Professional Documents
Culture Documents
Project report
By
Kristian Knudsen and Espen Seljemo
Telephone: 76 96 60 00
Title Date
Installation and demonstration of 20.10.2006
ABB IndustrialIT 800xA SYSTEM Gradation:
at Narvik University College Open
Abstract
This project is an introduction to the IndustrialIT 800xA system made by the firm Asea
Brown Boveri (ABB). It is a very large, modern automation- and control system and it
is installed at many oil and gas facilities world wide. The 800xA system is not a plug
and play equipment. There are many options that must be taken before system
installation and during the installation to create exactly the environment you want.
The different communication forms and the width of possibilities with the I/O modules
make the 800xA hardware very scaleable against existing systems that already exist on
the market.
Keywords
Asea Brown Boveri, ABB, IndustrialIT, AC 800M controller, Automation, Network
topology, software, hardware, I/O modules, analogue input and output, digital input and
output, 800xA system, interface, cable connection, communication
Preface
The problem with most automation control systems is that they are seldom more than a
control system. This is where IndustrialIT system shows its true colors as a complete
system including control, analysis and maintenance in only one package.
This report is written by two master degree students at Narvik University College (NUC),
and is a part of the course Prosjektfag. We both have a Bachelor degree in Automation
from Høgskolen i Tromsø.
The object of this project is to set up a simple system using IndustrialIT 800xA system
from ABB. This is also an introduction project to our Master thesis. The duration of this
project is 15 days.
The main sources of this report are the research we have done and the documentation by
ABB. The documentation made by ABB is very thorough and extensive, this makes it
both good and hard to use. The total size of the documentation is approximately 16.000
pages which is renders it difficult to get trough it all.
The project main goal is to make us comfortable with IndustrialIT. This could have been
done by sending us on the courses held by ABB. But as NUC has a “no course” policy,
we are learning this by ourselves doing the trail and fail method. It actually makes us
understand the system better. Our journey trough the installation, configuration, and
finally, testing our system will give us the insight needed to show why IndustrialIT is such
a success.
We would like to thank our supervisor Bjørn Solvang for the help he has given us during
this project and our laboratory chief Tony Inge Ludvigsen. We would also like to thank
ABB by Ståle Stenberg and Arne- Ivar Iversen for their outstanding support on
IndustrialIT system.
Narvik 20.10.2006
_______________________ _______________________
Kristian Knudsen Espen Seljemo
1
Abstract
This project is an introduction to the IndustrialIT 800xA system made by the firm Asea
Brown Boveri (ABB). It is a very large, modern automation- and control system and it is
installed at many oil and gas facilities world wide, onshore and offshore and at other
industrial facilities. For example Statoil`s LNG facility Snehvit located at Hammerfest.
IndustrialIT 800xA is a huge and flexible system with many communication opportunities
to already exciting technology like Fieldbus, profibus and Hart. This makes it easy to
communicate with other systems and at the same time give the users the benefits that
IndustrialIT system gives.
It is equipped with powerful hardware and software which have many opportunities to
design and implement the system exactly after the given requirements.
We created a small system which consists of: One computer, one AC 800M controller
and I/O modules. Made a short program where we simulated the movement on sliding
doors in a shop when customers arrive. This program gave us an opportunity to test data
communication between computer and 800xA hardware equipment.
The 800xA system is not a plug and play equipment. There are many options that must be
taken before system installation and during the installation to create exactly the
environment you want. This makes the system very flexible and it can be installed or
implemented in almost any industrial environment.
In this project we had to read the following installation manuals for the 800xA system
and installed hardware and software systems separately before trying to communicate
with both parts. When installing this system we got a few but solid problems. We
discovered that the 800xA system is not just a Plug and Play package. There are many
opportunities and choices that must be made in planning the system and during the
installation. We used the trail and fail method to solve different problems that was not
explained in the manuals. Some problems that occurred in the installation process where
very strange and we could not find a solution to it so we needed to contact ABB for
support.
The different communication forms and the width of possibilities with the I/O modules
make the 800xA hardware very scaleable against existing systems that already exist on
the market.
Future work with 800xA system is to install a bigger solution which includes 3 nodes in a
network. One server node connected to a main controller with analogue or digital
equipment attached. On the other two nodes in this network we will create one operator
workplace and one engineering workplace.
2
Vocabulary
AC Alternating current, where current direction vary cyclically.
AC 800M Controller A controller which handles the signals from I/O modules.
AluRack A homemade rack for using in school experiments. These are
equipped with DIN rail for connecting electrical components.
Aspect Server “A server that runs the central functions of the Aspect Object
architecture, such as Aspect Directory, Structure and Name
Server, Cross Referencing, File Set Distribution, and so on.
The Aspect Server is normally used as the Windows domain
controller for the control and client/server networks.” [9]
Connectivity Server A server that provides access to controllers and other sources
for real-time data, historical data, and alarm and event data. A
node containing this is in our case connected to the AC 800M
controller. [9]
Control system A system used to automate a facility or process. Example;
controlling the air and heat in a building.
DC Direct current, constant flow of electrons in one direction.
DIN rail Standardized 35mm wide metal rail where electronic
equipment easily can be mounted on.
Foundation Fieldbus Fieldbuses are a type of industrial communication standard.
You can use several forms of transmitting data such as copper
cable, fiber optics or wireless. [8]
Hardware Physically equipment.
IndustrialIT ABB’s vision for enterprise automation. [10]
I/O Module Blocks that are connected to the AC 800M controller. These
can be either analog or digital, and handle input or output
signals.
IP Internet protocol standard for communication between nodes
in a network
LED Light Emitting Diode.
MAC Media access control is a unique ID address on the network
card. This address determines who is allowed to connect
physically to the media or node.
Node A computer communicating on a network e.g. the Internet,
Plant, Control or I/O network. Each node typically has a
unique node address with a format depending on the network
it is connected to.
3
Profibus A type of Fieldbus communication standard. This is one of
the most universal Fieldbuses.[8]
RJ 45 Connection plug on Ethernet communication cable
Software Computer programs for different use.
Topology The method or specific way computers and other network
devices are put together in network.
4
Figure list
Figure 1 Historical review .................................................................................................. 9
Figure 2 View over different aspects in IndustrialIT 800xA system ................................. 10
Figure 3 AC 800M controller ........................................................................................... 12
Figure 4 MTU Bracket...................................................................................................... 13
Figure 5 I/O Module ......................................................................................................... 13
Figure 6 AC 800M with two I/O modules ........................................................................ 14
Figure 7 Power Supply SD 821 ........................................................................................ 15
Figure 8 Own designed AluRack...................................................................................... 16
Figure 9 Connection example [5] ..................................................................................... 17
Figure 10 Internet protocol TCP/IP settings on PC .......................................................... 18
Figure 11 Topology tree of computer, controller and I/O [3]........................................... 19
Figure 12 Interference between interfaces in the 800xA system [7] page 43................... 22
Figure 13 Process portal and OPC server placing ............................................................ 23
Figure 14 Hardware tree in program Control Builder M Professional ............................. 23
Figure 15 Plant explorer workplace layout window ......................................................... 24
Figure 16 Program editor window .................................................................................... 25
Figure 17 Real object, Process window and Aspect objects [4] ....................................... 27
Figure 18 System connections on our 800xA system....................................................... 29
Figure 19 Future topology with tree nodes ....................................................................... 30
Figure 20 Command prompt window ............................................................................... 36
Figure 21 Setup wizard for OPC server account .............................................................. 37
Figure 22 Configuration Wizard start ............................................................................... 82
Figure 23 Configuration Wizard....................................................................................... 82
Table list
Table 1 Contents of 800xA system.................................................................................. 11
Table 2 Hardware requirement ......................................................................................... 11
Table 3 I/O modules information...................................................................................... 13
Table 4 Connection table 220V ........................................................................................ 15
Table 5 Connection table 24V .......................................................................................... 15
Table 6 Example of IP adresses ........................................................................................ 18
Table 7 Scheme over diagnostic LED’s on AC 800M [1]................................................ 36
5
Contents
1. Introduction..................................................................................................................... 7
2. Asea Brown Boveri (ABB)............................................................................................. 8
3. Historical review of automation systems........................................................................ 9
4. IndustrialIT 800xA system............................................................................................. 10
5. Hardware....................................................................................................................... 11
5.1 Computer requirements..................................................................................... 11
5.2 AC 800M Controller ............................................................................................... 12
5.3 I/O modules....................................................................................................... 13
5.4 Power supply..................................................................................................... 15
5.5 AluRack ............................................................................................................ 16
6 Communication......................................................................................................... 17
6.1 Cabling and Connections .................................................................................. 17
6.1.1 Switch or a hub ................................................................................................ 18
6.1.2 Directly to AC 800M controller....................................................................... 18
6.2 Network addresses ............................................................................................ 18
6.3 Firmware communication ....................................................................................... 19
6.4 Network topology ............................................................................................. 19
7 Software .................................................................................................................... 20
7.1 Software license ................................................................................................ 20
7.2 Software requirements ...................................................................................... 21
7.3 How to use the IndustrialITSoftware ................................................................. 21
7.4 Project explorer...................................................................................................... 23
7.5 Creating a new project ............................................................................................ 23
7.6 Plant Explorer ......................................................................................................... 24
7.6.1 Make a program ............................................................................................... 25
7.7 Offline programming .............................................................................................. 26
7.8 Draw network topology of a system ....................................................................... 26
7.9 Aspect object technology........................................................................................ 27
8. Result of the project ...................................................................................................... 28
8.1 Our 800 xA system ........................................................................................... 29
8.2 Future system configuration ............................................................................. 30
9 Capabilities of the 800xA system ............................................................................. 31
10 Discussion ............................................................................................................. 32
11 Conclusion ............................................................................................................ 33
12 References.................................................................................................................... 34
Appendix I. Documents attached on project CD .............................................................. 35
Appendix II. Troubleshooting........................................................................................... 36
Appendix III. Task description for IndustrialIT 800xA system project............................. 38
Appendix IV. Activity schedule for this project............................................................... 40
Appendix V. System installation ...................................................................................... 41
Appendix VI. Post installation.......................................................................................... 82
6
1. Introduction
This project ultimately started when NUC got sponsored the IndustrialIT 800xA system
from ABB. A package which contained of 4 sets with one AC 800M controller and
several analogue and digital modules. Since this is a completely new system there was no
one to set it up in the lab at NUC. We took upon us this task in May 2006, but we really
got the project going when the course Prosjektfag started.
As mentioned before there where no one but us who could set up the IndustrialIT system
at NUC. This was the beginning of our task.
Usually persons with background knowledge on the system would set it up. There are
different courses varying from beginner to expert and they are lasting up to three days. It
was not an alternative for us to go on these courses since we are under the impression that
we would learn more by figuring it out on our own, and some help from the instruction
manuals.
The report is built up in the following manner: First explaining what IndustrialIT is, then
we will present a short historical review on automation systems before we explain what
the system consist of. The Industrial IT 800xA can be divided in two parts, one hardware
part and one software part, this will be reflected in our report. The two main chapters will
describe these parts and a final part will explain the communication between software
and hardware. Our activity schedule and description on this project task can be seen in
Appendix III and IV.
This project is the evaluation form in the course Prosjektfag and it will also make the
introduction to our Master thesis and other future school projects.
We restrict our work to just install a small single node system with enough options to
make a presentation and introduction of this powerful software and hardware package.
7
2. Asea Brown Boveri (ABB)
The company which has produced the IndustrialIT is called Asea Brown Bovery (ABB).
Here is a little background on the firm.
In the late 1880`s the start of today’s firm ABB was created by Asea in Sweden and BBC
in Switzerland.
Asea was established back in year 1883. They where manufacturing electrical lightning
and generators in Sweden. Eight years later in Switzerland the firm Brown, Boveri and
Cie (BBC) was established in year 1891. They where working with high voltage AC
power equipment.
In year 1988 the two companies Asea and BBC merged into one company Asea Brown
Bovery. Today ABB is a world leading firm within electrical power, automation
technology and robotics. Within the firm there are different divisions who are focusing on
their core strengths: Power products and systems, automation products, process
automation and robotics.
ABB is located all over the world. This gives them a short distance to their markets
within power and automation.
Their vision is to provide leading power and automation technology to customers around
the whole world. A broad application know- how gives their customers fast and reliable
support which is some of their qualities.
8
3. Historical review of automation systems
If we look back in time and see with a historical perspective on which control, and
automation systems we got. An illustration on when the different automation system was
created is shown in Figure 1.
Early forms of automation were driven by clock type mechanisms or similar devices
using some form of artificial power source, a wound-up spring, channeled flowing water,
or steam.
In 1801, the patent was issued for the automated loom using punched cards. In 1835 the
relay was invented and was used up to late 1960 in automation, and it is still used today
in small and less complicated systems. Programmable Logic Controller (PLC) was
invented 1968 and replaced the relay automation. The PLC is still one of the most used
controllers in automation, but it has its lacks.
In 2004 the IndustrialIT 800xA system was released by ABB, and it soon became a
success in the world of industry.
9
4. IndustrialIT 800xA system
IndustrialIT 800xA system is a control system developed by ABB and was launched in
January year 2004. It is based on the principle of a PLC with the thought of a “brain”
controlling several I/O modules, but it is far more advanced. You might say that it is the
next generation of automation and control system.
The 800xA system includes many automation processes in one environment. It collects
many process controls and windows that can be presented on one system platform. With
this system there is no need for many different software packages and different hardware
solutions to make your process system speak together. IndustrialIT 800xA has everything
implemented and it can be connected to almost any old hardware communication systems
and new devices. For example (PLC, profibus, Fieldbus or HART)
Every control, maintenance and other important processes are collected and integrated
into one environment. Such as: Supervision of devices (motors, valves, etc), maintenance
data and documents, device and system drawings, control values, process values, and
other important information can be presented into one interface. System 800xA gathers
information from all these different sources in the process and presents this data in an
interface which is being used by: Technicians, production managers, operators or
engineers.
10
.
5. Hardware
The IndustrialIT 800xA hardware used in this project is delivered by ABB. Other
equipment and materials is delivered by NUC. This chapter will describe the different
parts used in this project.
In Table 1 there is a list over the hardware that NUC got sponsored from ABB. This
hardware can be assembled into a big system or it can be divided into max four small
systems. All hardware can be mounted onto standardized DIN rails. We decided to create
only one small system, which is described in part 8.1 in this report.
A hardware system consist of a main unit, the AC 800M controller and some analogue or
digital I/O modules attached. Numbers of modules that can be used depends on your
process and what it requires.
11
5.2 AC 800M Controller
AC 800M controller, shown in Figure 3, is the main unit in hardware system. This unit
contains of a 24 MHz CPU and 8MB of internal memory. Up to 12 I/O modules can
directly be connected to the controller via the electrical Modulebus and 84 I/O modules
can be connected to I/O clusters via the optical Modulebus. The controller is also
equipped with a backup battery and a compact flash memory slot which can be used to
store programs or be a safety device to prevent data loss when power failures interfere.
Main task of the controller is to send and receive I/O module signals from/to a computer.
Controller is equipped with two Ethernet ports for communication with other subsystems,
in a network such as operators or engineers. It also has two RS-232 ports for 3rd party
devices or for communication with program/debugging tools. There is also connection for
the usage of fiber optics communication which is recommended in areas with high
electromagnetic interference.
The mounting bracket on the AC 800M controller is made of metal. Because of this the
entire system will be grounded when you mount it to a DIN rail, if the DIN rail is
grounded. This means that the I/O modules that are attached to AC 800M controller are
also are grounded from this connection. Grounding is done to prevent interference from
surrounding systems that can interfere with the internal logic.
AC 800M controller is very flexible to communicate with other existing systems like:
RS-232, Profibus, Foundation Fieldbus, HART, TCP/IP Network or Fiber optics.
12
5.3 I/O modules
To open up for communication with equipments in the field it is necessary with a link
between the AC 800M controller and the equipments. This is where the I/O modules
enter. Equipment out in the field is connected directly to the modules.
There are 4 main groups of modules: Analogue in (AI), analog out (AO), digital in (DI)
and digital out (DO). What type of modules that are being used depends on if there is an
analogue or digital signal that is being sent out from the equipment. See Table 3 I/O
modules informationfor details about analogue and digital modules.
I/O modules are attached to a MTU bracket. This must be done manually by pressing the
I/O module into the MTU bracket. There are some switches that must cohere before this
can be done. MTU bracket is shown in Figure 4 and the I/O module is shown in Figure 5.
Switches on the I/O module is not shown in the picture since it is on the backside of the
module.
13
Different I/O modules that can be attached to the AC 800M controller by sliding them
into the controller. This is shown in Figure 6 where you have a control unit and two I/O
units. These are clipped on a DIN rail which is mounted on the AluRack.
For more information about installing the modules please see [2] page 76.
I/O modules can be switched and replace when system is running and powered on. Only
the devices that are connected to this module will not work properly when failure
interfere
In oil and gas business a total shut down of entire system can cost a lot of money.
Application data can be stored at compact flash memory at every AC 800M controller so
it will be no data loss after a power failure or during module replacements. In case there
should be an error on the modules a LED on the front of the module will light up.
14
5.4 Power supply
A power supply is used to serve the 800xA hardware system with power. The power
supply converts 220V AC (input current) into 24V DC (output current), the power supply
is shown in Figure 7.
Power supply has a LED in upper left corner witch can tell if the power signal is OK or
not. The input current (220V AC) is placed underneath the power supply and the output
(24V DC) is placed on top. The connections are described in Table 4 and Table 5.
24V DC is coming out pins L+ and L-. When handling direct current it is very important
to connect positive (+) to positive and negative(-) to negative. These must not be crossed.
Power cables from L+ and L- on the controller must also be connected on L+ and L- on
the MTU bracket.
15
5.5 AluRack
We have designed a rack where all 800xA hardware equipment can be mounted.
The rack is made of aluminum and plastic profiles which are attached together. These
profiles are a patent from a Danish company named Porsa. See http://www.porsa.dk for
more details.
16
6 Communication
This chapter will describe different forms of communication between computer and
controller in the 800xA system.
AC 800M controller has fiber optic as a connection option. With use of the fiber optic
port a 800xA system can be placed at any extreme electromagnetic conditions and still be
unaffected by it.
In Figure 9 we see an example on how the connection should be done and what type of
cable that should be used.
17
There are to ways of connections that can be used between the computer and AC 800M
controller, it is directly or using a switch or hub in a network.
18
6.3 Firmware communication
Program Control builder M professional and AC 800M controller must have the same
version of firmware. If they do not have same version the system will not work properly.
See [6] for more details on how to check the firmware versions.
19
7 Software
The software we use in this project is a package named IndustrialIT developed by ABB. It
is a multi-usage package for automating and analyzing processes and activities in a
facility. To make the IndustrialIT software pack work there are some necessary steps that
needs to be taken.
The software is integrated in Windows platform enabling the IndustrialIT to take full
control over the computer. An operator logs on to Windows and gain the user rights an
operator should have. When an engineer logs on the user rights will change to what an
engineer needs.
Every network card in a computer has a unique identification address called Media
Access Control, or better know as MAC. This address is found by using command
prompt window and typing in the command ipconfig /all
Recognize the name on the network card that you are connecting to the AC 800M
controller. Under this network card the correct MAC address is listed.
This MAC address is implemented into the license file.
20
7.2 Software requirements
The IndustrialIT 800xA system has some software requirements. These are important
when installing the IndustrialIT system.
When all pre- and post installation is done to the system it is ready to make an
automation system on the computer. To make such a system there are two important
programs that are being used, it is Project explorer and Plant Explorer. See Figure
12Figure 12 for interference between these to software interfaces and the AC 800M
controller.
More details on how to do the post installation is described in appendix VI
From now on there are different windows and possibilities in the computer system
because of the different user rights between an engineer and operator.
21
Figure 12 Interference between interfaces in the 800xA system [7] page 43
22
7.4 Project explorer
The program Control Builder M Professional is also called Project Explorer after all
installation and configuration is done to the system. In project explorer it is possible to
make and set up a new project for your system.
The same 800xa hardware system that is mounted together must be remade in a hardware
tree in the program Control Builder M Professional. All I/O modules in the system must
are placed under ModuleBus in the hardware tree. After creating this tree the next step is
to download this setup to the AC 800M controller. This is done in the same program
where the hardware tree is made. See Figure 14 Figure 14 Hardware tree in program
Control Builder M Professionalfor more details on the placing of the hardware tree.
23
7.6 Plant Explorer
The Plant Explorer is the heart of all IndustrialIT programs. This is where all
configurations and calibrations to the 800xA system are done. In Plant Explorer it is
possible to make automation programs.
See Figure 15 for Plant explorer workplace layout. Here the same hardware tree that was
made in Control Builder M Professional is reproduced. There is also created a new
Control project called HiN.
In Plant explorer alarms and events for the whole system is calibrated and configured.
Every changes made in Plant explorer are automatically updated in the program Control
Builder M Professional.
24
7.6.1 Make a program
A control program is made by starting Program editor in Program1, 2 or 3 under
Programs in the hardware tree. In the program editor it is possible to use different kinds
of programming languages like: Structured text, structured function chart etc.
See Figure 16 for layout on Program editor. In this example there is made a program of
simulation sliding doors in a shop.
25
7.7 Offline programming
Test a program in offline mode is important to do before sending it to a controller. A
offline test is a safe way to check for errors and malfunctions in a program
26
7.9 Aspect object technology
In a process window ABB uses aspect object technology to present and sort all
information about a process in an interface.
The Aspect Server collects all information about real time process and devices are
present in one graphical interface. In this interface there is collected many types of
information on a device like: Trend graphics, alarms, engine data, controls, maintenance
objects and other graphic elements. See Figure 17 for more details on aspect technology.
All field devices that are connected to AC 800M and I/O modules can be configured,
monitored and controlled by an operator.
Aspect object technology is both time and money savings if there are any failure at a
device or processes. The operator has all information collected on this device or
processes just a few mouse clicks away, instead of spread at different locations or other
peoples.
This reduces downtime, and highly efficiency maintenance of the different devices and
processes.
27
8. Result of the project
The goal of this project was to explore the possibilities with the IndustrialIT 800xA
system. To do this we created a small system with a simple automation program.
When we started this project we only knew that IndustrialIT 800xA system was the next
generation automation system. So we soon realized this was a comprehensive system
with lots of possibilities for creating control and analysis systems. This made it
impossible to get trough it all in the given time we had available in this project. We
decided to concentrate our effort on the creation of a small system which consists of:
We also created a system installation guide on how to plan and install a single node
system on a computer.
This project has given us the big picture on how the IndustrialIT 800xA system works and
how to install it on a computer. To emphasize that the installation is not just like
installing plug and play software like Microsoft Office on a home computer. The
IndustrialIT 800xA system requires a full day to just plan and install the core system on
one computer alone. After that all configurations on the installed system must be done
before the user can take advantage this automation system.
When we first started installing the core system on the computer we realized that it did
not has the necessary software and hardware for the IndustrialIT 800xA system.
This delayed the project substantially.
Throughout the project there have been lots of obstacles that we had to conquer. One of
the biggest problems has been the network topology and network communication. Since
we are on NUCs local area network we did not have all the possibilities we needed. This
meant that we had to come up with different kind of solutions. We still have the problem
of running Internet on the single node computer.
28
8.1 Our 800 xA system
The IndustrialIT system on NUC has 4 licenses with one core system, one operator and
one engineer. The core system can be divided on several nodes and the other nodes can
be used as workplaces for operators and engineers.
In our case we installed a single node system, having all servers on one node. This is best
on small systems and where the persons acquired for the system can use the same
computer. Our 800xA system consists of: One AC 800M controller, one digital input
module (DI 810) and one digital output module (DO 810). This was the only hardware
we needed to simulate our digital program. Network topology for our system is shown in
Figure 18.
Since NUC did not have any analogue equipment to put in our system so we could
control it, the only option we got left was to use a digital solution.
We wanted to simulate customers who are going through sliding doors by activating a
photo cell in a shop. This program we are going to simulate digitally on the 800xA
system.
The programming will be done in structured text where we implement these variables:
- Doors opening
- Doors closing
- Photo cell
- Motor for sliding door 1
- Motor for sliding door 2
- Opening frequency
- Total openings
29
Our finished program will first be tested in offline mode. This is done to discover and
prevent any failures in our program that can damage the 800xA hardware.
When testing program in offline mode we see that every variable in the program changes
its value when they are being activated by simulation.
In online mode with the AC 800M controller we are going to test the same program but
now LED on each channel on the module will light up when a channel is activated.
Server node
Network link
Equipment
Figure 19 Future topology with tree nodes
30
9 Capabilities of the 800xA system
The main capabilities of the IndustrialIT 800xA system is flexibility, personalized
workplace and security.
Flexibility is strength
Flexibility in creating a small system with few I/O modules, or create a big system with
multiple of main controllers and I/O modules.
With different communication types like: Profibus, HART, and Fieldbus. The 800xA
system can easily be connected to almost any existing systems that are in today’s market.
Personalize workplace
An operator or engineer workplace in the 800xA system is behind various computerized
interfaces which can control an entire process or just a valve in the process.
There are many opportunities to personalize a workplace with graphics windows and
different colors and layouts.
Security
Different users have different needs in their access level. An operator does not need to
make changes in the program. The engineer on the other hand has to have rights to
change both the program and the external equipment settings. These user rifts definitions
is easily done in IndustrialIT.
31
10 Discussion
To really understand the capabilities of the IndustrialIT system you have to ask yourself
three questions.
Why should I use the system?
Where should I use it?
What can it do in my project?
It gives you:
- With all the packages it gives you one program to control and analyze the whole
process
- A future orientated control system
- Both local and centralized supervision
When this system is installed in the process it will start to improve the facilities results.
The new changes will be seen in controlling the processes, maintenance work and
calibrating equipments in the process. All data will be presented in a centralized interface
(process window) where logging trends, data sheets and documentation can be arranged
after the operator or engineer’s choices.
All documentation from ABB is very detailed and it explains every aspect on the 800xA
system. Every document and equipment got its own part number which makes it easy to
use. Since the documents contain so much information about different aspects we created
our own installation guide. This will help the user to easily installation and create a new
system. It is not necessary to read and understand all the following documentation from
ABB to create a small system.
32
11 Conclusion
Our result on this project is both the physical system that we have created and installed,
and also the knowledge we have learned us about the IndustrialIT 800xA system.
This knowledge about the system will be a background basis for future work on our
Master thesis that starts late of October 2006.
This project was a great opportunity for us to get more knowledge about this new
automation system from ABB. Since we both have a bachelor degree in Automation we
already have some background knowledge on automation systems and hardware. It is
recommended to have background knowledge about these objects for installing 800xA
system:
- Electronic
- Network and computer communications
- Windows platform and program installations
- Production and operation control interfaces
- Programming languages
The physical system we created was a single node installation of the 800xA system where
it is possible to communicate with one controller and its attached I/O modules. This
system can attach analogue or digital equipments that can be controlled with the
IndustrialIT environment. With this systems flexibilities there are almost no limits of what
this system can do.
Future work with 800xA system is to install a bigger solution which includes 3 nodes in a
network. One server node connected to a main controller with analogue or digital
equipment attached. On the other two nodes in this network we will create one operator
workplace and one engineering workplace. In the future this system can be used in other
school projects or in education.
Overall, the IndustrialIT 800xA system extends the scope of traditional control systems to
include all automation functions in a single operation and engineering environment so
that plants/mills can run smarter and better at substantial cost savings.
33
12 References
All internet addresses worked 20.10.06
34
Appendix I. Documents attached on project CD
ABB@HiN:
− Project report, word format
− Project report, pdf format
− ABB@HiN System installation guide
ABB documents:
(These documents are in property of ABB)
− 3AFE68237432RevC_AC800M_CI858.pdf
− 3BSE020923R4101_CIO_General.pdf
− 3BDS011225R4001_Sys_Topology Designer.pdf
− 3BSE036903R4101_Sys_BasicOperation.pdf
− 3BSE036351R4101_AC800M_HWOp.pdf
− 3BUA000156R4101_Sys_PostInstall.pdf
− 3BSE035980R4101_CIO_BasicSW.pdf
− 3BDS011222R4101_Sys_Configuration.pdf
− BSE034463R4101_Sys_AutomationSystemNetwork.pdf
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Appendix II. Troubleshooting
IP communication trouble with AC 800M controller
Remove power supply cable from outlet.
Unscrew two front panel screws on AC 800M. Remove the whole module and let the
back plate still be attached on the DIN rail. This will reset AC 800M controller, it will
still have the same IP settings that has been made earlier in the IP Configuration program.
Wait 15 seconds and reattach module. Try to ping AC 800M IP address in command
prompt window (cmd). Write ping followed by the IP address of the controller. See
Figure 20 for more details on this ping command.
36
Account in OPC server
When entering service username and password in this window it is important to type in
exactly the same username and password as the windows user account.
Example: SINGLENODE1\800xAServiceAccount
37
Appendix III. Task description for IndustrialIT 800xA
system project
The system contains two parts, one software part and a hardware part that are working
and communicating together. 800xA can be implemented in different environments or
laboratories, both for industrial and educational needs.
ABB 800xA@HiN
Department of industrial engineering at HiN got sponsored 4 complete Industrial IT
800xA systems from ABB in year 2005. We are going to install and demonstrate this
system in a laboratory at HiN.
Because of the systems magnitude it is not just inserting a CD in the computer and install.
There are several pre-requisites that have to be considered before installing such as
server/network settings and topology.
This system can be used in future teaching or courses at industrial engineering. Give
students an introduction in high technological control system which are being installed
and used at almost every on- and offshore installation here in Norway.
(Example: Statoil`s LNG fabric Snehvit at Hammerfest.) For future student work this
system can be a platform to do research and development for ABB or other companies
who use this system.
38
Main tasks of the project work are:
1. Study software installation guides on ABB Industrial IT 800xA SYSTEM.
Decide server topology and network settings.
2. Install software and control system on ABB 800xA@HiN computers
(Room A 4220).
3. Assemble 800xA modules on DIN rack and connect to industrial IT computer
system.
4. Describe possibilities and capabilities on ABB Industrial IT 800xA SYSTEM.
5. Demonstrate Industrial IT 800xA SYSTEM at HiN.
6. Write and deliver project report.
Narvik 26.09.2006
_______________________ _______________________
Name Name
39
Appendix IV. Activity schedule for this project
Project time
We have calculated to use 15 days to complete this project.
Costs
All material we need in this project is already in place. So there are no extra costs in this
project. Materials that we need for this project are:
DIN grid plate, DIN rail, own designed system rack, ABB 800xA system modules,
800xA system software, different software, and computers in network.
40
Appendix V. System installation
This document contains the steps needed to do when installing IndustrialIT 800xA system
on a computer. All of the pictures and figures used in this installation guide are
screenshots of the actual installation.
ABB Industrial IT
800xA system
41
1. Shell installation
Installation Shell
First window that pop up
when you insert the
installation CD.
Installation Shell
Press Install
If not Microsoft.NET Framework 1.1 is not installed. This system shell wizard will
automatically install this. When this is done system shell is finished with installation
42
2. Automated installation
Automated Installation
System Planner
This is the system planner.
It will make the system you
want for your
network/computers.
Press Next
43
Choose Medium
Choose CD/DVD and push
DVD button in this window
44
System planner wizard
Press Next
Windows
Here you can choose to use
computer with Windows
installed or if you want to
install windows.
If you choose to use
preinstalled Windows read
the System Installation
guide for prerequisites
before installing the
software.
We have used blank pc’s
This option makes a silent
installation of Windows on
c:\
Press Next
45
Nodes
The wizard prompts you to
choose a node setup.
We have used single nodes,
this creates the entire
system on one computer.
Press Next
Connectivity
Choose the device
connectivity. In this system
there is only the AC 800M.
Press Next
46
Field bus
There is no usage of field
bus.
Press Next
Workgroup/Domain
In this system we use
workgroups.
Press Next
47
Summary
Press Next
Installation
Press Next
48
System Configuration
Choose workgroup, service
account,
password(Narvik8515) and
system description.
Press Next
Summary
Use the default settings on
all but password. Choose
an easier password. We
have used abb here.
Press Next
49
Node Name
Write in the name you
want to use for your
node/nodes
Press advanced
If you want to change the
IP-adress of the
node/nodes. This is not
necessary.
Press Next
System configuration IP
Mark the box as shown in
figure.
Press Next
50
System configuration IP
This will show the IP-
address for the node.
Press Next
Summary
Press Next
51
Setup Package
Choose where to store the
package. Use a diskette.
Press Next
Setup Package
Press Next
52
Setup Package
For information about the
setup package click on the
link in the window.
Press Next
Finished
You have now completed the
System Planner and are
ready to start with the
installation of Industrial IT.
Press Finish
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Computers without Windows
If you are using computer without Windows, or want to reinstall Windows you have to
choose this in the System Planner.
To do a silent installation insert the Windows CD and the diskette created in System
Planner. This will install Windows automatically with the needed configurations on your
local hard drive (c:\). NB: Silent installation will format all data on local hard drive (c:\)
Installing Windows with the help of the disk you have created in System Planner is the
safest way of installing the system. This is because most of the settings needed by
Industrial IT are set automatically.
When using a pre-installed Windows there are a lot of requisites that have to be done to
your system. These are described in the System Installation book.
54
3. Industrial IT Single node installation guide
The installation of Industrial IT on a computer is self-explaining. We have done a single
node installation and created an installation guide. It is very important that you read the
information given in each step, and that you have patience with each step. If you rush
trough the installation and don’t let each step finish it might compromise the rest of the
installation.
- Start
- Programs
- ABB industrial IT 800xA
System
- System Installation Shell
-Continue System installation
55
Manual start of installation, this requires a System Planner diskette
- Start
- Programs
- ABB industrial IT 800xA
System
- System Installation Shell
- Setup a new system
Manually Installation
Start
Manually Installation
Start
Click on Browse
56
Manually Installation Start
Browse after the stored
installed package. File
ending *.cct
Press Next
Press Next
57
Automated installation, this requires a System Planner diskette.
Installation Start
This is the start of the
installation of Industrial It
on your computer.
This will automatically
start when you have done a
silent Windows
installation.
Press Next
Installation Wizard
The wizard shows what is
about to be done.
Press Next
58
Network Settings
On the installation the
network settings from the
diskette will be used.
Press Next
Network Settings
Shows computer name and
network settings.
Press Next
59
Network Checklist
Press Next
Network Checklist
Press Next
60
Restart
Finish
Installation
Press Next
61
Installation Wizard
Press Next
Windows Components
Press Next
62
Checklist Windows
Press Next
Checklist Windows
Press Next
63
Restart
Press Next
Installation Wizard
Press Next
64
Choosing Workgroup
Here you choose the
workgroup you want to
use.
Press Next
Checklist Windows
Press Next
65
Checklist Windows
Press Next
Restart
Press Next
66
Installation Wizard
Press Next
Add Groups
Creating the groups used in
the 800xA program.
Use the default settings.
Press Next
67
Add Users
Setting up the users.
Press Next
Press Advanced
Press Next
68
Checklist Windows
Press Next
Checklist Windows
Press Next
Press OK
69
Installation Wizard
Press Next
System Checker
Gives you general
information about the
system. Also checks if you
have the needed
administrator rights.
Press Next
70
System Checker
Checks if your PC satisfy
the requirements.
Press Next
System Checker
Checks if needed programs
are installed.
Press Install
Press Next
Restart the PC
71
Installation Wizard
Press Next
Installation Wizard
Press Next
72
Check user rights
Press Next
Check hardware
Press Next
73
System Checker
Checks if the Windows
components where
installed.
Press Install
If there is a program
missing, press install on it.
Press Next
System Checker
Checks if 3rd programs are
installed.
Press Install
Install the programs
needed.
Press Info
This will give additional
information on the 3rd party
programs needed.
74
WMI SNMP Provider
This message appears
when pressing info.
Follow this to install WMI
SNMP.
Press Details
75
WMI SNMP Provider
Mark the checkbox as
shown in the figure.
Press OK
Press Next
When Windows
Component Wizard
window opens. This will
install the component.
System Checker
Press Next
When all 3rd party
programs have been
installed1.
1
Visual Basic 6.0 does not need to be installed at this point.
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System Checker
Displays the installation
report.
Press Finish
Backup
We have chosen not do
make a backup in the
installation.
Press Skip
77
Install Industrial IT
This is when you start to
install the Industrial IT
software.
Press Install
Press Cancel
78
Information Box
Press OK
Installation
Write the password you
have chosen in the
password block.
Press Next
79
Installation
Settings that will be
executed.
Press Next
Installation
Press Next
80
Installation
The rest of the steps are
automated.
When installation is
complete, do a restart of
the computer.
The installation takes time
and you should not restart
the computer or start any
other programs while
install.
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Appendix VI. Post installation
After system installation has been done, your new system must be configured on your
computer. This is a walkthrough of what is necessary to do in the post installation.
Open Post installation document file [6]. Follow this instruction and start Configuration
wizard from the Start menu as shown in Figure 22.
82