We reserve all rights in this document and in the information contained therein.

Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
” Copyright 2002 ABB. All rights reserved

TITLE
 OMAN INDUSTRIAL COMPLEX PROJECT
P0220
Vale N
0
PAGE
OMAN INDUSTRIAL COMPLEX – PHASE I 1 / 14
0
Project Rules & Guideline CONTRACTED N Rev.

Interface Concept E.VAIN001-IE1-0001 0

REVISIONS
ISSUE TYPE IT A - PRELIMINARY C - FOR INFORMATION E - FOR CONSTRUCTION G - AS BUILT
B - FOR PROPOSAL D - FOR QUOTATION F - AS PURCHASED H – CANCELLED

Rev. IT Description By Chec Appr. Aut Date

0 E First issue AE EA MM 2008-09-25

Based on OIC Vale Contract Project OIC-Vale

Prep. A. Eckert 22.09.08 1-2019660
Appr. E. Aufschlager Approved File OIC-Vale_R0_Interface.doc
Doc. kind Project Rules & Guidelines Doc. =2E0 Item

Title Interface Concept des. des.

Resp. dept. ATBPA

Document number
Lang. Rev. ind. Page 1
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
 CONTENT
1. General ......................................................................................................................................3
1.1 Definitions and Abbreviations ..............................................................................................3
2. Interface Description ................................................................................................................4
2.1 Serial Communication..........................................................................................................4
3. I/O specification ........................................................................................................................5
4. Typical Interface to Generic SCS ............................................................................................7
4.1 Interface Description............................................................................................................7
4.1.1 Power Supply ................................................................................................................7
4.1.2 Digital Signal Interface ..................................................................................................7
4.1.3 Analog Signals ..............................................................................................................8
4.1.4 Counter Signals.............................................................................................................8
4.1.5 Serial Communication ...................................................................................................9
4.1.6 Terminals.....................................................................................................................10
4.2 Required Documentation for SCS .....................................................................................10
5. Measurement...........................................................................................................................11
5.1 Field Devices .....................................................................................................................11
5.2 Transmitters.......................................................................................................................11
5.3 Required Documentation for Measurement Equipment.....................................................11
6. Attachments ............................................................................................................................12
6.1 Interface to Sub Control System Figure 1..........................................................................12
6.2 Interface to MV Drives Figure 2 .........................................................................................13
6.3 Interface to MV Incomer/Feeder Figure 3 ..........................................................................14

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 2
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
1. General
Different supplier delivers the electrical equipment of industrial plants. Therefore, it is necessary to
define the interfaces between Sub Control Systems (SCS), Drives Systems, Instrumentation, Field
Devices (local safety and supervision devices) and the Central Process Control System.
This concept describes the following interfaces:
x Power circuits
x Control circuits
The document belongs to the document set "Project Rules & Guidelines", which describes and
defines the general rules for the electrical engineering.

1.1 Definitions and Abbreviations

Abbreviation Description
LCB Local Control Box
PCS Process Control System
SCS Sub Control System

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 3
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
2. Interface Description
For complete plants we have endeavored to produce a concept through which the control of all
drives is treated in a consistent and standardized manner.
Within each plant there are some local systems, which will be supplied as an integral part of some
specialized mechanical equipment. We call these systems SCS (Sub Control System). A
standardized interface is applied to them. Please refer to chapter 4 for details.
Basic principle of our central process control system is to use fail safe signals for supervision and
fault indication (process healthy, contact closed). By means of it, cable breakage as well as loss of
voltage is detected and treated as fault. The reliability and safety of the plant is assured.
Regarding the electrical interface following standards must be followed when designing the SCS:
Digital signals from SCS to PCS: Potential free (“dry”) contacts.
Digital signals from PCS to SCS: Interposing relays 24 V DC / 1 W with anti-parallel diode (or
alternative method for spark suppression) in SCS.
Analog signals SCS  PCS: Live zero signal 4 ... 20 mA; galvanic isolated on SCS side
All switches have to be provided that they can be connected accordingly.

2.1 Serial Communication

Alternatively to the above standards, the interface between SCS and PCS can be realized via the
serial communication links Profibus DP (preference) or Modbus / Modbus TCPIP. Serial
communication links might be advantageous when a huge amount of signals need to be
transferred. Decision whether a serial link applies for a specific SCS will be taken on a case-by-
case basis while the project advances.
The mechanical supplier also supplies many instruments and field devices with the mechanical
equipment; others are supplied by the electrical supplier or other parties. The interface to all these
equipment has to be standardized to meet the general control requirement. Please refer to chapter
5 for details
For reducing interface problems, cost of training as well as the amount spare part it is preferred
using ABB AC800M Controller with S800 I/O’s in sub control systems.

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 4
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
3. I/O specification
The I/Os of the process control system (S800 I/O) have the following specification.
Digital Input (DI810) DI
Number of channels 16
Rated voltage 24 V DC
Nominal input channel current 6 mA @ 24 V DC
Input impedance 3.5 k
Maximum field cable length 600m
Digital Output (DO810) DO
Number of channels 16
Type of output Transistor current source, short circuit proof
Voltage rating 12..32 V DC
Load current, maximum 0.5 A
Short circuit current, maximum 2.4 A
Maximum field cable length 600 m
Digital Output (DO 820) DO
Number of channels 8
Type of output Relay (NO)
Voltage range 5 - 250 V DC
Load current, maximum 3A
Max. make current 30 A, 220 ms, L/R > 10 ms
Maximum field cable length 600 m
Analog Input (AI810) AI
Number of channels 8
Resolution 12 bit
Signal level 4 … 20 mA
Input impedance (at current input) 230><275 
Maximum field cable length 600 m

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 5
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
 Analog Input (AI815) AI (supporting Hart)
Number of channels 8
Resolution 12 bit
Signal level 4 … 20 mA
Input impedance (at current input) 250 
Maximum field cable length 600 m
Analog Output (AO810) AO
Resolution 14 bit
Output range 4 … 20 mA
Output load < 500 
Maximum field cable length 600 m
Pulsed Input
Same specification as Digital Input DI (no pulse
board used)
Pulse length for high and low signal > 150 ms
Maximum frequency 3 Hz

High

Low

min 150 ms min 150 ms

The potential against ground (earth) of all signal types mentioned above are defined by means of
solidly grounding within I/O’s of the Process Control System.
All incoming signals to I/O’s have to be galvanic isolated and absolutely floating against ground
respective earth potential.

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 6
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
4. Typical Interface to Generic SCS

4.1 Interface Description

Attachment 1 shows the generic interface between SCS, low voltage distribution and process
control system.

4.1.1 Power Supply

415 V 3-phase with PEN, 50 Hz or 240 V AC single phase, 50 Hz
Necessary control voltages for the SCS have to be generated internally in the SCS by suitable
transformers/power supply devices.

4.1.2 Digital Signal Interface

As a minimum, the SCS must have the following input/outputs:
Drive command (from PCS to SCS); Signal abbreviation DC:
The "ON/OFF command" affects the SCS as a whole. Contact closure (relay energized) causes
the SCS to start-up automatically with the correct sequence and carries out its service (if
internal circuits are correct). Contact opening (relay not energized) causes the SCS to stop
automatically in the correct sequence and terminate its service.
Availability (from SCS to PCS); Signal abbreviation AV:
The "availability" contact affects the SCS as a whole. The information "available" shall signal to
the process control the readiness of the SCS before operation. It is not dependent on whether
the "run" signal is present or not.
The following conditions must be continuously fulfilled in order that this contact may remain
closed:
- Control voltage available
- No fault in the system (neither "overload", nor "emergency", nor "off"- switches, etc. must be
activated)
- All switches "service" or "remote" must be in the "remote"-position.
If any of the conditions given above is no longer fulfilled, the contact "availability" will open
immediately.
Running (from SCS to PCS); Signal abbreviation ON
The "run" is the feedback signal after a normal start. It means that the SCS is carrying out its
service. If the "run" signal does not appear within a reasonable time after starting, the relays
"ON/OFF command" (D) is de-energized by the process control.
Depending on the requirements for operation, above interface may be extended by additional
signals (e.g. signals for detailed alarm annunciation, remote alarm reset, etc.). The supplier of the
SCS has to specify such additional signals and describe their functionality.

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 7
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
 Following signals might be useful as additional information to the PCS
WRN Warning (from SCS to PCS); Signal abbreviation WRN
The "warning" signal is a pre-alarm, which does not (or not yet) stop the normal "run" of the
SCS. The warning contact shall open as long as the warning condition prevails.
Trip (from SCS to PCS); Signal abbreviation TRP
The "trip" signal is an alarm, which causes the SCS to stop automatically. The failure contact
shall open until the fault has been locally reset.

4.1.3 Analog Signals

Optional, depending on requirement specifications:
Analog input and output signals must be of type “live zero” 4 … 20 mA DC. Transmitters can be
of type 2-wire (preference) or 4-wire. If active transmitters (4 wire technique) are provided, it is
mandatory that the signal outputs are floating against ground and isolated from power source.
The SCS documents have to indicate clearly whether two or four wiring technique is applicable.
Actual Value (from SCS to PCS):
The "set point" will be supplied in form of an active 4 … 20 mA signal. The signal has to be
completely galvanically isolated (against ground and possible power supply) in the SCS unit.
Set point (from PCS to SCS):
The "actual value" shall be a 4 … 20 mA signal. The signal has to be galvanically isolated
(against ground and possible power supply). An external load of up to 500 Ohm shall be
allowed.

4.1.4 Counter Signals

Counter signals are an optional possibility, which depends on requirement specifications. Any
pulsed signal for counting total flow, weight etc. has to meet the pulse length and frequency
specified in chapter 3.

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 8
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
 4.1.5 Serial Communication
Serial communication can be used for SCS’s with large amount of signals.
For complex instruments, our preference for serial communication is Profibus DP. Profibus DP is a
high-speed master-slave communication link. The process control system emulates the master
protocol; the SCS emulates the slave protocol. The physical connection between PCS and SCS is
via electrical RS485 for distances up to 200m, for longer distances physical connection is via fiber
optical link. SCS shall monitor the serial communication and stop in case of communication error.
The Profibus Station address shall be selectable on the SCS. The Baud rate has to be 1.5 Mbit/s.
For the Serial Communication to the MV-Switchgear Modbus is used. Modbus is a master-slave
communication link. The process control system emulates the master protocol; the MV-Switchgear
emulates the slave protocol. Since Modbus is a low speed communication link we exchange the
compulsory signals Drive Command, Availability, Running to the Fix-Speed MV-Motor of the Raw
Mill by a conventional parallel digital interface in order not to prejudice the overall response time of
the system. All other signals will be exchanged using the Modbus communication link. The
complete signal exchange can be realized using exclusively the Modbus protocol. The physical
connection is via RS232 (point to point, up to 30m) or via RS485 (multi drop)
SCS with own process control system should use ABB AC800M Controller with S800 I/O’s for
reducing interface problems, cost of training as well as the amount spare part.
Communication between PCS and SCS can be realized via MMS (TCP/IP or COMLI (RS232 /
RS485).

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 9
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
 4.1.6 Terminals
The terminals for the power supply and control system interface have to be grouped as follows:
x -Power terminals (size according to power cable)
x -Digital input terminals
x -Digital output terminals
x -Analog signal terminals
x -Counter signal terminals
Terminals for control signals have to ensure the connection of control cables between 0,5mm2 and
1,5mm2.

4.2 Required Documentation for SCS

For the design of the low voltage distribution and the process control system following information /
documentation is required:
A) For power supply
power consumption kW or kVA @ 415 V AC (PEN)
rated current In
CB rating (incoming feeder) IF
Power circuit diagrams
B) For digital signals connected to PCS, terminal diagrams including signal name,
description and reference to SCS documentation.
C) For analog signals connected to PCS additionally to B) the range and unit is
required.
D) For serial communication links:
Profibus: GSD file and interface description including signal mapping and data
formats.
Modbus: link characteristics, available function codes, signal descriptions and
corresponding register addresses, data formats etc.
E) Function Description of the SCS.
Detailed description of functionality and action for all non standard signals.

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 10
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
5. Measurement

5.1 Field Devices

(Limit-, Level-, Temperature-, Emergency-, Rope Switches etc.):
Sufficient contacts (at least 1 NO and 1NC) have to be provided for switches connected to both -
the process control system and another control circuit for safety reasons (e.g. emergency stop,
fundamental interlocking, pull rope switches etc.).

5.2 Transmitters
For process measurement equipment like pressure-, flow- or level-measurements, either
transmitter with 4 … 20 mA standard signals shall be used for the signal transmission from the
analogue instruments to the process control system or direct Profibus-DP based sensors shall be
installed:
Transducer supply:
preference 24 V DC, 2-wire connection
exceptionally 240 V AC, 4-wire connection
A galvanic isolated 4…20mA output signal is mandatory for transducers connected to the I/O’s of
the process control system!

5.3 Required Documentation for Measurement Equipment

A) Data sheets indicating:
supply voltages
consumption
B) Terminal diagram
C) List of equipment indicating
equipment no.
type of device

Revision
Rev. Page (P) Description Date
ind. Chapt.(C) Dept./Init.
0 First issue 2008-09-23
ATBPA / AE

Doc. kind Project Rules & Guidelines Project OIC Vale

Title Interface Concept 1-2019660

Document number
Lang. Rev. ind. Pages 11
ABB Switzerland Ltd 3BHS 263 371 en 0 No. of p. 14
3BHS 263 371 E01
3BHS 263 371 E01
3BHS 263 371 E01