from production in a cloud-based database and called up from there by the reporting tool. All KPIs are available at any time and are always up to date.

The cloud: much more than just additional storage space Increasing amounts of data are collected and then need to be saved securely. A cost-effective and highly scalable option is offered by cloud storage. When zenon is used in conjunction with a cloud connection, many more options become available than would be the case when large amounts of data are simply archived.

Data from production that is saved in the cloud can be read out again at any time and used in real-time KPIs, historical comparison reports, etc. You therefore quickly benefit from cross-location reporting, can obtain information anytime and anywhere at the touch of a button, or make key data available to employees virtually in real time. The combination of zenon and Microsoft Azure offers you an innovative and stable basis for your individual reporting. zenon in the cloud zenon provides you with several ways of using cloud technology in your company. For example, an outsourced archive can be set up in the cloud to save historical data.

Combined with a gateway, you can also transfer data directly from the controller to a cloud database and use it for live dashboards across several locations. The

high security standards and encryption technologies incorporated into zenon ensure secure transfer and data storage.

`` Cost-effective scalability of data archives `` Dashboards and reports across locations `` Use of historical and live data `` Benchmark several plants and locations

equipping machines

Get up to speed on the current data from all your equipment anytime and

additional information

You can now carry out reporting across locations extremely quickly and easily.

zenon in operation

Reporting across Locations with Cloud Technology

zenon in operation

76

ceo

production manager

shift manager

Depending on the type of application and user requirements, zenon provides various options for accessing production processes and information on the fly. This allows the CEO to access figures relating to multiple company sites, the production manager to maintain an overview of production lines at all times, and the shift manager to receive alerts directly to his or her smartphone device, for example.

77

immediately when incidents occur. That’s because he now receives the most important KPIs and alarms conveniently and quickly on his smartphone. And even if he can’t respond straight away, alarms don’t go unanswered. In such cases, the alarm is simply sent on to the next person in the communication chain – this all takes place automatically and can be configured individually.

Mobile solutions with zenon zenon offers various options for accessing production processes wherever you are which, when combined, provide an optimal mobile solution. zenon makes available compatible applications for iOS, Android, Windows, and the web. The information provided can be configured to suit the user and their requirements.

The zenon Web Server brings projects to the intranet or Internet. Without having to make any extra changes to the project, zenon projects are available for visualization via zenon Web Client or as HTML5 application for the zenon Web Engine. The zenon Terminal Server also brings comprehensive projects to lower-performance devices.

What’s more, certain applications are available as zenon apps for tablets and smartphones – take the zenon Notifier App, for example. In conjunction with zenon Message Control, it enables alarms to be acknowledged on a smartphone.

`` Rapid response `` Access to production anywhere and anytime `` Individual adaptation to user requirements

additional information

Rapid access to real-time data anywhere and anytime zenon ensures that alarms and information can be communicated via many different means – e-mail, SMS, voicemail, or smartphone app. At the same time, it enables secure access to current production data anytime and anywhere, making it easier to respond quickly to faults or incidents. All you need is a smartphone to read out performance values, respond to alarms, deal with problems proactively, and remain able to take action at all times.

equipping machines

The production manager cannot be everywhere at once. But he still responds

zenon in operation

Always up to Speed

zenon in operation

78

IEC 62443

Encrypted communication

User authentication

Patch management Firewalls

zenon provides you with crucial technologies to protect your production sites from cyber attacks. Key components of these technologies include integrated user administration and authentication, robust encryption mechanisms, and much more.

79

live data anywhere and anytime from their smartphones. But how do they know that only authorized employees have access to current production figures and to data in the cloud? Smart Factories and IIoT require expert knowledge to ensure software is as secure as possible and to prevent unauthorized access.

How zenon supports your security precautions For many versions, it has been possible to update zenon while production is under way without the need for downtime. This makes it easy for you to continually benefit from up-to-date security standards and new features.

When it comes to user authentication too, zenon is on your side. In addition to zenon user administration, Active Directory is also supported. Logins and access rights can then be conveniently linked to Windows user authentication. Easy-to-configure authorization levels ensure that only users authorized to do so can perform an action. It goes without saying that the entire communication chain is highly encrypted, provided the connected machines support this. You are, therefore, not only safeguarding communication within the company, but also safeguarding access via mobile communication.

`` Secure operation for IIoT and the Smart Factory `` User authentication and authorization for access security `` Make security updates and upgrades while production is underway

additional information

Only up-to-date systems are secure systems Production plants used to be pretty much isolated from the outside world. Yet IIoT and Industry 4.0 require a wide range of connections and ports for external access.

As a result, the topic of cyber security is becoming more and more important for production plants. Cyber attacks are becoming increasingly real risks. And gaps in security need to be detected and closed. But when doing this, the specific conditions of production plants also have to be observed. For example, installing a security patch must not lead to production being stopped. The argument that you should “never change a running system” and put off updates for as long as possible if production is running smoothly now represents a major risk factor. Gaps in security need to be closed early on to ensure that the company‘s regulations are always up to date.

equipping machines

The new web view for production data is online. Employees can now access

zenon in operation

The Smart Factory Requires Security

80

zenon in operation

10,897 m

>2 h 1,803 m Without zenon

With zenon

~20 min

8-hour work day

~ 5walking km/ h speed

zenon shortens the distances a production employee has to walk between machines during the day. The time saved in this way can then be used more efficiently.

81

day when he has to walk from machine to machine to perform each action, read measured values, and deal with each alarm? Before zenon, nearly eleven kilometers were recorded on one packaging line for one machine operator over the course of one day. With zenon, these distances were reduced significantly.

Multi-Project Administration in zenon Projects in zenon make decentralization and horizontal transparency exceptionally easy. With the aid of MultiProject Administration, you can create, for example, a project package consisting of several small projects, rather than one large project. This enables projects from different areas of production to be brought together into one master project in a clear and structured manner. You can launch, monitor, and control several

visualization projects on a PC at the same time, and the optimized distribution of the workload in a decentralized structure provides a better overview as well as increased performance and security.

Multi-Project Administration also makes zenon circular redundancy possible. In this special form of seamless redundancy, a project server also functions as a standby server, and the other way round. With just a small amount of hardware, this ensures data consistency and reduces the risk of failures occurring.

`` Added transparency and improved overviews `` Shorter distances covered, therefore saving time `` Efficient project changes and maintenance

additional information

Ergonomic software for faster responses The solution to take the strain off operators is known as horizontal transparency: this makes it possible to access and operate the project of the local machine and the projects of other machines on the same device. This cross-project operation enables the user to respond to problems in production quickly without having to cover large distances in the production hall. This is made possible with Multi-Project Administration in zenon.

With respect to project changes, Multi-Project Administration also ensures that hardly any downtime is required. What’s more, risk, maintenance, and revalidation work in strictly regulated environments remain easily manageable in the event of updates.

equipping machines

Have you ever tried to estimate the distance a machine operator covers each

zenon in operation

Cut Down on Distances Traveled through Decentralization

zenon in operation

82

ISO 50001

Line management for one line

Step 1

Line management for two lines

Step 2

ISO 50001

Energy management in accordance with ISO 50001

Cloud integration

Step 3

Step 4

The high scalability of zenon allows you to grow on a step-by-step basis. For example, you can start with line management for a single production line, and then expand production in the future to include an energy data management system, complex OEE calculations, integration with the cloud, and so on. With zenon, there are no limits to what you can do.

83

solution is often sufficient for a production line. But what will happen later on?

The company will grow, new tasks will arrive, and more machines will need to be added. And how will you ensure informative reporting? zenon’s high scalability allows you to grow one step at a time with ultimate ease.

Start small, grow with purpose zenon enables automation projects to start small and evolve over time – and software versions – to form a high-end solution. So you can develop your production plant one step at a time, and the automation environment will grow along with it.

New production plants are exceptionally easy to integrate and expand. With zenon, scalability doesn’t just mean growth in terms of size, but also constant growth in terms of functionality. For example, you might start with an OEE calculation and then later extend your

application to include energy efficiency analysis, batch control, alarm analysis, or many other aspects, even in the same project.

Because projects remain consistent, project components complement each other and can be reused.

So you can take a basic project and develop it into a sophisticated application, including mobile solutions that pull in data from the cloud or from other sites and issue diagrams containing comprehensive batch reports.

With zenon, the doors to growth are always open.

`` Reduced financial risk `` Room for potential growth `` Step-by-step investment

additional information

Step by step A limited time frame and tight budgetary constraints often define the boundaries and limits in project management. zenon is designed in a scalable manner to allow projects to grow step by step. This keeps the cost risk low, as investments are only made when the development of the company needs them. For example, you might start with just a few machines, with their KPIs displayed centrally in a small control room. Later, you implement a simple energy management system. And, as time progresses, you allow the system to grow and evolve.

equipping machines

When it comes to automation, you need to look far ahead. At the start, a basic

zenon in operation

High Scalability

84

zenon in operation

Effort required with system X

Effort required with zenon Update 1

Update 2

Update 3

Updates can be performed efficiently with zenon. With zenon’s future-proof compatibility, projects from older versions can be maintained with little effort. In addition, the equipment can continue to run undisturbed during the update.

85

systems. However, the Industrial Internet of Things and requests for real-time reporting are turning poorly maintained and obsolete operating systems into gateways for malware. But how should systems be updated? How long will systems be down? And will all projects run as seamlessly afterwards as they did before? With zenon, they will run better than ever.

Retain version-independent flexibility zenon is always backward-compatible for several versions and allows you to work with multiple versions without any problems. For example, you can create a project in version 7.50 and then run it on a Runtime application with zenon 7.00. Different versions can also be used in a network at the same time. So you can use the right version for your requirements and update at an affordable price only when you need to.

When you switch to the latest version, you can rest assured that all your projects will continue to function without any problems – as well as being able to benefit

from new features and security standards. All data, such as from the Alarm Message List, Chronological Event List, or Recipegroup Manager, is also version-independent and can be used in any version without any problems.

So you benefit from new features and solutions without losing the project work you have already completed and your investments remain secure for the long term.

`` Long-term investment security `` Always up to date with security requirements `` Benefit from the latest functions `` Seamless transition, no downtime

additional information

Use projects over the long term Regular updates and upgrades are necessary in industrial plants in order to satisfy the latest security standards.

This isn’t just true of operating systems. Even the visualization should be updated regularly. zenon makes this exceptionally easy, as it has been designed with future compatibility in mind. Projects from an older version will still run in the brand-new version and can also be maintained there without a great deal of effort.

The plant can generally continue with production untroubled while zenon is being brought up to date.

equipping machines

“Never change a running system” has long been a maxim for productive

zenon in operation

Future-Proof Projects with Seamless Updates

86

Archive

Server

Server outage

zenon in operation

Standby

Server Interruption-free data recording

Process

The seamless redundancy in zenon guarantees interruption-free data recording, thus preventing data loss even in the time between a server outage and switchover to the standby server.

A-Server B-Standby C-Client

B-Server C-Standby A-Client

C-Server A-Standby B-Client

As per the circular redundancy concept, the server of project A is also the standby server for project B and client for project C, thus reducing costs as well as the risk of outages in the network.

87

in documentation required by law cause a lot of stress and involve high costs.

Redundant systems guard against this and ensure continuous production should the worst happen. With zenon, you won’t even notice the problem – nothing will be lost and production will continue to run seamlessly. And all with low hardware costs.

Seamless redundancy and circular redundancy zenon combines seamless redundancy and circular redundancy to form a highly fail-safe system. In the event of a server failure, seamless redundancy transfers all tasks and data to a standby server. This records all historical data in parallel while production is underway, ensuring that in the time between the server failure and switch to the standby server no data is lost.

With its “rated redundancy”, zenon enables a particularly intelligent redundancy mode to be achieved.

This involves analyzing and rating the quality of the data flow. If defined criteria are not adhered to, a standby server that can ensure a higher data quality will take over straight away.

If several projects are running in parallel or in a network, you can implement highly secure and extensive circular redundancy with just a small amount of hardware. zenon can manage several projects at once on one Runtime computer. With circular redundancy, the server of project A is simply also used as the standby for project B and the client for project C. This enables you to significantly reduce the failure risk for multiple projects as well as keep costs manageable.

`` Data security and consistent data flow thanks to intelligent redundancy modes `` Failure safety `` Cost savings because less hardware is required

additional information

Data consistency and security The redundancy concept from zenon primarily provides you with two advantages: it makes sure that operation continues perfectly without downtime, even in the event of a server failure. What’s more, zenon ensures that no data is lost. zenon’s seamless redundancy maintains the flow of data, even when switching between the server and standby server. The security and consistency of data is therefore guaranteed.

equipping machines

A server failure can become very expensive: downtime, data loss, and gaps

zenon in operation

Redundancy and Secure Data Flow

zenon in operation

88

Quick overviews, flexible input, and location-independent alerts guarantee an optimal level of control over the facility.

89

But discovering and locating faults in large plants is just not that simple.

In such cases, assistance is provided by alarms that use distinct symbols to indicate when a limit value has been exceeded, images which allow you to zoom into the source of the alarm in detail, and useful detailed information about the alarm.

Smart alarm administration increases efficiency zenon makes it easier to discover faults and their causes quickly, and therefore to respond to incidents and problems promptly. The ability to respond quickly is essential when it comes to reducing plant downtime and ensuring a high level of productivity. Yet, at the same time, it is important not to trigger too many unnecessary alarms. zenon prevents this with functions such as threshold values and dynamic alarm limits.

Incoming alarm analysis sheds light on the alarm causes and frequency of certain alarms. As a result, you obtain valuable information on how to improve your OEE.

provides documented evidence that alarms have been registered and processed. Operators record the causes of alarms immediately on site in predefined context lists and customizable filters guarantee you an overview of all alarms. In addition, with the optional Message Control module, you can issue alarms to staff via various communication methods and according to different criteria including who is on shift.

`` Rapid response times and increased productivity

equipping machines

If something goes wrong, it is important to respond quickly and correctly.

zenon in operation

Manage Alarms Intelligently

`` Improved OEE `` User-friendly overviews and communication channels `` Compliant with alarm administration standards such as ISA 18.2 and IEC 62682

additional information

Clarity and rapid response times Alarm administration is integrated consistently in zenon.

Even if production plants have been developed over time and have a range of different equipment, zenon can be used for alarm administration without the need for additional software components.

Alarms can be clearly arranged and grouped.

Together with the zenon Worldview, clear views are produced in which the level of detail can be finely adjusted. The feature requiring you to acknowledge and delete alarms, which can be configured as you wish,

zenon in operation

90

Machines and equipment are controlled and monitored with zenon. zenon supports flexible machine configuration, secure connectivity, and optimum usability for the operators. With zenon, machines and equipment can be seamlessly integrated in smart environments. zenon contributes to higher Overall Equipment Effectiveness, increases customer satisfaction, and provides a real competitive advantage.

additional information

machines

equipping machines

Equipping

92

EN

equipping machines

DE

The design of the user interface supports the machine operators in their work and makes operation of the machine safer. With zenon you can implement Multi-Touchenabled projects and the switching of languages and color palettes both quickly and efficiently.

93

Optimum Usability – Efficiently Executed

User interfaces are created quickly, covering multiple projects and conforming to the chosen corporate design. Without onerous programming tasks – featuring easy configuration and with consistent reuse of elements that need be created only once. The machines are now so easy and safe to operate that the time required for staff training is kept to a minimum. The machine operators love the user-friendly touch operation – as

Efficient engineering of excellent user interfaces Functional user interfaces, which comply with stateof-the-art usability standards, are easy to create in the zenon Editor through configuration. You see immediately how the interface will look on the panel. zenon provides

you with a range of functionalities out-of-the-box which ensure user-friendliness. For example, you can easily program your interfaces to accept Multi-Touch gestures or use templates in order to create complete screens with a single mouse click.

The central symbol administration, styles, and much more make it easy for you to design your projects efficiently and consistently. You can reuse designs and projects over and over again – even across multiple projects – and you can then make subsequent changes quickly and easily.

`` Individual customer requirements fulfilled efficiently `` Easy transfer of elements from project to project `` Intuitive and responsive user interfaces ensure enthusiastic customers `` Create consistent designs with minimal effort

additional information

Impressive user-friendly operation The Human Machine Interface (HMI), as a connection between human and machine, ensures safe operation, prevents faults, and guides the machine operator through all processes, even if he or she is not yet familiar with the machine. The interface of the operating panel must therefore impress users with exceptional usability and deliver operating security; security being a central sales argument for modern machines.

HMIs using zenon allow you to benefit from numerous user-friendly functionalities, such as the simple internationalization capability with the option to switch between languages and measuring units, the native Multi-Touch technology, and the live switching of color palettes. zenon provides reliable support to machine manufacturers in the efficient implementation of a diverse range of requirements and the perfect fulfillment of customer needs.

equipping machines

responsive and intuitive as you would expect from a smartphone or tablet.

94

im ta tio a d p (o

equipping machines

automate d en gin eer ing e d n e gine omat eri aut ng

Automated engineering

p na ort l)

zenon Editor

Different system configurations can be implemented in custom visualization and control projects with the zenon Editor using automated procedures.

95

Modular Systems via Automated Engineering

Machine and facility builders have to overcome a wide range of challenges. For example, customers demand machines with ever greater customization and a modular approach to design. At the same time, price is a significant competitive factor. The custom programming of visualization and control software is no longer sufficiently

Automated engineering with zenon Recurring project processes, such as importing variables, elements, etc., or the creation of images, can be easily automated using zenon. Monotonous tasks in which project developers often tend to develop a lack of

concentration and make mistakes can be completed automatically.

You can even adopt configurations from external upstream systems in your engineering with zenon.

These are then automatically processed in the project.

You can even automate the creation of entire projects, thus building individually manufactured and special modules for facilities, where visualization no longer requires a great deal of effort. To summarize, you will be able to noticeably accelerate the engineering process with automated engineering, even when there are many different machine variants and custom configurations.

`` Reduce time to market with optimum efficiency `` Modular machines and systems for custom market requirements `` Competitive advantage through costeffectiveness and flexibility

additional information

Build modular systems and configure customized machines The modular construction of facilities and machines enables highly customized configurations. This, in turn, ensures high flexibility and quick responses to market requirements – even up to finished products with a batch size of one. Businesses that wish to remain competitive will have to implement a high level of automation even at the engineering stage.

With zenon, you can apply automated engineering for the efficient development of visualization and control projects – even for numerous different machine versions and custom configurations. Consistent modularization reduces your time to market, optimally supported by fast and flawless engineering. As a machine manufacturer, you can not only remain competitive in a hotly contested market, but also gain significant advantages.

equipping machines

competitive. The solution is automated engineering.

equipping machines

96

Energy efficiency

Batch output

Informative reports, on completed batches, for example, can be created directly at the machine.

Quality

Quality

Performance

Availability

OEE

97

Access Reporting at the Machine

How much energy does the machine use per production unit? What does that mean in terms of cost? Was the temperature of the just-produced batch still within the green range? Easily understandable figures, generated and displayed on the panel in an aesthetically appealing format, involve all members of staff in efficient management.

Supply tailored information Tailored reports appearing on your operating panel can be implemented with a very small amount of engineering effort because the reporting is seamlessly integrated in the zenon software system. This means that there‘s no need for any additional software tools. Configuration, data collection, and preparation are carried out efficiently and consistently in zenon. Variables and other project

information need only be created once in the project – and you can use them straight away for reporting.

Reports are prepared so they are immediately usable and are presented in a clear and graphically elegant way.

As a result, you can turn your operating panel into an effective tool for displaying key figures and data relating to production.

`` Create informative KPIs and reports with ease `` Efficient engineering of reports displayed on the machine panel `` Graphical processing for easily understandable presentation

additional information

Comprehensive reporting at all levels zenon makes it possible to supply machine operators in the production process with important information. The panel becomes an information interface, providing data relating to previous production batches, energy usage, and much more.

The comprehensive reporting options can be activated and displayed directly on the machine‘s operating panel.

Operators will thus have all the information they need in a timely manner, presented in an easy-to-understand format. The machine operator can immediately access the production data of the batch just completed and forward batch reports. Of course, reports can also be distributed to specific personnel within your company and subjected to further processing, as necessary.

equipping machines

With zenon, you can provide comprehensive KPIs and reports right at the machine.

equipping machines

98

After writing the recipe, zenon makes sure that all recipe values are set correctly on the controller.

99

Flexibly Configure Recipes

Recipes are at the heart of production in many industries. Custom configuration and high flexibility are particularly important for machine manufacturers. The rules regarding when a recipe is still in draft status, released, or suspended must be defined repeatedly by machine manufacturers. Moreover, rules about the way in which a recipe can be used or whether multiple recipe versions are permitted for simultaneous use are also

Implement recipes flexibly The templates provided ensure quick and reliable engineering. Freely designed layouts offer all the necessary space for customized, creative implementations.

The status of a recipe (e.g. draft, released) can be set according to your specific needs. You are also free to define status handling rules. Recipes can be imported flexibly from other systems and exported again for further processing, as necessary.

Of course, recipe handling in zenon complies with all important international safety specifications. It can be linked easily with user administration and is easy to configure. You can therefore define the operating tasks and who should be doing them without any problems.

The freely configurable Recipegroup Manager allows you to manage even the most complex recipes with confidence. You don‘t need to have any programming expertise because recipe creation is performed in the usual zenon way – very easily and by configuring parameters.

`` Flexible recipe handling `` Gain a competitive edge through custom solutions `` No programming necessary

additional information

Smart recipe management For zenon, writing a recipe means to transfer it to the controller. Confirmation from the PLC is then required, signaling that the recipe has been received. This ensures that production can proceed exactly according to plan.

You can define how you manage your recipes according to your specific needs. Every machine builder has their own approach to dealing with recipes. Custom solutions with regard to recipe management set each solution apart from its competitors and provide a competitive advantage. These requirements can be fulfilled in an easy and flexible way with the zenon Recipegroup Manager – without additional software or extra programming.

equipping machines

frequently subject to tailoring or revision.

100

zenon project A zenon project can be updated and modified without the need to consider or apply updates, upgrades, or patches.

zenon version The zenon version can be upgraded without having to recreate the project.

Operating system zenon allows patches and upgrades to the underlying operating system.

equipping machines

PC/panel hardware PC/panel hardware can be replaced, and zenon can continue running on the new hardware.

Life cycle of machines

Over the entire life cycle of the machine, updates to the operating system, hardware, and software version will be required. The zenon project remains consistent during the entire life cycle or can be adapted to add particular functions.

101

Stay Compatible – across Generations of Machines

The customer needs a software update for his aging filling line. He wants to minimize security risks while also reaping the benefits of the latest version. But is that so easy to achieve? Is an update not risky for a facility which is running with no problems? For

Easy maintenance of older projects With zenon, it is possible to use different Runtime versions on the same system at the same time, and they interact with each other. This allows your customers to use their different machine generations together in a network. As a result, even with a highly heterogeneous machine landscape, comprehensive line management or complex OEE calculations can be carried out with ease.

In the Editor, you can convert older projects to the latest version with no risk of any losses. In addition, you can also use the current Editor version to easily create a project compatible with an older Runtime version. This way, you can use and renew projects over many years.

Existing engineering services are easily incorporated into the new version and do not have to be configured again.

Upgrades and updates can be performed quickly and easily with zenon. This makes it easy for you to maintain your systems at the current standards of safety and performance.

`` Low risk and high efficiency for software updates and upgrades `` Longevity of projects and sustainable serviceability `` Use the convenience of new zenon versions for older projects as well

additional information

Long life cycles – for machines and projects zenon projects are designed for longevity, as are the machines on which they run. The special approach to compatibility adopted by zenon ensures that longevity also means renewability.

The engineering effort required for maintenance, updates, and upgrades during the course of the product life cycle remains straightforward and manageable with zenon. Customers choose their production machines and their software versions with freedom and flexibility.

With zenon, different machines – even ones with old and new software versions – can communicate with each other without any problems. zenon also allows you to load updated projects and install new versions during operation without the need for any downtime.

equipping machines

machines equipped with zenon, this dilemma is a thing of the past.

102

Robust system

Connectivity

Upgrades & security

Project updates

equipping machines

Sophisticated redundancy

Ready-made functionalities

Direct interfaces

zenon

Many factors influence the robustness of industrial systems. zenon addresses each of these factors with innovative approaches.

103

Effective Production Requires Robust Software

Machine outages have huge consequences – both financially and in terms of lost confidence and unhappy customers. Supply bottlenecks and high additional costs can cause damage to businesses, and the ramifications for machine builders may include loss of confidence, lots of maintenance work, and – in the worst-case scenario – lost customers. Machines which are intended to operate with reliability and integrity in the

Robust and fail-safe production The robust and stable zenon software is run all over the world on the production machines of numerous companies in industries such as automotive, pharmaceutical, food and beverage, chemical, and other sectors. The straightforward design, sophisticated redundancy mechanisms, and innovative update methods help ensure zenon‘s trouble-free operation.

These features are available out-of-the-box without the need for onerous programming work.

Projects can be subjected to extensive testing, even during the engineering stage, whereby real conditions can be simulated, thus saving you time and money during both commissioning and maintenance. Updates and upgrades can be installed during operation without the need for production downtime. You can therefore increase the reliability of the entire facility on an ongoing basis.

With its direct connectivity, zenon also minimizes risk and performance losses which might arise from heterogeneous facilities and numerous different interfaces. zenon also provides its own drivers and protocols, so it connects to most machines with ease.

`` Satisfied end customers thanks to robust software `` Risk reduction through reliability `` Less effort expended on maintenance and support `` Reliable and easy updates

additional information

Focused prevention of machine outages Unplanned machine outages normally cause enormous problems and entail high costs. The basic requirements for machines are therefore a durable construction, easy operation, and robust software. zenon can alleviate all these concerns for you and your customers. zenon projects run in a stable and fail-safe manner – over a period of years and with many versions. Even updates can usually be installed without having to stop the machine. For machine builders, this primarily means fewer machine outages and therefore less effort expended on maintenance and support.

equipping machines

long term also require robust software that can be relied on: zenon.

104

Cloud

equipping machines

zenon project

Machine 1

Machine 2

Third party

Machine 3

zenon enables secure and flexible communication with other machines and systems.

Machine 4

105

When Machines Communicate with Machines

The Industrial Internet of Things (IIoT) is becoming ever more important. It refers to machines which communicate directly with each other, release orders in a just-in-time schedule, provide information on production processes and status, avoid unnecessary detours, and save time. This also makes “batch size of one“ feasible: customized products and extras for every end customer with color, size, and properties being configured according to customer requirements. The market is moving away from mass-

Open systems for secure networking The ability of zenon to communicate with differing systems is the perfect basis for networked factories.

It enables simple communication between machines (M2M). zenon supports numerous standards, norms, and protocols such as the Weihenstephan Standards, OMAC PackML standardization, and OPC UA.

As a result, heterogeneous hardware and existing software systems will find a central communications interface in zenon. With strong encryption, zenon also provides additional security over the network.

Machines which are equipped with zenon can be conveniently integrated into cloud-based IoT infrastructures – for example, following standards such as MQTT or AMQP. As a result, zenon applications can be implemented across multiple systems and factories.

`` Secure networking thanks to openness and connectivity `` Make the digital factory a reality `` Competitive advantage through digitization

additional information

On the best path to the digital factory The Smart Factory requires high connectivity and communication capabilities. With zenon, you can integrate different machines and equipment into intraand inter-organizational systems without any problems.

The many communication protocols and open interfaces supported by zenon enable machines to communicate not only with each other, but also with other process levels, such as logistics. This enables effective networking with different systems along the entire production chain – from ordering to the end user of the product. This means that you and your customers can be best prepared for future developments in the Smart Factory. Sophisticated digitization and secure networking of facilities will secure your competitive edge.

equipping machines

produced items. But with which systems can this be achieved?

106

User administration

Secure interfaces IT security

Shop-floor IT security

Current systems

equipping machines

User authorization Machine security

In order to ensure security in a production facility, many aspects must be taken into account, including the machines. Because of their growing communication capabilities, security precautions must also be taken on the machines.

107

The Secure Route to the Smart Factory

Networked machines, IIoT, Smart Factory – these all sound like new opportunities for clear advantages over the competition. But what about security? Do new technologies and outward communication directly from production pose new risks? With zenon, there is no reason to forgo the advantages of smart technologies, because zenon can

Ready for networked structures The increasing networking within production facilities demands effective security measures. Data theft and tampering with production data or processes have become real risks. Software used in the field of production today must be integrated seamlessly with the general security systems. zenon has many features relating to security – leveraging COPA-DATA‘s expertise in protecting facilities and machines against attacks. zenon is there to provide you with the best support for protecting machines against tampering and unauthorized access. You will then be better placed to integrate your machines with the networked structures of a digitized factory.

be configured with ease, e.g. the user authentication which enables integration with Microsoft Active Directory. Automation-level user administration can therefore be integrated with the company‘s existing IT user administration services without any issues. zenon enables the easy implementation of secure communication between machines, but also with higherlevel applications which require communication with infrastructure outside the machine level. It is therefore possible to realize modern and secure line management or energy data management without any problems.

equipping machines

help enormously in ensuring networked systems are secure.

`` Easy configuration of user authentication

Out-of-the-box security features zenon relies on security by design and provides many out-of-the-box security features. Even the development of zenon itself was carried out in accordance with security standard IEC 62443 for “Industrial communication networks. Network and system security”.

As a result, many components, such as digitally signing files or strong encryption over the network, are already used as standard in zenon. Safety features can

`` Integration of automation with Active Directory user administration on the company IT network `` Out-of-the-box security in networked structures

additional information

`` Protection of critical operating tasks

equipping machines

additional information

110

Index Symbols

D

3D view............................................................................. 61

Dashboard............................................................... 47, 71, 75 Data consistency................................................ 25, 35, 43, 87 Decentralization........................................................... 25, 81 Distributed engineering....................................................23 Drivers................................................................ 27, 29, 33, 53 Dynamic alarm limits....................................................... 89

A Active Directory...........................................17, 37, 49, 79, 107 Active Directory Lightweight Directory Services............ 49 Aggregated archive......................................................41, 43 Alarm administration............................................. 45, 65, 89 Alarm analysis.................................................................. 89 Alarm causes.................................................................... 89 Alarm Message List...................................................... 17, 45 AMQP.............................................................................. 105 API............................................................................... 15, 65 App....................................................................................77 Archive data..................................................................... 47 Archiving...................................................... 41, 43, 69, 73, 75 Audit-Trail.................................................................... 17, 65 Automated engineering................................................... 95 Automated project creation.............................................. 15

B Batch Control.............................................................. 47, 65 Batch report................................................................ 65, 97 Batch size of one................................................... 55, 95, 105 Big data.............................................................. 41, 43, 73, 75

additional information

C Calculations....................................................................... 31 Chameleon Technology.....................................................57 Chronological Event List.................................................. 45 Circular redundancy..................................................... 81, 87 Cloud........................................................ 27, 41, 69, 73, 75, 83 Color palette................................................................. 57, 93 Communication..................................................... 27, 55, 105 Communication Port........................................................ 49 Communication protocol.............................. 27, 29, 33, 53, 105 Compatibility..................................................... 21, 39, 85, 101 Connectivity........................................... 27, 33, 53, 73, 103, 105 Context lists..................................................................... 89 Context sensitivity........................................................... 59

E Encryption.................................................................. 49, 79 Energy data management................................................. 13 Energy management........................................................ 83 Engineering environment................................................. 13 Ergonomics................................................................... 19, 57 ERP system.................................................................. 27, 55

F Faceplates.......................................................................... 71 FDA......................................................................... 17, 65, 69 File signature.................................................................... 49 Filter............................................................................ 59, 89

G GAMP 5 software category 4............................................ 17 GIS (geographic information system).............................. 63 GMP (Good Manufacturing Practice)............................... 17

H Hardware independence......................................... 29, 53, 65 Heterogeneous equipment..................................... 33, 53, 101 Historian................................................................. 41, 43, 69 Horizontal transparency...................................................81 Hot Reload................................................................... 21, 45 HTML5......................................................................... 13, 77 Human Machine Interface (HMI).................................... 93

I IECÂ 61131-3............................................................. 13, 29, 31 IECÂ 62443................................................................... 49, 107 Industrial Internet of Things...................27, 33, 49, 55, 79, 105 Industry 4.0.................................................................. 55, 79

111

K Key performance indicators.................................... 47, 71, 75

L Language switch........................................................... 57, 93 Limit................................................................................. 45 Line management............................................................ 101 Live data...................................................................... 47, 69 Logical checks................................................................... 31

M M2M communication...................................................... 105 Maintenance....................................9, 11, 21, 25, 39, 81, 85, 101 Measuring unit switch................................................. 57, 93 Message Control.......................................................... 77, 89 Microsoft Azure...................................................... 27, 41, 75 Microsoft Dynamics..................................................... 27, 55 Mobile solutions...................................................... 27, 77, 83 Modular systems.............................................................. 95 MQTT.............................................................................. 105 Multi-Project Administration...................................... 25, 81 Multi-Touch........................................................ 19, 61, 63, 93 Multi-user projects...........................................................23

N Network..................................................... 9, 17, 25, 27, 37, 43 Notifier App......................................................................77

O Object orientation.................................................... 11, 13, 25 OEE............................................................................. 83, 101 OMAC PackML................................................................ 105 OPC UA........................................................................... 105 Operating safety...................................................... 61, 67, 93 Operational technology (OT)........................................... 27

Out-of-the-box....................................... 17, 35, 43, 67, 93, 103

P Password protection........................................................ 49 Patch................................................................................ 79 Performance............................................................ 25, 33, 43 Pharmaceutical industry................................................... 17 Predictive Analytics..........................................................73 Programming environment............................................... 31 Programming interface.................................................. 9, 27 Project simulation............................................................. 31

R Rated redundancy........................................................ 35, 87 Reaction Matrix............................................................... 45 Real-time data.................................................................. 69 Recipe.......................................................................... 65, 67 Recipegroup Manager................................................. 67, 99 Recipe status.................................................................... 99 Redundancy.......................................... 9, 17, 25, 35, 43, 69, 87 Remote Desktop................................................................ 21 Remote Transport......................................................... 21, 45 Report................................................................ 17, 41, 69, 71 Report Generator.............................................................. 71 Reporting...................................................... 43, 47, 71, 73, 97 Report Viewer................................................................... 71 Reuse................................................................................. 11 Robustness.............................................................35, 37, 103

S SAP............................................................................... 27, 55 Scalability....................................................... 13, 41, 55, 75, 83 Seamless redundancy......................................... 35, 47, 81, 87 Security....................................................... 33, 49, 79, 85, 107 Security by design.......................................................... 107 Simulation.................................................................. 21, 103 Smart Factory......................................................... 25, 41, 49 Soft logic........................................................................... 31 Soft PLC........................................................................ 29, 31 Stability............................................................................. 33 Standalone project............................................................23

additional information

Information technology (IT)............................................ 27 Integration project............................................................25 Interface........................................................... 27, 29, 55, 105 ISA-88.............................................................................. 65 IT infrastructure................................................................55

112

Styles........................................................................11, 19, 93 Symbol...................................................................... 9, 11, 19 Symbol administration..................................................... 93 Symbol Library.................................................................. 11

T Template.............................................................19, 47, 93, 99 Terminal Server.................................................................77 Threshold value................................................................ 89 Topology............................................................................37 Touch............................................................................ 19, 61 Trend................................................................................ 69 Two-hand operation.......................................................... 61

U Update........................................................ 39, 79, 85, 101, 103 Upgrade........................................................... 39, 85, 101, 103 Upstream systems............................................................ 95 Usability............................................................. 19, 57, 61, 93 User administration........................... 17, 49, 65, 67, 79, 99, 107 User authentication................................................... 79, 107 User interface................................................................... 93 User levels........................................................................ 49

V Validation........................................................ 9, 17, 25, 65, 81 Variable............................................................................. 11 Versioning.................................................................... 21, 67 Visual Studio.................................................................... 27

additional information

W Web applications............................................................... 13 Web Client.........................................................................77 Web Engine.......................................................................77 Weihenstephan Standards.............................................. 105 Wizard............................................................................... 15 Worldview.............................................................. 59, 63, 89 WPF element..................................................................... 19 Write recipe...................................................................... 99

Z zenon Analyzer............................................................ 47, 71 zenon Automotive Generator............................................ 15 zenon Editor...................................................................... 13 zenon Logic.................................................................. 29, 31 zenon Web Server.............................................................77

113

Ing. Punzenberger COPA-DATA GmbH KarolingerstraĂ&#x;e 7b, A-5020 Salzburg Commercial Register No.: FN56922i Tel.: +43 (0)662 43 10 02-0 Fax: +43 (0)662 43 10 02-33 sales@copadata.com www.copadata.com

linkedin.com/company/copa-data-headquarters plus.google.com/+Copadata1987 facebook.com/COPADATAHeadquarters twitter.com/copadata xing.com/companies/copa-data youtube.com/copadatavideos

Š Ing. Punzenberger COPA-DATA GmbH. All rights reserved. This document and all the texts and images it contains are protected by copyright. Any use or duplication is not permitted without prior permission from COPA-DATA. The technical data contained herein has been provided solely for informational purposes and is not legally binding. All trademarks and product names are registered by Ing. Punzenberger COPA-DATA GmbH. All other brands or product names may be the trademarks of their representative owners and have not been specifically earmarked.

Subject to change.

additional information

Publication Number: ZB-EN-2017-07