abbSEPE97

Prepared by: A K Karn Page 1 of 36

ABB 800xA Engineering

RCU linkconnection

CommunicationExpansion CEX-bus

CPU

S800I/O’s on theElectrical ModuleBus

Ethernet ports COM 3-4 portsFiber opticaleModuleBus

S.M. No. : SNTI/SM/020 Rev. No. : 00

Effective Date : 10-Jan-2008


The Industrial IT System 800xA is a comprehensive process automation system. It covers operation and configuration of continuous and batch control applications. As such, ABB controllers are not new to Tata Steel but ABB AC 800 M controllers have been introduced in Tata Steel around year 2005 at various plants of Tata Steel, like in Sinter plant 3 and 4, New Bar mills and H Blast Furnace. This system might find its application in many more plants because of its robust control ability and easy adaptability to Field Bus systems. Profibus _DP and Foundation Field Bus technology have been easily integrated with ABB AC 800 M Controllers working satisfactorily at SP # 3 & 4. Integration of AC 800 controllers with Foundation FieldBus , Profibus, Module Bus and other communication technologies make this AC 800 controllers a DCS in true sense where the control is fully distributed up to the field devices level.

Therefore a strong need of training on this ABB control technology has been been felt from various plants of Tata Steel. This study material mainly covers the hardware portion and concept of structures and can be used for SNTI regular training on ABB DCS programming & Maintenance (Course Code- SEPE97) and has been designed for the plant engineers/ technicians who are involved in ABB 800 M Controller Engineering activities and its day to day maintenance activities. Field Bus has been kept away form the scope of this study material as Field Bus itself is a subject and should be dealt with separately with proper emphasis.

Prepared by

Approved by

Akhilesh K Karn Mr. S Bhowmik Manager, EEI Group Head - EEI


Sl. No. Topic Page #

1. System 800xA Architecture 4

2. Aspect Object Concept…………….. 5

3. AC 800 M Hardware 8

4. Engineering Workplace 22

5. Concept of structures 26


System 800xA Architecture The Industrial IT System 800xA is a comprehensive process automation system. It covers operation and configuration of continuous and batch control applications.

Instrumentation& Drives

InformationManagement

AssetOptimization

S88 ProductionManagement

Safety

Motor ControlCenters

Advanced ControlAnd Industry Solutions

System 800xA

Process and Logic Control

Within System 800xA there are a number of Core Functional Areas. These are:

• Operations

• Engineering

• Control and I/O

• Production Management

• Batch Management

• Manufacturing Management

• Information Management

• Safety systems

• Asset Optimization

• Device Management


Aspect Object Concept A central problem in plant operations, as well as asset life cycle management, is the need to organize, manage, and have access to information for all different aspects of a great number of plant and process entities.

The Aspect Objects architecture is a cornerstone of the Industrial IT concept. It provides:

• A consistent, scalable concept that integrates Process Control & Automation, Substation Automation and Safety products.

• Information-centric navigation – a consistent way to instantly access all information without having to know how and by which application the information is handled.

Aspects and Objects These entities, or real world objects, are of many different kinds. They can be physical process objects, like a valve, or more complex, like a reactor. Other examples are: products, material, batch procedures, manufacturing orders, and customer accounts.

• They are called Aspect Objects

Each of these real world objects can be described from several perspectives. Each perspective defines a piece of information and a set of functions to create, access, and manipulate this information.

Examples are: graphic, alarm, trend, report, order definition, mechanical layout etc.

• We call this an Aspect of the object.

It is necessary to be able to implement these aspects using many different applications, both existing and new, from ABB, third parties and customers. It is desirable to be able to do this without changes to the applications. It is not reasonable to require that all these different applications be aware of each other. Still, the applications must cooperate to provide an integrated view and functionality of the object.

Examples are: Graphics Builder for graphics, Auto CAD for mechanical layout, SAP for order handling etc.

• These applications are called Aspect Systems, which implements one or several Aspect types.


Intuitive Navigation Quick access to displays and information is provided with web browser tools. Favorites, history lists, shortcuts, and hot keys provide navigation through a process production facility quickly and accurately. Use of the right mouse button provides access to additional details via a context menu

Alarm

Engineering-Specification

AspectsAspects

ObjectsObjects

Machine Drawing

Live-Video


Single Node System A Single Node System is intended for very small applications, where all 800xA server and workplace functionalities reside in a single PC.

Automation Network

Fieldbus

Controllers

Field devices

Aspect ServerConnectivity ServerWorkplace (Client)

The system has only one PC node, within which all servers as well as the client applications are installed. Only a few controllers can be connected and applications are small.

Redundancy System 800xA provides the highest degree of fault tolerance to meet the most demanding application needs for maximum system uptime.

Optionally redundant I/O, controllers, control networks, fieldbus networks, Connectivity Servers, Aspect Servers, and Operator Workplaces with automatic switchover provide the required functional integrity to meet the most demanding process needs.


AC800M Hardware The CPU consists of a base plate TP830 and a replaceable processor module PM8xx with various speed and memory combinations.

The CPU is a Motorola Processor and runs at 48MHz for PM851..PM861 and at 96MHz for PM864..PM865.

CPU Baseplate

Fuses for Modulebus and

CEX-bus

The base plate TP830 is the housing for the module termination board. It is where the majority of the external connections take place.

• Two built-in RS-232 serial ports: COM3 with modem support COM4 intended as tool port for Control Builder

• Two built-in Ethernet ports (IEEE 802.3, 10BaseT with TCP/IP): CN2 used for redundancy or routing

• Built-in Modulebus for direct I/O communication

• Built-in CEX-bus (Communication Extended Bus)

NOTE! In a configuration with redundant CPUs, COM3 and the electrical ModuleBus cannot be used.


Different Processor Units The key differences between the different CPUs are memory and frequency, also some can only be used in stand alone mode and others can be used in redundant mode.

PM856

8MB24 MHz

PM851

8MB24 MHz

PM865Redundant

32MB96 MHzSIL2

PM864Redundant

32MB96 MHz

PM861Redundant

16MB48 MHz

PM860

8MB48 MHz

Start Modes The controller may be started with the following start modes:

Mode Invoked by Description Warm Init

Power Off/On with a battery backed up CPU

Applications restart with retain values.

Cold Init

Press Init < 2.5 s Applications restart with cold retain values.

Reset Press Init > 3 s or until Run LED flashes

Applications are deleted in controller.


Unit Description On-line replacement

Redundancy

PM851 24 MHz (48MHz for communication) / 8 Mbytes RAM 1 Ethernet port, 1 Serial port and 1 tool port. Application speed is half of PM860. Maximum one CEX bus module.

No No

PM856

24 MHz (48MHz for communication) / 8 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port. Application speed is half of PM860.

No No

PM860 48 MHz / 8 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port.

No No

PM861 48 Mhz / 16 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port. Singular or redundant.

Yes Yes

PM861A Same as PM861 but can use redundant communication unit CI854A, CI860 and BC810.

Yes Yes

PM864 96 Mhz / 32 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port. Singular or redundant. PM864 is 50% faster than PM861 in executing an application.

Yes Yes

PM864A Same as PM864 but can use redundant communication unit CI854A, CI860 and BC810.

Yes Yes

PM865 (PA/HI)

96 Mhz / 32 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port. PM865 can be used in an AC 800M High Integrity system.

No Yes


Battery The memory is backed up by an internal or an external battery. You should mount the battery when the CPU is up and running with a loaded application.

Internal External

The backup time varies depending on CPU type and battery types.

NOTE! A Compact Flash card can be used for non-volatile storage of application and data.

CPU Type Internal Battery min time (hours)

External Battery min time (weeks)

PM851/PM856/PM860 48 4

PM861 36 4

PM864 36 3

PM861A 118 12

PM864A 235 24

PM865 HI 235 24

PM865 PA 235 24


AC 800M Ports Here is a detailed description of the communication ports of the CPU:

RCU linkconnection

CommunicationExpansion CEX-bus

CPU

S800I/O’s on theElectrical ModuleBus

Ethernet ports COM 3-4 portsFiber opticaleModuleBus

External expansion units for communication are attached to the CEX-bus. Interfaces are replaceable online under power.

• Programmable RS-232 ports for COMLI (data transfer), MODBUS and S3964R

• Ethernet ports for Control Network or third party MMS

• Module Bus ports for optical or electrical connection to I/O.

A Compact Flash (CF) can be inserted to the card slot located at the front of AC 800M controllers.

The card will be activated and read after a long controller reset (or power failure) and your application(s) can be loaded into the controller without performing an application download from a Control Builder station.

NOTE! Compact Flash cannot be used in an AC 800M High Integrity controller.


800M High Integrity AC 800M can easily be configured for usage in safety critical applications. The main components of such a system are PM865, SM810, SS823 and the S800 I/O High Integrity system, running a High Integrity version of Control Software.

The PM865 processor unit has higher HW fault tolerance, compared to PM864. The added functionality on PM865 includes:

• Double over voltage protection on internal voltages

• Additional watchdog timer updated with data from SM810

• Increased oscillator supervision

• Support for S800 I/O High Integrity system

• Support for SM810

• Increased system diagnostic and online self tests.

The main function of the SM810 is to act as a monitor for the HW and SW execution of PM865 and these two modules together are a SIL2 compliant system according to IEC61508 and TÜV qualification is pending. The SM810 is running a SIL2 certified operating system and have a very high degree of self-diagnostic.


Communication Interface Units : General description This section presents a number of communication modules that can be connected to the CEX bus.

The table below is a summary of the interfaces (for details refer to hardware manual):

Unit Description On-line replacement

Redundancy

CI851 PROFIBUS DP-V0 communication interface unit. CI851 has been replaced by the CI854 communication interface.

No No

CI853 RS-232C serial communication interface unit. No No

CI854 PROFIBUS DP-V1 communication interface unit. Redundant Profibus cabling possible.

No No

CI854A

PROFIBUS DP-V1 communication interface unit. Redundant Profibus cabling and redundant interface cards.

Yes Yes

CI855 MasterBus 300 communication interface unit for the AC 800M. Yes No

CI856 S100 I/O system communication interface unit. Up to five S100 I/O racks can be connected to one CI856 where each I/O rack can hold up to 20 I/O boards.

Yes No

CI857 INSUM communication interface unit. Yes No

CI858 Communication interface for ABB Drives using DriveBus. No No

CI860 Fieldbus Foundation HSE communication interface unit. Not possible to use in AC800M HI.

Yes No

CI862 TRIO blocks (remote I/O) communication interface. Manages the channel data for the AC 800M controller.

Yes No


S800 I/O Connections: I/O Connection Possibilities I/O units are connected in two ways: • Modulebus (electrical or optical) • Profibus DP

An I/O cluster consists of one CI830 or TB820 and a number of I/O modules. Max. 12 I/O modules can be included in one I/O cluster.

S200 or S900 I/O can only be connected through Profibus DP.

The optical modem TB820 acts as an adapter from optical to electrical Modulebus. A maximum of 7 optical modems can be connected to the CPU.

The Profibus slave CI830 can be also be supplied with an adapter TB810 to extend the Modulebus by optical cable.


S800 I/O Connected with Modulebus • Max. 96 I/O modules

• 1 base cluster

• 1-7 I/O cluster

• 1-12* S800 I/O modules/cluster

• Optical Modulebus

• Simplex or Duplex, plastic / HCS glass fiber

Base cluster

Modulebusextension

max. 2.5 meters

I/O cluster 1TB820

Optical modem

TerminationTB807

max. 15 or 200m

I/O cluster 2

Simplex

I/O cluster 3

Duplex

I/O cluster 4

max. 15 or 200m

Note that the TB820 is not visible in the Project Explorer. The I/O cluster is only indicated by the position of the I/O modules e.g. I/O modules in cluster number 3 have positions from 301 to 312.


S800 I/O Connected with Profibus • Max. 24 I/O modules / I/O Station

• 1 base cluster

• 1-7 I/O cluster

• 1-12* S800 I/O modules/cluster *The memory size in the CI830 and bus load in CI830 or TB820 limits the no. of I/O modules/cluster

• Max. cluster length 2.5m (electrical modulebus)

• Optical modulebus, Simplex or Duplex

Base cluster

CI830Profibus slave

CI851Profibus master

Max. 2.5 meters

I/O cluster 1

withTB810

I/O cluster 2

Simplex

I/O cluster 3

max 15 or 200m

Duplex

I/O cluster 4

max 15 or 200m

TB820Optical modem

NOTE! CI830 is going to be replaced by CI801 in the future to support the HART protocol.


ABB Range of I/O Units The following I/O types can be connected to an AC 800M system:

• S800 modular I/O

• S800 modular I/O with intrinsic safety (IS)

• S800L I/O This is a compact I/O with an integrated I/O and terminal unit. The I/O cannot be replaced on-line.

• S200 I/O This I/O must be connected through an APB12 ProfiBus module.

• S900 I/O This I/O must be connected through a CI920 ProfiBus module. The I/O is suitable for use in hazardous areas.

• S100 I/O This I/O must be connected through communication module CI856


MTU – Module Terminal Unit The S800 I/O unit is attached to an MTU, Module Terminal Unit. A number of MTUs are available. They can however be divided into two major groups, depending on the physical layout:

• Compact / 1 connection per channel

• Extended / 3 connections per channel

Compact Extended

NOTE! Mechanical key protection prevents wrong I/O module type from being inserted.


Hardware Redundancy: Controller and I/O Redundancy Use of redundancy will reduce the maximum number of S800 channels. Each cluster may contain up to 12 single S800 I/O units or up to 6 redundant S800 I/O units.

Optical ModuleBusCable

RedundancyLink Cable

CEX -bus splitter BC810

Redundant PROFIBUS CICI854A

Redundant or SingularS800 I/O

Redundant S800 I/O as direct I/O


Redundant Modulebus I/O Connections When you use redundant IO module configuration, the maximum number of IO modules in one cluster is 6 pairs.


Redundant Profibus I/O Connections When you use redundant IO module configuration, the maximum number of IO modules in one cluster is 6 pairs.

• TU846 is used for Redundant I/O modules

• TU847 is used for non redundant I/O modules

• CI840 is connected to CI854 Profibus master

TU846 or TU847


Engineering Workplace / Plant Explorer Engineering Workplace / Plant Explorer is the tool that is primarily used for 800xA system configuration. The Engineering Workplace is the workplace used for all project work done by application engineers.

The Project will exist in the Aspect Integrator Platform but the control part of it will use Control Builder as an aspect system for its configuration. Therefore when a new project is created we work partly in the Platform and partly in the Control Builder.

NOTE! Before you start, make sure that the ‘System’ is ‘Up and Active’

What is a Workplace? This is the working environment for a particular group of people who might wish to access the system. In a newly installed system there are 4 default workplaces provided, intended for various users.

• Engineering Workplace

• Operator Workplace

• Plant Explorer Workplace

• Two Screen Plant Explorer Workplace

In a delivered system there may be more. A delivered application is likely to have a workplace tailored to the requirements of the customer.

The main difference between the Engineering Workplace and the Plant Explorer Workplace is that only the Engineering Workplace allows you to use advanced tools such as Function Designer and Bulk Data Manager.

NOTE! The system extension “Engineering Base” must be loaded to have the Engineering Workplace available.


How to Start the Engineering Workplace You can access the Engineering Workplace by right-clicking on “My ePlant” on your computer desktop and then select ‘Engineering Workplace:

Another method is to navigate through the Windows menu structure from the Start button as shown below:

Start | Programs | ABB Industrial IT 800xA | System | Workplace

The Workplace logon screen has two selection panes:

• The ‘System’ selection pane

• The ‘Available workplaces’ pane

In a typical plant there will be only one System available. This will be the system that was built for the application.


Browse the Aspect Directory Plant Explorer is used to browse and navigate in the Aspect Directory. It is used to create and manage Aspect Objects.

Aspect Directory

Structure Selector

Object list

Aspect list

Aspect Preview

FaceplateGraphic display

T = 67 C

Browse the aspect server

Plant Explorer is based on the concept of Windows Explorer. When viewing a structure, objects are in the left-hand window (pane) and aspects of the selected object are in the right-hand window (pane).

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Context Menus By right-clicking on an object, the corresponding aspects will appear. Each object has certain aspects available, which can be different from one object to the other.

Also the aspects have a context menu to handle the aspects themselves

Object Context Menu:Used to handle the objects

Aspect Context Menu:Used to handle the aspects


Concept of Structures The Aspect Object concept allows organization of objects and aspects into different structures, depending on which context is to be viewed. Structures are the graphical representations of the relations that exist between different aspect objects.

Plant Explorer organizes the 800xA system into Structures that can be accessed from the pull-down menu in the upper left-hand window.

NOTE! The same object can be seen in different structures.

There are 19 structures by default. The use of these structures will vary from system to system depending upon the needs of the person(s) that are configuring and using the system.

The majority of time we use only a few of theses structures, which are marked in blue:

• Control Structure

• Functional Structure

• Location Structure


Structures used for Application Engineering These are the main application structures of the 800xA system. These structures are primary structures, because it is assumed that most Application Engineers will perform most of their work within these structures.

Functional Structure The Functional Structure describes the functionality of the plant. It is used to structure the plant into systems and subsystems according to how the plant equipment operates together.

By this it can also be used to organize displays, alarm sectioning and other functions that are related to the structure of the plant.

It is built up by placing aspect objects according to their hierarchical relations. The objects relate to the process and are linked with the Control Structure.


Control Structure The Control Structure contains the networks and nodes that are used to control the process that is the equipment of the system. It is also used to organize the process control environment in the system.


This structure contains control networks, control projects, applications, controllers, stations, different types of sub-objects (like I/O boards and process objects as well as signals assigned to different objects within this structure).


Location Structure The Location Structure is supplied to help the user identify the geography or location of the objects in the plant. This structure must be built with the knowledge of what buildings, rooms and locations that exist in the site.

NOTE! The Location Structure is optional for most projects.

Library Structure The Library Structure is used to categorize and store reusable entities.

It contains all object type libraries and its versions. The object types of these libraries are stored in Object Type Structure.

It contains the templates for such object types as the Alarm and Event List configuration, History Logs, and Trends.



Object Type Structure Almost all aspect objects are instances of an Object Type. The intent is to make it possible to create and efficiently re-use standardized solutions to recurring problems.

An example would be a control valve. Rather than create a new and unique Aspect Object for every valve in your plant, it would be more efficient to create a few valve types. When you needed a particular solution, you would use an instance of one of your valve Object Types.

When you use an instance of that object type, the aspects that are pre-defined for that object type are automatically instantiated and associated with the new instance.

Structures used for Administration: User Structure The User Structure holds the defined users and user groups allowed to work in the system. You define user roles in the Configuration Wizard.

All users must have a related Windows user account. The user aspect primarily contains information about a user and what the user is allowed to do within the system (his user role).


Workplace Structure The Workplace structure is used to define and create the layout of the screens for user interface to the system. This includes workplaces for operations, maintenance, management etc.

The workplace objects types of aspect that can be placed here are numerous, and they control the layout and function of a workplace, for example tool bars and menu items.

Service Structure The Service Structure holds the services. A service provides a function in the system, for example, the Basic History service is associated with Log configuration.

The services are arranged into “Service Groups” and within any group there may be one or more “Service Providers”. One or more services can run on a server node.


Maintenance Structure The Maintenance Structure is used to define and work on Backups, System Configuration Versions, and Synchronizations.

Additional Structures Other structures that contain important information or may require a one-time configuration for the system include:

• Admin Structure

• Aspect System Structure

• Node Administration Structure

• Graphics Structure


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