H651-15 1 Minerals Applications - RevE

800xA Minerals Training
Chapter 15 Minerals Library Minerals Applications
TABLE OF CONTENTS
Chapter 15 Minerals Library Minerals Applications....................................................................................................................1
15.1 General Information.............................................................................................................................................................2
15.1.1 Objectives.....................................................................................................................................................................2
15.1.2 Legend..........................................................................................................................................................................2
15.1.3 Reference Documentation for Minerals Library AC800M Connect............................................................................2
15.2 Minerals Library Overview.................................................................................................................................................3
15.2.1 Object Categories..........................................................................................................................................................3
15.2.2 Library Modules...........................................................................................................................................................5
15.2.3 Library Module Locations in the Aspect Directory....................................................................................................10
15.3 Minerals Applications Overview.......................................................................................................................................11
15.3.1 Application Layout and Data Flow.............................................................................................................................11
15.3.2 Connection Principles and Data Flow........................................................................................................................12
15.4 Structure and Base Configuration of Minerals Applications.............................................................................................16
15.4.1 Application Structure..................................................................................................................................................16
15.4.2 Variable Structure and Data Types..............................................................................................................................17
15.4.3 Control Modules Base Configuration.........................................................................................................................23
15.4.4 Interlocking of Consumer Objects or Groups.............................................................................................................36
15.5 Steps to create a Minerals Application with Control Modules..........................................................................................40
15.5.1 Description..................................................................................................................................................................40
15.5.2 Procedure....................................................................................................................................................................40
15.5.3 Step 1 Create Data Types for Global Structured Variable IO..................................................................................40
15.5.4 Step 2 Declare the Global Structured Variable IO...................................................................................................43
15.5.5 Step 3 Connect I/O-signals to Hardware.................................................................................................................44
15.5.6 Step 4 Create Single Control Module (SCM)..........................................................................................................47
15.5.7 Step 5 Declare the External Variable in SCM..........................................................................................................48
15.5.8 Step 6 Create Control Module Instances (CM).......................................................................................................49
15.5.9 Step 7 Connect Parameters of CM instances...........................................................................................................50
15.5.10 Step 8 Configure or Program Interlocks................................................................................................................53
Chapter 15 - 1
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15.1 General Information

Objectives
On completion of this chapter you will be able to:
Utilize the Minerals Libraries that are used as a base for application configuration
and programming.
Explain the different object types and their basic functionality from the controller
point of view.
Describe the application and variable structure of Minerals Applications.
Insert a motor in an existing group.
Configure and program interlocks.
Legend
>
Indicates when you go from one menu to a sub-menu
Italic
Indicates object and file names
Indicates dialog box buttons, tabs, menus etc.
Bold
Indicates important topics

Indicates start/explanation of student activity or important note
Reference Documentation for Minerals Library AC800M Connect
Chapter 15 - 2
3BHS 161554
Product Guide
3BHS 161555
Overview reference manual
3BHS 161556
Basic Objects reference manual
3BHS 161562
Loop Objects reference manual
3BHS 161557
Consumer Objects reference manual
3BHS 161561
Group Objects reference manual
3BHS 161558
Dosing Objects reference manual
3BHS 161559
Communication Objects reference manual
3BHS 161560
Report Objects reference manual
3BHS 240189
Process Panel reference manual
3BHS 259604
Wrapper Objects reference manual
3BHS 259605
MNSiS MBTCP reference manual
3BHS 253000
Power Distribution Monitoring Objects reference manual
3BHS 294896
GraphiXs user guide
15.2 Minerals Library Overview

Object Categories
The Minerals Library object types can be grouped in nine different object categories.
For each category there is reference documentation available (please refer to 13.1.3).
Basic Objects
Basic Objects (AI, AO, DI, DO) provide access and control for process IO-signals and
calculated IO-signals.
AIS
Analog input module for 1 process signal.
AOS
Analog output module for 1 process signal.
DIS
Digital input module for 1 process signal.
DOS
Digital output module for 1 process signal.
AIC
Analog input module for 1 calculated signal.
AOC
Analog output module for 1 calculated signal.
DIC
Digital input module for 1 calculated signal.
DOC
Digital output module for 1 calculated signal.
Communication Objects
Communication object to establish and supervise the MMS communication.
MMS_COM Provides communication between two AC800 controllers.
Consumer Objects
Consumer objects provide access and control for the physical devices (consumers) in
the plant.
MOT1
MOT1_VVVF Motor with one direction variable speed.
MOT2
Motor with two directions (two speeds).
MOTP
Motorized valve or damper.
VLV1
Normally-closed one-way valve with one or two coils.
VLVNO1
Normally open one-way valve with one or two coils.
Motor with one direction.
Chapter 15 - 3
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Dosing Objects
Dosing objects provide access and control for weigh feeder proportioning.
WFC
Weigh Feeder main control object.
WF_Prop
Dosing object instance (single feeder).
Group Objects
The Group Objects provide access and control for a process group.
GROUP
GrpCycleCtrl Group cycle controller of group members.
PREBIN
Pre-selection of group members.
STW
Start up warning module.
Group sequence control of group members.
Loop Objects
One loop object providing access and control for analog control loops.
PIDCtrl
PID Closed loop controller.
Power Distribution Monitoring Objects

Power monitoring objects to supervise and control power distribution equipments.
CircuitBreaker
Control an IED Control Device.
CircuitBreakerABBREF542Plus
Interface to an ABB REF542+.
Report Objects
Report objects provide access to the production counters.
PulsCount
Pulse Counter for production data reports.
ReportingCount
Reporting counter with shift, day and month log values.
Composite Object Templates - Serial Communication Objects

This category contains wrapper framework to compose project specific consumer
objects having serial communication interface like Profibus or Modbus between
control system and device. This category provides samples to be used as template of
how to implement project specific serial devices. Some examples here:
Chapter 15 - 4
VVVFSerial
ABB Drive system with ProfibusDP

for ACS500, ACS600, ACS800 or ACS1000
MOT1Insum
ABB INSUM with Ethernet / LON
UMC22 ABB
UMC22 MCC device
MOT1_MNSiS_MBTCP
ABB MNS iS MCC with Modbus over TCP/IP
Chapter 15 - 5
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Library Modules
Before starting the application development with the Control Builder M insert the
Minerals main library module in your project:
BMIStandard
This needs some helpers, from Minerals Library, as well as from standard library. The
following Minerals Library modules will be automatically inserted with BMIStandard:
BMIAdaptions
BMIConstAndVar
BMISupport
When weighing feeders are part of your application, the following Minerals Library
module has to be inserted as option:
BMILib_WeighFeeder
The complete library set is called ControlIT AC800M Minerals Library. It contains
all the controller software modules that are used to configure Minerals applications
(main focus being in Minerals Industry) with ControlIT AC800M controllers.
These default standard libraries are

always inserted in your project.
Minerals Library main module.
Helper modules for the main
module are automatically inserted.
Optional Minerals Library module.
These standard libraries are inserted
automatically when inserting the
Minerals Libraries.
Library Module: BMIStandard

The main library module BMIStandard contains the actual set of purpose-build
software module types that are used to configure the Minerals applications.
These software modules have been developed with the ABB Control Builder M
Professional programming tool compliant with the IEC 61131-3 standard.
Chapter 15 - 6
The object related software modules have been developed as Control Module types.
The most Minerals Library object types are included in this part:
Some supporting functions have been developed as Function Block types:
Chapter 15 - 7
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Library Module: BMIAdapations

The library module BMIAdaptions, contains specific Control Modules, that are used
in Minerals applications as an extension to certain Object Types, providing LCB
Local Control Box functionality (local control via push buttons).
Library Module: BMIConstAndVar

The library module BMIConstAndVar contains Data Types and Project Constants
that are used in the other Minerals Library modules and Minerals applications.
Right click
BMIConstAndVar
to select Project
Constants via pop
up menu.
This list of
Data Types
is truncated.
Example:
CM DIS needs
DISData connection
type.
Right click Project

to select all Project
Constants via pop up
menu.
Chapter 15 - 8
The Project Constants window opens:
Each project constant has a structured name that is used to connect the constant value
in the Minerals Library modules internally or in the application. In the example above,
the selected project constant named cBMI.AE.AlarmTr has the value of 3 of data
type dint.
Example of the usage of project constants in CM GROUP parameters:
The parameter (23) AlarmTr gets as initial value from the project constant
cBMI.AE.AlarmTr the value of 3.
Chapter 15 - 9
329668552.doc
Library Module: BMISupport

The library module BMISupport contains specific Function Blocks that can be used
in BMI applications in addition to the standard function blocks delivered with the
system libraries.
Library Module: BMILib_WeighFeeder

The library module BMILib_WeighFeeder, contains the software modules that are
used to configure weigh feeder objects in the Minerals applications.
To become a Weigh Feeder Control proportioning function when designing an

application one Control Module Instance WFC will be combined with several
WFC_Prop Control Module Instances (between 2 to 8).
The WFC proportioning function is normally also used in combination with:
Group
Loop objects
Consumer objects
Preselection
Start Warning
For further details, see the reference manual for Dosing Objects.
Chapter 15 - 10
Library Module Locations in the Aspect Directory

The Minerals Library modules are located after installation and system extension load
in aspect directory in following structures:
Minerals Library part (BMI*) in Library Structure:
NOTE!
Minerals Library part (BMI*) in Object Type Structure:
These lists are truncated, focusing on Minerals Library!
Chapter 15 - 11
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15.3 Minerals Applications Overview

Application Layout and Data Flow
A Minerals Application needs always one global variable IO, several SCMs (Single
Control Modules) and CMs (Control Modules) as well as process connections via HW
(Hardware).
The global, structured variable called IO with its many sub components can be seen
as a big multilayer-multicore software cable acting as a data highway through the
application. It connects the different objects together and enables them to talk to each
other. They can exchange status information like: Run, Value, Limit Status, HW IO
Status, Warning, Failure, Mode, etc. or commands like: Start, Stop, Interlock, Mode
Change, etc. The layers and cores (constructions) are defined on several Data Type
panes and collected on the pane named IO_Type. The global variable IO is declared
(IO of IO_Type) on the application level.
SCM structures its members (CMs) and holds the additional control logic (e.g.
interlocks) if needed.
CM fulfills a control function like: AIS-handling, Group Control, Motor Control, etc.
Global VariableIO
IO editor provides the process connections to the global variable IO.
One application
Naming exampleofIOvariable:
IO.AIS._561_BM1_T1.H1.Normal
SCM (Single Control Module)
AIS(collection)
CM (Control Module)
AIS(AnalogInputSignal)
SCM (Single Control Module)

Customer Logic
Process connections
IO
HW
Chapter 15 - 12
IO
Editor
CM (Control Module)
GROUP(Groupcontrol)
CM (Control Module)
MOT1 (Motorcontrol)
CM (Control Module)
VLV1(Valvecontrol)
Connection Principles and Data Flow
Digital Input Signal (DIS)

HWconnection,IOvariableandControlModule
IO
variable
Control
Module
Digital Input Signal(DIX)

HWconnectionandIOvariable
IO
variable
DIS
Name1
IO.DIS.Name1
oftypeDISData
IO.DIS.Name1.SigHW
oftypeBoolIO
IO
Editor
IO
PCC
HW
HWconnection,IOvariableandControlModule
IO.AIS.Name3
oftypeAISData
IO.AIS.Name3.Signal
oftypeRealIO
IO
Editor
HW
IO
Editor
HW
AnalogInputSignal(AIS)
IO
variable
IO.DIX.Name2
oftypeBool
Control
Module
Analog Input Signal (AIX)

HWconnectionandIOvariable
IO
variable
AIS
Name3
IO
PCC
IO.AIX.Name4
oftypeReal
IO
Editor
HW
Chapter 15 - 13
329668552.doc
Motor Controller(MOT1)anditshelpers
HWconnections,IOvariableconnections,SingleControlModuleandControlModules
DIS(CM)
Name1
IO.DIS.Name1
oftypeDISData
IO
PCC
IO.GroupName1.Name5
oftypeMOT1Data
AIS(CM)
PCC interlockconnections(Method2)
IO.AIS.Name3
oftypeAISData
IO.DIX.Name2 oftypeBool
IO
PCC
IO.DOX.Name6 oftypeBool
Name3
(PCC=ProcessControlConnection)
Single Control Module (SCM)
Customer Logic
&
e.g.PCCLightinterlocksignalslike:
IC,IB1,IB2,IB3,IB4,IA(Method1)
Control Module(CM)
MOT1
Name5
IO
Editor
Chapter 15 - 14
IO
OvertemperatureM1
OverloadM2
AvailabilityM3
FeedbackRunFdBckRun
StartOrderOrd
Group and Process Control Connections

Software Modules in the Minerals Library are able to exchange data on predefined
interface so called control connections (data highway)
o Thestatusformchildobjectsarealwaysreportedtotheparentobjectandvice
versa
o Commandscanbesentfromparentstochildrenandfromchildrentoparents
Group Control Connection GCC Bus
o Executesthestartandstopofconsumersconnectedtothegroupinagivenor
dynamicstart/stoporder
o Summarizestostatusofallconnectedconsumersandindicatesitonthegroup
object
o Selectorsallowconditionalstart,routing,dutystandbyandflyingchange
overapplications
o GCCbusisincludedinIOvariable
Process Control Connection PCC Bus - PCC interlock
o Connectsconsumerobjectswiththeirinterlockingandprocesscontrolsignals
o Parametersonthesignalmodulesdefinetheinterlockbetweenthesignaland
theconsumer
o Theoperationalstatusoftheconsumerisusedtodefinethealarmbehaviorof
thesignal
o PCCbusisincludedinIOvariable
Group and Process Control Data Flow

Group
control
Group(CM)
Consumers
Motor (CM)
GCC
Bus
PCC
Bus
Signals
AIS (CM)
DIS (CM)
AIS (CM)
Valve (CM)
DIS (CM)
AIS (CM)
PID (CM)
DIS (CM)
Chapter 15 - 15
329668552.doc
Control Modules (CM) and variable connections for GCC and PCC connections. GCC
and PCC are components of the structured IO variable.
Chapter 15 - 16
Group and Process Control Connections
IO
variable
Groupcontrol
ControlModule(CM)
Consumer: Motor/(Valve/PID)
ControlModule(CM)
Signal: AIS/(DIS)
GCC
Bus
ControlModule(CM)
PCC
Bus
PCC interlock
configuration
Chapter 15 - 17
329668552.doc
Chapter 15 - 18
15.4 Structure and Base Configuration of Minerals Applications

Application Structure
1 Process section 1 Application 1 Controller:
For each Process Section (e.g. raw mill, cement mill, kiln, etc.) one Application is
created in the corresponding project. The general rule is that one application is
assigned to one Controller.
The application N1
is connected to
controller N1.
One Minerals Application typically consists of three major items:

Global Variable
:
Variable called IO.
Data Types
Structure (the construction) of the IO variable.
Control Modules
Functionality of the application.

Application object holds
the global variable IO.
Data Types of the application
define the structure and the
component types of the global
variable IO.
Control Modules define the

functionality of the application.
Chapter 15 - 19
329668552.doc
An application could have own

Function Block Types, Control
Module Types and Programs too.
Chapter 15 - 20
Variable Structure and Data Types

Declaration of Global Variable IO and Task Pointers
The global variables are declared on the application level. Every application consists
of one, global, structured variable called IO. The data type of the IO variable is
IO_Type, which is defined in the application too. The variable is hidden from OPC.
In order to connect controllers tasks to the SubControl modules of the BMI_Standard
Lib, the corresponding global variables must be defined as task pointers in the
application. The data type is string constant.
Data Types
The Data Types are used for the following purpose:
To set-up the structure (via structured data types) of the global variable IO.
To define all the variable components and their data types that are going to be
needed in the application.
Chapter 15 - 21
329668552.doc
Sample of the data types in the Minerals Applications:
Open the
Data Type Editor.
Data Type: IO_Type

The data type IO_Type is open in the editor.
Components for
I/O-signals
Components for
Group Controls
Other components
All components and their data types defined here are going to be needed in the
application. The actual signals for each Data Type (Component Type) are defined in
separate tables, in so-called Data Types. The IO_Type collects all underlaying type
definitions together into common structure.
Chapter 15 - 22
Reference Table, Classification of Digital Input Signals:

Name
DIS
DIX
DIC
Functionality
Digital Input Signals, that are going to be presented on the operator station
(as alarm and/or dynamic point in a graphic display)
Digital Input Signals, that are NOT presented on the operator station
(only used in the application in the Control Builder). The signal is in general
connected to an input of an object, like an availability signal for a motor.
Digital Input Calculated. Signals that are going to be presented on the operator
station (as alarm and/or dynamic point in a graphic display) and that are the
result of a calculation or control logic in the application.
The principle is the same for the following type of signals:

AIS/AIX/AIC
:
Analog input signals
DOS/DOX/DOC
Digital output signals
AOS/AOX/AOC
Analog output signals
Data Type: DIS_Type

All the variables for the digital input signals of the type DIS are defined in the Data
Type DIS_Type, in the corresponding application (N01):
Component names
=
Variable names
=
Signals
Each digital input signal itself contains a set of pre-defined sub variables, which are
defined by Data Type DISData. DISData in turn is defined in the library module
BMIConstAndVar (which is read only).
Examples of connecting the global, structured variable IO:

IO.DIS._561_BC1_D1
; Complete variable connection.
IO.DIS._561_BC1_D1.SigHW
; S800 HW I/O connection.
IO.DIS._561_BC1_D1.Signal.Value; Picking up the value only.
IO.DIS._561_BC1_D1.Signal.Normal
; Picking up the normal state.
Chapter 15 - 23
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Data Type: DIX_Type

All the variables for the digital input signals of the type DIX are defined in the Data
Type DIX_Type. The most signals are inputs (of type bool) for control modules:
Component names
=
Variable names
=
Signals
Example of connecting the global, structured variable IO:

IO.DIX._561_BC1_M1_ON
Data Type: AIS_Type

All the variables for the analog input signals of the type AIS are defined in the Data
Type AIS_Type:
Each analog input signal itself contains a set of pre-defined sub variables, which are
defined by Data Type AISData. AISData in turn is defined in the library module
BMIConstAndVar.
IO.AIS._561_BM1_T1
IO.AIS._561_BM1_T1.Signal
; S800 HW I/O connection.
IO.AIS._561_BM1_T1.FilteredSignal
; Filtered value connection.
IO.AIS._561_BM1_T1.H1.Normal
; Normal state of H1 limit connection.
Chapter 15 - 24
Data Type: Group_Type

Example: Components for the Group GR_591_1:
AllthevariablesfortheobjectsandgeneralsignalsfortheGroupGR_591_1 are
definedinthetableGR_591_1_Type.
Variables for
Preselections
General variables
for the Group
Variables for the

Consumer Objects
Each Preselection (P1 P5) contains a set of pre-defined sub variables, which are
defined in the Data Type PreBinData. PreBinData in turn is defined in the library
module BMIConstAndVar.
The principle is the same for all other objects that can be part of a group:
MOT1, MOT2, MOTP, MOT1_VVVF :
Motor objects
NOTE!
PIDCtrl
VLV1, VLVNO1 :
PID Controller
Valve objects
Each object type (MOT1, MOT2,) has its corresponding set of pre-defined sub
variables that are defined in its object type specific Data Type, in the library
BMIConstAndVar.
E.g.
MOT1 -> MOT1Data

MOT2 -> MOT2Data
VLV1 -> VLV1Data

IO.GR_591_1.P1.PreSel
; P1 Preselection on.
IO.GR_591_1.GrpDrvCon
; Group Control Connection.
IO.GR_591_1._591_AS2_M1.Out.Rfs
; Motor ready for start.
IO.GR_591_1._591_AS2_M1.In.IC
; Do safety interlock motor.
Chapter 15 - 25
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Schematic Data Structure of a typical Minerals Application
Variable component name

(collection) and its data
type
IO IO_Type
Global variable IOof

DataTypeIO_Type
AIS
AIS_Type
AIC
AIC_Type
AIX
AIX_Type
AOS
AOS_Type
AOC
AOC_Type
AOX
AOX_Type
DIS
DIS_Type
DIC
DIC_Type
DIX
DIX_Type
DOS
DOS_Type
DOC
DOC_Type
DOX
DOX_Type
<Grp1>
<Grp1>_Type
<Grp2>
<Grp1>_Type
<Grp3>
<Grp1>_Type
<Grp4>
<Grp1>_Type
STW
System
MMSCom
Chapter 15 - 26
STW_Type
System_Type
MMS_Type
Variable
names
Predefined data types from

BMIConstAndVar
or simply data types
<AI Var 1>
AISData
<AI Var 2>
AISData
<AI Var 3>
AISData
<AO Var 1>
AOSData
<AO Var 2>
AOSData
<AO Var 3>
AOSData
<DI Var 1>
bool
<DI Var 2>
bool
<DI Var 3>
bool
In
GrpInput
Out
GrpOutput
GrpDrvCon
GrpDrvCon
<P1>
PreBinData
<P2>
PreBinData
<Cons 1>
MOT1Data
<Cons 2>
MOT2Data
<Cons 3>
VLV1Data
<My Var 1>
bool
<My Var 2>
real
<STW 1>
STWData
<STW 2>
STWData
<Board1>
dint
<Board2>
dint
<MCC1>_AV
bool
N1_N2
N1_N2_Type
<Signal1>
real
N2_N1
N1_N2_Type
<Cons1>_RFS
bool
<Cons1>_RUN
bool
Variable names for

AIS signals
--C_Type always
uses --SData type
--X type always

uses simply data
type
(bool or real)
In, Out and

GrpDrvCon are
always required for
a Group
Variable names for
Pre-selections
Variable names for
consumer objects
Optional Group
specific variables, if
needed
Control Modules Base Configuration

There are two categories of control modules:
Single Control Module - SCM
SCM is structuring / grouping the underlaying Control Modules (CM) and
holding the control code for glue logic / interlock logic (PCC-Light method, done
with POU editor) for CMs. Additionally an External Variable is referencing the
global variable IO.
Control Module - CM
CM is normally located under SCM and executes a given function like handling
of an Analog Input Signal (AIS) or controlling a Motor Object (MOT1), etc.
For each type of I/O-signal

there is one SCM.
SCMs for process I/O-signals
and calculated I/O-signals.
Under SCM there are CMs:
CMAIS
Handlesoneanaloginput
signal.
For each Group there is

one SCM.
Under SCM there are
CMs:
CM GROUP
Performs group control.
CM PREBIN
Handles a preselection.
CM MOT1 & MOTP
Controls a motor object.
CM Instance Name
NOTE!
CM Object Type
SCMs: DIX, DOX, AIX, and AOX do not have any CMs. They are intended to be
container for seldom needed special control logic with --X type signals.
Chapter 15 - 27
329668552.doc
Single Control Modules (SCM) for I/O-signals

For each type of I/O-signal collection one Single Control Module (SCM) is created if
needed, as shown below:
Under the corresponding SCM, a collection of CM instances of the corresponding

Object Type are created.
DIS Collection SCM

All CM instances for the digital input signals of the type DIS are created under the
SCM, which is called DIS.
For each DIS-Signal there is one

CM instanceoftheObjectType
DIS.
RULE:
Chapter 15 - 28
The instance name of the CM DIS must be the same as the variable name created in
the Data Type DIS_Type !
AIS Collection SCM

All CM instances for the analog input signals of the type AIS are created under the
SCM, which is called AIS.
For each AIS-Signal there is one

CM instanceoftheObjectType
AIS.
RULE:
The instance name of the CM AIS must be the same as the variable name created in
the Data Type AIS_Type !
Other Signal Collections SCMs

The principle is the same for all --S and --C type of signals:
DIS, DIC; AIS, AIC; DOS, DOC; AOS, AOC. (The --X types do not have any CM).
RULE:
The instance name of the CM must be the same as the variable name created in the
Data Type!
Single Control Modules (SCM) for Group and Start Warning Objects
For each Group and Start Warnings belonging to a process section / application, one
Single Control Module (SCM) is created, as shown below:
Group GR_561_1_Control SCM

Under the corresponding SCM for a Group, CM instances of the Consumer Objects
that are member of that Group are created.
This Group has the following instances:

1CMinstancefortheGROUP
object
5CMinstancesforthemotorsof
thetypeMOT1
RULE:
Data Type!
Chapter 15 - 29
329668552.doc
Group GR_591_1_Control SCM

As example here the cement transport group is shown. Under the SCM
GR_591_1_Control the CM instances for the objects that are member of that Group
are created.
This Group has the following instances:

1CMinstancefortheGROUP
object
20CMinstancesfordifferent
kindofobjects.
RULE:
Data Type!
Start Warning StartWarn collection SCM

Under the SCM the CM instances of type STW are created to provide start up
warnings for the consumer objects or for the groups.
RULE:
Chapter 15 - 30
Data Type!
Single Control Modules (SCM) hosting External Variable to IO

An External Variable is declared on SCM to point at the global variable IO. This
allows that SCM and the underlaying CMs accessing that variable.
The Global Variable IO has to
be linked by External Variable
to get it visible under SCM.
Control Modules (CM)

Each CM instance under the corresponding SCM has to be configured via the
Parameter List of that instance. We also say the parameters of the instance need to
be connected.
CM DIS
Configuration of the CM digital input signal of the type DIS, which has the
instance name _561_BC1_R4. Open the Connections Editor:
Chapter 15 - 31
329668552.doc
If no initial
value, then
parameter must
be connected!
Chapter 15 - 32
The description part of the CM DIS:
Example: Parameter entry No. 3 - Connection to DISData variable of IO

NOTE!
Parameters that have no Initial Value must be connected, otherwise a red error
indication will be shown, in the Project Explorer.
RULE:
The instance name of the CM and the variable component name in IO must be the
same.
The connection with the parameter IO must be done and follow the rule. In this
example the parameter IO is connected to the variable IO.DIS._561_BC1_R4
(structured variable of type DISData).
Generally:
NOTE!
Parameters that have an Initial Value can remain unconnected if not needed. If
unconnected, the Initial Value is used as the default connection instead.
MORE:
Please, see Basic Objects reference manual
3BHS 161556
Chapter 15 - 33
329668552.doc
CM AIS
Configuration of the CM analog input signal of the type AIS, which has the
instance name _561_BM1_T2. Open the Connections Editor:
If no initial
value, then
parameter must
be connected!
Chapter 15 - 34
The description part of the CM AIS:
MORE:
Please, see Basic Objects reference manual
3BHS 161556
Chapter 15 - 35
329668552.doc
CM GROUP
Configuration of the CM GROUP, which has the instance name GR_561_1.
Open the Connections Editor:
GrpDrvCon
is the
communication bus
between group
members
Chapter 15 - 36
The description part of the CM GROUP:
MORE:
Please, see Group Objects reference manual
3BHS 161561
Chapter 15 - 37
329668552.doc
CM MOT1
Configuration of the CM MOT1, which has the instance name _561_BC1_M1.
Open the Connections Editor:
Start and stop No. of

the motor in the
group.
Chapter 15 - 38
MOT1 parameters (continues):
MORE:
Please, see Consumer Objects reference manual
3BHS 161557
Chapter 15 - 39
329668552.doc
The description part of the CM MOT1:
Chapter 15 - 40
Interlocking of Consumer Objects or Groups

The basic sequential control (automatic sequential start-up and shut-down) of the
different consumer objects that belong to a group is performed by the GROUP object.
Nospecificapplicationprogrammingisrequired
forthis,onlytheconfigurationoftheConsumerObjects,isrequired.Asexample
youneedtoconfigurethestartstepandthestopstepviatheparameters
GrpStartStepandGrpStopStep.
Interlocking of consumer objects can be done by two ways:

- By configuring the PCC interlock parameters on Signal Level (newer, method 2).
- By programming the PCC-Light interlock logic in the SCM (older, method 1).
Configuring PCC Interlock Parameters on AIS / DIS CM

Example of method 2: PCC interlock parameters on DIS CM pane:
AISPCCisconnectedtoaconsumer
(temperaturemeasurementtomotor).
PCC interlockconfiguration:
IfthetemperatureexceedsH2,thena
safetyinterlockisactivated.
PCC interlockconfiguration:
IfthetemperatureexceedsH1,thenan
equipmentinterlockisactivated.
Chapter 15 - 41
329668552.doc
(See also section: Connection Principles and the Data Flow).
Chapter 15 - 42
Possible configuration settings for Interlock Type:

IntrlkType
Configuration
Description
PCC_Disabled
No alarm or interlock forwarding on PCC bus
No_Interlock
No interlock forwarding, only alarm forwarding
PD_PrevDrive
Previous drive interlock, group remains ready for start
IA_Process
Process interlock
If the consumer is in Auto mode the IA interlock is not reset again on
the ok condition. It is only reset by an Auto_Start command from
another PCC limit or signal
IA_Process_RFS
Process interlock, group remains ready for start

Same functionality in Auto as described above.
IB_Equipment
Equipment interlock
IB_Equipment_RFS
Equipment interlock, group remains ready for start
IC_Safety
Safety interlock
IC_Safety_RFS
Safety interlock, group remains ready for start
Auto_Start
Only used if consumer is in Auto mode: removes retained IA

interlock if it is not active anymore and thus the drive will start
(IO.In.IA also needs to be ok)
Possible configuration settings for Interlock Direction:

IntlkDir
Configuration
Description
DirX
Configured interlock is only valid for direction X
DirXStart
Same as DirX, but once the consumer is running in direction X (or

has reached end position X) the interlock is disregarded.
DirY
Configured interlock is only valid for direction Y
DirYStart
Same as DirY, but once the consumer is running in direction Y (or has
reached end position Y) the interlock is disregarded.
DirXY
Configured interlock is valid for direction X and Y
DirXYStart
Same as DirXY, but once the consumer is running in direction X/Y

(or has reached end position X/Y) the interlock is disregarded.
Chapter 15 - 43
329668552.doc
PCCinterlockparameterconfiguration
method2isvaliduptheMineralsLibraryversion5.1/2.
FormoreinformationseealsothereferencemanualBasicObjects,Common
Data
Programming PCC-Light Interlock Logic on SCM level

The SCM can host code blocks for interlock logic (method 1).
Different Code Blocks contain the necessary Glue or Interlock Logic.
One Code Block contains

the Pre-Selection Logic
(only if preselection is
available in the Group;
PREBIN objects).
One Cod Block contains

the Interlock Logic for the
GROUP itself.
Chapter 15 - 44
For each COMSUMER

object one Code Block
contains the corresponding
Interlock Logic.
NamingconventionoftheCodeBlocks:
PreSelection
PreSel_Control
Groupinterlocks
Intrl_<GROUPNAME>,e.g.Intrl_291_GR1
Consumerinterlocks
Intrl_<OBJECTNAME>,e.g.Intrl_291_BC3_M1
Chapter 15 - 45
329668552.doc
Reference Table, Interlocks (described behavior can be changed by project constants):

IC
IB1
IB2
IB3
Type of interlock
Safety interlock
Active in all control modes.
Process interlock
Not active in control mode Local
Process interlock
Process interlock
IB4
Process interlock
IA
Auto or Chain interlock
Description
Stops the motor and prevents the motor from
starting as long as the interlock is on.
starting as long as the interlock is on
Functions as start interlock when the parameter
IBF=1.
starting as long as the interlock is on
Functions as start interlock when the parameter
IBF=1.
Not included in Group ReadyForStart signal.
If Object is in Seq Auto Mode or Central Auto
Mode IA Starts and Stops the Motor.
This can be used to start and stop an object by
process once the group or operator has put it to
Auto.
If Object is in Seq Manual Mode or Central
Manual mode, IA stops the motor and the motor
must be started from Seq or Cen again.
PD
Chain interlock, previous drive
Not included in Group ReadyForStart signal.

Chapter 15 - 46
15.5 Steps to create a Minerals Application with Control Modules

Description
This section describes the main working steps to create a part of a motor group e.g. a
conveyer group for the mill feed using Minerals Library Control Modules. It assumes
that the new application is created and connected to controller. The controller has its
hardware created.
Procedure
To create a part of a conveyer group using Control Modules the following main steps
need to be done:
1. In the corresponding application, create all the Data Types needed for the global
variable IO.
2. Create the global variable IO on the application level.
3. Connect the corresponding components of the global variable IO to hardware
I/O-signals.
4. Create a Single Control Module (SCM) under the branch control modules.
5. Declare the External Variable in SCM to reference the global variable IO.
6. Create Control Module Instances (CM) under the new SCM.
7. Connect the Parameters of the CM instances to the components of the global
variable IO or enter direct parameters.
8. Define the needed interlocks, preselections and control logic. The most
interlocks and preselections can be done in two ways: Either configuring the
parameters in the corresponding IO control modules or programming the logic
in SCM.
Step 1 Create Data Types for Global Structured Variable IO

1.1 In the application right click Data Types and select New Data Type.
1.2 Type the Name of the Data Type you want to create and click OK.
Chapter 15 - 47
329668552.doc
1.3 The Data Type DIX_Type has been created.
1.4 Right click DIX_Type and select Editor.
1.5 The Data Type Editor with DIX_Type opens.

Insert the needed Signal-Components (data type is bool).
1.6 Save your work.

1.7 Repeat the steps 1.1 - 1.5 for DIS_Type
1.8 and save your work.

1.9 Repeat the steps 1.1 - 1.5 for all signal types you need and save your work.
Chapter 15 - 48
1.10 Continue with the creation of Data Types for the Groups. Right click Data
Types and select New Data Type.
1.11 Type the name of the Data Type for the group click OK.
1.12 Right click GR_561_1_Type and select Editor
1.13 The Data Type Editor with GR_561_1_Type opens.

Insert the needed variable components for the group.
1.14 Finally create the main data type the IO_Type which collects the all created sub
types.
1.15 The name of the data type is IO_Type:
Chapter 15 - 49
329668552.doc
1.16 Right click IO_Type and select Editor
1.17 The Data Type Editor with IO_Type opens.

Insert (collect) here the all created sub types.
Step 2 Declare the Global Structured Variable IO

2.1 Right click IO_Type and select Editor
2.2 Declare the Global Variable IO and the task pointers.
2.3 Save your work
Chapter 15 - 50
Step 3 Connect I/O-signals to Hardware

The I/O parameters of a Control Module Instance are connected to components of
the global variable IO which in turn will be connected to the corresponding I/Ochannels. Do following steps to connect the I/O-signals:
3.1 Right click the corresponding I/O-module under the branch Controllers and select
Editor or just double-click on the I/O-module
3.2 Now the I/O Editor window is opened. Select the tab Connections.
Chapter 15 - 51
329668552.doc
3.3 Perform the connections to the corresponding variables, channel by channel:

- Select the Variable-field of the I/O channel.
- Use the navigator Insert Parameter from Tree and select the variable
component intended for the I/O part by double clicking the component.
Data Type of
Signal
Data Type of
selected I/O
component
Tree
navigator
I/O component
of structured
global variable
NOTE! Signal type BoolIO accepts component types BoolIO and "Bool
3.4 Add the I/O Description and save your work.
Example of Digital Input Module

3.5 Repeat connecting next I/O channels.
Chapter 15 - 52
3.6 Following examples about connections to different module types:
Example of Digital Input Module
Example of Digital Output Module
Example of Analog Input Module
Example of Analog Output Module

NOTE! Signal type BoolIO accepts component types BoolIO and "Bool
Signal type RealIO accepts component types RealIO and "Real
Chapter 15 - 53
329668552.doc
Step 4 Create Single Control Module (SCM)

The Single Control Module constitutes a way to group variables, parameters and
Control Module instances into a single unit as well as provides code blocks for
additional control logic. There can be several Single Control Modules in one
application. Do following steps to create a Single Control Module:
4.1 In the application right click Control Modules and select New Single Control
Module.
4.2 Type the name of the Single Control Module you want to create and click OK.
4.3 Single Control Module GR_561_1 has been created.
Chapter 15 - 54
Step 5 Declare the External Variable in SCM

An External Variable declared inside a SCM is a pointer to a global variable declared
on application level allowing direct access to that. If the External Variable is missing,
the global variable is not seen from SCM. Minerals Applications allways reference
here to a structured global variable called IO. Do following steps to declare the
External Variable:
5.1 Right click Single Control Module and select Editor.
5.2 Select the External Variables tab. Type in the reference to the global variable IO
(or copy it from application level) on the declaration line.
5.3 Save your work.
Chapter 15 - 55
329668552.doc
Step 6 Create Control Module Instances (CM)

Control modules could be called super function blocks which normally fulfills a
bigger function like group control, motor control, valve control, pid control, etc. In
this example two first CMs are created, a CM for the group control and a CM for the
mill motor. Do following steps to create a Control Module instance:
6.1 Right click Single Control Module and select New Control Module.
6.2 Select the Library, the Control module type and give the Instance name, do
not Connect parameters yet, terminate with OK. Repeat steps 6.1 and 6.2.
(Entry e.g. BMIStandard, GROUP, GR_561_1 and BMIStandard, MOT1,
_561_BM1_M1.
NOTE!
Rules for the Instance Name:

Numbers are not allowed as first character.
Spaces and special characters are not allowed.
Only the character underline _ is allowed.
6.3 The Control Modules GROUP and MOT1 have been created and are shown in the
project explorer. The red triangles indicate that some mandatory parameter
connections in CMs are not done yet.
Chapter 15 - 56
Step 7 Connect Parameters of CM instances

Parameters are inputs to or outputs from the Control Module (CM). If the
parameter has an Initial Value it is connected by need, if not, then the parameter
must be connected (otherwise a red triangle indicates this deficiency). The parameters
are connected to global variable IO or seldom to local variables defined in the
surrounding SCM or as direct entry parameter. Do following steps to connect the CM
parameters:
7.1 Right click CM instance and select Connections or just double click it.
7.2 Now the Connections window is opened. Here you can perform the necessary
parameter connections. Start entering the direct entry parameters like Name,
Description, StwFirst and so on. The string parameter needs -delimiters
(high comma).
Direct entry
parameter
Chapter 15 - 57
329668552.doc
7.3 Continue connecting the parameters to the global variable IO. Use the
navigator Insert Parameter from Tree. Connect variables like IOIn,
IOOut, IOGrpDrvCon and so on.
Tree
navigator
Data types
matching
Component of
structured global
variable
As result, the group parameters are connected to the components of the global
variable IO.
If no initial value then

parameter must be
connected!
7.4 Save and Close your work. The red indication has disappeared now, because all
the necessary connections to the CM instance are correct.
Chapter 15 - 58
7.5 Repeat the steps 3.1 3.4 for MOT1 (mill motor). The relevant parameters could
be as follow.
and after saving and closing there are no red triangles any more.
Chapter 15 - 59
329668552.doc
Step 8 Configure or Program Interlocks

Interlocking of consumer objects can be done by two ways:
ByconfiguringthePCCinterlockparametersonSignalLevel.
Thisisthenewer(method2)preferredwaytoengineertheinterlocks.
ByprogrammingthePCCLightinterlocklogicintheSCM.
Thisistheolder(method1)waytoengineertheinterlocks.
Configure PCC Interlock Parameters on Signal Level

8.1 Right click CM instance DIS or AIS and select Connections
or just double click it.
8.2 The Connections pane opens. Enter the parameters for PCC interlocks you
need.
Parameter 4: PCC points at the consumer object belt conveyer.

Parameter 14:
IntlkTypeAlarm defines the safety interlock.
8.3 Save your work.
Chapter 15 - 60
Program Interlock Logic on SCM Level

1. Right click the corresponding SCM and select Editor
2. The window of POU Editor is open. Right click the code block tab, insert a new
one and program the needed interlock logic.
This example shows: If the drift switch (DIS) goes out from normal state, then the
IC-signal (safety interlock) for the motor trips it.
- Signal is high = OK
- Signal is low = Interlock active.
3. Save your work
Chapter 15 - 61

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800xA Minerals Training

Chapter 15 Minerals Library Minerals Applications

15.1 General Information

Describe the application and variable structure of Minerals Applications.

Insert a motor in an existing group.

Configure and program interlocks.

Indicates when you go from one menu to a sub-menu

Indicates object and file names

Indicates dialog box buttons, tabs, menus etc.

Indicates important topics

Reference Documentation for Minerals Library AC800M Connect

Overview reference manual

Basic Objects reference manual

Loop Objects reference manual

Consumer Objects reference manual

Group Objects reference manual

Dosing Objects reference manual

Communication Objects reference manual

Report Objects reference manual

Process Panel reference manual

Wrapper Objects reference manual

MNSiS MBTCP reference manual

800xA Minerals Training

Power Distribution Monitoring Objects reference manual

GraphiXs user guide

15.2 Minerals Library Overview

Analog input module for 1 process signal.

Analog output module for 1 process signal.

Digital input module for 1 process signal.

Digital output module for 1 process signal.

Analog input module for 1 calculated signal.

Analog output module for 1 calculated signal.

Digital input module for 1 calculated signal.

Digital output module for 1 calculated signal.

MMS_COM Provides communication between two AC800 controllers.

MOT1_VVVF Motor with one direction variable speed.

Motor with two directions (two speeds).

Motorized valve or damper.

Normally-closed one-way valve with one or two coils.

Normally open one-way valve with one or two coils.

Motor with one direction.

Weigh Feeder main control object.

Dosing object instance (single feeder).

GrpCycleCtrl Group cycle controller of group members.

Pre-selection of group members.

Start up warning module.

Group sequence control of group members.

PID Closed loop controller.

Power Distribution Monitoring Objects

Control an IED Control Device.

Interface to an ABB REF542+.

Pulse Counter for production data reports.

Reporting counter with shift, day and month log values.

Composite Object Templates - Serial Communication Objects

ABB Drive system with ProfibusDP

ABB INSUM with Ethernet / LON

800xA Minerals Training

UMC22 MCC device

ABB MNS iS MCC with Modbus over TCP/IP

These default standard libraries are

Library Module: BMIStandard

800xA Minerals Training

Some supporting functions have been developed as Function Block types:

Library Module: BMIAdapations