System 800xA Training

Chapter 2 System 800xA Architecture

TABLE OF CONTENTS

Chapter 2 System 800xA Architecture ...................................................................................................................................... 1

2.1 General Information ........................................................................................................................................................ 2
2.1.1 Objectives ................................................................................................................................................................ 2
2.1.2 Legend ..................................................................................................................................................................... 2
2.1.3 Reference Documentation ........................................................................................................................................ 2
2.2 System Overview ............................................................................................................................................................ 3
2.2.1 The Power of Integration .......................................................................................................................................... 4
2.2.2 Options Grouped in Functional Areas....................................................................................................................... 5
2.2.3 Controller Integration ............................................................................................................................................... 6
2.2.4 Use of Standards ...................................................................................................................................................... 6
2.3 Aspect Objects Concept .................................................................................................................................................. 7
2.3.1 Aspects and Objects ................................................................................................................................................. 7
2.3.2 Example of a Control Valve ..................................................................................................................................... 8
2.3.3 Intuitive Navigation ................................................................................................................................................. 8
2.3.4 Aspect Framework ................................................................................................................................................... 9
2.4 System Topology ...........................................................................................................................................................10
2.4.1 Domain Server ........................................................................................................................................................11
2.4.2 Aspect Server ..........................................................................................................................................................11
2.4.3 Connectivity Server.................................................................................................................................................11
2.4.4 Application Server ..................................................................................................................................................11
2.4.5 Plant Network .........................................................................................................................................................12
2.4.6 Client/Server Network ............................................................................................................................................12
2.4.7 Control Network .....................................................................................................................................................12
2.4.8 Single Node System ................................................................................................................................................13
2.4.9 Typical System .......................................................................................................................................................13
2.4.10 Large System ........................................................................................................................................................14
2.4.11 Large system with Remote (Thin) Client ...............................................................................................................15
2.4.12 Virtualization of Server Nodes ..............................................................................................................................15
2.4.13 AC 800M Redundancy ..........................................................................................................................................16
2.4.14 System Online Upgrade.........................................................................................................................................16
2.5 Client / Server Principle .................................................................................................................................................17
2.5.1 Aspect Directory .....................................................................................................................................................17
2.5.2 Example: Graphic Display ......................................................................................................................................17
2.5.3 Distributed Engineering ..........................................................................................................................................18
2.5.4 Multi-System Integration ........................................................................................................................................19
2.6 Configuration Utilities ...................................................................................................................................................20
2.6.1 Configuration Wizard..............................................................................................................................................20
2.6.2 System Configuration Console ................................................................................................................................23
2.7 System Information .......................................................................................................................................................24
2.7.1 Max Number of Nodes per Node Type ....................................................................................................................24
2.7.2 Parameters for AC 800M Controllers ......................................................................................................................25

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2.1 General Information

2.1.1 Objectives
On completion of this chapter you will be able to:
 Tell how 800xA fits into the Extended Automation strategy
 Describe the network structure in an System 800xA architecture
 Describe the functionality of the major components of 800xA
 Explain the concept of Aspects and Objects
 Explain the Client/Server principles

2.1.2 Legend
> Indicates when you go from one menu to a sub-menu
Italic Indicates object and file names
“ “ Indicates dialog box buttons, tabs, menus etc.
Bold Indicates important topics
Indicates start/explanation of student activity

2.1.3 Reference Documentation

3BSE038018-610 System 800xA System Guide – Functional Description
3BSE041434-610 System 800xA System Guide – Technical Data and
Configuration
3BSE034463-610 System 800xA - Network Configuration
2PAA101888-610 System 800xA -Tools

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2.2 System Overview

The Extended Automation System 800xA is a comprehensive process automation
system. It covers operation and configuration of continuous and batch control
applications.
System 800xA has been developed incorporating Information Technology with the
experience and know-how collected over decades of successful deliveries and
customer installations.

800xA System offers more than a traditional Distributed Control System. It gives you
a single application to organize and access all plant information.
As expected, you have functionality like graphics, faceplates, alarm management and
trending available. However, with the unique integration principles based on the
Aspect Object technology, you can easily integrate information like Live Video,
Documentation (using Word for example), Quality Analysis, and Maintenance
Information (from SAP or Maximo for example).
System 800xA provides a secure, reliable, control environment with built in security
features such as access control, user authentication, and audit trail capability.

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2.2.1 The Power of Integration

In order to be competitive, various plant entities, departments, and personnel have to
work as one flexible, integrated, collaborative environment.
Integration of systems, applications, and devices creates a powerful information
architecture where all information is available for use in the system and can be
provided to the plant personnel. Imagine a system where with one click an operator
could access any information required to make an informed decision regardless of
where it resides, or a maintenance technician could access device commissioning
displays, documentation, current health status, and a list of active work orders.

System 800xA Extended Automation is an integration platform with connectivity to

enterprise and plant systems, applications, and devices that improves operations,
engineering, control, and maintenance. It also provides a collaborative environment
where real time decision making is a reality.

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2.2.2 Options Grouped in Functional Areas

The 800xA System functionality is divided into a Base System and a set of options,
grouped in Functional Areas. The options represent functions that can be added to the
system based on the needs of the process that should be controlled.

Operations
Provides a consistent method for accessing enterprise-wide data and for interacting
with multiple applications from any connected workstation in the plant or office.
Engineering
Integrated engineering environment supports the complete lifecycle of the automation
project, from planning, through configuration and library management, to
commissioning and operation to minimize system ownership costs.
Safety
Scalable IEC 61508 and IEC 61511 compliant SIS (Safety Instrumentation System)
that spans the entire safety loop, including SIL rated field devices, I/O modules,
controllers, and field actuators.
Information Management
Collects, stores, retrieves and presents historical, process and business data to enhance
the usefulness of data from all operations.
Batch Management
Recipe management, batch and procedural control according ISA S88.01
Asset Optimization
Assess and reports equipment conditions in real-time to optimize maintenance and
calibration work flows.
Control and I/O
Suite of standards-based hardware and software, complimented with a full line of
industrial I/O interfaces.
Field Buses / Device Management
Integration of intelligent field devices via all major fieldbus standards.

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2.2.3 Controller Integration

Controllers are integrated with the system through “Connectivity packages”, which are
offered as options to the 800xA System. These packages provide access to real time
data, historical data, and alarm & event data using predefined faceplates.
Any of the traditional ABB control systems can be evolved using System 800xA. In
addition, connectivity packages and services exist to bring 3rd party PLCs and DCS
systems into an 800xA environment.

2.2.4 Use of Standards

System 800xA uses standard hardware, operating system software and protocols. This
allows data to be obtained not only from ABB systems but from a variety of sources
such as other brands of control systems or from lab entries.
It also allows making this data available to ABB and other manufacturers systems
such as historians and maintenance management programs.

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2.3 Aspect Objects Concept

A central problem in plant operations, as well as asset life cycle management, is the
need to organize, manage, and have access to detailed information for a great number
of plant and process entities.
The Aspect ObjectsTM architecture is a cornerstone of the IndustrialIT concept and
enables enterprise wide information availability in a unified way. It provides
information-centric navigation – a consistent way to instantly access all information
without having to know how and by which application the information is handled.

2.3.1 Aspects and Objects

The system model objects of the real process equipment or entities are called Aspect
Objects. They can be physical process equipment, like a valve, or more complex, like
a reactor. Other examples are: products, material, batch procedures, manufacturing
orders, and customer accounts.
Each of these Aspect Objects is a container of references to all information pertaining
to a real object. The various types of information related to the object are called
Aspects. Examples are: process graphic, faceplate, alarm list event list, trend display,
report, order definition, mechanical layout etc .

It is necessary to be able to implement these aspects using many different applications,

both existing and new, from ABB, third parties and customers. These applications are
called Aspect Systems and must cooperate to provide an integrated view and
functionality of the object.
Examples are: Graphics Builder for graphics, Auto CAD for mechanical layout, SAP
for order handling etc.

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2.3.2 Example of a Control Valve

For example, a valve is a real object and has many types of data associated with it. It
has manufacturer’s specifications, mechanical drawings, a maintenance schedule and
history, ordering information for parts, physical location in the plant, faceplate for
operator interface, graphic symbol for display on graphics, and many other possible
types of information.

Traditionally, these types of information are found in many separate systems or in

many different document formats. An Aspect Object presents this data as a menu of
choices accessible by right clicking on the object anywhere it appears in the system.
The various types of information related to the object, in this case the valve, are called
Aspects.

2.3.3 Intuitive Navigation

Quick access to displays and information is provided with web browser tools.
Favorites, history lists, shortcuts, and hot keys provide navigation through a process
production facility quickly and accurately.

Use of the right mouse button provides access to additional details via a context menu.
The same context menu is available, showing all aspects, independent whether you
select it e.g. in the graphic display or in the alarm list.

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2.3.4 Aspect Framework

From a software architecture perspective, the foundation of the 800xA System is the
Aspect Framework (afw). It is a software package that integrates all 800xA products
via their Aspect Objects, irrespective of where they may reside in the network.

Although the various aspects and their associated software may reside on multiple
networks or computers, each Aspect Object carries with it the built-in collection of
characteristics or Aspects. All aspect objects are stored in a central location called the
Aspect Server.
NOTE! The Aspect Framework can handle up to 200,000 Aspect
Objects.
Although all objects reside in this central location, data needs to be configured only
once for use throughout the system. There are many Aspect Systems and thus many
options for where data can be entered. There are also many places where the same data
can be viewed so that generally, data can be entered and viewed where it is relevant.

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2.4 System Topology

The System 800xA architecture assumes a system of computers and devices that
communicate with each other over different types of communication networks, as
illustrated conceptually here.
The Workplaces use either dedicated client computers or combined Client/Server
machines allowing both client and server applications to run in one PC.

System communication in the 800xA System is based on Ethernet and TCP/IP

networks. Servers run software that provides system functionality, Workplaces run
software that provides various forms of user interaction.
NOTE! Server selection and configuration are important factors
for system performance.

The 800xA system uses a central licensing mechanism. One designated computer,
typically the Primary Aspect Server will contain the central licensing server (CLS).
All other nodes will be licensing clients.

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2.4.1 Domain Server

Small systems can run without a Domain Controller. In this case the nodes and users
are handled by a Windows Workgroup. The configuration of users and security must
then be done on all nodes separately within the Workgroup.
The user handling in a Windows Domain is done from a central location – the Domain
Server. Every domain must have at least one domain server, but for resilience a
domain should have multiple domain servers.
e.g. when a user logged into the computer which is a part of domain then active
directory checks whether the user is a normal or admin user.

2.4.2 Aspect Server

The Aspect Server contains the Aspect Directory and provides the services related to
object management, names, security, etc. It is the heart of the 800xA system. As such
it must be accessible to all nodes all of the time.
In small system the Aspect Server can be combined with other functions such as
Application or Connectivity Servers in a single node (computer).
The Aspect Server supports “1 out of 2” or “2 out of 3” redundancy. In “1 out of 2”
redundancy, the Aspect Directory is readable and writable as long as one Aspect
Server is on-line. With “2 out of 3” redundancy, two Aspect Servers must be running
to write to the Aspect Directory, but with any one Aspect Server on-line, the system is
useable for operation but not for configuration (Aspect Directory in read only mode).

2.4.3 Connectivity Server

The Connectivity Server provides access to the controllers and other data sources
throughout the network. Several groups of Connectivity Servers may exist in a system,
each serving one set of data sources. The AC 800M Connectivity Server is one of
many different types of Connectivity Servers in the 800xA System.
Examples of services running on the connectivity server are:
 OPC Data Access
 OPC Alarm and Event
 System messages
NOTE! Maximum 48 AC 800M controllers (single or redundant)
can be connected to one Connectivity Server (single or
redundant).

2.4.4 Application Server

Run various types of system applications, such as:
 Batch Management
 Asset Optimization
 Information Management

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2.4.5 Plant Network

The Plant network can be dedicated for process automation purposes or be a part of
the plant intranet already available on a site.
Further connection of the Plant network to the Internet or any other type of external
network should be performed in accordance with adequate network security practices.

2.4.6 Client/Server Network

The Client/Server network is used for communication between servers, and between
client workplaces and servers.
Via a router, the Client/Server network can be connected to a plant intranet, and via a
firewall to the Internet. For performance and integrity reasons, connection of foreign
systems directly to the Control and Client/Server networks should be avoided. The
Client/Server network can, optionally, be made redundant.
For any installation larger than a Single Node system (or a small system that use
Windows Workgroup), the 800xA system nodes must reside within a dedicated
Windows Domain. This requires you to set up a domain controller and DNS server.
All other 800xA System server and client nodes must be configured to be members of
the domain.

2.4.7 Control Network

The Control network is a local area network (LAN), optimized for high performance
and reliable communication, with predictable response times in real time. It is used to
connect controllers to the connectivity servers. Controllers are nodes that run control
software.
Controllers and Connectivity Servers are connected to the Control network. The
Control network can, optionally, be made redundant.
Field buses are used to interconnect field devices, such as I/O modules, smart sensors
and actuators, variable speed drives, PLCs, or small single loop devices, and to
connect these devices to the system, normally via a controller.

NOTE! For smaller systems, if network separation is not desired,

the Client/Server Network and Control Network can be
combined in one Automation System Network.

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2.4.8 Single Node System

A Single Node System is intended for very small applications, where all 800xA server
and workplace functionalities reside in a single PC.

The system has only one node, within which all servers as well as the client
applications are installed. Total system capacity is reduced (fewer controllers, fewer
clients, etc.,). Refer to the System Guide – Technical Data and Configuration manual
(3BSE041434-600) for details.

2.4.9 Typical System

This is a typical system for medium sized projects without the possibility to get access
from the factory office or over the internet. Because the networks are isolated from the
outside world, this is a relatively secure setup.

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2.4.10 Large System

If the total number of nodes on the Control Network exceeds 60, it is necessary to split
the Control Network on two or more Network Areas.

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2.4.11 Large system with Remote (Thin) Client

Thin Clients enable remote access to an 800xA system from a standard PC without
ABB-specific software installed. Only the Internet Explorer is required to access the
data.
The Thin Client provides operation capabilities and access to historical information.
Configuration capabilities are limited on the remote client.

2.4.12 Virtualization of Server Nodes

Virtualization based on VMware ESX can be used in 800xA systems to combine
multiple 800xA server nodes onto a single computer. The total number of physical
computers required in an installation is reduced significantly.

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2.4.13 AC 800M Redundancy

System 800xA provides the high degree of fault tolerance to meet the most demanding
application needs for maximum system uptime. Optionally redundant I/O, controllers,
control networks, Fieldbus networks, Connectivity Servers, Aspect Servers, and
Operator Workplaces are available with automatic switchover.

2.4.14 System Online Upgrade

System 800xA SV6.1.1 supports upgrading a running system without interrupting the
production, provided that all servers are redundant. Online upgrade is supported from
800xA SV5.0 onwards.
General workflow
1. Decouple redundant nodes (start with AS,CS, a client)
Or use new hardware if it will be exchanged
2. Upgrade the decoupled nodes
3. Build parallel system with upgraded nodes
4. Gradually move over nodes (clients, remaining servers)
Upgrade remaining nodes before connecting to the upgraded system
5. Enable redundant mode

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2.5 Client / Server Principle

2.5.1 Aspect Directory

The Aspect Framework includes an Aspect Directory, where all aspect objects and
their aspects are registered, and also all aspect systems and the operations they
support.

To perform an operation on an Aspect Object, an application (i.e. an Aspect System)

retrieves an interface for that operation from the framework.

2.5.2 Example: Graphic Display

Let’s take a process graphic as an example. The Aspect “Graphic display” is installed
on the Aspect Server and will be called by the Operator Workplace.

If we look at a valve within the process display, the icon is provided by the Aspect
Server and the dynamic status indication (open/closed) is provided by the Connectivity
Server.

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2.5.3 Distributed Engineering

The 800xA System supports distributed engineering:
Off-Site Engineering
In an off-site environment, engineering tasks may be performed off-line in an isolated
manner from other users. When the off-site tasks are completed, the user
modifications can be applied to the on-line system through the export/import features.
On Site Engineering
The onsite Engineering Environment is used for final testing of applications before
introducing them into the Production Environment, and for changes and additions
occurring once the Production System is in operation.

The import/export feature allows for selective transfer of configuration data between
systems. In addition, it is possible to compare configuration data between the different
systems and create reports on the differences.

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2.5.4 Multi-System Integration

System 800xA SV6.1.1 supports multiple 800xA Systems. Multi-System integration
makes it possible to view and operate objects configured in one 800xA System
(provider) from another 800xA System (subscriber).
This feature provides:
 Geographically separate 800xA Systems with local control rooms to be controlled
from a common/central control room
 Sectioning of multiple line processes to increase integrity and simplify
maintenance
 Making staged commissioning without interfering with running processes possible

NOTE! All engineering is done locally at the Provider system;

the Subscriber system is for operation only.
NOTE! Not all 800xA Connectivities can be used with Multi-
System integration. For further information refer to
System Guide Technical Data and Configuration
(3BSE041434-600)

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2.6 Configuration Utilities

2.6.1 Configuration Wizard

The configuration Wizard is slowly being phased out. In System 800xA version 6.1.1
most of the functionality of the Configuration Wizard has been transferred to the
System Configuration Console. When the Configuration Wizard is started there is a
warning that you should use the System Configuration Console for most of the tasks.
In older systems (up to version 5.1) This was the main configuration utility.
The Configuration Wizard is the central place to:
 Create/Delete an 800xA System
 Start/Stop an 800xA System
 Add extensions to the 800xA System
 Connect/Disconnect clients and servers

2.6.1.1 Example of how to Connect/Disconnect Clients

Clients as well as servers can be connected /disconnected from the Aspect Server only.
To connect a client, follow these steps:

1. Open ABB Start Menu > ABB System 800xA > System > Configuration Wizard
2. Select “System Administration” and click “Next”.

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3. Select your system and click “Next”.

4. Select “Nodes” and click “Next”.

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5. From the next menu you can add/remove clients and servers.

NOTE! Refer to the separate course T305 “Administration and

Installation” for more information.

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2.6.2 System Configuration Console

Beginning in SV5.1, the System Configuration Console is a dashboard that provides a
single entry point for the global configuration settings of an 800xA system, such as:
 Creation of an 800xA system
 Adding Servers and Clients
 Appearance and personalization
 Client and server load balancing
 Maintenance configurations
 Security configurations
 User administration
To start the System Configuration Console, select “Open ABB Start Menu > ABB
System 800xA > System > System Configuration Console”.

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2.7 System Information

2.7.1 Max Number of Nodes per Node Type

The number of nodes that can be added to an 800xA System is limited. It depends,
among other things, on the operating system. The hardware setup for the System also
is of influence.

For instance a DCI Connect Aspect Server has to run on Windows 2016/2019 server.
An AC800M aspect Server can run on windows 10.

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2.7.2 Parameters for AC 800M Controllers

 Exercise 2.1

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