HARDWARE & SOFTWARE

CONFIGURATION FOR ABB DCS

 ABB DCS HARDWARE
• ABB AC 800M DCS (used in lab)

• The AC 800M controller consists of a selection of units mounted on horizontal DINrails, which can be housed within an
enclosure. The majority of units consist of a base mounting plate and removable cover attached with screws.

• The hardware units that form the AC 800M controller are:

• Central Processor Unit (CPU)
• Communication interface units
• S800 I/O modules
• Power supply modules
 ABB DCS HARDWARE

• Central Processor Unit (CPU)

• The CPU consists of a base plate TP830 and a
replaceable processor module PM8xx with various speed
and memory combinations.
• The base plate TP830 carries the majority of the
connections to processor, the power supplies and
communication interfaces, as well as to the external buses.
 ABB DCS HARDWARE

• Compact flash card.

• A Compact Flash (CF) can be inserted to the card slot located at
the front of AC 800M controllers.
• The card will be activated and read after a long controller reset
(or power failure) and your application(s) can be loaded into the
controller without performing an application download from a
Control Builder station.
 ABB DCS HARDWARE
• Types of processor module
 ABB DCS HARDWARE

• Communication Interface Units

• Communication modules is connected to CEV bus
• Up to 12 communication units can be placed on the CEX
bus.
• The CEX-bus must be terminated if a communication unit is
connected. A CEXbus termination is delivered with the
CPU: TB850 (male) or TB851 (female).
• An extension cable TK850 with connector DB25P with
metal housing and a length of 0.7 meter (2.3’) can be
used for extending the CEX bus to a second DIN rail.
 ABB DCS HARDWARE

• Input / Output Modules

• Analog and digital types
• Analog : AI801, AI810, AI820, AI830, AI835, AO801, AO810,
AO820, AO845
• Digital : DI802, DI803, DI810, DI811, DO801, DON802, DO810
 ABB DCS
HARDWARE
• Basic mounting and installation
 HARDWARE REDUNDANCY

• Redundancy is applied to increase the reliability of the system.

• Normally used in critical industry like oil and gas industry.
• In a system with redundant Processors, the controller contains two processor units, each including
memory for system and application software.
• One unit is acting as primary, the other is backup (hot stand-by). The primary processor unit
controls the process. The backup stands by to take over in case of a fault in the primary. The
primary CPU is always updating the backup CPU.
 HARDWARE REDUNDANCY

• In a redundant configuration an automatic switch-over from the Primary CPU to the Backup CPU
occurs in the following situations, provided they are in synchronized state (DUAL LED is lit):
• Memory or other hardware error in the Primary CPU.
• Severe communication errors on the Control network, that is, loss of both network ports in the Primary
CPU.
• Severe communication errors on the ModuleBus.

• The changeover is done bumpless and in less than 10 ms.

HARDWARE REDUNDANCY
 ABB DCS SOFTWARE

• Basic software for ABB DCS

• Control Builder M
• Project Explorer
• Plant Explorer / Engineering Workplace (800xA workplace)
 ABB DCS
SOFTWARE
• The Project Explorer in Control
Builder M and the Plant
Explorer / Engineering
Workplace should be
considered as two separate
interfaces for building and
maintaining control projects.
• Engineer will continuously shift
between the Project Explorer
(Control Builder M) and the
Engineering Workplace
(800xA workplace) while
building Control Projects.
 ABB DCS SOFTWARE

• Hierarchy used throughout Control Builder:

• An automation system might contain a number of Control Networks representing different parts of a
large plant.
• Within each Control Network, you can create a number of Control Projects. A Control Project contains
the configuration data for libraries, applications, connected hardware, etc.
• Each application contains programs and additional objects (data types, function block types, control
module types) that are used within the application.
• Each program is connected to a task, which decides how often the program is executed.
 Control Builder M

• The following actions can/should only take place from the Project Explorer in Control Builder M:
• Build the control logic
• Creating hardware and downloading the firmware
• Setting an application in Test and Simulate mode
• Upgrading applications
• Downloading applications to controllers
• Setting task connections
 Control Builder M

• The Project Explorer is a tool you can use to create, modify

and navigate in a project. You can select all objects such as
data types; functions and function block types and display
them in an editor.
• In the upper pane, the project is displayed in a tree view
control with folders and in the lower pane there are three
tabs for Description, Check and Message.
 Control Builder M

• Hardware units are added to the tree structure in the Project

Explorer representing physical hardware units.
• Some units contain sub units, such as serial channels, that are
automatically created.
 Control Builder M
• Toolbar Buttons
 Control Builder M

• Project Tree
• Contains 3 directories
• Libraries
• Applications
• Controllers
 Control Builder M

• Libraries
• contains all libraries used in a project. By inserting a library in to a project,
its type will become available to connect to an application.
• When a project is created, the libraries folder contains the System folder
(containing firmware functions that can be used throughout your
applications) and two libraries that are always connected to a project, the
Basic and the Icon libraries. There are a number of additional libraries
available that can be inserted.
• There is also a Hardware folder available, containing several hardware
libraries. These libraries are available to connect to a controller and thus
we can mix different hardware versions in one Control Project.
 Control Builder M

• Applications
• A Control Project may contain one or more applications. The application is
the largest organizational unit in any controller. However a controller may
execute several applications. Each application may be considered as an
independent object in the controller.
• In the application create the program(s) or control modules containing the
program code to be compiled and downloaded for execution in the
controller(s). Each application to be used must be connected to a controller.
• An application may contain up to 64 programs. This means that you can
split the control strategy into different parts, depending on required
interval times and priorities.
 Control Builder M

• Controllers
• The hardware definition and the I/O connection are done in the Controllers
folder. In the root of the Controllers folder of each project, several
controllers can be created. Hardware units are added to the tree structure
representing physical hardware units.
• The applications containing the code are not executed unless a “work
scheduler” – a task - is connected and serves as an “engine” running the
code in the controller. In the root of the Tasks folder of each Controller,
several tasks can be created. Each controller has three default tasks
labeled Fast, Normal and Slow with their interval times set to 50ms, 250ms
and 1000ms respectively.
 Engineering
Workplace /
Plant Explorer
• Engineering Workplace / Plant
Explorer is the tool that is
primarily used for System
800xA configuration.
• The Engineering Workplace is
the workplace used for all
project work done by
application engineers.
• It is used to create and manage
Aspect Objects and their
related Aspects.
 Engineering Workplace

• This is the working environment for a particular group of people who might wish to access the system. In
a newly installed system there are 4 default workplaces provided, intended for various users.
• Engineering Workplace
• Operator Workplace
• Plant Explorer Workplace
• Two Screen Plant Explorer Workplace

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

• The Engineering Workplace is based on

the concept of Windows Explorer. When
viewing a structure, objects are in the
left-hand window (pane) and aspects of
the selected object are in the right-hand
window (pane).
 CONTROLLER & I/O ASSIGNMENT

• Controller and I/Os are assign using Control Builder M

• Hardware units are added to the tree structure in the Project Explorer representing physical
hardware units. Some units contain sub units, such as serial channels, that are automatically
created.
 CONTROLLER & I/O
ASSIGNMENT
• On the example of a hardware configuration, there are 4
I/O modules connected to ModuleBus and 3 I/O modules
connected to PROFIBUS.
 Adding a controller CPU

• In the Project Explorer, right click on Controllers and choose

“New Controller”.
• Then choose the new CPU type that you wish to insert.
Adding a Communication Interface
Module
• Open the just inserted controller structure, right click
on Hardware AC 800M and choose “Insert
Unit”.Then choose the new CPU type that you wish to
insert.
• Choose the communication interface module that you
want and click “Insert”
 Adding S800 I/O on ModuleBus

• Open the just inserted controller structure, right click

on ModuleBus and choose “Insert Unit”.
• Then choose the appropriate S800 I/O and the
position (slot).
 Hierarchical Dot Notation

• The hardware address of a hardware unit is

composed from the hardware tree position numbers
of the unit and its parent units, described from left to
right and separated by dots.
 Changing the IP Address

• Right click the Controller, choose “Properties >

System Identity” and then set the desired IP address
of the controller.
• The System Identity is the network address of the
selected controller. The network address is shown
beside the controller icon in the Project Explorer tree.
 Changing the IP Address

• Open the controller’s PM8xx/TP830 and then double

click the first Ethernet.
• This will open a new window, click on the “Settings” tab,
then set the same IP address and subnet mask as you
have set
 APPLICATION DOWNLOAD

• During a download, the code that has been written is checked and compiled. The controller receives
the compiled application and begins executing it immediately.
• Once your application has been compiled, you can:
• Download the application and go Online.
• This updates the application in the controller.
• Go online without download of the application.
• Useful when, for example, monitoring values in the controller without disturbing the controller.

• A version analysis of the applications is made when you download. The analysis results are used to
determine if and how applications shall be updated to new versions in the controllers.
 APPLICATION DOWNLOAD

• Type of restart
• WARM RESTART
• At a warm restart, variables with the attribute <retain> or <coldretain> are protected by the battery during
restart. During the time that the controller is stopped, all output I/Os will keep their last value.
• COLD RESTART
• At a cold restart, variables with the attribute <coldretain> keep their values, since they
• are stored on the hard disk(actually, in the Aspect Directory, each time Control Builder goes to Offline mode
or at intervals specified in the OPC Server configuration, see chapter 16). Variables without the attribute
<coldretain> lose their values. During the stop time, all output I/Os will keep their last safe state/OSP
values.
• INIT RESTART
• At a Init restart, variables with the attribute <coldretain> or <retain> are returned to the initial value.
 Download

• Select “Tools > Download Project and go Online” in the

CBM.
• If changes have been made to one or several
applications in Offline mode, the version analysis detects
it. You can then decide how to restart the changed
applications.
 CONTROL LOOP CONFIGURATION

• Function block diagram (FBD)

• Function Block Diagram (FBD) is a high-level graphical programming language. It describes the POUs in terms
of processing elements and displays the signal flow between them, similar to electronic circuit diagrams.
• It represents the function block and functions by graphical symbols (boxes), their input and output parameters
by pins of the boxes and the assignment of parameters by lines between the pins. A comprehensive basic
range of function blocks and functions are available.
CONTROL LOOP CONFIGURATION
 Function Block Diagram (FBD)

• The execution order of function blocks and functions is defined at first by the order of their creation.
The execution order is represented by the order of the graphic symbols (boxes) in FBD "from the left to
the right" and "from the top to the bottom".
• The execution order can be change by moving the selected function blocks and functions "up" or
"down" within the structure pane. Just drag-and-drop the function block within the structure pane.
 Function Block Diagram (FBD)
• Basic function of FBD