00 Minerals Library Product Guide

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.
Ó Copyright 2016 ABB. All rights reserved.
Product Guide
Control and Operation – AC800M – Minerals Library

Operation – AC400 Connect – Minerals Library
Version 6.0/0
Based on Project Minerals Library Standard

Prep. PIMIN-PD / P.Topfmeyer 01.09.2016
Appr. PIMIN-PD / G.Schuetz 12.09.2016
Doc. kind Product Guide Doc. Item
Title System 800xA des. des.
Minerals Library Version 6.0/0 Resp. dept. CHIND / PIMIN-PD

Document number Lang. Rev. ind. Page 1
3BHS 161554 en Q
ABB Switzerland Ltd No. of p. 123
1. OVERVIEW .........................................................................................4
1.1 Related Documents ................................................................7
2. THE AC800M MINERALS LIBRARY FEATURES IN A NUTSHELL ...8
2.1 Look and feel adapted to your needs......................................8
2.2 Point of Control (POC)............................................................9
2.3 The alliance of the Control Connection (-CC) .......................11
2.3.1 Process Control Connection (PCC) ........................11
2.3.2 Group Sequence Control (GCC) .............................17
2.3.3 Loop Control Connection ........................................28
3. SYSTEM 800XA CONTROL AND OPERATION AC800M MINERALS
LIBRARY ........................................................................................... 31
3.1 Control AC800M Minerals Library.........................................31
3.1.1 Basic Objects..........................................................32
3.1.2 Consumer Objects ..................................................34
3.1.3 Group Objects ........................................................35
3.1.4 Loop Objects ..........................................................36
3.1.5 Dosing Objects .......................................................36
3.1.6 Communication Objects ..........................................37
3.1.7 Report Objects........................................................37
3.1.8 Power Monitoring Objects .......................................39
3.1.9 Composite Object Templates..................................40
3.1.10 Energy Management ..............................................41
3.2 Support for Process Panel 800 .............................................42
3.3 Operations AC800M Minerals Library ...................................43
3.3.1 Example of a motor Faceplate (Extended View) .....44
3.3.2 Basic Objects..........................................................45
3.3.3 Group Objects ........................................................50
3.3.4 Consumer Objects ..................................................58
3.3.5 Loop Objects ..........................................................73
3.3.6 Reporting Objects ...................................................75
3.3.7 Composite Object Templates..................................77
3.3.8 Electrical Control – Energy Management ................78
3.3.9 Power Distribution Monitoring .................................78
3.3.10 Energy Management ..............................................83
3.4 Technical and Performance Data .........................................93
3.4.1 System Performance and Capacity.........................93
3.4.2 Typical cement plant example with Minerals
Library ....................................................................93
3.4.4 System Example.....................................................95
3.4.5 Memory Space Requirements and Execution
Times......................................................................96
3.4.6 Performance Data...................................................97
3.6 Licenses and Ordering Minerals AC800M Control and
Operation .............................................................................99
3.6.1 Minerals Library License .........................................99
Doc. kind Product Guide Project Minerals Library Standard

Title System 800xA
Minerals Library version 6.0
Document number Lang. Rev. ind. Pages 2
3BHS 161554 en Q 123
ABB Switzerland Ltd No. of p.
3.6.2 Minerals License Point ............................................99
3.6.3 Ordering Examples ............................................... 100
3.6.4 Ordering Example 1 .............................................. 100
3.6.5 Ordering Example 2 .............................................. 100
4. SYSTEM 800XA OPERATIONS AC400 CONNECT MINERALS
LIBRARY ......................................................................................... 101
4.1 Functional Description ........................................................ 101
4.1.1 Analog Input (AI, AIandUnit, AIBar) ...................... 102
4.1.2 Analog Output (AO, AOandUnit) ........................... 103
4.1.3 Digital Input (DI) .................................................... 104
4.1.4 Digital Output (DO, DOTxt) ................................... 105
4.1.5 Group Sequence Start / Stop Controller
(GROUP) .............................................................. 106
4.1.6 Pre-Selection (PREBIN)........................................ 107
4.1.7 Start Warning (STW) ............................................ 108
4.1.8 Motor Controller (Motor)....................................... 109
4.1.9 Damper/ Actuator Controller (MOTP) .................... 110
4.1.10 Valve Control (Valve) ............................................ 111
4.1.11 PI Controller (PIControl)........................................ 112
4.1.12 PID Controller (PIDControl) .................................. 113
4.2 Licenses and ordering PPA AC400 Minerals Connect ........ 114
4.2.1 Tag ....................................................................... 114
4.2.2 Ordering Example ................................................. 114
5. SUPPORT AND TRAINING ............................................................. 116
5.1 Minerals Support ................................................................ 116
5.1.1 Design Review...................................................... 116
5.1.2 Life Cycle Services ............................................... 116
5.2 Minerals Training Courses.................................................. 116
5.2.1 CHH658 IndustrialIT 800xA Applications for Minerals
– Engineering with EBase and Control Builder M.. 117
– Configuration and Operation .............................. 118
5.2.3 CHH652 Industrial IT 800xA Applications for Minerals
– Operation ........................................................... 120
– Configuration and Operation Utilizing BMI
Library .................................................................. 121
REVISION HISTORY .............................................................................. 123

Title System 800xA
3BHS 161554 en Q 123
1. OVERVIEW
Minerals library is a complete and comprehensive library for building industrial
applications in System 800xA with AC800M connectivity. Originally developed for
building control applications specific to cement industry, it has since gained
widespread use in other industries such as mining, mineral processing, energy
and metals industries, etc with a total of over 450 references.
Benefits of using Minerals Library include:

§ Fully integrated with ABB System 800xA
§ Complies with international standard for programmable logic controls
(IED61131-3)
§ Standardized, reusable and flexible out of the box solutions
· Provides standard displays and logic that can be easily duplicated and
reused.
· Easily adaptable to users’ needs and/or process requirements. (for
example, customization of colors, alarm and event list, etc)
· integrated powerful viewers
· The parametrized software modules enable an optimized use of efficient
bulk engineering tools (combined E&I - EBase)
· Multi language support
The System 800xA Minerals Library comprises of

· Control AC800M Minerals Library, which contains the software modules that
are used to configure applications using the AC800M controllers.
· Operations AC800M Minerals Library GraphiXs, which provides display
elements and faceplates for monitoring and control of objects, defined by
means of the AC800M Minerals Library.
· Operations AC400 Connect Minerals Library, which provides display
elements and faceplates for monitoring and control of objects defined by
means of the AC400 BMI Type Circuit Library.

Title System 800xA
3BHS 161554 en Q 123
Figure 1 - Minerals Library Example
800xA System Extension Structure

The Minerals Library is imported into the System as Extensions, and comprises
multiple System Extensions to cover the different Installation options The
following Figure shows the complete Structure of all available System
Extensions:

Title System 800xA
3BHS 161554 en Q 123
800xA Base AC800M Connect
Minerals Library AC800 Setup

Common and GraphiXs
Status Viewer
Minerals Library AC800
Log Configurations
Legacy Libraries
Yard and Port Extension
800xA for Advant Master Energy Management
Minerals Library AC400 Setup
Minerals Library AC400

Title System 800xA
3BHS 161554 en Q 123
1.1 RELATED DOCUMENTS
The figure below shows the structure of all related documentation.
Function Description
MINERALS (BMI)
Project Documentation Documentation Guideline

<Project> <Project>
<Customer> <Customer>
Configuration Standard Minerals Library

MINERALS Standard Product Manuals
Documentation
System 800xA Manuals
Compact 800 - Process

Panel
Figure 2 Document Organization

Title System 800xA
3BHS 161554 en Q 123
2. THE AC800M MINERALS LIBRARY FEATURES IN A
NUTSHELL
2.1 LOOK AND FEEL ADAPTED TO YOUR NEEDS

The library contains several possibilities to adapt its behavior both visually and functionally. The
customization possibilities are described in the reference documentation (01 Minerals Library
Overview). Following four examples of the different Styles that are coming pre-defined with the
standard Installation Package:
Minerals Standard ASM Standard
VALE Standard Holcim Standard
Figure 3 - Minerals Library Styles (incomplete)
In addition to the configuration possible per Object and Graphic Element, Colors
and some Settings can be done per Operator Workplace to re-use the same
Display Graphics for different Environments. Furthermore, Minerals Library

Title System 800xA
3BHS 161554 en Q 123
comes with National Language Support (NLS) that allows to provide each User
with Descriptions, Texts and Alarm Messages in his native Language.
2.2 POINT OF CONTROL (POC)

Group and consumer objects have four different Point of Control (modes):
SEQuence
CENtral
LOCal
Out of
Service
All POC are selectable from the operator workplace. The point of control defines from
where the object will be controlled. In order to control an object the corresponding POC
must be selected before giving any command to the object. For safety reason, stopping
an object or closing a gate is always possible, no matter which control mode has been
chosen.
Sequence: The object is controlled by a superior application program e.g. from a drive
group sequence. Sequence mode can be set from the operator station or by the
application program.
Central: The object is controlled by the operator station by means of the start/stop or
open/close push buttons on the faceplate. Start/stop or open/close from a superior
application program is also possible in this mode. The Central mode can be set from
the operator workplace only.
Consumer Objects in POC Sequence and Central have two sub-modes:
Manual Mode
Auto Mode
Man (default): An object is controlled by a rising edge start / stop command, either
released from the operator station or from the superior application program.

Title System 800xA
3BHS 161554 en Q 123
Auto: An object is controlled by an input IA (IA =1 starts the motor, IA=0 stops the
motor). Typical use of the auto mode is on/off control by thermostats, level switches,
etc.
In Central Auto and Sequence Auto mode the operator cannot control the object any
more from the operator station. Stopping a motor and closing a gate is always possible.
Local:
The object is controlled from the field via the pushbuttons on the local control box
(LCB). To operate a drive locally, the drives need the local release from the CCR
operator. The point of control has to be changed in the CCR and can be set for a
complete drive group or for every object individually.
The interlocks are de-activated in this mode except the safety interlock IC (Rope
Switches, Bearing/Winding Temp., Vibrations etc.). Furthermore the two feedback
signals (FB1 and FB2 – for example speed switch) are also de-activated while pressing
and holding the start/open push button. Typically, the Local mode is for maintenance
purposes.
Note: Alarms are disabled when an object is in Local mode (no alarm acknowledgment on
the operator station necessary when object is operated from the field).
Out of Service: The object is not in service and cannot be started from any location. It
also means that the object will be skipped when running a superior group sequence. Out of
Service mode can be set and reset from the operator station only with special user rights.

Title System 800xA
3BHS 161554 en Q 123
2.3 THE ALLIANCE OF THE CONTROL CONNECTION (-CC)
Software Modules in the Minerals Library are able to exchange data on predefined
interface so called control connections – (data highway)
· The status form child objects are always reported to the parent object and vice versa
· Commands can be sent from parents to children and from children to parents
2.3.1 Process Control Connection (PCC)

PCC is used in the application program to implement logical connections
between various application objects. It uses structured variables and hence
lowers the engineering time (requiring only one logical connection) while
increasing the amount of information exchanged (multivariable connection)
between application objects.
This overview shows the logical structure of a Minerals Library Application
Program:
Through the PCC Bus it is possible to see the DIS, DIC, AIS and AIC limit that is
causing some fault to the consumer object on the Group and Motor Faceplates.
The tag name of the alarming input signal is shown on the faceplate of the
consumer. In the same way you will find the link from DIS, DIC, AIS and AIC
faceplate to the consumer tag name.
Alarms can be acknowledged at any Faceplate, i.e. the acknowledgement given
on the Group level will be propagated through the Motor down to the Signal level.

Title System 800xA
3BHS 161554 en Q 123
Example to illustrate the simplicity and benefits of the PCC
Basic situation of 2 Signals connected to a consumer by PCC
The program code in the CBM diagram editor with the minerals library elements is shown on
the left and on the right the corresponding graphical elements on the HMI, as they are
presented to the operators.
Minerals Library object: DIS

Control Module: _562_BM1_FS1R The axial plain bearings of the mil are supplied by
Module Parameter “Name”: 562-BM1.FS1R oil. The unit is equipped with a flow switch 562-
BM1.FS1R that detects the flow of the oil supplied.
The Signal is in a heathy state and therefore shown
in a grey background
Minerals Library object: MOT

Control Module: _562_BM1_M1R The grinding process is actuated by the mill main
Module Parameter “Name”: 562-BM1.M1R drive that is shown in its running state on the HMI.
Minerals Library object: AIS

Control Module: _561T101_R The mill bearing temperature is monitored by an
Module Parameter “Name”: 562TI101R analogue signal located at the bearings. The
analog signal is shown as a digital number in its
normal state to the operator.

Title System 800xA
3BHS 161554 en Q 123
Example to illustrate the simplicity and benefits of the PCC:
Mineral Library standard consumer MOT1
The standard motor module of the minerals library is highlighted on the process HMI, in the
code we would like to draw the reader’s attention to the PCC bus that interconnects the motor
and the analog and digital signal presented in the page before.
By clicking on the motor on the HMI the In the faceplate is the PCC Viewer located. A click
faceplate of the motor opens. on this icon brings up the window shown below.
This table provides a complete and consistent
overview of the interlocks acting on the consumer.

Title System 800xA
3BHS 161554 en Q 123
Alarm forwarding through PCC between IO signal and the control object
In the following illustrated situation the mill motor was stopped due to an unhealthy flow
switch signal. The motor does not show a running status anymore and an alarm indication is
present on the digital signal and on the motor itself. A consistent exchange of information
exchange between the assets is provided over the PCC.
Additional details about the motor stop are

revealed by opening the faceplate of the The PCC viewer of the motor also indicats the
motor. The reason of trip signal is written in actual reason for tripping the motor with a
highlighted red line. 1 Active safety interlock.
text highlighted with a violet frame

Title System 800xA
3BHS 161554 en Q 123
Drill down navigation through faceplate link
Starting from the motor that was stopped by the interlock, the faceplate of the motor is opened from
the process HMI.
As mentioned before the reason for tripping is

indicated on the faceplate, also in the PCC
Interlock tab (visible with the extended view of
the
faceplate the IC interlock is active.
By clicking on the navigation button , the The status of the signal is shown with a red
faceplate of the flow switch is opened for a alarm frame (unhealthy condition)
indeep root cause analyize.
In the PCC tab of the Signal faceplate the PCC

alarm configuration is shown as IC Safety valid
for both direction X/Y.

Title System 800xA
3BHS 161554 en Q 123
Drill down through PCC viewer
Like in the illustrations above the navigator, opens faceplate of the motor. This time the navigation to
the Signal (root cause for motor stop) is done over the PCC viewer as an alternative option.
The PCC viewer is opened by clicking on the Clicking on the highlighted bar in the PCC will
corresponding icon in the motor faceplate. open the facepalte of the flow switch.

Title System 800xA
3BHS 161554 en Q 123
2.3.2 Group Sequence Control (GCC)
For Group Control the Minerals Library applications provide state of the art functionality
for sequence start, stop, route and monitoring of all process objects in the plant.
Group Status Indications and monitoring
The figure below shows all possible status indications of the group as presented in the
process display.
Off
Starting
Startwarning
Running
Running
restart required as pre-selection has changed
Stopping
Running, warning
in some of connected equipment
on Hold (not off but as well not fully running)
Failure, not ready for start
on Hold
Off
Start interlock
Running
Stop interlock
Off
not ready for start because of Failure in at least
one of the connected consumers

Title System 800xA
3BHS 161554 en Q 123
The group constantly monitors all process objects assigned to it and updates the status in real time.
The faceplate provides additional detailed indication on:
· Tag Name of the Object not ready for start or in hold
· Interlock text for group start and stop interlocks
· Actual step and tag during Start-up and stopping
· Indication of pre-selection missing or error
Group not Ready for Start Group Starting Group in Hold

GR_592_1 not RFS GR_552_1 in actual Step First Object in hold:
(not Ready for Start) GR_562_1
Figure 4 - Example of Group Faceplate indicating

Title System 800xA
3BHS 161554 en Q 123
Starting a group
A group may be started, if all pre-selected equipment assigned to the group is ready for
start, the pre-selection is set correctly and no group start interlock is active. Initial
starting is possible from status “Off / Ready for Start”. A group restart can be performed
from the status: “Stopping”, “Hold” or “Running”.
Before starting the group, the pre-selections such as selecting alternative routing,
standby units, set points, etc., may be adjusted. The new settings are indicated in the
process display and the faceplate.
Pressing the “start” button in the faceplate the following steps are executed:
1. An audible start-up warning is activated for all related equipment, optional the start
warning can be configured to be executed prior the start of individual equipment.
The group indicates “Starting / PreWarning”
2. After a certain adjustable time, the start-up warning stops and the equipment starts
to run, respectively moves into the position according to the programmed
sequence and used pre-selections. The group indicates “Starting” and the step
number and tag name of the actually started equipment can be monitored on the
faceplate.
3. A successful start-up is indicated by the group status indication changing to

“Running”. In case any important equipment fails during the start-up, the group
indicates “Hold” resp. “Drive(s) not Ready for Start”.
Unconditional Start (available in extended Faceplate)

Additionally a group can be started by an unconditional start, even with equipment not
ready for start. That means that the group will start until the start step of the equipment
which is not ready for start. This function is not active in case of a group start interlock.
Stopping a group
A group may be stopped in case there is no stop interlock active (e.g. group can’t be
stopped because another group is still not off). Stopping is possible from any status,
even the group “Starting” status.
Pressing the “Stop” button changes the indication to stop and all equipment will be
sequentially stopped or moved to the defined “off” position, leaving the equipment in a
suitable condition for the next start-up – transport systems emptied of material,
dampers turned to safety position. After a successful stop the group indicates “Off /
Ready for Start”.

Title System 800xA
3BHS 161554 en Q 123
Instant Stop / Quick Stop
A stop may be performed instantly disregarding the programmed appropriate stop order
by pressing the “quick stop” button in the faceplate. The “instant stop” stops all
equipment in the group simultaneously. For actuators and Loop controllers the specific
action to be executed at a quick stop can be adjusted individually. The instant stop can
be activated at any time (even if a stop interlock is active). In such a case the other
drives and/or groups are stopped according to the process interlocks.
If an alarm condition arises during the group start sequence (e.g. fault or process
interlock of equipment starting or already running) the start-up will be interrupted
automatically and the group indicates, “Hold / Drive(s) not Ready”. The object name of
the equipment causing the fault is presented in the group faceplate and the operator can
directly link to the equipment faceplate to get more detailed information.
“Hold” means that only a part of the group is in operation (not completely started or
stopped). At this state by pressing the “stop” button, the rest of the group is stopped in
accordance with the stop sequence or if the fault can be removed, the start sequence
may be reactivated by selecting the group and pressing the “start” button again.
A group may be started, if all pre-selected equipment assigned to the group is ready for
start, the pre-selection is set correctly and no group start interlock is active. Initial
starting is possible from status “Off / Ready for Start”. A group restart can be performed
from the status: “Stopping”, “Hold” or “Running”. Additionally a group can be started by
an unconditional start, even with equipment not ready for start, meaning the group will
start until the start step of the equipment which is not ready for start.
Before starting the group, the pre-selections such as selecting alternative routing,
standby units, set points, etc., may be adjusted. The new settings are indicated in the
process display and the faceplate.
Manual Hold
The operator may manually interrupt the starting or stopping or quick stop procedure of
a group at any time by pressing the “hold” button on the faceplate. In this case the group
will indicate hold until the starting or stopping process is continued.
Pre-selections
The pre-selection function allows motors to be included in the start-up process of a
group. By setting and resetting the pre-selections, the operator may define which objects
should be activated or deactivated by the next start command. Even a flying change of
the pre-selection (e.g. automatic change of silo filling) may be programmed. This is a
fully automatic change of the pre-selection during the group running status.

Title System 800xA
3BHS 161554 en Q 123
By clicking with the left mouse button on the pre-selection button, the pre-selection will
be set/reset. The status of the pre-selection is shown on the button. At the group start
any changes of the pre-selections will be taken into account and the new configuration
of the pre-selections is activated.
The figure below shows the possible status of a Preselection.
Off /not selected
Selected to Start (Flashing)
Started / Running
Selected to Stop (Flashing)
Off / not Ready for Start
The operator is allowed to change the pre-selections when a group has following status:
· Group is stopped completely

· Group is running (flying change over)
· Group is in HOLD mode
· Pre-selection change is not interlocked by the process (dimmed indication)
During a start-up or a stop of the group, a pre-selection change is prohibited.
If only one pre-selection setting is allowed to be active at the time, the other pre-
selections are deactivated automatically (radio button function). If more pre-selection
settings are possible at the same time, the operator can manually chose the
configuration.
Missing – and wrong pre-selection combinations prevent a group start. There is then an
indication on the group faceplate.

Title System 800xA
3BHS 161554 en Q 123
Example to illustrate the simplicity and benefits of the GCC (Group Control Connection)
Basic situation of a group containing 3 consumers
The program code in the CBM diagram editor with the minerals library elements is shown on
the left and on the right the corresponding graphical elements on the HMI, as they are
presented to the operators.
Minerals Library object: GROUP In this process the group contains 3 consumers,
which are the two pumps 1 & 2 and the mill main
Control Module: GR_562_2R
motor. The mill motor has already been used and
Module Parameter “Name”: GR_562_P2 explained in the pcc example. This 3 consumers
are connected by the GCC, hightlighted with blue
colour in the picture showing the code. The GCC to
the mill motor is connected with a grey link
connector.
Minerals Library object: PREBIN The axial plain bearings of the mil are supplied by
oil. The oil pressure is produced by two redundant
Control Module: GR_562_2R_P1
pumps. There is only one out of the 2 pumps
Module Parameter “Name”: GR_562_2R_P1 running at any given moment.

Title System 800xA
3BHS 161554 en Q 123
Minerals Library object: PREBIN The pump not running is selected as standby.
Means that the second pump will be started in case
Control Module: GR_562_2R_P2
the first one fails.
Module Parameter “Name”: GR_562_2R_P2
Example to illustrate the simplicity and benefits of the GCC

Mineral Library standard group module
The standard group module of the minerals library is highlighted on the process HMI with a
blue frame. The functionalities presented on the following pages are all provided by the GCC
highlighted with blue lines in the code.

Title System 800xA
3BHS 161554 en Q 123
In the faceplate the link to the group status viewer is
by clicking on the group icon on the process located. A click on the button brings up the window
HMI the faceplate of the group opens. shown below.

Title System 800xA
3BHS 161554 en Q 123
Forwarding of Warning and Alarms through GCC and PCC
In the following illustrated situation the mill motor was stopped through an unhealthy flow switch
signal. The exactly same situation was illustrated in the PCC example, but this time the starting
point of fault finding is the group and not the motor.
Additional
information about the group stop are revealed by
opening the faceplate of the group. The first The Group status viewer of the group also indicates
consumer not running is written in text. the actual status of the group

Title System 800xA
3BHS 161554 en Q 123
Additionally the status viewer also contains information
about the signal connected through the consumer.

Title System 800xA
3BHS 161554 en Q 123
Drill down navigation from group to consumer to signal
Starting from the group that does not show running anymore, the faceplate of the group is
opened from the process HMI.
As mentioned before the reason why the group is

not running anymore is indicated on the faceplate.
By clicking on the navigation button , the

faceplate of the consumer is opened
by clicking again on the on the navigation
button in the faceplate of the motor, the
faceplate of the flow switch is opened (root
cause)
As explained in the PCC example the reason for

tripping is indicated on the faceplate of the motor
Title System 800xA
3BHS 161554 en Q 123
2.3.3 Loop Control Connection
With the loop control connection (LCC) the Minerals Library applies the successful bus
concept to the world of loop control. The persistent linking between objects enables
engineers to design complex control concepts with a standardized structured approach.
A structured Datatype LoopControlData is available with all Loop Objects and several
Consumer Objects, for Building analog Control Loops with one Single Connection
between Blocks.
Together with forwarding the Setpoint from the Controller to the Actuator Object,
navigation between the Blocks connected by LoopControlConnection is available for the
Operator in the Faceplate, and any Alarm State of the Actuator with corresponding
Color is shown for the related Output Value in the Controller Faceplate as well.
Backtracking is an important Feature of the LoopControlConnection Concept. A

Setpoint Consumer always transmits the actually used Value in reverse direction so that
the producer can adjust for the Situation, to enable bumpless transfer between the
Modes and Anti-windup function in PID Control Loops.
The LoopControlConnection inherits the features of the ControlConnection available

within the Standard AC800M Control Libraries. For a detailed Description of the

Title System 800xA
3BHS 161554 en Q 123
ControlConnection Datatype, please refer the “AC800M Binary and Analog Handling”
Manual (3BSE035981).
Backtracking is an important Feature of the LoopControlConnection Concept. A

Setpoint Consumer always transmits the actually used Value in reverse direction so that
the producer can adjust for the Situation, to enable bumpless transfer between the
Modes and Anti-windup function in PID Control Loops.

Manual (3BSE035981). Backtracking is an important Feature of the
LoopControlConnection Concept. A Setpoint Consumer always transmits the actually
used Value in reverse direction so that the producer can adjust for the Situation, to
enable bumpless transfer between the Modes and Anti-windup function in PID Control
Loops.

Manual (3BSE035981).

Title System 800xA
3BHS 161554 en Q 123
PID PID faceplate
SplitRange SplitRange faceplate
Consumer Consumer faceplate

Title System 800xA
3BHS 161554 en Q 123
3. SYSTEM 800XA CONTROL AND OPERATION AC800M
MINERALS LIBRARY
The Minerals Library for AC800M is a complete Solution to control a Minerals
Processing Plant with the 800xA System.
This version runs on System 800xA Version 6.0, and supports Applications
programmed using the Control Builder M Diagram Editor (FD).
3.1 CONTROL AC800M MINERALS LIBRARY

Control AC800M Minerals Library contains controller software modules that are
used to configure applications (main focus being in Minerals Industry) using the
AC800M controllers.
A set of purpose-built, software modules has been developed, supporting the
process requirements for these applications. These software modules are
developed with the ABB Control Builder M Professional programming tool, as
Control Module Types (CM). The types of the exceptions of this rule are stated
separately.
These software modules comprise the Minerals Library, and are grouped in eight
different object categories:
· Basic Objects
· Communication Objects
· Consumer Objects
· Dosing Objects
· Group Objects (sequencing)
· Loop Objects
· Power Monitoring Object
· Report Objects
· Energy Management
A separate Reference Manual is available for each object category providing

more details.

Title System 800xA
3BHS 161554 en Q 123
3.1.1 Basic Objects
The Basic Objects (AI, AO, DI, DO) provide access and control for process IO-
signals and calculated IO-signals.
Basic functions such as blocking and forcing of signals, control of output and limit
level changes are integrated in these objects.
A detailed description of the basic objects and their interfaces is given in the
reference manual Basic Objects.
Reference Table: Basic Objects for process IO-signals
Name Function Usage Example

AIS Analog input module for 1 process signal. The Analog Input,
functions are blocking & forcing of input value, 4 Analog
alarm limit levels, 2 process limit levels, 3 alarm Measurement,
priorities, alarm delay, alarm blocking, alarm Sensor
disabling/enabling.
AOS Analog output module for 1 process signal. The Analog Output,
functions are manual / auto mode, tracking of mode Actuator Setpoint
and output changes, 2 output limits.
DIS Digital input module for 1 process signal. The Digital Input, Binary
functions are blocking and forcing of input value, 3 Sensor, Switch
alarm priorities, alarm delay, alarm blocking, alarm
disabling/enabling from application software.
DOS Digital output module for 1 process signal. The Digital Output
functions are manual / auto mode, tracking of mode
and output changes.
Reference Table: Basic Objects for calculated IO-signals

AIC Analog input module for 1 calculated signal. The Calculated Analog
functions are the same as for the AIS. AIC uses the Value
same data type as AIS.
AOC Analog output module for 1 calculated signal. The Manual Analog
functions are the same as for the AOS. AOC uses the Setpoint
same data type as AOS.

Title System 800xA
3BHS 161554 en Q 123
DIC Digital input module for 1 calculated signal. The Calculated Binary
functions are the same as for the DIS. DIC uses the Value
same data type as DIS.
DOC Digital output module for 1 calculated signal. The Manual Binary
functions are the same as for the DOS. DOC uses the Setpoint
same data type as DOS.
Table 1 - Basic Objects for PCC
Name Type Function Usage Example

PCC_Connect FB The PCC Connect can be used if one signal shall be Signals stops
linked to multiple consumers through PCC: several Motors
· Forwards alarm and interlock on signal to all
consumers depending on their state
· Individual interlock forwarding mask for each
consumer
PCC_ FB The PCC ThresholdAND3 allows defining complex Combine (and,
Threshold_AND3 interlock conditions thru PCC. or) several
conditions to
one interlock
PCC_Intlk CM Single Interlock Condition through PCC Interlock of a
· Group several PCC Signals to one single Signal to a
Interlock for a Drive consumer,
· Configurable Interlock and Ready Time Delay where the ready
time delay can
be set from the
Faceplate.

Title System 800xA
3BHS 161554 en Q 123
3.1.2 Consumer Objects
Consumer objects provide access and control for the physical devices
(consumers) in the plant.
Basic functions such as operator orders, detailed interlock and alarm
indication, tracking of mode and status changes, are integrated in these
objects.
A detailed description of the consumer objects and their interfaces is given in
the reference manual Consumer Objects.
Reference Table: Consumer Objects

MOT1 Control a motor with one direction (one speed) in a Direct online
drive group or standalone. Ventilator, Belt
Conveyor, Rotary
Feeder
MOT1_VVVF Control a motor with one direction and variable speed Variable Speed
in a drive group or standalone. Drive, Weighfeeder
MOT2 Control a motor with two directions (two speeds) in a Reversible Belt
drive group or standalone. Conveyor
MOT2_VVVF Control a motor with two direction and variable Reversible Variable
speed in a drive group or standalone. Speed Drive
MOTP Control a motorized valve or damper with or without Motorized Damper,

analog position feedback in a drive group or standalone. Diverter
VLV1 Control a normally-closed one-way valve with one or Valve with Coil and
two coils in a drive group or standalone. Up to two Spring with default
position limit switches (open and closed) can be position closed
supervised.
VLVNO1 Control a normally open one-way valve with one or two Valve with Coil and
coils in a drive group or standalone. Up to two position Spring with default
limit switches (open and closed) can be supervised. position open
Actuator Control a Valve or Damper with Analog Output and Damper with external
Position Feedback. Up to two position limit switches Position Control Unit
(open and closed) can be supervised.

Title System 800xA
3BHS 161554 en Q 123
3.1.3 Group Objects
The Group Objects provide access and control for a process group or
process group related features.
Basic functions such as operator orders, detailed interlock and alarm
indication, tracking of mode and status changes, pre-selection of group
members and startup warnings are integrated in these objects.
A detail description of the group objects and their interfaces is given in the
reference manual Group Objects.
Reference Table: Group Objects

GROUP Group sequence. The functions are starting, Mill Lubrication
stopping of group members in a sequential order, Sequence, Transport
summary status indication of all pre-selected group Sequence
members (ready, run, off), 4 start and 4 stop
interlocks, emergency quick stop.
DriveGroup Technological group can handle auxiliary equipment Long Belt Conveyor
and main drives like one system with multiple Drives
and Lubrication
(Auxiliary
Consumers)
GrpCycleCtrl Cycle controller for the group. This control module Silo Aeration, Filter
can be used for cyclic activation and deactivation of rapping Sequence
group members by means of a script (e.g. silo
aeration, cool down lubrication etc.). Several
GrpCycleCtrl objects can be added to one GROUP.
PREBIN Pre-selection module. The function is to activate or Transport Group
deactivate one or a set of group members such as Way Selection
consumer objects or loops during the group start up.
STW Start Warning module. The function is to provide a Startup Warning
startup warning for an individual consumer object or Horn and Flash Light
a group.

Title System 800xA
3BHS 161554 en Q 123
3.1.4 Loop Objects
Loop objects provide access and control for analog open and closed control
loops.
Basic functions such as operator orders, detailed alarm indication, tracking of
mode and status changes, are integrated in these objects.
A detailed description of the loop objects and their interfaces is given in the
reference manual Loop Objects.
Reference Table: Loop Objects

PIDCtrl State-of-the-art PID closed loop controller with feed PID controlled closed
forward, anti-wind-up functions. loop
PIDAdvCtrl PID closed loop controller with advanced Functions, for Cascade loop,
cascade control loops, gain scheduling, adaptive PID Adaptive PID closed
control. loop control
RatioCtrl Calculates an Output (Setpoint) by an Input Signal with Setpoint for Additive
Gain and Offset as Percentage of
Total Feed Setpoint
SplitRange Connect Setpoint from PIDCtrl or RatioCtrl to 2 Objects 2 Valves in Split-
in parallel or split-range configuration Range configuration
3.1.5 Dosing Objects

Dosing objects provide access and control for Setpoint Values for weigh feeder
proportioning or other Analog Value controlled Objects.
A RecipeControl Block is provided to control multiple Dosing Objects operating
with relative Setpoints with a single Total Setpoint.
A detailed description of the dosing objects and their interfaces is given in the
reference manual Dosing Objects.
Reference Table: Dosing Objects

RecipeControl Main control object for a Recipe that handles up to 6 Cement Mill Total
dosing object instances of the type Feed Control with
SetpointCommInterface. Recipe of
Multiple RecipeControl Blocks can be connected Percentages of
together to control a Recipe with more than 6 multiple Materials
Setpoints.

Title System 800xA
3BHS 161554 en Q 123
3.1.6 Communication Objects
Communications objects establish and supervise the communication between
two AC800M controllers or between different applications or diagrams.
A detail description of the objects and their interfaces is given in the module
description Communication Objects.
Reference Table: Communication Objects

GCC_Com_ The GCC_Com_M / S extend the group drive bus to Motor located in
M/ another diagram, application and/or controller via one different Area or
GCC_Com_ point-to-point Communication Variable. shared between
S different Diagrams
PCC_Com_ The PCC_Com_Drive / Signal is used to connect the Signal located in
Drive / PCC bus if the Signal is located in a different Diagram, different Area or
PCC_Com_ Application and/or Controller than the Consumer Object shared between
Signal (Drive). It allows to connect the PCC Bus via one point- multiple Diagrams
to-point Communication Variable.
3.1.7 Report Objects

Report objects provide access to counter values or summarize Analog Values
over time (integrator). They provide a focused historical archiving for
detailed information.
The different counter types provide total following functions:
· Total and shift value summation (two independent counter values)
· Reset counter value from controller or from the Operator Station (via the
faceplate)
· Adjustment (positive & negative) of counter value and constant from the
Operator Station (via the faceplate)
· Operator Station Interface (graphic element and faceplate)
A detailed description of the report objects and their interfaces is given in the
Reference Manual Report Objects.
Reference Table: Report Objects

PulseCount Count pulses or integrate an Analog Value over time. Total Feed Value (in
tons, integrated from
tons per hour), Used
Energy

Title System 800xA
3BHS 161554 en Q 123
Reporting Count pulses or integrate an Analog Value over Production Reports
Count time, with historical values for the last shift, day
and month.

Title System 800xA
3BHS 161554 en Q 123
3.1.8 Power Monitoring Objects
Power monitoring objects are intended for supervision and control of power
distribution equipment such as switchgear, and protection relays using serial
connectivity (e.g. Profibus or Modbus). The objects are designed as
composite control modules containing one module for the communication.
This module can be modified to adapt to the requirements of the equipment.
A detail description of the objects and their interfaces is given in the
Reference Manual Power Monitoring Objects.
Reference Table: Power Monitoring Objects
Name Type Function Usage Example

Circuit Breaker CM Control an IED Control Device MV Circuit
with up to 2 Breakers with Breaker
Isolator and Earth Switch in a
drive group or standalone
CircuitBreakerA Composite CM: Interface to an ABB REF542+ ABB REF542Plus
BBREF542Plus connected via ModBus IED
Circuit Breaker +
3 AIC (Current,
Voltage, Power) + 1
Counter (Energy)
PFCCtrl CM Power Factor Correction Power Factor
Controller with up to 8 Circuit Control
Breaker (Steps)

Title System 800xA
3BHS 161554 en Q 123
3.1.9 Composite Object Templates
The library contains a so called wrapper framework to compose project
specific consumer objects having serial communication interface (Profibus,
Modbus, etc.) between control system and device. The intention is to provide
samples of how to implement project specific serial devices. The samples
included in the library shall be used as templates, i.e. copied and adapted to
the project specific requirements if required.
The Control Module Types and their corresponding Structured Data Types
are located in a dedicated Library per Interface like BMI_MNSIS,
BMI_MNSiS_MBTCP, BMI_UMC100 and BMI_ACS8x0.
Reference Table: Serial Communication Objects
Name Type Usage

MOT1VVVF_ACS8x0 Composite CM: ABB Drive system
MOT1_VVVF with Profibus DP
interface
ACS500, ACS600,
ACS800 or ACS1000
MOT2VVVF_ACS8x0 Composite CM : ABB Drive system
MOT2_VVVF with Profibus DP
interface
ACS500, ACS600,
ACS800 or ACS1000
MOT1_MNSIS Composite CM ABB MNS iS MCC
MOT2_MNSIS MOT1 + AIC (Current or Power) with ProfibusDP
Interface to MLink
MOTP_MNSIS MOT2 + AIC (Current or Power)
MOTP + AIC (Current or Power)
MOT1_MNSiS_MBTCP Composite CM: ABB MNS iS MCC
MOT2_MNSIS_MBTCP MOT1, MOT2, MOTP with Modbus TCP/IP
Interface to MLink
MOTP_MNSIS_MBTCP
MOT1_UMC100 Composite CM: ABB UMC100 MCC
MOT2_UMC100 MOT1, MOT2, MOTP with PDP or PDQ
PROFIBUS Interface
MOTP_UMC100

Title System 800xA
3BHS 161554 en Q 123
3.1.10 Energy Management
Energy Management functions are licensed as an option to Minerals Control
Library.
Energy Management Objects are intended for supervision of the electrical
feeders, monitoring and controlling of loads with the target to ensure that the
Energy consumption of the Plant respects given conditions.
The Control Module Types for Energy Management objects and their
corresponding Structured Data Types are located in the library BMI
EnergyMgmt for Control Builder Professional.
Reference Table: Examples of Energy Management Objects
Name Type Function

Load Composite CM Load :
Enable grouping of MV-Switchgear according Plant Sections
Load
in order to monitor and control their Energy consumption
Composed from : Load +
3 DIC (Warning, Interlock,Tripping) +
1 Reporting_Counter (EnergyCost)
Load Load Shedding Load Shedding:
Shedding Enable to ensure that the Energy consumption of the Plant
respects certain conditions according priorities
Power Composite CM PowerDemand Supervision:
Demand Enables input of tariff structure and their given conditions to
PowerDemand
Supervision respect coming from the Energy supplier
Supervision
Composed from : PowerDemandSupervision +
8 Tariffs / each Tariff composed from 8 TariffSet +
1 DIC (syncPulseAlarm) +
6 AIC Total Power, Total Current, ActualEnergyInInterval,
ForecastEnergyAtIntervalEnd,
EnergyMovingInterval,PeakPowerExceededTime,

Title System 800xA
3BHS 161554 en Q 123
3.2 SUPPORT FOR PROCESS PANEL 800
BMI standard symbol library for Process Panel P800 is included in the
Minerals Control and Operation Library.
The Process Panel 800 Interface provides access and control for the
following Minerals Library AC800 control modules:
· AIS
· AOS
· DIS
· DOS
· AIC
· AOC
· DIC
· DOC
· MOT1
· MOT1VVVF
· MOT2
· MOT2VVVF
· MOTP
· VLV1
· VLVNO1
· GROUP
· DriveGroup
· PREBIN
All Process Panel objects have the following common basic functions:
· Manual control from the Process Panel (via commands and input fields)
· Status and operation indication
· Mode selection from the Process Panel (via commands)
· Data exchange through a single access variable
For more info consult the documentation: Process Panel Reference Manual
3BHS240189
Control - AC800M - Minerals Library
Operation - Process Panel - AC800M Connect - Minerals Library

Title System 800xA
3BHS 161554 en Q 123
3.3 OPERATIONS AC800M MINERALS LIBRARY
Operations AC800M Minerals Library integrates the Control AC800M
Minerals Library with the Process Portal. The AC800M Connect Minerals
Library provides display elements and faceplates on the Process Portal, for
monitoring and control of objects defined by means of the AC800M Minerals
Library.
The figure below shows examples of the display elements with status
indication of equipment as presented on the process displays.
Consumer Objects
Motor Fan Pump Valve Damper Diverter
Off / Ready for Start
Starting
Running
Running (Dir X)
Position X / Open n/a n/a n/a
Running (Dir Y) n/a n/a
Position Y / Close n/a n/a n/a
Intermediate Position n/a n/a n/a
Object Fault / Alarm
Object Interlock
Run with Warming

(High Current)
Warning Interlock
(PCC)

Title System 800xA
3BHS 161554 en Q 123
3.3.1 Example of a motor Faceplate (Extended View)
Tag name
Descriptio
n
Point of Call up Call up

Control Object Object
Indication Alarm Event
List List
Motor
status
Indication
Start
Change Point of
motor
Control
Stop
motor Seq => Sequence
Cen => Central
Loc => Local
Acknowledge Alarm Extended View

Title System 800xA
3BHS 161554 en Q 123
3.3.2 Basic Objects
Analog Input (AIS, AISandUnit, AISBar)
Main purpose of Module: Analog Input Interface
AISandUnit AISBar
Value
Block
Limit Alarm
Signal Error

Title System 800xA
3BHS 161554 en Q 123
The analog input module for 1 IO-signal provides the following features:
· Blocking and forcing of input value generating event (even on new forced
values)
· Threshold detection and alarming on 4 alarm limit levels (L2,L1,H1,H2)
· Threshold detection and event on 2 Process Limit levels (Plo, Phi)
· Adjustable Low Pass Filter.
· Filtered Signal Rate of change calculation and alarm. The ROC is
presented in % of Total Range per second.
· All Sub status for DP, PA and FF Field Devices will generate error control
when quality is Bad or Uncertain for AIS Control Module.
· Common or Individual alarm delay for all 6 limits.
· Alarm blocking (from faceplate). All alarm limit levels will be blocked.
· Alarm disabling/enabling of each alarm limit individually (from application
program / Faceplate); generating events when blocked.
· Trend for Signal Value, Filtered Value and Rate of Change
· Signal Error Pre-Warning with adjustable alarm delay
· Process Panel status indication and operation

Title System 800xA
3BHS 161554 en Q 123
Analog Output (AOS, AOSandUnit)
Main purpose of Module: Analog Output Interface
Manual control
Automatic control
The analog output module for 1 IO signal provides the following features:
· Automatic control from a superior application

· Manual control from the Operator Station (via the faceplate)
· Tracking of mode and output changes

· Output limitation high/low
· On-Line trend with actual output value shown in the faceplate.
· All Sub status for IO and FF Filed Device will generate error control when
quality is Bad or Uncertain for AOS Control Module

Title System 800xA
3BHS 161554 en Q 123
DIGITAL INPUT (DIS)
Main purpose of Module: Digital Input Interface
DISTxt DIS
Status
Block
Alarm
The digital input module for 1 IO signal provides the following features:
· Blocking and forcing of input value generating event (even on new forced
values)
· Alarming if input value differs from pre-defined (healthy; normal position)
state
· Warning time to be used to generate a pre warning alarm or event before
the main alarm (failure) occurs.
· Ready Delay time to hold the alarm position in order to prevent noisy
signals to clear and re-activate the alarm very often.
· Alarm delay
· Alarm blocking (from faceplate). All alarm limit levels will be blocked.
· Alarm disabling/enabling (from application program)
· On-Line trend with actual input value
· Process Panel status indication
Title System 800xA
3BHS 161554 en Q 123
DIGITAL OUTPUT (DOS, DOSTXT)
Main purpose of Module: Digital Output Interface
DOSTxt DOS
Status
Manual
Block
Alarm
The digital output module for 1 IO signal provides the following features:
· Automatic control from a superior application

· Manual control from the Operator Station (via the faceplate)
· Manual control from the Process Panel

· Tracking of mode and output changes
· On-Line trend with actual output value shown in the faceplate.
Title System 800xA
3BHS 161554 en Q 123
3.3.3 Group Objects
Group Sequence Start / Stop Controller (Group01)
Main purpose of Module: Sequence controller for starting / stopping a
drive group
Off
Starting
on Hold
Running
Stopping

Title System 800xA
3BHS 161554 en Q 123
The group sequence start / stop module provides the following features:
· Starting / stopping of group members (up to 999 motors, valves, etc) in a

sequential order with Supervision of First Step in Hold, First Step Not Off
on Faceplate.
· Consumer objects have 4 different Point of Control (POC): SEQ, CEN,
LOC, and Out Of Service.
· Modularity on Group control : Settings of the Consumer POC when Group
starts (immediate, only on Step, never)
· Summary status indication of all pre-selected members (Ready, run, off)
· Alarming when exceeding maximum start-up / shut-down time
· 1 Safety interlock, 1 Chain Auto interlock, 4 start and 4 stop interlocks
· Emergency quick stop
· Hold function. Interrupts start-up respectively shut-down sequence
· Show Tag function. Displays the tag numbers of the group members on
the process display (adjacent to the graphic symbol of the members)
· Show Mem function. Emphasizes the group members on the process
display and indicates the start step number of each member.
· Simulation mode (Analog value, motor feedback….), to simulate feedback

signals of all group members.
· Auto Mode, starting and stopping the group with a delays from IA
Interlock
· Unconditional Start, the operator or maintenance user is enabled to start
the group disregarding any preselected Drives that are not Ready for Start
(Start Interlock, IC interlock, Presel Missing still active).
· Remaining Time Indication for the step shown in the Group faceplate and
in the Consumer Objects as well
· Indication of TagName on the Group Faceplate for Consumers /
StepOneGroup / StepTwoGroup and PID in case of:
§ Consumer not ready for start
§ Group in Hold
§ Actual Starting / Stopping Step

Title System 800xA
3BHS 161554 en Q 123
· A Link button to access the faceplate of the indicated object
· indication of 4 start and 4 stop interlocks

· In the case that sub-ordinate object is causing an interlock then the
actual Tag name of the faulty object is dynamically propagated into the
Group for the operator quickly to see the reason for a problem

Title System 800xA
3BHS 161554 en Q 123
Title System 800xA
3BHS 161554 en Q 123
Group Sequence Cyclic Controller (GrpCycleCtrl)
Main purpose of Module: Sequence controller for a cyclic activation of
equipment
GrpCycleCtrl GrpCycleCtrl_Info
Off
Running

Title System 800xA
3BHS 161554 en Q 123
The module handles sequential and cyclic activation and de-activation of devices.
Typically used to control silo aeration valves when silos containing fine bulk materials
are discharged. The module provides:
· Program selector with 3 programs selectable from faceplate or application

· 1 Safety interlock, 1 Chain Auto interlock, 2 start interlocks, 1 Previous
drive
· Consumer objects have 4 different Point of Control (POC): SEQ, CEN,
LOC, and Out Of Service.
· 2 External Alarm inputs and 2 External Warning inputs
· Sequence cycle time supervision, Alarming when exceeding maximum
start-up / shut-down time
· Continuous execution or execution during a defined number of cycles
· Next step control from faceplate or application
· Modularity on Group control : Settings of the Consumer POC when Group
starts (immediate, only on Step, never)
· 2 stepping modes (ByTime, ByTime and condition)
· 2 restart modes (step 1, last step)
· Automatic step over if all drives of a step are out of service or not selected
· Ready for start summary of all drives included in the selected program.
· Show Mem function. Emphasizes the group members on the process

display and indicates the start step number of each member.
· Simulation mode (Analog value, motor feedback….), to simulate feedback

signals of all group members.
· In the case that sub-ordinate object is causing an interlock then the
actual Tag name of the faulty object is dynamically propagated into the
Group for the operator quickly to see the reason for a problem

Title System 800xA
3BHS 161554 en Q 123
Pre-Selection (PREBIN)
Main purpose of Module: Routing control
Preselection Preselection Preselection

and StdBy and StdBy
Deselected (valid)
Deselected
Selected
Selected (valid)
PREBIN has no faceplate. Clicking on the push button symbol toggles the state. In
case stand-by preselection is configured, an additional button is provided for each
pre-selection to define the current stand-by selection.
The pre-selection module allows the operator to select or de-select a single device
or a set of devices within a group. By e.g. pressing “Silo1” all objects belonging to
the route to silo 1 are pre-selected. This does however, not cause a start-up of
equipment, it is just a selection. When initiating a group sequence start, selected
devices will start up in a sequential order; de-selected devices will shut down in a
sequential order (provided they were in a running state).
In case stand-by pre-selection is active, a pre-selected and running drive will initiate
a switchover (group start) when tripping, automatically starting up the stand-by pre-
selected drives.

Title System 800xA
3BHS 161554 en Q 123
Start Warning (STW)
Main purpose of Module:
Control for buzzers and flashlights, prior to a remote start of equipment
Drive Object Group

PreWarning
Active
STW has no stand-alone graphic element and no faceplate. It is tightly integrated

with motor and group control. See Group control graphic element.
The start warning module is integrated with the consumer objects (e.g. MOT1, MOT2,
MOTP, etc.). When a start command for a motor is initiated, the start warning module
first triggers the buzzers and/or flashlights before it returns the actual start release
for the motor. Different buzzers and flashlights can be assigned to appropriate start
warning modules, which in turn are assigned to appropriate consumers.

Title System 800xA
3BHS 161554 en Q 123
3.3.4 Consumer Objects
Motor Controller – non reversing (MOT1)
Main purpose of Module: Controller for a motor with one direction (one
speed)
Starting
Running
Object Interlock

Title System 800xA
3BHS 161554 en Q 123
The control module for a one-direction motor provides the following features:
· Tight group sequence control integration (start/stop or open/close) from the

corresponding drive group. Sequence order within a group can be
configured by simply entering the step number parameter (1..999).
Could be simulated from the group, with or without any alarms.
· Tight integration of object control and start warning in order to

automatically actuate audible and/or visible warning devices prior to
starting up.
· Out of service function. Enables the operator to take single motors out of
control (No Action from the group, Faceplate neither LCB)
· Motor current indication and high limit warning supervision
· User definable Warning indication
· 3 additional interface inputs with MCC; for e.g. Overtemp, Overload &
Availability
· 2 functional back process inputs with feedback time supervision for e.g.
speed, pressure or flow supervision. Pulsed feedback supported as well
with actual Period time shown on the Faceplate.
· 1 Safety interlock, 1 Chain Auto Interlock, 4 Process interlocks, 1
Previous drive
· 2 of the in total 4 Process (run) interlocks, can be configured as pure start
interlocks
· Totalisation and indication of run time (in hours) and number of starts
· Operator Station Interface (graphic element and faceplate) including
detailed alarm and interlock indications, separated between the object
and its TagName
· Alarming during Simulation can be enabled for testing the Interlock,
Feedback
· Alarming Condition defined by a Project Constant :
For Standard BMI Library, the consumer object alarming is enabled on:
§ Start order given, or
§ Consumer object in Auto mode
For Non Standard BMI Library, the consumer object alarming is
enabled on:
§ GroupStart and Motor Preselect (or StandBy), or
§ POC is in Cen and Motor is started, or
§ Otherwise Not Ready Treatment is shown

Title System 800xA
3BHS 161554 en Q 123
Variable Speed Drive Controller (MOT1_VVVF)
Main purpose of Module: Controller for a variable speed drive motor

Title System 800xA
3BHS 161554 en Q 123
The control module for a variable speed drive has basically the same functionality as
MOT1, with the following additions:

configured by simply entering the step number parameter (1...999).

starting up.
· Motor speed indication
· Speed set point coming from the corresponding drive group (Automatic) or
from the Operator Station / Process Panel (Manual)
· Speed set point low and high limitation
Availability
Previous drive
interlocks
· Totalisation and indication of run time (in hours) and number of starts
and its TagName
Feedback, etc.
· Alarming Condition defined by a Project Constant:
enabled on:
Title System 800xA
3BHS 161554 en Q 123

Title System 800xA
3BHS 161554 en Q 123
Motor Controller – reversing (MOT2)
Controller for a motor with two directions (or two speeds)
The control module for a reversing motor has basically the same functionality as
MOT1, however with the following adaptations:


starting up.

Title System 800xA
3BHS 161554 en Q 123
Availability
· 2 feedback run signals (one feedback for each direction)
Previous drive
interlocks
· All interlocks, except equipment interlocks, are direction related
· Totalisation and indication of run time (in hours) and number of starts.
· New Remaining Time Indication for the step shown in the Group faceplate
and in the Consumer Objects as well
and its TagName
FeedBack,..
· Alarming Condition clearly defined by the mean of Project Constant :
enabled on:
§ GroupStart and Motor Pre-selection (or StandBy), or

Title System 800xA
3BHS 161554 en Q 123
Variable Speed Drive Controller – reversing (MOT2_VVVF)
Main Purpose of Module: Controller for a variable speed motor with two
directions
The control module for a reversing variable speed motor is a combination of the
MOT2 and MOT1_VVVF modules, with the following features:


starting up.

Title System 800xA
3BHS 161554 en Q 123
· Speed set point and limitation from the corresponding drive group
(Automatic) or from the Operator Station / Process Panel (Manual) separately
for X and Y direction
Availability
· 2 feedback run signals (one feedback for each direction)
Previous drive
interlocks
· All interlocks, except equipment interlocks, are direction related
· Totalisation and indication of run time (in hours) and number of starts.
and its TagName
· Supervision of the Actual Speed feedback during Start and Stop as
configurable condition for alarming and feedback to the drive group
enabled on:
§ GroupStart and Motor Pre-selection (or StandBy), or

Title System 800xA
3BHS 161554 en Q 123
Damper/ Actuator Controller (MOTP)
Controller for a motorized damper with or without analog position
feedback

Title System 800xA
3BHS 161554 en Q 123
The control module for a motorized damper/actuator provides the following features:

configured by simply entering the step number parameter (1..999). Could be
simulated from the group, with or without any alarms.
· Tight integration of object control and start warning in order to automatically

actuate audible and/or visible warning devices prior to starting up.
· 2 additional interface inputs with MCC; for e.g. Overload & Availability
· 2 position feedback signals with error indication if both are present at the
same time
· 2 running feedback signals
· 1 Safety interlock, 1 Chain Auto Interlock, 1 Process interlock
· 1 Force interlock
· All interlocks are direction related
· Automatic position control either with internal or external set point, Analog or
Digital
· Position set point low and high limitation.
· Operator Station Interface (graphic element and faceplate) including detailed
alarm and interlock indications, separated between the object and its
TagName
FeedBack,..
· Alarming Condition clearly defined by the mean of Project Constant :

Title System 800xA
3BHS 161554 en Q 123
Normally-closed Control (VLV1)
Main purpose of Module: Controller for a normally-closed one-way valve or
actuator

Title System 800xA
3BHS 161554 en Q 123
The module controls valves with one or two coils and up to two position limit switches. It
provides:

configured by simply entering the step number parameter (1..999). Could be
simulated from the group, with or without any alarms.

· 1 additional interface inputs with MCC; for e.g. Availability
same time. Timer delay.
· 1 Safety interlock, 1 Chain Auto Interlock, 2 Process interlocks, 1 Previous
drive.
· One or two-coil, energized till Feedback or steadily features enabled.
TagName
FeedBack,..
· Alarming Condition enabled by a Project Constant :
For Standard ML, the consumer object alarming is enabled on :
For Non Standard ML, the consumer object alarming is enabled on:

Title System 800xA
3BHS 161554 en Q 123
Normally-open valve Control (VLVNO1)
Main purpose of Module: Controller for a normally-open one-way valve or
actuator

Title System 800xA
3BHS 161554 en Q 123
The module controls valves with one or two coils and up to two position limit switches. It
provides:

configured by simply entering the step number parameter (1...999). Could
be simulated from the group, with or without any alarms.

· 1 additional interface inputs with MCC; for e.g. Availability
same time. Timer delay.
· 1 Safety interlock, 1 Chain Auto Interlock, 2 Process interlocks, 1 previous
drive.
· One or two-coil, energized till Feedback or steadily features enabled.
TagName
Feedback, ...
For Non Standard BMI Library, the consumer object alarming is enabled
on:

Title System 800xA
3BHS 161554 en Q 123
3.3.5 Loop Objects
PID Controller (PIDCtrl)
Loop Controller with parametrical proportional,

integral and derivative characteristics
Manual Mode
Automatic Mode
Setpoints for every mode may come from Faceplate (Operator) or

External (E1A, E2A, E1M, E2M)
MV à Measured Value
SP à Setpoint

Title System 800xA
3BHS 161554 en Q 123
PID module for closed loop control has the following options:
· Auto tuning of control parameters P, I and D

· Gain scheduling
· Feed forward control
· Anti wind up
· 2 external set point references, that can be written from the application
· 2 external controller output references, that can be written from the
application
· Limit supervision of measured value and deviation, with integrated alarm
annunciation
· Alarm and event handling with 3 alarm priorities
· Set point high and low limitation
· Controller output high and low limitation
· Event logging for control mode changes and set point changes
· Tracking and balancing modes
· FF State Machine possibility to set Cascade Mode position automatically when
requested from the faceplate or from the FF Function Block.
· Status of MV, ActuatorPos and OUTP signals. All Sub-status for DP, PA and
FF Field Devices will generate error control when quality is Bad or Uncertain
for MV and OUTP
· Threshold detection and event treatment on 2 Process Limit levels (Plo, Phi)
· Alarm disabling/enabling of each alarm limit individually (from application
program / Faceplate); generating events when blocked (same for MV).

Title System 800xA
3BHS 161554 en Q 123
3.3.6 Reporting Objects
Reporting Count (ReportingCount)
Main purpose of Module: Report objects provide access to counter values
Counters Control Module Type supports the following functions:

· Total and shift value Summation
· Reset counter value from controller or from the Operator Station (via the faceplate)
· Adjustment (positive & negative) of counter value and constant from the
Operator Station (via the faceplate)
· Operator Station Interface (graphic element and faceplate)
4 different modes can be used as:

· Pulse Counter (used to count pulses and multiply them with a factor)
· Integrator (used to integrate an Analog Input signal in case no pulse is available)
· Accumulator with external pulse (used when getting counter values from serial
interfaces)
· Delta Accumulator (used when getting counter values from serial interfaces)
And additionally a focused historical archiving for detailed information is also available:
· Actual Shift / Last Shift
· Actual Day / Last Day
· Actual Month / Last Month
Title System 800xA
3BHS 161554 en Q 123
Such as on kWh consumption for Cement Mills, Tons of material used for
production, running time of production critical equipment.

Title System 800xA
3BHS 161554 en Q 123
3.3.7 Composite Object Templates
Main purpose of composite objects is to provide serial communication interface and
methods to retrieve and present the extensive amount of information provided by the
“intelligent” devices.
The library contains a so called Serial Object Framework in form of a composite Control
Module for implementing serial (fieldbus, etc.) connected equipment. The modularity of
the Control Module allows equipment specific adaptation of the communication part to
be used with the standard object (MOTx, VLVx, CircuitBreaker, etc.) functions.
Serially connected, usually intelligent devices have the ability of providing much more
information of their functional status. The faceplate with its limited space is not seen as
a suitable media to present all the additional information, most of which is not process
operation related.
Therefore configurable link buttons have been provided in the Faceplate “Extended Info”
Area to allow direct access to additional aspects of the serial object from the Operator
Station.

Title System 800xA
3BHS 161554 en Q 123
3.3.8 Electrical Control – Energy Management
The Electrical Control functionality is implemented in the 800xA Minerals Library
using the same basic software and system functions as process control. The
equipment interfaces and the electrical control applications can be located in
dedicated controllers or they can co-exist with the process control applications
hence allowing a cost optimized implementation for small electrical rooms and
sub stations.
The Electrical Control functionality contains following main categories of functions
· Supervision and visualization of Power Distribution network(s) – “single
line diagram”. The information can be provided on the Operator
Workplace terminal or on dedicated Electrical Workplace terminals or
both.
· Energy Management functions (Optionally available).This functionality is
based on a specific Library which is an extension to the Minerals Control
library.
3.3.9 Power Distribution Monitoring

The Power Distribution Monitoring objects provide access and control for
supervision and control of power distribution equipment such as switchgear, and
protection relays using serial connectivity (e.g. ProfibusDP, Modbus or
IEC61850).
The functional scope of the Power Distribution Network Monitoring contains
- the connectivity to the power distribution feeders and protection relays
- implementation of the feeder objects into system 800xA
- operating faceplates and the associated functionality of the objects
- graphical display (single line display) of the power network
- indication of the main measured values of each feeder
- access to detailed status data of each equipment (scope of data
dependent on each device and used communication)
The functions are available on all (or selected) Operator Workplaces or on
dedicated Electrical Workplaces.

Title System 800xA
3BHS 161554 en Q 123
Title System 800xA
3BHS 161554 en Q 123
Circuit Breaker
The Control Module Type CircuitBreaker is used to control a motorized Circuit
Breaker with up to 1 CB and 2 Isolators, in a drive group or standalone.

Title System 800xA
3BHS 161554 en Q 123
Next to the common basic functions for consumer objects, the following functions
are supported for CircuitBreaker:
· Operation modes
· Selection of individual Breaker for operation
· Open / Close order to operate the breaker
· Indication of Breaker status
· Indication of Switches
· Current, Voltage and Power indication
· 3 additional interface inputs for each CB; for e.g. Trip, General Alarm &
Ready
· 2 functional back process inputs with feedback time supervision; for e.g. CB,
Isolator or Earth Switch ( ESW) Pos.Closed, Pos.Open
· 3 Process interlocks for the CB and 2 per Isolator.

Title System 800xA
3BHS 161554 en Q 123
· Totalisation and indication of CB Close time (in hours) and number of CB
Trips and Close Operations
Example Graphic Configurations:
MV Feeder with 2 Bus bars and Disconnector

with integrated Earth Switch.
Central Mode (operator) [C] indication,
indication of Disconnector Positions
MV Feeder rack-in/out type with Earth Switch.

Indication of Breaker status
ANSI support
MV Feeder with 2 Bus bars and Disconnector

with integrated Earth Switch.
indication of Disconnector Positions
MV Feeder rack-in/out type with Earth Switch.

Indication of Breaker status

Title System 800xA
3BHS 161554 en Q 123
3.3.10 Energy Management
The Energy Management System consists of three major modules
communicating together:
· Power Demand Supervision
· Load Shedding Control (optional automatic switching-off)
· Load (Definition of a set of Circuit Breakers)

Title System 800xA
3BHS 161554 en Q 123
Title System 800xA
3BHS 161554 en Q 123
The Energy Management objects provide access and control for supervision of the electrical
feeders, monitoring and controlling of loads with the target to ensure that the Energy
consumption of the Plant respects given conditions.
This is an Example where at 19:42 a load was switched on
Forecast Energy At Interval End

Actual Energy In Interval
Energy Moving Interval
Warning Level (90% pf alarm Level)
Alarm Level
For this example, the ForeCast Energy At Interval End shows nicely that is based on the
ActualEnergyInInterval and the TotalPower. It calculates how much Energy will be used at the
end of the Metering Interval if the actual Power is steady till then.
This is the fastest method as shown on the trends : the light blue curves is the first to cross the
Warning Level !

Title System 800xA
3BHS 161554 en Q 123
Load
The Load Control Module Type enables grouping of MV-Switchgear according
Plant Sections in order to monitor and control their Energy consumption.
It contains following features :

· Communication between LoadShedding Module and the connected MV-
Switchgear (up to 8 MV-Switchgear, otherwise please use the corresponding
Function Block included in the EnergyMgmt Library “Loads_CB_Compacting”
(§3.4 Function Block)
· Possibility to connect MV-Switchgear into Load for monitoring only and not for
shedding (MV/LV Trafo.Feeder).
· Calculation of total momentary load (active and reactive power)
· Calculation of momentary total load factor (utilization factor)
· Issuing of warnings and alarms. For example in the case of:
o Locking off of loads
o Disconnection of loads
All of these Informations are available to the operator through standard interfaces from the BMI
Library:
· Faceplate (see extended Faceplate §3.3.3.2)
· Multi-Trends (see extended Faceplate §3.3.3.2)
· Graphical Elements (see §3.3.1)

Title System 800xA
3BHS 161554 en Q 123
The Load Object is moreover extended by graphical Elements of
· DIS for direct access to Eventing / Alarming
· Counter for direct access to Cost Supervision

Title System 800xA
3BHS 161554 en Q 123
Loadshedding
The LoadShedding Control Module Type permit to ensure that the Energy
consumption of the Plant respects certain conditions according priorities.
It contains following features :

· Communication between PowerDemand Module and the Loads
· Locking / releasing of loads according to the load situation within the metering
period.
· Disconnection (load shedding) of loads according to the load situation within
the metering period.
· Operating modes Eventing & Selection: Manual / Auto / Ext
· Consideration of certain priorities for disconnection of loads

Title System 800xA
3BHS 161554 en Q 123
Link from LoadShedding to CB’s via Load
Title System 800xA
3BHS 161554 en Q 123
PowerDemandSupervision
The Powerdemandsupervision Control Module Type enables input of tariff

structure and their given conditions as defined by the Energy supplier
Actual Tariff
conditions
Permanent
conditions
Actual Tarif always shown on the base View

Title System 800xA
3BHS 161554 en Q 123
It contains following features:
· Consideration of a certain tariff structure given by the energy supplier up to 8
different tariffs each of them including up to 8 different TariffSets
· Supervision of time synchronisation for metering period.
· Calculation of total energy consumption over metering period
· Calculation of total energy consumption forecast at end of metering period
· Calculation of momentary total power factor and limit supervision
· Issuing of warnings (90%) and alarms. For example in the case of:
o Forecast Energy At Interval End
o Actual Energy In Interval
o Energy Moving Interval
o Peak Power Exceeded Time
o TotalCurrent
· As well as Issuing of warnings (90%) and alarms in case of :

o Missing time-synchronization signal if the Signal is missing for longer
than two times Metering Interval time.
o Impending change of tariff interval

Title System 800xA
3BHS 161554 en Q 123
This is an Example where at 19:42 a load was switched on
Forecast Energy At Interval End

Actual Energy In Interval
Energy Moving Interval
Warning Level (90% pf alarm Level)
Alarm Level
On this exemple, the ForeCast Energy At Interval End shows nicely that is based on the
ActualEnergyInInterval and the TotalPower. It calculates how much Energy will be used at the
end of the Metering Interval if the actual Power is steady till then.
This is the fastest method as shown on the trends : the light blue curves is the first to cross the
Warning Level !

Title System 800xA
3BHS 161554 en Q 123
3.4 TECHNICAL AND PERFORMANCE DATA
3.4.1 System Performance and Capacity
Here are some key numbers by which the system configuration is verified.
Several parameters will limit the system size and it is highly dependent on the
application which parameter will hit the limit first. Direct result of this is that it is
difficult to give any strict system size number. It is even possible to exceed some
limits if other parameters are reasonably below their respective limit. For
example, more controllers may be viable if the total data flow between them and
to the server and workplace layer is well within the limit.
Regarding the capacity of the connectivity server, performance is heavily
dependent on the configuration and the machine hardware. A dedicated
connectivity server will have very high performance, for example, a dedicated
connectivity server, ≥3GHz, with 8Gbyte RAM will provide 32 000 OPC-
items/second.
3.4.2 Typical cement plant example with Minerals Library

Definition
DEFINITION: Minerals Controlled Object = Loop/Motor/Drive/Actuator/Valve/Group
Assumptions
On Average, 1 Minerals Object 10 OPC items
# of Minerals Objects per display = 200
# of OPC Items per display = 2000
# of Screens (Clients) per Connectivity Server = 16

Limitation
· Up to 12000 I/O or 16 simultaneous operator screens (32 000 OPC items) per 1 of 1oo2
Connectivity server with 8GB RAM.
· Workplace PC with 4GB RAM
· The maximums of the platform values always apply.

Title System 800xA
3BHS 161554 en Q 123
Platform values: (see 3BSE041434) Per system
# of controllers 48 per connectivity server
# of clients (depends on server configuration) 80
# of remote clients (simple viewing client) 10 per remote server
# of connectivity servers 12 out of which 8 for AC800M controllers
# of aspect servers 1 (1oo2 or 2oo3 redundant)
# of Tags (Aspect Object with Faceplate) 60’000
# of Aspect Objects 200’000
# of concurrently updating data points (OPC

50’000/second per connectivity server
items)
The latest platform values should always be checked with the ABB Products group before any
commitment is made.

Estimation based on Controlled objects
PM861: 100 controlled objects per controller

For the following two controller load estimation it is assumed that more than half of the cyclic controller
load is due to “application glue logic”
Expected Results
CPU Execution time
500ms for all objects,
Results in about 45% CPU cyclic load
50 to 150ms for dedicated part of the code (e.g.
stop on limit switch, local start/stop)
I/O to HMI time Approximately 1.5 s
Download time per node Less than 60 s
HMI update stop during download Less than 5 s
S800 I/O on Profibus, DI and DO minimal scan Approximately 120 ms with 1200 I/O per bus
time

Title System 800xA
3BHS 161554 en Q 123
3.4.4 System Example
Following picture illustrates the maximum capacity values in terms of I/O signals (HW I/O and
SW signals) in an application that has a mixture of 20% analogue signals and 80% digital
signals. Note that this conversion to I/O signals is purely mathematical and fully based on the
mixture of analogue/digital given above. It is made to help in practical configurations where
normally only the number of I/Os is known. Changes in the mixture will impact the maximum
limits, that is, an increase of analogue signals will reduce the maximum limits.
200 – 250 Objects / display (= 2000 OPC Items) max 32’000 OPC Items = Max 16 Screens / Server
PP Client PP Client PP Client PP Client PP Client PP Client PP Client PP Client PP Client PP Client
Client/Server Network (TCP/IP)

Aspect Server Engineer IT
Connectivity Max 12’000I/O per

200‘000 Objects Server
Con Server pair
Control Network (Ethernet)
Minerals Lib.
PM861: Up to 500 I/O
Profibus Profibus
PM866: Up to 2500 I/O Profibus
PM891: Up to 5000 I/O

S800/S800L Universal S800/S800L Universal S800/S800L Universal
I/O Motor
Controller
I/O Motor
Controller
avg. 10 I/O (hw&serial) I/O Motor
Controller
per Object

Title System 800xA
3BHS 161554 en Q 123
3.4.5 Memory Space Requirements and Execution Times
The following table shows the memory space requirements and typical execution
times for the AC800M Minerals Library control modules. The execution times
and the memory requirements were measured using a PM866 and the Control
Builder TC1 Version 6.0.0.-0, with the 5.1/5b release of the Minerals Library.
For more information about execution times for I/O, see AC800M User’s Guide.
Note that the Control Modules make heavy use of conditional execution and the
Peak Load (esp. Alarm Generation) is multiple times higher than the typical Load.
Our experience has shown, that the cyclic load is 2 times higher because of
hardware execution time and application glue logic.

Title System 800xA
3BHS 161554 en Q 123
There is a calculator for cyclic load estimation, to be requested by a mail to the
mineralslibrary.orderbox@ch.abb.com
Performance Data
Application Performance Data
The SystemDiagnostics Interaction Window can be used online to check the
Performance of the running Controller with loaded Application. To ensure the
application reliability, you should pay attention of following Points:
Cyclic Load should not exceed 50%. Changing the application task connection
and / or the task properties (Period time) influences the load.
Used memory should not exceed 50%. Otherwise successful download of
changes during running cannot be guaranteed in all cases, and Stop time could
increase if there is not enough free Memory during download.

Title System 800xA
3BHS 161554 en Q 123
This interaction Window can be found in the System Control Module

Title System 800xA
3BHS 161554 en Q 123
3.6 LICENSES AND ORDERING MINERALS AC800M CONTROL AND
OPERATION
This section aims to help project personnel when ordering the Minerals Library for
integration with System 800xA SV6.x Control and Operations products.
Preferably, use Wizard 800xA with the Minerals 3BHS128715/x.wcat and
3BHS128715/x.wprc installed. Ordering is made using the EDI file generated by
Wizard Order module and sending it to MineralsLibrary.OrderBox@ch.abb.com.
3.6.1 Minerals Library License

Minerals Library License is sized using the minerals license points (MLP).
Minerals Library does not use a Tag license (Tag). This is to simplify the ordering
and handling of the licenses.
Since version 5.1 and introducing the Minerals license enforcement in the
system, the Minerals License size is counted based on the effective application
size using Minerals Library. Only the MLPs related to Minerals applications are
considered in the license size.
Prerequisites for use of the Minerals Library:
§ The System 800xA SV5.x Core System and its standard system libraries
are installed and licensed.
§ Minerals Library licenses for the number of used MLPs has to be ordered.
§ Minerals Library has to be installed and added as a system extension
§ The license Key (an .SLA file) for the Minerals Library has to be
generated in ABB SoFa and installed in the 800xA system licensing
server.
3.6.2 Minerals License Point

The Minerals License Points are calculated by the number of used Minerals
Library Control Modules:
Type of Block MLP count
Digital I/O (DIS, DOS) 1
Analog I/O (AIS, AOS) 2
Consumer Objects (MOTx MOTX_VVF 5
etc.)
Loop Objects (PIDCtrl) 4
Circuit Breaker 5
Note: Group Objects are not contribute to the MLP count.
Suggestion: add 20% to the total MLP count to leave a margin for further growth.

Title System 800xA
3BHS 161554 en Q 123
3.6.3 Ordering Examples
The CD-ROM with the software and documentation should be ordered.
From the Price List for 1.2 Control and Operation; AC800M; Minerals Library
6.0/x:
1 of Control&Operation; AC800M; MineralsLib6.0/x; SW&DocCD
3.6.4 Ordering Example 1

For this example, take the following configuration: Three controllers with different
capacity and different MLPs.
· Controller 1 has 350 MLPs
The above configuration requires the price list items listed below.
6.0/x:
System-wide license for 2000 MLPs (350+550+1100) is calculated as follows:
1 of Control;AC800M; MineralsLib6.0/x; BaseLic
3BHS200491R04
20 of Control;AC800M; MineralsLib6.0/x; 100 MLP;<=5000 MLP
3BHS200492R04
3.6.5 Ordering Example 2

For this example, assume 8000 MLPs are required, this needs the price list items
listed below.
6.0/x:
1 of Control; AC800M; MineralsLib6.0/x; BaseLic
3BHS200491R04
50 of Control; AC800M; MineralsLib6.0/x; 100 MLP;<=5000 MLP
3BHS200492R04
30 of Control; AC800M; MineralsLib6.0/x; 5001-20000 MLP
3BHS200493R04

Title System 800xA
3BHS 161554 en Q 123
4. SYSTEM 800XA OPERATIONS AC400 CONNECT MINERALS
LIBRARY
4.1 FUNCTIONAL DESCRIPTION

Operations AC400 Connect Minerals Library integrates the BMI AC400 Type
Circuit Library with the 800xA Operator Workplace. The AC400 Connect Minerals
Library provides display elements and faceplates on the Process Portal, for
monitoring and control of objects defined by means of the BMI AC400 Type
Circuit Library. These are intended for sites with an installed based of AC400
controllers and AS500 that need to connect to the Process Portal.
The process display elements and faceplates have the same look and feel, as
well as similar functionality, as the AC800M Connect elements listed above.
There is a display element and a faceplate for each BMI Type Circuit Library
element in the AC400.

Title System 800xA
3BHS 161554 en Q 123
4.1.1 Analog Input (AI, AIandUnit, AIBar)
Main purpose of Module: Analog Input Interface
AISandUnit AISBar
Value
Block
Limit Alarm
Signal Error

Title System 800xA
3BHS 161554 en Q 123
4.1.2 Analog Output (AO, AOandUnit)
Main purpose of Module: Analog Output Interface
Manual control
Automatic control

Title System 800xA
3BHS 161554 en Q 123
4.1.3 Digital Input (DI)
Main purpose of Module: Digital Input Interface
DISTxt DIS
Status
Block
Alarm

Title System 800xA
3BHS 161554 en Q 123
4.1.4 Digital Output (DO, DOTxt)
Main purpose of Module: Digital Output Interface
DOSTxt DOS
Status
Manual
Block
Alarm

Title System 800xA
3BHS 161554 en Q 123
4.1.5 Group Sequence Start / Stop Controller (GROUP)
Main purpose of Module: Sequence controller for starting / stopping a
drive group
Off
Starting
on Hold
Running
Stopping

Title System 800xA
3BHS 161554 en Q 123
4.1.6 Pre-Selection (PREBIN)
Main purpose of Module: Routing control
Preselection Preselection Preselection

and StdBy and StdBy
Deselected (valid)
Deselected
Selected
Selected (valid)
PREBIN has no faceplate. Clicking on the push button symbol toggles the state.
The pre-selection module allows the operator to select or de-select a single device or a
set of devices within a group. By e.g. pressing “Silo1” all objects belonging to the route
to silo 1 are pre-selected. This does however, not cause a start up of equipment, it is just
a selection. When initiating a group sequence start, selected devices will start up in a
sequential order; de-selected devices will shut down in a sequential order (provided they
were in a running state)

Title System 800xA
3BHS 161554 en Q 123
4.1.7 Start Warning (STW)
Control for buzzers and flashlights, prior to a remote start of equipment
Group
PreWarning
Active
STW has no faceplate. The symbol is mainly used for presentation purposes on the
faceplates for MOT1, MOT2, MOTP, etc.
The start warning module is tight integrated with the control modules for MOT1, MOT2,
MOTP, etc. When a start command for a motor is initiated, the start warning module first
triggers the buzzers and/or flashlights before it returns the actual start release for the
motor. The start warning function can be configured depending on the point of control,
e.g. point of control Sequence and Central with start warning, Local without start warning.
If configured, the graphic symbol is displayed on the corresponding faceplate.

Title System 800xA
3BHS 161554 en Q 123
4.1.8 Motor Controller (Motor)
Main purpose of Module: Controller for a motor with one direction (one
speed)
Starting
Running
Object Interlock

Title System 800xA
3BHS 161554 en Q 123
4.1.9 Damper/ Actuator Controller (MOTP)
Controller for a motorized damper with or without analog position
feedback

Title System 800xA
3BHS 161554 en Q 123
4.1.10 Valve Control (Valve)
Main purpose of Module: Controller for a normally-closed one-way valve or
actuator

Title System 800xA
3BHS 161554 en Q 123
4.1.11 PI Controller (PIControl)

Manual Mode
Automatic Mode

Title System 800xA
3BHS 161554 en Q 123
4.1.12 PID Controller (PIDControl)

Manual Mode
Automatic Mode

Title System 800xA
3BHS 161554 en Q 123
4.2 LICENSES AND ORDERING PPA AC400 MINERALS CONNECT
Preferably, use Wizard 800xA with the 3BHS128715/x.wcat and
3BHS128715/x.wprc installed. Ordering is made using the EDI file generated by
Wizard Order module.
4.2.1 Tag
The licensing system for AC400 Connect is based on calculating Tags. A Tag
represents an object regardless of the number of data points it holds, examples
are:
• signal objects, i.e. AI, AO, etc.
• motor, valve objects
• generic OPC items with one or several OPC properties
• user defined object types
Licenses
Minerals AC400 Connect is an add-on to standard System 800xA AC400M
Connect and both licenses are required.
Minerals AC400 Connect contains display elements and faceplates for the BMI
AC400 objects/type circuits.
Prerequisites for use of this software:
· The System 800xA SV5.x Core System is installed, with the AC400
Connect Option.
· The AC400 controllers have the BMI Type Circuit Library installed.
4.2.2 Ordering Example

Assume the following configuration:
· Controllers, with different capacity and different Controller License Points
(CLPs).
· Three Process Portal workplaces
The tag count is calculated at 17’000 tags.
This configuration requires the following licenses:
From the Price List 1.6 Operation; AC400M Connect; Minerals Library 5.1/x:
System-wide license for 17’000 tags is calculated as follows:

1 of Operation;AC400Connect;MineralsLib5.1/x;BaseLic
3BHS200501R02
Title System 800xA
3BHS 161554 en Q 123
7 of Operation;AC400Connect;MineralsLib5.1/x;1000Tags
3BHS200503R02
1 of Operation;AC400Connect;MineralsLib5.1/x;10000Tags
3BHS200504R02
The CD-ROM with the software for above functions should also be ordered.
1 of Operation;AC400Connect;MineralsLib5.1/x;SW&Doc CD
3BHS200505R02

Title System 800xA
3BHS 161554 en Q 123
5. SUPPORT AND TRAINING
5.1 M INERALS SUPPORT

5.1.1 Design Review
ABB offers the service to execute a Design Review for the 800xA system
configuration and application design in a Minerals delivery project. This review is
based on defined documents and will be executed by the Minerals Library
Development Center or by a certified engineering unit.
Within ABB this review service is mandatory in projects where Minerals Library
certified personnel is not available.
The Design Review Service can be ordered from Minerals Library price list. The
Service fee contains the coverage of the working hours at the home location of
the executing unit. Possible expenses for executing the review in another location
must be covered by the ordering unit.
5.1.2 Life Cycle Services

Please see the price list for Minerals: Life Cycle Services for ordering 24 hours or
other support for Minerals Library.
5.2 M INERALS TRAINING COURSES

Training is an important part for successful project engineering and hence a
prerequisite for certification.
Please see the schedule and information from the Cement, Minerals and Mining
Learning Center – ABB University Switzerland for training that is available on the
Minerals Control Libraries.
For ordering, see the price list for:
· IndustrialIT 800xA Applications for Minerals – Engineering with EBase and
Control Builder M (CHH658)
· IndustrialIT 800xA Applications for Minerals – Configuration and Operation
(CHH651)
· IndustrialIT 800xA Applications for Minerals – Operation (CHH652)
· IndustrialIT 800xA Applications for Minerals – Configuration and
Operation Utilizing BMI Library(CHH653)

Title System 800xA
3BHS 161554 en Q 123
5.2.1 CHH658 IndustrialIT 800xA Applications for Minerals –
Engineering with EBase and Control Builder M
Duration 7 days.
Objectives
Participants will follow the engineering workflow and utilize Engineering Base (EBase) to
handle bulk data and create efficiently and professionally Minerals control applications for
System 800xA with AC800M Controllers.
Upon completion of this course students know the basic functionality of EBase and know
how to set up a project and import customer data in EBase. Using EBase, they are able
to configure Minerals control applications and generate bulk data via typicals. They know
how to export the prepared application from EBase to Control Builder M, where they will
finalize it by programming the interlock (glue) logic for the different consumer and group
objects. They can use the import / export, download / upload and copy functions. They
know the detailed functionality of the different objects in the Minerals library with the
required data types and understand the program structure.
Contents
· Engineering workflow
· Minerals Library
· Introduction to EBase Electrical
· Application configuration with EBase
- Import customer data
- Generate object related signals
- I/O allocation
- Configure objects and start/stop sequences
- Parameterized Interlocks and Preselections
· Export to Control Builder M
· Programming of interlock (glue) logic
· Download to Controller AC800M and online test
Methods
The course flow is based on a practical exercise, where students will configure and
program a complete Cement Transport Group. Group. Lectures and demonstrations are
done before each main exercise. The teacher is then guiding the students through the
exercises, step by step.
Participants
Engineering and planning personnel responsible for the bulk data handling and control
programming for Minerals applications at the start phase of the project.
Prerequisites
Attendance of course CHH561.

Title System 800xA
3BHS 161554 en Q 123
Configuration and Operation
Duration 10 days.
Objectives
Participants learn the operation and configuration of the IndustrialIT Extended
Automation System 800xA by using the Minerals application libraries.
Upon completion of this course, the students know the architecture of the
automation system and the hardware components of the controller. They know
how to configure, modify and test controller application programs with the Control
Builder M programming tool. They are able to operate the user interface Process
Portal and can configure process graphics, trends and alarms. They know the
basic functionality of the different objects in the Minerals Library with the required
data types and understand the program structure.
Contents
· System 800xA architecture
· Controller AC800M Hardware Configuration
· Plant Explorer, Engineering Workplace and Control Builder M
· Variables and Data types
· Monitoring and testing applications
· Programming according IEC 61131-3,
Function Block Diagram (FBD) and Structured Text (ST)
· Advanced configuration with Control Modules and Structured Data Types
· Minerals Libraries and Minerals Applications
· OPC Communication
· Operator Workplace
· Configure Process Graphics
· Configure Alarm and Events
· Configure Historical Data Collection and Trend Displays
· Backup / Restore of the System
· Workshop Engineering
Methods
Lectures, demonstrations and practical exercises. At the end of the course a
workshop is done. This workshop covers a larger exercise and is used to
consolidate the most important items from the training which the students will
need for their future work.

Title System 800xA
3BHS 161554 en Q 123
Participants
Engineering, planning, operating, commissioning, maintenance and service
personnel, working in the field of Minerals Applications
Prerequisites
Students shall know the fundamentals of working with Control Systems, have
basic knowledge of Windows Operating System and of technical English.

Title System 800xA
3BHS 161554 en Q 123
5.2.3 CHH652 Industrial IT 800xA Applications for Minerals –
Operation
Duration 2 days.
Objectives
Participants learn to operate a plant that is controlled by an IndustrialIT Extended
Automation System 800xA, based on Minerals application libraries.
Upon completion of this course, the students know the basic system architecture
and are able to log on into the system. They understand the user interface
Process Portal and know how to navigate through the system. They know the
basic functionality of graphic displays and faceplates. They are able to monitor
and control relevant objects of the plant. They know how to acknowledge alarms
and are able to use event and alarm lists as well as trend displays.
Contents
· Overview IndustrialIT 800xA System
· Basic System architecture
· Log on into the system
· Operator interface
· Navigation through the system
· Graphic displays
· Faceplates
· Operation
- Basic objects
- Consumer objects
- Group objects
- Loop objects
· Events and alarms
· Historical data and trend displays
· BMI Search tool
Methods
Lectures, demonstrations and practical exercises
Participants
Operators who need to control and supervise the plant
Prerequisites
No special knowledge required

Title System 800xA
3BHS 161554 en Q 123
Configuration and Operation Utilizing BMI Library
Duration 5 days.
Objectives
Upon completion of this course the participants should be able to:
· Monitor and control the BMI minerals process objects
· Navigate in the system and create new objects and aspects using Plant
Explorer
· Use the standard libraries and the Minerals Library as well as create
project specific libraries
· Design and configure applications using Control Diagram Editor (CDE)
within CBM utilizing BMI Library
· Customize and use the operator’s workplace and its functions and
operate the Minerals Library objects
· Configure process graphic displays and define navigation links
· Manage and configure events and alarms
· Use the import/export tool
· Backup and restore the System 800xA
Contents
· Operating minerals process objects
· Overview of BMI Library
· Data types in BMI Library
· Application and system structures utilizing BMI structure
· Using Control Diagram Editor (CDE) for programming applications with
functions, function blocks and control modules utilizing BMI Library
· Monitoring and testing applications
· Minerals Library and minerals applications
· Task assignment and memory (optional)
· IAC communication
· Operator workplace (based on tabbed workplace)
· Process graphics
· Import/export tool (optional)
· Backup and restore of the System 800xA (optional)

Title System 800xA
3BHS 161554 en Q 123
· Workshop engineering
Methods
This is an instructor led course with lectures, demonstrations, interactive
discussions and practical exercises. At the end of the course a workshop is done.
This workshop covers larger exercises consolidating the most important items
from the training which the students will need for their future work.
Participants
This training is targeted to engineering, planning, advanced operating,
commissioning, maintenance and service personnel working in the field of
minerals applications.
Prerequisites
Participants should know the fundamentals of working with control systems and
have basic knowledge of the Windows XP or Windows 7 operating system,
800xA configuration and programing and technical English.

Title System 800xA
3BHS 161554 en Q 123
REVISION HISTORY
Rev. Page (P) Description Date
ind. Chapt.(C) Dept./Init.
draft Original document 26.07.03 ATBAM/GPC

A Reviewed and corrected, added AC400 Connect 04.09.03 ATBAM/GPC
B Reviewed and updated to 2.1/1 08.03.04 ATBAM/GPC
C Reviewed and updated to 3.1/1 01.06.04 ATBAM/GPC
D Reviewed and updated to 3.1/3 10.11.04 ATBAM/GPC
E Updated to 4.0/0 27.05.05 ATBAM/HT
F Update for Minerals Library Release 5.0/0 16.01.2006/N.B
G Updated license structure for SV5.0 08.12.06 / HT

H Updated for Minerals Library Release 5.0/1 28.06.2007 / MB
I Document structure changed. 11.10.07 / HT
Changed license structure and ordering for 2008 SV5.x
Added Design Review
Added Siemens CEMAT connectivity
J Updated for Energy Management Release 5.0/2 27.08.2008 / NB
K clean up and new Performance Measurements for 5.0/2 24.04.2009 / LK
L Added license structure changes and enforcement 5.1/1 22.12.2009 / HT
M Updated for Minerals Library Release 5.1/3 30.09.2010 / CT
N Updated for Minerals Library Release 5.1/4 16.04.2012 / YM
O Update for 5.1/4a Release 16.09.2013 / LK
P Update for 5.1/5b Release 12.06.2015 ATBPA/LK
Q Update for 6.0 Release 04.07.2016 PASUN /
TP,GS

Title System 800xA
3BHS 161554 en Q 123

00 Minerals Library Product Guide

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

00 Minerals Library Product Guide

Uploaded by

Copyright:

Available Formats

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

Control and Operation – AC800M – Minerals Library

Based on Project Minerals Library Standard

Title System 800xA des. des.

Minerals Library Version 6.0/0 Resp. dept. CHIND / PIMIN-PD

Doc. kind Product Guide Project Minerals Library Standard

Doc. kind Product Guide Project Minerals Library Standard

Benefits of using Minerals Library include:

The System 800xA Minerals Library comprises of

Doc. kind Product Guide Project Minerals Library Standard

800xA System Extension Structure

Doc. kind Product Guide Project Minerals Library Standard

Minerals Library AC800 Setup

Minerals Library AC800

Yard and Port Extension

800xA for Advant Master Energy Management

Minerals Library AC400 Setup

Minerals Library AC400

Doc. kind Product Guide Project Minerals Library Standard

Project Documentation Documentation Guideline

Configuration Standard Minerals Library

System 800xA Manuals

Compact 800 - Process

Figure 2 Document Organization

Doc. kind Product Guide Project Minerals Library Standard

2.1 LOOK AND FEEL ADAPTED TO YOUR NEEDS

VALE Standard Holcim Standard

Figure 3 - Minerals Library Styles (incomplete)

Doc. kind Product Guide Project Minerals Library Standard

2.2 POINT OF CONTROL (POC)

Consumer Objects in POC Sequence and Central have two sub-modes:

Doc. kind Product Guide Project Minerals Library Standard

Doc. kind Product Guide Project Minerals Library Standard

2.3.1 Process Control Connection (PCC)

Doc. kind Product Guide Project Minerals Library Standard

Minerals Library object: DIS

Minerals Library object: MOT

Minerals Library object: AIS

Doc. kind Product Guide Project Minerals Library Standard

Doc. kind Product Guide Project Minerals Library Standard

Additional details about the motor stop are

Doc. kind Product Guide Project Minerals Library Standard

As mentioned before the reason for tripping is

In the PCC tab of the Signal faceplate the PCC

Doc. kind Product Guide Project Minerals Library Standard

Doc. kind Product Guide Project Minerals Library Standard

Group Status Indications and monitoring

Doc. kind Product Guide Project Minerals Library Standard

· Tag Name of the Object not ready for start or in hold

· Interlock text for group start and stop interlocks

· Actual step and tag during Start-up and stopping

· Indication of pre-selection missing or error

Group not Ready for Start Group Starting Group in Hold

Doc. kind Product Guide Project Minerals Library Standard

3. A successful start-up is indicated by the group status indication changing to

Unconditional Start (available in extended Faceplate)

Doc. kind Product Guide Project Minerals Library Standard

Doc. kind Product Guide Project Minerals Library Standard

The figure below shows the possible status of a Preselection.

Off /not selected

Selected to Start (Flashing)

Selected to Stop (Flashing)

Off / not Ready for Start

· Group is stopped completely