WinCC/ODK (Open Development Kit)

Description

Would you like to considerably expand the functionality of WinCC for a sector-specific application? Do you want to integrate your own data in WinCC tools, e.g. the reporting and logging system? The WinCC options package Open Development Kit WinCC/ODK specifies open programming interfaces, which you can use to gain access to data and functions of the WinCC configuration and runtime system. The interfaces are designed as C-Application Programming Interface (C-API). Programming examples show the use of C# and VB.NET with WinCC /ODK.

Benefits

• Individual system expansions via an open standard programming language (C++, C#, VB.NET)

• Access to data and functions of the WinCC configuration and runtime system

• Development of your own applications and add-ons for the WinCC basic system

Functionality

For example, ODK functions can be used

• to generate a message

• to determine the value of a tag

• to change the object properties in a screen

• to export a database table

In the delivery kit for WinCC/ODK there is a CD-ROM with several examples and a voucher for a one-day training session and expanded support via a telephone hotline.

ODK functions are also employed by the WinCC Competence Centers and partner firms for the development of technology and industry-specific WinCC Add-Ons.

WinCC/IndustrialX

Description

Using only the basic functions, you can configure SIMATIC WinCC in a user-friendly way. WinCC/IndustrialX is an option that further simplifies the solving of a visualization task by standardization of user-specific objects. No separate display object is required any more for each motor, pump, valve, etc., instead objects of the same type are standardized. Engineering become more cost-efficient, if functions and displays can be used repeatedly.

Benefits

• Easy creation using configuration wizards

• Fast-track starting due to the use of standards: ActiveX technology, creation using Visual Basic

• Central creation and modification of object representations of the same type (type-coding) saves you time and money

• Configuration of intelligent, vertical market and technology-specific objects (graphic representation and logical processing) with expertise protection

• Can be used on a diverse basis: in WinCC pictures and other Windows applications (e.g. Internet Explorer, Excel)

Functionality

IndustrialX employs the ActiveX technology for the process visualization. Configuration wizards make the creation of your own standard displays easy. IndustrialX controls are flexible and can be tailored to meet the requirements of the most varied applications, for example specific for applications in the chemical, glass or paper manufacturing industries. IndustrialX offers code templates for easy linking customerspecific ActiveX controls to WinCC data sources that are themselves suitable for use on Web Navigator clients.

Quick and easy to configure

Using the IndustrialX Control Designer, you create one IndustrialX control for process objects of the same type, e.g. for several motors. Linking is carried out of the individual data of a data record e.g. the target value, actual value, temperature and operating mode. Once you have created the IndustrialX control, you can integrate it into pictures as often as you like. At integration, you only need to specify the name of the data record. At runtime, each integration of the IndustrialX Control then automatically works with the data of the assigned data record. Each time the IndustrialX Control is used, you do not need to spend time and effort on linking the individual data.

Carry out modifications on a central basis

If you have a lot of IndustrialX Controls, which are already integrated in process pictures, you can easily change them later. Such changes are made once at a central location and can affect the graphic representation as well as the processing logic. All the changes affect all the IndustrialX controls in all the process pictures that have already been configured. If, for example, there are 47 motors of the same type in a plant that are visualized in 13 different process pictures using IndustrialX controls, you only need to make the changes once at a central location. These changes are then effective everywhere. This obviates the need to carry out time-consuming, errorprone changes at 47 different locations!

Rapid processing, know-how protected

IndustrialX controls are composed of compiled Visual Basic code that guarantees fast, effective processing. The technological know-how that you invested in creating your controls can - if necessary - be protected from copying if the source code is not supplied.

SIMATIC BATCH for WinCC

Description

In the processing industry, discontinuous processes – so-called batch processes – are becoming increasingly important; the shorter and shorter product life cycles as well as the product variety desired by the consumer are only a few of the reasons for this.

Constant product quality also for the umpteenth batch, a quick response to changing market conditions, requirements on the traceability of the production (FDA compliance) and the meeting of legal rules and regulations, the economic and technological pressure of flexibly and optimally utilizing the production facilities – all these make high demands on the flexibility and reliability of the plant automation.

WinCC offers the right solution for the inexpensive and effective implementation of batch processes: SIMATIC BATCH (for WinCC). With it, tasks ranging from simple single-line/single-product processes up to complex multi-line/multi-product processes can be flexibly solved – easily and at the same time conveniently – and that in compliance with standards

Benefits

• Modular architecture with flexible scalability and optimal matching to system size and individual requirements, e.g in a heterogeneous PLC environment

• High degree of availability through redundant system configurations protects against loss of batch data.

• Greater production flexibility

• Shortening of the time to market through centrally changeable, hierarchical recipes in accordance with ISA S88.01

• Optimized utilization of your facilities through simplified management of subsystem-neutral recipes, which can be flexibly assigned while in runtime

• Easy quality management through documented and reproducible production sequences

• Validation support in accordance with 21 CFR Part 11

• Reduced operating and life cycle costs through the use of standard products

Functionality

Integrated Data Storage

For the user, the access by SIMATIC BATCH to SIMATIC WinCC configuration data means an easy handling, safe operator guidance and quick response to process malfunctions. The modular architecture with flexible scalability assures an optimal matching to the system requirements and thus provides future-proofing.Additionally heterogeneous PLC environments aresupported. Redundant system configurations guarantee a high availability and ensure that no production data is lost. With SIMATIC LOGON, SIMATIC BATCH (for WinCC) furthermore supports the validation according to 21 CFR Part 11 through a central user administration featuring access protection and electronic signature.

Fig. Batch-Project represented by SIMATIC BATCH Control Center

Subsystem-neutral, hierarchical recipes in accordance with ISA S88.01

SIMATIC BATCH for WinCC allows to create and manage subsystem-neutral recipes, e.g. for a mixer or oven subsystem of a bakery. The use of the type/instance concept results in a minimization of the engineering work. In addition, centrally changeable ROP (Recipe Operation) libraries and a subsystem-neutral configuration guarantee a high degree of reusability.

Flexible operating parameters enable an optimal system utilization, since the subsystems are not assigned until in runtime. For a processing-oriented recipe creation, hierarchical recipes in accordance with ISA S88.01 are available.

The transparency of the production is provided by the storage, archiving and logging of the batch data on the basis of the XML format

The validation of systems for the compliance with quality standards is increasingly necessary these days. SIMATIC BATCH for WinCC fulfills the key requirements of FDA 21 CFR Part 11 and enables the logging of

• changes made to recipes,

• recipe operations,

• changes made during the production

• as well as manipulations on the individual control level

With it, the production processes can be traced at any time

SIMATIC Logon- Central cross-plant user management

Description

Up to version 6.2 of WinCC SIMATIC Logon was available as an optional software package to supplement the user administration of the WinCC basic system in order to facilitate FDA validation
.With WinCC V7 the enhanced security functions of SIMATIC Logon are part of the WinCC basic software.

Benefits

• Central, cross-plant user management, integrated in Windows User Management

• High levels of security due to measures on both the administrator and user sides

• Configurable login procedures (Keyboard input, chipcard)

• Can be used in different configurations (single-user, client/server systems up to highly available solutions)

Functionality

User management with SIMATIC Logon integrates itself in the safety system and user management of Windows and in this way meets the FDA requirements.

SIMATIC Logon offers a number of security mechanisms on both the administrator and user sides. Users are uniquely identified in the usual way by means of a user ID, a user name and a password. Functions like password aging, automatic log-off after a predefined time and blocking the password after entering it wrongly several times guarantee the highest levels of operating security. In addition administrators can set up new users online on a cross-plant and cross-application basis as well as lock these users.

A configuation tool allows user specific settings:

• Language (german, english, french)

• Environment : Domain and workgroup

• Login device: Keyboard / Chipcard Reader/other devices

Thus users can login in their own language via keyboard or with a chipcard on which name, domain and password are encrypted.

In the SIMATIC WinCC environment, you can use Logon on a wide variety of different structures such as single user stations or client/server configurations. With SIMATIC Logon, the high availability is provided by primary/ secondary domain controllers and the local Windows User Management system.

WinCC/ChangeControl

Description

Monitoring project changes is possible with WinCC/Audit and with the option package WinCC/ChangeControl as well. In this connection, WinCC differentiates between configuration changes that affect the WinCC database, e.g. changes in Tag Management or creating a user group and configuration changes that are limited to changes to files, what is known as document control. Document control involves process pictures, scripts and log layouts and customer-specific documents. This means that WinCC/Change Control can monitor all these documents or files for changes, create intermediate versions or retrieve them using a rollback function. The entire monitoring process can be activated very easily and conveniently. This means that in the case of plant standstills, for example, plant engineers and operators can quickly and easily comprehend the changes that have been made to the plant. This supports trouble-shooting and reduces plant downtimes

Benefits

• Project versioning and document control

• Compliant with the requirements of the Food and Drug Administration (FDA)

• Reduced engineering effort to comply with 21 CFR Part 11 & EU 178/200

Functionality

Using a project versioning tool

• WinCC projects can be archived, restored and deleted,

• WinCC data including the project database, project files (e.g. screens, reports, scripts) and user documents can be archived

• Activities of the project versioning tool can be recorded

Fig. Administrating a WinCC project by employing the project versioning tool

In this way all changes made to a plant beginning from the production start and continuing throughout the entire life cycle can be recorded and - using defined versions - be documented.

WinCC/Audit

Description

WinCC/Audit is for monitoring changes in operator activities in runtime operation as well as for recording project changes at the engineering stage. The system records all the change data in a secure database known as the Audit Trail. You can view the Audit Trail using the Audit Viewer.

This means that using WinCC/Audit provides continuous traceability of both operator activities and changes to projects and, at the same time, also helps machine tool builders and plant operators to reduce the amount of engineering time and effort involved in complying with the requirements of 21 CFR Part 11 and EU 178/2002. The engineering measures that are necessary for making validation easier are documented in a white paper.

Benefits

• Reliable recording of operator actions and project changesin Audit Trails

• Project versioning and document control

• Compliant with the requirements of the FDA (Food and Drug Administration)

• Reduced engineering effort to comply with 21 CFR Part 11 & EU 178/200

Functionality

Monitoring runtime operation

In runtime operation the system records the following in the audit trail:

• Operating activities carried out,

• Activities within the scope of central user management using SIMATIC Logon

• Starting and changing recipes

Apart from this, plant operators can individually record specific events by means of an audit entry function:

• Operation of pushbuttons and sliders

• Record Pressing of a key

Audit Trail database and Audit Viewer

The Audit Trail database stores all the change data that is subject to document control; this includes user actions, confi guration changes and other changes. Components of Audit Trails include:

• date and time of the change

• project ID, PC and database name

• old value and the new one

• user name

• event/function

• Comment/reason for change

The system visualizes the Audit Trail data by means of the Audit Viewer. Operators use filters to selectively set the desired view of the Audit Trail data and they can export this data to an Excel file. The Audit Trail data is stored securely on a tamper-proof basis and this means that you cannot change or delete it.

This means that WinCC/Audit meets the FDA requirements of 21 CFR Part 11 in this respect too.

Fig. Access to the Audit Trail database using the Audit Viewer

Tracking project changes

Monitoring project changes is possible with WinCC/Audit and with the option package WinCC/ChangeControl as well. In this connection, WinCC differentiates between configuration changes that affect the WinCC database, e.g. changes in Tag Management or creating a user group and configuration changes that are limited to changes to files, what is known as document control. Document control involves process pictures, scripts and log layouts and customer-specific documents. This means that WinCC/Audit can monitor all these documents or files for changes, create intermediate versions or retrieve them using a rollback function. The entire monitoring process can be activated very easily and conveniently. This means that in the case of plant standstills, for example, plant engineers and operators can quickly and easily comprehend the changes that have been made to the plant. This supports trouble-shooting and reduces plant downtimes.

Fig. Administrating a WinCC project by employing the project versioning tool

Using a project versioning tool

• WinCC projects can be archived, restored and deleted,

• WinCC data including the project database, project files (e.g. screens, reports, scripts) and user documents can be archived

• Activities of the project versioning tool can be recorded

In this way all changes made to a plant beginning from the production start and continuing throughout the entire life cycle can be recorded and - using defined versions - be document

WinCC/B.Data

Description

In light of diminishing energy resources and increasing energy prices, reducing costs by reducing the consumption of energy is a prerequisite for successful corporate endeavors in the future.

This cost factor can be significantly reduced by influencing energy consumption and utilizing procurement possibilities arising as a result of the liberalized energy markets. In order to be able to tap the entire potential, integrated system solutions are needed; starting at the automatic energy data recording, through to data processing and plausibility testing, right up to the analysis, accounting and forecasting of the relevant energy data and figures.

Benefits

WinCC/B.Data forms the basis for an economic and optimized energy management system and provides you with the following immediate benefits:

• Combined technical and commercial data processing systems

• Transparency in the company through complete energy and material balancing of power generation and consumption plants

• Generation of variables for substantiated statements in order to increase the efficiency of power generation, distribution and consumption systems

• Consumeroriented energy cost distribution and connection to the accounting system (e.g. SAP® R/3)

• Planning reliability through a production-related load and consumption forecast

• Support for the Purchasing Department in energy procurement

• Fulfillment of legal obligations for the monitoring and reporting on greenhouse gas emissions (CO2 emissions)

Functionality

Recording and preprocessing of energy and operating data from upstream systems

• b.data supports the current interface standards such as OPC, ODBC, ASCII or XML, whilst - in addition to the integration into WinCC - also offering direct interfaces to SICAM230, SIMATIC Powercontrol with automatic configuration adjustment

• Preprocessing of energy data in a freely configured real-time accounting kernel including a formula editor for the definition and planning of new calculation functions (temperature-rise computations for boiler systems, ratings of CHP systems, etc.)

• b.data Mobile for the mobile energy data recording including route planning for the meter-reading process

Administration and analysis of energy data

• Automatic plausibility testing and generation of substitute values

• Long-term archiving with versioning, compression and summarization functions

• Measured value editor for the entry and editing of energy and operating values as well as for meter management

• Trender for the representation of current (online) and historical curves (trends) as well as for target/actual analyses

Energy and material balance

• Freely parameterized balancing of energy flows of various media such as electricity, heat, gas, steam and emissions (CO2) in b.data Plant Explorer

• Determination of characteristic data (KPIs, efficiency figures, etc.) with direct reference to production (batches, quantities, etc.)

Energy accounting (Expenses and Revenue Accounting)

• Calculation and allocation/assignment of energy costs to plants and/or customers/cost units according to the costs-by-cause principle. The bottom up (measurement) and top down (allocation) processes are supported

• Flexible modeling of the hierarchically structured accounting in Plant Explorer

• Rates for quantities, flexible price rating with rate and price time series

• Transfer of expenses/revenues into the ERP system (e.g. SAPR/3)

Energy planning

• Consumption forecasts based on production-related factors (production planning) and basic load profiles (typical days)

• Creation of an energy schedule for registration at the energy suppliers

Energy reporting system

• Freely parameterized Report Generator for drawing up balance sheets, reports, shift log books and invoices

• Fully-automatic reporting system with task management, e-mail distribution and document administration

• b.data Intranet/Internet Viewer (WEB Client) for accessing reports and results throughout the company

SIMATIC powerrate for WinCC

Description

SIMATIC powerrate for WinCC is a WinCC option that ensures transparency in energy consumption from the infeed to the load. Energy data is continuously collected, archived and further processed. With an exact knowledge of the consumption profile, it is possible to identify savings potential, optimize your power supply conditions, and hence lower your energy costs. Monitoring the contractual power limits mitigates unnecessary costs and/or penalties and provides you with the capability to approach the power limit closely. Full integration into WinCC enables problem-free use of the standard interfaces or standard functionalities of WinCC.

Benefits

• Identification of energy-intensive loads and processes for the purpose of deriving measures for improving power efficiency

• Comparison of consumption profiles for more efficient processes

• Optimizing the company according to energy parameters based on an assessment of consumption and costs.

• Prevents limit overshoot and the resulting additional costsI

Design

SIMATIC WinCC powerrate comprises the following components:

• Modules for energy data acquisition and processing

• Faceplates for displaying and processing the energy data

• Allocation of the energy data to cost centers using Excel macros.

• Modules for load management (calculation of trend, limit monitoring, release/inhibit consumers

• Faceplates for display of results and configuration of load management

• Excel macro for determining the duration line, thus establishing decision base for load management

Functionality

• Energy data acquisition and processing:
  Using off-the-shelf modules, energy data can be collected from any Profibus-enabled devices. The data can be available on the modules in the form of counter pulses, counter values, or power values. From this data, the module calculates the power averages and the work values for a specified period. This data is archived in the WinCC tag logging archive. In addition, a limit forecast is extrapolated for each period. A sample function (heat calculation) that can be adapted to the needs of the process at any time by means of open interfaces, has been implemented for the purpose of visualizing customized calculations. The data from manually read counters can be entered direct into the system and used for further analysis.

• Presentation of the energy data:
  The currently collected energy data is presented as power averages/ work values per time interval. Trend displays enable analysis of archived energy data as well as its representation in tables.

• Further processing of data:
  The archived data can be exported directly from WinCC to Excel. Using predefined macros several reports can be obtained:

• Cost center report:
  In this report, the costs are allocated to different cost centers and the costs calculated on the basis of predefined rates. The results are provided as a table or as a bar graph

• Duration line
  Based on the archived medium power values, powerrate calculates how often a certain medium value has occurred in a predetermined elapse of time. This characteristic shows whether short-term power peaks exist. The exported energy data can be customized and processed. WinCC can access the data since it is archived in the WinCC archive.

• Load management
  Contractual power limits (for current typical usage is the 15 minutes power average) must be adhered to, otherwise drastically increased prices or penalties might be imposed. The load management of SIMATIC WinCC powerrate cyclically executes a trend analysis. If the limit is overshot, it will deliver an alarm or a warning, and will also turn off consumers if configured to do so. In order to prevent unnecessary switching there are a number of parameters that allow you to adapt the load management to the current process. all of this can be done user friendly on the faceplate. Consumers distributed across several PLCs can be incorporated in the load management by specific AS - AS communication modules.

• Additional functions
  To prevent the loss of data in the event of a communication fault, the data are temporarily stored in a circular buffer on the SIMATIC S7. To ensure synchronicity with the power supply company, it is possible to evaluate the synchronization pulse from the power supply company

WinCC/Calendar Scheduler

Description

The Calendar Scheduler supplements WinCC by a calendarbased HMI in the style of Microsoft Office. It includes editors with which events and associated actions can be configured and managed. The planned events and actions can be connected directly to WinCC variables or global scripts.

Benefits

• Simple and reliable scheduling of events and actions

• User-friendly HMI in the style of Microsoft Office

• Guaranteed comprehensibility:
  Events and actions are logged and displayed in the WinCC alarm logging

Functionality

In order to control the plant process, several calendars, events and associated actions can be created, filtered, edited andmanaged. For example, the action editor can be used to execute C scripts.The editor supports events and interruptions which occur regularly, e.g. holidays or maintenance work.

Multi-level user privileges protect the scheduling from unauthorized access. The alarm logging logs and displays every action carried out.
This guarantees comprehensibility of the corresponding events.

WinCC/User Archives

Description

The WinCC/User Archives option allows the application of User Archives, in which related data is stored in data records. WinCC and its automation partners (e.g. a SIMATIC S7 PLC) can write to these data records and exchange them among one another if required.

Functionality

Fig.:WinCC/User Archives Editor

An operator, for example, can input parameter records in WinCC, store them in the User Archive and forward them to the automation level if required. Vice versa, a PLC can continuously acquire production parameters during a shift and transmit them to WinCC at the end of the shift. Other applications include the acquisition of batch data, the specification of production parameters and the control of inventory data.

WinCC User Archives are conveniently created and preset with data using a separate editor. Special ActiveX Controls are used to display data from User Archives in runtime.

WinCC/Downtime Monitor

Description

With the WinCC/DowntimeMonitor, the machine data management software, downtimes in machine-oriented or line-oriented production facilities can be detected and analyzed centrally. For individual units, machines or entire production lines, the following specific parameters can be derived from this.

• OEE (Overall Equipment Efficiency),

• MTBF (Mean Time Between Failures)

• MTFF (Mean Repair Time)

• and other so-called Key Performance Indicators (KPI).

In doing so, production equipment can be defined individually by plant

Benefits

• Complete transparency about the plant and machinery as the basis of optimizing plant productivity, this means:
  - Avoiding disturbances and bottlenecks
  - Increasing availability

• Deriving specific parameters (KPI)

• Integrating appropriate display instruments (controls) in WinCC process pictures

• Can be used for individual machines up to complete production facilities

• Distributing evaluations to different people across the Web

Functionality

Error cause analyses provide information about the frequency and duration of machine or plant downtimes. Corresponding indicators can easily be integrated into the WinCC process screen.

Fig. DowntimeMonitor - Key Performance Indicators at a glance

In the DowntimeMonitor, the time model of the production equipment is determined from the production times, maintenance times and downtimes. Via a shift calendar, the shifts can also be included in the analysis. All plant statuses relevant for the analysis are parameterized in a detailed reason tree. The acquired data provides information about the efficiency of individual machines and entire production plants. The transparency of the data makes it possible to quickly respond to malfunctions and to take corrective measures, which again increases the machine availability.

All analysis results are integrated into the WinCC screens in the form of controls. Here, several indicators are distinguished between

• Gantt- and Pareto-charts

• Bar or column charts

• Trends or tables

The displayed data can be processed with WinCC and the WinCC options, and be distributed to different persons via Web.

Fig. DowntimeMonitor - Analysis via Gantt Charts

WinCC/IndustrialDataBridge

Description

WinCC/IndustrialDataBridge uses standard interfaces to link the automation level (controls) to the IT world and to ensure a flow of information in both directions.

Examples of these types of interfaces include OPC in the field of automation and SQL database interfaces in the IT world. You can integrate systems made by different manufacturers using a large number of different standard interfaces. You carry out configuration (without programming) on a favorably priced basis using a standard software package.

Typically, WinCC (or other SIMATIC products like WinCC flexible) with its OPC DA server interface is the data source and an external database is the data destination. Apart from this, you can also access the archived messages and process values in the WinCC database via the WinCC OLE-DB Provider. Depending on the volume of data, licenses are offered with 128 / 512 / 2,048 and 10K tags.

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Benefits

• Connecting the automation level to the IT world

• Integrating systems made by different manufacturers using a large number of different standard interfaces (amongst others OPC, OLE-DB, office formats)

• Simple, favorably priced configuration using standard software (without programming)

• High-performance data exchange between several systems at the same time

Functionality

Flexible switching between applications

IndustrialDataBridge makes a connection between the source and destination interface and transfers the data as follows

• depending on a change in value

• after a configurable time has expired

• or if a specific event occurs.

Data is exchanged between automation systems made by different manufacturers via IndustrialDataBridge, for example via OPC. Connecting OPC servers via the IndustrialDataBridge makes possible communication between different devices, data sources and destinations.

• Linking SCADA and supervisory systems made by a wide variety of different manufacturers via the OPC interface.

• Storing process data in office formats like MS Excel or MS Access.

• SQL databases are available as the data destination for production data acquisition. The system can either transfer the data from the data source using OPC on an event-driven basis or transmit it directly to the controller.

• With a database as the data source, you can transfer recipes or specified values directly to WinCC or to a controller

Fig. Linking to databases and IT systems

Client Access Licenses (CAL)

To directly access current WinCC data via OPC DA, you do not need a separate license.

You always need WinCC/CAL whenever you want to access WinCC data across the interfaces of the options WinCC/Connectivity Pack and WinCC/IndustrialDataBridge from any computer which has not installed (and licensed) neither the basic WinCC system nor a WinCC option.

If desired, the WinCC/CAL pro Processor License even provides access for all the computers in your configuration to the interfaces of the Connectivity Pack or allows them to use the IndustrialDataBridge.

WinCC/Connectivity Pack and Connectivity Station

Description

In WinCC, non-proprietary communication in the field of automation has always been very important.

WinCC has as standard an integrated OPC DA 3.0 server (Data Access) that gives you access to all the online values in the system and, on the other hand, can as a client read data from another application - across the Web too. The WinCC/ Connectivity Pack offers additional options.

This means that the system can transfer pre-processed process and production data to higher level systems for information conditioning (e.g. Manufacturing Execution Systems, Enterprise Resource Planning systems or office packages, e.g. Microsoft Excel, Microsoft Access, etc.)

Benefits

• Simple IT and business integration by means of standard interface.

• Access to online and historical data from any computers you like via standard interfaces. (OPC XML DA, OPC HDA, OPC A&E, WinCC OLE-DB)

• Further processing or analysis of data using separate tools is possible.

Functionality

Access to messages and historical data via OPC / WinCC OLE-DB

The WinCC/Connectivity Pack includes the OPC HDA 1.1 (Historical Data Access) and OPC A&E 1.0 (Alarm & Events) servers for accessing historical data of the WinCC archive system or for transferring/acknowledging messages. As an OPC XML DA 1.0 server, WinCC can even send data on a cross-platform basis across the Web to PPS/MES systems; in the opposite direction, it can take OPC XML DA client order or recipe data. As an HDA server WinCC makes available historical data from the WinCC archive system to other applications. The OPC client (e.g. a reporting tool) can specify the start and end times of a time interval and thus selectively request the data to be transferred. Apart from this, the client can request already conditioned data from the HDA server, i.e. actively trigger data compression before the data is transferred. The OPC HDA server can also be used in redundant configurations.

Fig. WinCC/ConnectivityPack: Access to WinCC via OPC & WinCC OLE-DB

In OPC A&E, the system displays a WinCC message as an alarm and, together with all the ancillary process values, passes it on to any subscribers on the production or company management levels. Due to the filter mechanisms and subscriptions, the system only transfers selected, changed data. It is, of course, also possible to carry out acknowledgement at the MES or ERP level.

The WinCC OLE-DB Provider makes it possible to directly access the archive data that WinCC stored in the Microsoft SQL Server database (alarms, process values, user data). In this connection, you can even use statistic functions. From a WinCC multi-client, a transparent process data access via the OLE DB is now also possible to redundant WinCC systems and distributed configurations with central archive server. For the addressing, only the symbolic computer name is needed.

WinCC/ConnectivityStation

If process visualization is not needed at a station, you can use this WinCC option package to confi gure any Windows computer you like as a connectivity station with access to WinCC via OPC and WinCC OLE-DB without needing a WinCC installation to do so.

Client Access Licenses (CAL)

To directly access current WinCC data via OPC DA, you do not need a separate license. You always need WinCC/CAL whenever you want to access WinCC data across the interfaces of the options WinCC/Connectivity Pack and WinCC/IndustrialDataBridge from any computer which has not installed (and licensed) neither the basic WinCC system nor a WinCC option.

If desired, the WinCC/CAL pro Processor License even provides access for all the computers in your confi guration to the interfaces of the Connectivity Pack or allows them to use the IndustrialDataBridge.

WinCC/DataMonitor

Description

The WinCC/DataMonitor is an important component for plant intelligence applications in combination with the process visualization system WinCC.

The DataMonitor is used for the display, analysis, interpretation and distribution of current process states and historical data from the process database. With the DataMonitor, WinCC process data can thus be made available to all functional levels in the enterprise via the Web.

Benefits

• Displaying and analyzing current process status conditions and historical data on office PCs using standard tools like Microsoft‘s Internet Explorer or Microsoft Excel.

• No additional time and effort for configuration, since you can directly use pictures from the WinCC project

• Evaluation via centrally administrated templates for detailed analyses of company processes (e.g. reports, statistics)

• Creating event- or time-controlled reports

• Information from the process can be grouped on an individual basis at runtime (information portal) and distributed to different people by e-mail

• User administration with user groups and individual access rights (read, write, create of WebCenter pages)

Functionality

Powerful tools for the depiction and interpretation of current process states and historical data (measured values, messages, user data) from the process database enable the production to be efficiently monitored and analyzed as well as reports to be created and distributed to the appropriate persons. For the display, a DataMonitor client can be set up on any office PC. The data provider - a WinCC/Web Navigator server or a WinCC/DataMonitor server - is installable on any WinCC single-user system, WinCC server or WinCC client.

The DataMonitor and its tools

For visualization and analyzing the WinCC/DataMonitor comprises several internet capable tools that support all common security features like Login/Password, firewalls and encrypting procedures.

• Process ScreensPurely for monitoring purposes of WinCC process screens

• Trends & AlarmsDisplay and analysis of archived process values and alarms in trends or tabular form

• Excel WorkbooksDisplay of archived process values in an Excel table for the analysis and storage on the Web or as print template for reports

• Published ReportsGeneration of time-controlled or event-controlled reports in Excel format or as Portable Data File (PDF)

• WebCenterCentral information portal for the access to WinCC data via user-specific views, clearly arranged Web-Center pages due to user-groups with individual rights for reading, writing or creating web-center pages.

Process screens

The function Process Screens is used purely for monitoring purposes and for the navigation across WinCC process screens with the MS Internet Explorer as a so-called "viewonly client" with an adjustable cursor.In doing so, the WinCC/DataMonitor employs the same mechanisms as the WinCC/Web Navigator, e.g. for the communication, the user administration, the display of screens.

Trends and Alarms

Trends and Alarms is a tool for displaying and analyzing archived WinCC process values and alarms. A predefined page already contains the displays for the process value table, the corresponding trends, the alarm table and the alarm hit list with the associated operator functions. Also included are the statistics functions from WinCC for process value patterns and alarms (e.g. average, standard deviation, variance). Tables only have to be linked with the desired WinCC archive data (measured values or alarms). Chosen data can also be exported to a CSV file and be processed further at a later time (e.g. compression)

Excel Workbooks

The Excel Workbooks are a reporting tool for the display of alarms and current or archived process values in an Excel table. The data can then be analyzed via Excel functions and also be graphically formatted and summarized in a report. Once Excel workbooks have been created, they can be published and made available to the Intranet/Internet, or be used as templates for reports to be automatically generated.Reports can also be generated offline and stored locally as a customer specific analysis.

Fig.: Excel Workbooks

Published Reports

Published Reports automatically generate print jobs from WinCC reports and prepared Excel workbooks. The reports are started time-controlled (e.g. at the end of a shift) or event-controlled (e.g. upon the change of a WinCC tag) and can be distributed by e-mail. Reports created by Excel are saved as XLS fi le. The corresponding fi le created by the WinCC Report Designer is stored in PDF format. and can be further processed and analyzed afterwards..

Fig.: PublishedReports: Workflow of creating reports

WebCenter

The WebCenter is the central information portal for the access to WinCC data via the Intranet or Internet.

Here, users with corresponding user rights can compile WinCC process data, alarms and process screens for any number of screen views for various groups of persons. By means of these views, WinCC data can be compared, analyzed, interpreted and if necessary also exported over absolute or relative time periods. When analyzing historical data, the connection or disconnection of swapped archives is possible via commands.

In a WebCenter page, the user can configure and save own screen views made from WebParts. WebParts are process value tables, trends, statistics displays, timesteps (for the clear depiction of precompressed values), and alarm tables (incl. hit list), as well as a display for graphics, links, and favorites. WinCC process screens can be integrated into the WebCenter without installation work using the WebPart Process Screens.

This allows various information from the plant to be generated in an understandable form for different user groups, corresponding to the function areas of a company, e.g for Quality Assurance (e.g. tables and trend diagrams with operating figures), the plant operator (e.g. pie charts with piece counters) or the service personnel (e.g. trends with temperature characteristics).

Fig.Webcenter: Example of an information portal

Selectable licensing

The licensing takes place sever-based, i.e. is made at the Web Navigator server or DataMonitor server. Depending on the selected license, the DataMonitor software package for the DataMonitor server contains either 1, 3, 10, 25 or 50 client licenses. The number of client licenses denotes the maximum number of clients that can be active at the same time, whereas in principle, any number of clients can be connected. For upgrading the number of simultaneously active clients, Powerpacks are offered.

SIMATIC Maintenance Station

Description

Consistently high productivity is the competitive requirement par excellence in every production. Production downtimes should be avoided if possible or - if that cannot be accomplished completely - be kept as minor as possible. Frequently, downtimes are also caused by less than optimal maintenance. Here, intelligent maintenance strategies can be employed, whose essential goal is to make the maintenance plannable, as a result of which downtimes are considerably reduced

Benefits

• Visualization of the maintenance information of the entire automation system

• Automatic derivation of the data from the hardware configurations

• Manufacturer-spanning display of service and maintenance data

• Traceability of events and operator actions via automated alarms, which form the basis for later analyses to optimize the plant

• Consistency and homogeneity of data, visualization and operation with the SCADA system and maintenance station

Functionality

Efficient maintenance is possible in connection with the WinCC option package SIMATIC Maintenance Station. Thereby it is irrelevant whether the process visualization and maintenance functionality run on a common computer or on separate devices. Since the same operating and monitoring tools are being employed, the display can be switched between SCADA and maintenance at any time. The advantage is obvious: The operator can - at any time - also obtain an overview of current identification & maintenance (I&M) information, without having to interrupt the process.

Fig. Monitoring of the plant status via automatically generated screens

Generating instead of programming

The maintenance station is configured by selecting the automation systems to be displayed from STEP 7 to create a hardware configuration. With this hardware configuration, the maintenance station recognizes which devices belong to the plant and creates an image for the maintenance in WinCC. The integration of components is based on established standards and is possible for a large number of devices from different manufacturers. The project generates itself automatically in the form of hierarchically structured, already connected WinCC screens - without additional programming work for the user- and then is automatically transferred to the Maintenance Station. New hardware components brought into the hardware configuration of STEP 7 are automatically made available to the maintenance station. A manual updating is not necessary, follow-up costs are avoided.

Corrective/preventive maintenance

In runtime, the maintenance station displays all connected control components, switching units, drives, etc. and monitors the current plant status using uniform symbols. In doing so, the program not just responds to errors once they have occurred (i.e. corrective maintenance), but also to measures entered into the system that are to prevent errors prior to their occurrence (preventive maintenance). Such timedependent or load-dependent measures take place regularly and/or after a certain number of operating cycles, operating hours or load peaks, and can be scheduled in such a way as to optimally utilize the existing resources. The SIMATIC Maintenance Station offers perfect support for performing the maintenance. In doing so, it generates a comprehensive database for the later optimization of the plant and ultimately results in reduced maintenance costs.

WinCC/ProAgent

Description

Increased productivity is being achieved more and more by cutting costs. In this context, the focus is increasingly on maintenance. The emphasis here is on rectifying faults as quickly and efficiently as possible. Ideally, the operating personnel should also perform part of the maintenance tasks. The operating personnel are on-site, they are familiar with the procedures and can intervene quickly. This saves time and reduces costs. It is precisely here that ProAgent can assist operating personnel in identifying faults quickly, particularly in the automotive and machine tool industries.

Benefits

• Component of Totally Integrated Automation: Increases productivity, minimizes engineering outlay, reduces lifecycle costs

• Support for troubleshooting, increased machine and plant availability, shorter downtimes

• No additional configuration costs for the diagnostics functionality due to automatic generation of the diagnostics- related parts for the controller and HMI

• Frees up controller capacity with regard to memory requirements and program execution time

• No special knowledge required to operate

Functionality

In the event of a process fault, process error diagnostics with SIMATIC ProAgent will provide information about the location and cause of that fault and support personnel with troubleshooting. The ProAgent solution has been optimized specifically for use with SIMATIC S7-300/S7-400 and SIMATIC WinAC. It can be used in combination with the S7-PDIAG, S7-GRAPH STEP 7 engineering tools. The ProAgent option package features standard displays that are updated with process-specific data during runtime.

Fig. Process diagnostics with WinCC/ProAgentand the Step 7 Engineering Tools

Standard views instead of configuration

ProAgent is available for various devices and software platforms from the SIMATIC HMI range: Panels and Multi Panels, WinCC flexible and WinCC. ProAgent contains standard views, which are attuned to the requirements of the process error diagnosis of a plant or machine. During configuration, the data that is relevant to process error diagnostics such as symbols, comments and alarm texts are saved in a standardized data management system. During runtime, the standard screens are then filled with process-specific data.

For SIMATIC WinCC, ProAgent directly accesses the engineering data and imports it into the WinCC project. The ProAgent standard screens needed for the diagnostics mode are automatically created in WinCC. ProAgent and STEP 7 engineering tools represent a standardized diagnostics concept for SIMATIC S7. No additional configuration overhead for the WinCC application is thus required for the diagnostics functionality. The standard views are: alarm view, unit overview, diagnostics detailed view, motion view and the sequencer operating display.

Functional scope

• Context-sensitive diagnostics initiation due to process error message

• Output of the operands with symbols and comment Switch-over capability between LAD, STL and signal list

• Supporting fault rectification by means of direct process access when using the motion view

• Output of the faulty operands directly in the alarm including address, symbol and comment

• Consistency test in runtime: Inconsistent diagnostics units are marked with icons. This permits quick locating of faults regarding configured data in the commissioning phase.

• Direct, unit-related entry point in the diagnostics view from user displays (by using ProAgent functions)

• Unit or alarm-related entry to STEP 7, e.g. LAD/STL/FBD editor, S7-GRAPH, HW CONFIG upon system error messages, is supported fully automatically

• S7-GRAPH OCX for the graphical display of step sequences (overview display)

WinCC/Redundancy

Description

Increasing system availability due to redundancy in the case of applications with WinCC is possible by using

• redundant servers,

• redundant communications paths

• and highly available controllers.

The WinCC/Redundancy option gives the user the opportunity to operate two linked WinCC single-user systems or server PCs in parallel, in order to monitor each other. For both redundancy partner servers you need one of the two redundancy licenses that are supplied with the option package. On the failure of one of the servers, the second server assumes control of the entire system. When the failed server resumes operation, the contents of all message and process value archives are copied back to the restored server. All in all, this results in significantly higher levels of system availability.

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Benefits

• Increased system availability with continuous data integrity

• Automatic switching in the case of a server failure or communications failure with the server

• Continuous operation and visualization due to automatic switching of the clients to the intact server

• Automatic matching of all the archives, alarm information and internal variables in the background after eliminating the disturbance

Functionality

In a normal situation, two WinCC stations or process data servers operate completely in parallel, i.e. each station has its own process connection and its own data archives.

If either of the WinCC stations fails, the other one takes over archiving of messages, process and user data. This guarantees constant data integrity. In clientserver operation, the system automatically switches clients from the failed server to the redundant machine. This guarantees continuous visualization and operation of the plant at each operator station.

When the failed server starts up again, the system automatically matches in the background all the process values, messages (incl. statuses, acknowledgements, lists and comments) and data from the user archive for the down period (without influencing online operation) – this means that two stations are available again that have the same data.

Additional increase in system availability

In addition to using the WinCC/Redundancy option for running two servers in parallel, it is possible in a WinCC application to also implement redundant communication channels to the SIMATIC S7 controller. You do this by installing two communication modules and implementing duplicate communication paths (communication software S7-REDCONNECT needed). By using H-series SIMATIC S7 controllers, you can, if required, additionally increase availability at the control level. By combining system solutions, you can create a security concept that meets even the most demanding requirements.

WinCC/TeleControl

Description

SIMATIC WinCC/TeleControl flexibly integrates remote terminal units equipped with SIMATIC automation components into the central process visualization system of the overall plant via a WAN (Wide Area Network).
The main fields of application can be found in the water/wastewater and oil and gas sectors. SIMATIC WinCC/TeleControl supports the three most important telecontrol protocols IEC 60870-5 101/104, DNP V3 (serial or TCP/IP), and SINAUT ST7 (serial or TCP/IP)

The software can be individually adapted to the requirements of a plant.The uniform user interface for local and remote processes minimizes the risk of error.
Less time is required for training of the employees, since the same SIMATIC WinCC process visualization system is used for telecontrol and for the actual process visualization.
Installation, commissioning and maintenance costs can therefore also be reduced considerably.

A security concept made to order

A security concept made to order

The separation of WinCC servers and web servers already ensures greater security and availability, and this can be even further enhanced by means of independent web servers on two independent SCADA clients. The operator stations on the web are included in the user administration of the plant on-site. Different authorization levels govern who has which access rights.The operator can either just view the plant (view only) or partially/ fully operate it, depending on the configuration of his access rights. Every login and logout can be traced by means of a system alarm. An optional logout after a configurable period of time is another security feature in addition to the option of disabling certain key combinations, and this allows the use of WinCC/Web- Navigator even where FDA requirements must be met. Furthermore, the WebNavigator supports all of the standard security mechanism that can be used for applications on the Internet such as routers, firewalls, proxy servers, SSL encryption and VPN technologies.

Thin-Client solutions

Via thin client solutions with MS Terminal Services, simple PCs under a Windows operating system (e.g. Windows 9x/ME), rugged on-site devices (e.g. SIMATIC Thin Client) and mobile clients (PDA – Personal Digital Assistant) under Windows CE can also be connected. Such solutions have few hardware requirements, because the clients only provide the screen display, while the application itself, i.e. the WebNavigator client, runs on the terminal server under Windows. Up to 25 thin clients can be connected to one terminal server.In contrast to typical WebNavigator installations, the thin clients are generally located on the same LAN as the server. Access via WAN, RAS and even via the intranet/Internet are, however, also permitted. Mobile devices can be connected via various media, such as mobile radio links or wireless LAN.

Fig. Thin-Clients on the Terminal Server

Server farms with load balancing

If a great many web operator stations are needed at the same time, server farms can be configured with several web servers. This requires a Load Balancing license for the participating web servers. With Load Balancing, a compensation of the load is possible by means of which newly connected web clients are automatically assigned to the web server with the currently lowest load. The web servers all have access to one and the same WinCC project and each can have up to 50 web clients assigned. In all, there can be several hundred operator stations on the web. If the assigned web server fails, the clients attempt to connect to another web server in the server farm

Fig. Load-Balancing with several web servers

Licenses as required

The WebNavigator client software can be installed as many times as required without the need for a license. A corresponding (server-based) license is required in order to use the WebNavigator server. Licenses are available for simultaneous access to the web server by 3, 10, 25, or 50 clients.
PowerPacks are available for upgrading the number of simultaneously active clients.

In addition, the diagnostics clients licensing is ideal for system integrators who are responsible for maintenance and service of widely distributed plants. WinCC/WebNavigator diagnostics clients have, regardless of the number of current accesses, guaranteed access to all web servers with the WinCC/WebNavigator license or the cost-effective WinCC/WebNavigator diagnostics server license.

WinCC/Web Navigator

Description

The WinCC/WebNavigator provides you with the capability of operating and monitoring your plant via the Internet or the company-internal intranet or LAN without the need for changes to the WinCC project.

This means that the Web Navigator offers the same archive display, operator input and access options as the local operator stations. This also means that the displayed process pictures can contain Visual Basic scripts for dynamic sequences, that you can access WinCC user archives, that the system now supports operator messages on the web client and that the operator stations on the Web are integrated into user management.

Benefits

• Operator control and monitoring over long distances with up to 50 operator stations simultaneously

• Fast update rates due to event-driven communication

• Optimally tailored clients for operating and monitoring, analysis, service and diagnostics

• Thin client solutions on different platforms (PC, onsite panel, mobile PDA)

• Web and terminal clients can be added whenever required

• Minimum maintenance costs due to central software administration

• Acceptance of configuration data for the web, generally without changes

• Increased security and availability due to separation of WinCC and web server

• Granting access rights using plant-wide user administration

• High Internet security standards

Functionality

New application areas

In addition to the typical use of the WinCC/WebNavigator in WANs (Wide Area Networks), the WinCC/WebNavigator can also be used for applications that must be implemented at minimal cost. This especially includes applications that have a pronounced distributed structure (e.g. water/wastewater), or in which access to process information is only sporadic (building management). In addition to this, web clients can also be used as normal operator stations on the LAN.

Web server and clients

For a web solution, the WebNavigator is installed on a WinCC single-user system or server and a WebNavigator client is set up on any Windows PC. This allows a running WinCC project to be operated and monitored via MS Internet Explorer, or via terminal services, without the need for a WinCC basic system on the computer.

Fig. WinCC SCADA Clients as web server for different clients in the web

It is also possible to use the web client without MS Internet Explorer; the visual appearance corresponds to the standard client. Such a web server can also be set up on each WinCC (SCADA) client. This means that a web client that is connected to the web server can access the projects of all (up to 12) redundant WinCC servers in a plant from anywhere in the world. The projects can be displayed simultaneously in different tabs, e.g. via the multi-tabbing functionality of MS Internet Explorer V7.In this case, the web client also switches transparently between redundant, lower-level WinCC servers. If the browser is started several times on the web client, it is even possible to simultaneously view several plants, i.e. also several web servers.

Fig. Web Navigator with Multi Tabbing

WinCC/Central Archive Server (CAS)

Description

Central data management, reliable and high-performance archiving of long-term relevant data and central backup mechanisms are the basis of an archive server solution. Integration in the SCADA world, data interfaces for accessing archived data and analysis capabilities are the associated existing components.

The CentralArchiveServer (CAS) option was designed for this purpose and is used to export the archived data of all servers in the system to an (optionally redundant) central archive server (CAS) and manage it. Through the integration of the CAS into the WinCC world, the data remains accessible to the WinCC clients as well as via the WinCC standard interfaces.

The WinCC/CAS can be configured with redundancy in order to increase availability. In addition, it is possible to use a RAID system on the CAS.

Benefits

• Central, high-performance, optionally redundant, archiving of alarms, process values and reports (emf)

• Integrated back-up system for the archive data

• Company-wide information hub with transparent access via WinCC clients, the WinCC/DataMonitor and the open interfaces in WinCC/ConnectivityPack or WinCC/ConnectivityStation

• Integrated Webviewer for data analysis in the MS Internet Explorer

Design and Functions

Both process value archives and alarm logs are created on the individual WinCC servers and transferred to the CAS and backed up, compressed and archived there when individual database segments have been closed. For long-term archiving of reports, the created emf files are swapped out to the CAS. There, they are also saved in the database. With "Store&Forward", when the network is interrupted between the WinCC server and CAS, data will be reliably transferred as soon as the network is operating again.In addition, data from any OPC DA servers or from external databases can be archived on the WinCC/CAS. The WinCC/CAS thus becomes a company-wide information hub, via which the centrally acquired data can be forwarded to the production level and the corporate management level MES/ERP. The access rights for the central archive server data are set in the WinCC user administration.

Accessing data for displaying and analysis is possible and transparent via the WinCC client or the WinCC/DataMonitor client option. It is of no consequence whether the data is on the WinCC server or already on the CAS. For displaying (e.g. in WinCC Online Trend or WinCC Alarm Control), the data is automatically and correctly delivered for the selected time range. In addition, the data saved on the CAS can also be viewed via the "StoragePlus Webviewer" in the options package with the aid of the MS Internet Explorer. It provides views of alarm tables, hit lists, process values in the form of trends or tables and WinCC reports. The data of the distributed WinCC system can also be accessed through the familiar interfaces (OPC DA, OPC HDA, OPC A&E, OPC (historical) A&E and OLE-DB) of the WinCC/ConnectivityPack option or WinCC/Connectivity Station. In this manner, the data saved in the CAS can be efficiently transferred to higher-level systems or used for the purposes of analysis.

Licenses

The WinCC/CentralArchiveServer (CAS) option contains all of the licenses for a central archive server with up to 1500 archive tags. If higher quantity structures occur over the course of the project, the number of usable archive tags can be upgraded via Archive PowerPacks by 1,500, 5,000, 10,000, 30,000 or 80,000 archive tags to a maximum of 120,000 archive tags.

WinCC/Server

Description

The application of the server option makes a WinCC single user system a powerful client/server system. It allows multiple coordinated operator stations to be operated together with networked automation systems. A server supplies up to 32 connected clients with process data, archive data, messages, screens and reports. This requires a network connection (TCP/IP) between the server computer and the connected clients.

Benefits

• Setting up a client/server system - for operating and monitoring relatively large plants with up to 32 coordinated clients

• Distributed functions or applications on several servers - with high performance profiles at high system performance levels

• Overview for the entire project - with access to all the servers in the plant from operator station

• Favorably priced configuration on the client (the lowest license is necessary)

Functionality

Servers and clients of your choice

Depending on the plant size, up to 12 servers can be employed. In general, the plant is controlled by WinCC (SCADA) clients that access one server or that possess a central view to multiple servers (see also "distributed system"). The clients only require the smallest runtime license (RT128) or complete license (RC128) if you also want to confi gure on the client. This makes it possible to configure reasonably priced operator and configuration stations in a network. You can of course carry out configuration online without affecting the function of the servers and operator stations.

Fig.: Simple client/server configuration

Operator stations are also possible in the form of Web clients. In heterogeneous configurations with SCADA and Web clients, this yields, amongst other things, the following performance profile limits (variations are possible).

• 50 WinCC Web-Clients and 1 WinCC SCADA-Client, or

• 32 WinCC SCADA-Clients and 3 WinCC Web-Clients

Distributed system

Thus, in a complex installation, WinCC can be configured as a distributed system, in accordance with the physical structure of the plant (e. g. body-in-white shop, paint shop), or on a functional basis, e.g. message server, archive server, etc. Distributing the complete application or the tasks to several servers makes possible a much higher performance profile, takes the load off the individual servers and ensures good performance. Distribution also takes into account the topology of a plant. A special example of a functional distribution is an archive server (option package: WinCC/Central Archive Server) that is used as a central crosscompany information exchange and that can be accessed using a Connectivity Station for example. The complete view of the plant is implemented using clients that have access to or a view of the screens and data of different server projects at the same time. You can configure a common message and trend view of the archives of different servers for these clients.