Ignition SCADA - FAQs - IACS Engineering

Below is a direct and technically detailed response to each typically asked question about Ignition SCADA:

Core Architecture

Web-Based Architecture Difference:
Ignition is built using a web-based, cross-platform architecture leveraging Java and web technologies (e.g., HTML5 for Perspective). Unlike traditional SCADA systems (e.g., WinCC, FactoryTalk) which are Windows-only and heavily client-installed, Ignition runs on any OS (Windows, Linux, macOS) with a single server installation, offering browser-based client deployment and updates with zero install.
Modules’ Role:
Modules are plug-and-play components.
- Platform Module – Core services like OPC UA, tag engine, historian, alarm system.
- Vision Module – Java-based desktop HMIs.
- Perspective Module – Mobile-first, responsive HMI in browser.
- Alarm Notification – Extends alarming with pipelines, SMS, email, voice.

Licensing & Scalability

Unlimited Licensing Significance:
No per-tag, per-client, or per-screen cost. Ideal for enterprises needing many tags/screens or remote clients. It supports expansive architectures like nationwide water networks or smart factories.
Modular Design and Scalability:
You can begin with just the platform and Vision, then incrementally add modules like Perspective or MQTT as needs grow. This minimizes upfront investment and supports growth.

Integration Capabilities

Protocols and Systems Supported:
Ignition supports:
- OPC UA (native server + client)
- MQTT via Cirrus Link modules
- SQL Databases (MySQL, MSSQL, PostgreSQL, Oracle)
- REST APIs, SOAP, and ERP systems via scripting and Named Queries
- Custom drivers via SDK

Tag Management

UDTs for Devices:
UDTs enable standardized, reusable templates for devices like motors or sensors. Each instance inherits structure, alarms, metadata, and scripting logic.
On-Change Tag History:
Configure tags with “On-Change” mode to only log values when they change, optimizing database performance and storage.

Alarming & Notifications

Conditional Delay Alarms:
Use “Active Pipeline” conditions or scripting in expression tags (e.g., if({[.]Temp} > 10, now(), 0) with time tracking).
Alarm Pipelines by Severity:
Pipelines can branch based on priority (e.g., critical alarms route to supervisors with escalations after delays).

Security & Access Control

Database User Sources & Roles:
Role-based authentication integrates with AD, internal, or DB. IP Security Zones restrict access by IP range, enforcing zone-based access.
Restricting Access by Role:
Components can use security settings (e.g., visible only if {session.user.roles} contains “Supervisor”).

HMI/Perspective Development

Dynamic Templates:
Use parameterized templates (Vision) or Views (Perspective) for scalable UI (e.g., bind to UDT tags for line status, motor health).
Mobile vs Fixed HMIs:
- Vision: Fixed layouts, desktop-focused
- Perspective: Adaptive UI using responsive design (Flex Containers, Breakpoints)

Data Handling

Historizing Real-Time Data:
Use tag historian to log values at fixed intervals or on-change. For peak values, aggregate with SQL (e.g., MAX(value) GROUP BY 1 MINUTE).
SQL Integration:
Named Queries and scripting provide real-time dashboards, order tracking, and downtime analysis via JDBC.

Scripting & Automation

Python Capabilities:
Uses Jython 2.7 (Python 2.x subset). Automate tasks like:
- Edge detection
- Report generation
- REST calls
- File I/O
- Scheduled maintenance logic
Named Queries:
Centralized parameterized SQL queries with role-based security. Reduce SQL injection risk and simplify UI logic.

Legacy & IIoT Integration

Connecting Older Equipment:
Use serial-to-Ethernet converters, protocol gateways (e.g., Modbus-TCP), or MQTT edge agents.
Monitoring Metrics for Maintenance:
Ingest data like vibration (via OPC or MQTT), temperature, and motor currents. Feed into ML models or alarms for early warnings.

Extensibility

Third-Party Modules:
Extend with:
- Python libraries (e.g., NumPy, Pandas via Jython workarounds)
- External REST APIs
- MQTT Sparkplug-B for IIoT
- Community modules or SDK-built drivers
MES/ERP Replacement:
With scripting, SQL, and modules like Sepasoft MES, Ignition can act as a lightweight MES/ERP for some plants (OEE, scheduling, traceability).

Operational Efficiency

Reducing Manual Checks:
Use event-driven scripts and alarms to automate supervision (e.g., notify if cooling temp > threshold for 10 mins).
ROI Metrics:
Clients report:
- 30% reduction in unplanned downtime
- 20–50% savings in engineering hours
- Real-time visibility = quicker response = cost savings

Mobile & Remote Access

Perspective for Alarms:
Push notifications, live alarms, and dashboards on mobile via secure HTTPS. Real-time with no custom app installation needed.
Security for Remote Access:
TLS encryption, identity providers, role-based access, and VPNs or reverse proxies (e.g., NGINX with JWT auth).

vs. Traditional SCADA

Web-Based Difference:
Unlike WinCC/FactoryTalk with heavy Windows dependency, Ignition runs headlessly on Linux, deploys instantly via web, and uses modern tech stack.
Cost Advantages:
No per-client or per-tag license. Lower total cost of ownership (TCO), especially in multi-facility/multi-client setups.

Use Case Fit

Industries Benefiting Most:
- Manufacturing – OEE, downtime
- Water/Wastewater – distributed assets
- Food & Bev – traceability
- Energy – remote sites, MQTT, analytics
Suitability for Small Scale:
Yes. Even small sites benefit from the free Maker Edition or small license tiers with 1–2 clients, while being future-proof for scale.

Stale Data Alarms:
Use system.tag.read and scripting to detect value unchanged over time (e.g., store last change timestamp).
Role-Based HMI Access:
Important for regulated industries (e.g., FDA/21 CFR Part 11). Use security levels + views to restrict actions/report access.
Legacy Machine Integration:
Often feasible with minimal hardware (serial-Ethernet gateways or MQTT edge).
Python Scripting:
Broadly used for tasks like dynamic report generation, custom charting, and data reconciliation from external sources.