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System 800xA Version 6.1 Efficient
ABB CONTROL TECHNOLOGIES | WEBINAR | CONTROL TECHNOLOGIES
Engineering
IACT Products, Global Product Management, Ralf Jeske
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Engineering Efficiency in System 800xA Version 6.1
Ralf Jeske
Global Product Management CT Products – Engineering Tools
Presenter Profile:
Ralf has more than 20 years of experience in Process Automation, with focus on Engineering Tools Your Photo
and system configurations in different automation systems. Current focus areas are xStream
Engineering, Modularization as well as impact of Digitalization on engineering activities,
organizations and tools
Synopsis:
Standardization is key to address cost pressure and generational change. This session proposes a
standard engineering workflow and tool set, which balances between customization and efficiency
What you will learn:
– Key success factors enabling for cost effective configuration
– How to standardize as much as possible allowing as much as necessary customization
– How you can split work effectively
– How you use different talents effectively
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Engineering Efficiency in System 800xA Version 6.1
Session Introduction
Common 800xA Engineering Workflow – 1st Release
– Focuses on I/O, Controller and HMI
– Presenting overview, concepts and best practice
Note: Subsequent updates will cover Fieldbus connections and intelligent sub systems
Recommendations on how to use which tools
– Scalable solution from small to large
– Covers interactive use cases as well as auto bulk generation
– Use the best off all worlds
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Engineering Efficiency in System 800xA Version 6.1
Common Engineering Workflow - Overview
Project Key elements:
Preparation
– Take time to prepare your projects well
– Fast-Track your Projects
Perform activities in parallel instead of sequential
• Configure and check software in-house
Hardware Software • Have Hardware be configured and checked at site early
Configurati Configuration
on • Bind Software and Hardware as late as necessary at site
– Bind I/O Hardware via Signals to Software
Hardware Software
Check Check
Late
Binding
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Engineering Efficiency in System 800xA Version 6.1
Common Engineering Workflow - Overview
Key elements:
– Take time to prepare your projects well
– Fast-Track your Projects
Perform activities in parallel instead of sequential
• Configure and check software in-house
• Have Hardware be configured and checked at site early
• Bind Software and Hardware as late as necessary at site
– Bind I/O Hardware via Signals to Software
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Engineering Efficiency in System 800xA Version 6.1
Tools
Control Builder provides HMI provides
– Control Diagrams – Tabbed Navigation
Editor of choice for new applications, which combines best Structuring element for HMI displays, supported by User
of all other editors in one. Integrates Sequential Function Interface controls on the HMI displays
Chart and Structured Text programming – Process Graphics 2
– Programs Easy to use Process Graphics design tool with rich library of
Editor with IEC 61131 features Function Block Diagram, ready made elements. Fully integrated in 800xA and allows
Structured Text, Sequential Function Charts and Ladder dynamic Tag elements with or without the control code
Diagrams being available
– Control Modules – Trends and logs
Graphics Editor for Control Modules that complements with Allows configuration of logs on existing objects and the
Structured Text code visualization into trends
Note: All Editors are supported, where focus on new
development is in the editor for Control Diagrams
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Engineering Efficiency in System 800xA Version 6.1
Prepare Project - Overview
Clarify the project Inputs and constraints as:
– I/O Signal list format, examples and schedule
– Instrument Tag list format, examples and schedule
– Piping and Instrumentation Diagrams schedule
– Function Design Specification schedule
– Standards to be followed
Create a new Project workplace
Identify and adapt types
– Select the types needed based on the application
– Reuse types may require adaptations
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Engineering Efficiency in System 800xA Version 6.1
Prepare Project – Example Inputs
Example for P&I Diagram Example for Instrument / Device Tag List
Example for I/O Signal List
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Engineering Efficiency in System 800xA Version 6.1
Prepare Project – Adapt Types
Out of the Box Libraries HMI Adaptation
Analog and Digital Monitoring blocks can be found in Signal Where the libraries already include a set of HMI elements as
Libraries. Scaled features are number of alarm levels for graphic elements and faceplates, there are multiple sites
analogs and diagnostics where adaptations are required. 800xA supports an Extension
Motor and Pump object types are included in Process Objects Library concept where delivered HMI extensions can be copied
Extended library, where such are designed as templates, and adapted. The product provided extension library can in
which can be copied and adapted to the projects needs. those cases be disabled in order to streamline operations
Process Objects Drive Library complements the types,
Simple PID and Cascade Loop types are provides in Control
Logic Adaptation
Solution Library. Control Solutions can be copied and adapted
to the projects needs In cases, where the types need to be adapted, it is suggested
Refer: to:
– 3BSE035981 and online help for functional specification a) Copy an existing type if the library is not protected
– 3BSE041434 chapter 5.1 for footprint b) Wrap protected types in a new type and copy and adapt
aspects
More specialized application libraries are available from ABB
Note: In order to ensure proper number of tags, wrapped
Control Technologies as for example dairies, sugar, fine
types should have the property „instantiate as Aspect Object“
chemicals.
disabled
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Engineering Efficiency in System 800xA Version 6.1
Hardware Configuration - OPTIONS
Independent Hardware
Configuration
Based on the I/O system and connectivity
hardware can be tested independent:
a) S800 and Select I/O on Ethernet
Configuration is supported by Ethernet
I/O Wizard and simple to create. Test
does only require a Windows node with
System 800xA field-kit installed
b) All other I/O connectivity and I/O
systems
Configuration is supported by Bulk Data
Manager. Users need to create Test
applications to test the I/O. A controller
and optionally PROFIBUS Communication
Interface is needed for test
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Engineering Efficiency in System 800xA Version 6.1
Hardware Configuration – S800 Modulebus Overview
– Prepare Hardware:
• Insert HW Libraries
• Create Controllers
– Create & Configure I/O Units and I/O Signals:
• Create I/O Units structure
• Configure I/O Units
• Assign I/O Signals to channels
– Functional I/O Loop Checks:
• Create test Application with Signals
Note: for non safe apps one can enable the Controller’s hardware object
settings “copy unconnected in/output channels”
– Download Controller
– Verify function of the I/O units, wiring and field devices
Notes: Observer system 6.1 provides automatic cross reference
navigation via signals and I/O variables called Process relations
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Engineering Efficiency in System 800xA Version 6.1
Hardware Configuration – S800 No Ethernet
Create Hardware Units
Create S800 I/O modules with simple BDM2
sheet
Notes:
– You may create one of each types
interactively and drag controller into BDM2
in order to know what field values are
needed
– Hardware objects have an identification
number and a name. As the name is seen
in the alarm messages it is suggested to
code the location into the name make
repair in runtime easier
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Engineering Efficiency in System 800xA Version 6.1
Hardware Configuration – S800 No Ethernet
Configure Units
Once create the unit can be read into the
CBHardwareUnitModification template
a) Turquoise columns configure Hardware
unit settings as signal range, filter times
and similar
b) Apricot columns configure allocation of
signals to channels and I/O channel
scaling parameters
Notes:
– Row Filters are not yet supported in CB
based sheets, subject to later revisions
Consider using find or replace
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Engineering Efficiency in System 800xA Version 6.1
Hardware Configuration – Test Application
Test Application without Faceplates Test Application with Faceplates
If no Faceplate is needed to test open loop and shortcut and if If a Faceplate is needed create a Test Application with BDM2.
the application does not require is safety level one can Two Phase creation with BDM2 “CBDiagramCreate Template”
enable “Copy unused channels ”
1.Create one signal object for each signal based on data type
(Real | Boolean | DWORD) and direction (IN | OUT)
2.“Save to CB” creates objects in a Diagram an creates a new
worksheet listing all I/O ports
3.Assign signals to I/O ports and save to CB
4.Connect Application to Controller and Task
5.Download Controller
Note: Ensure the setting is disabled after use as it may load
the controller and is not supported in plant operations
conditions
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Engineering Efficiency in System 800xA Version 6.1
Hardware Configuration – Device Simulation and Configuration
Device Configuration and Test - DTM Device Configuration and Test – FDI and EDD
System 800xA has build in support for Device Management A new System 800xA Option called Field Information Manager
PROFIBUS HART 1.3 has been added
ABB Library hosts a DTM library for all commonly used Device Find info on packages at www.abb.com/fieldinfo
Drivers FIM 1.3 can be use to:
The System 800xA can be use to: – Observe HART devices
– Observe HART devices – Configure HART devices based on templates
– Configure HART devices – Simulate / Force output values of HART devices
– Simulate / Force output values of HART devices – Document configuration
– … – Supports NAMUR device parameter
– Allows access to device data via OPC UA
– …
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Engineering Efficiency in System 800xA Version 6.1
Hardware Configuration – System 800xA 6.1 News
I/O Connection via Signals Process and Device Relations NE 107 Status indication
I/O connection can be routed via: Control Builder links the device and the All Unit status alarms and events for
a) I/O Signals or process objects as per I/O connections S800 and Select I/O on Ethernet have
Process Objects offer a new Aspect been assigned to a NE 107 category for
b) already defined I/O variables easier recognition of the urgency and
Category the Device Alarm Event list
showing messages from connected potential impact
devices
Process objects allow to navigate via
context menu to connected device
objects
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration - Overview
Software Configuration can start in two streams:
a) Application
Configuration of the Applications, Diagrams and Tags as
per the specification
b) HMI
Engineering of the HMI starts with creation of the
functional structure. Next the Alarm and event lists and
bands are being configured and the Process Graphics with
Statics and Dynamic content. Once the alarm bands and
lists are available the Operator workplace and its menus
and options can be done
c) Software Binding
After the Applications are done the HMI and Application
can be correlated and logs and trends can be configured
d) Software Test & Factory Acceptance Test
The AC800M Soft Controller option allows software test
and FAT to be done in an office environment or clouds with
remote dial in capabilities.
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration Application - Overview
Preparing Applications
– Checking if all necessary Libraries are inserted under Project Libraries if not inserting the
missing ones.
– Creating the desired number of Applications.
– Connecting Libraries into the Applications under Connected Libraries folder (for each
Application).
Creating Diagrams & Tag Objects
– Creating Diagrams in Applications according to the I/O List, TAG List and Functional
Description
– Control Module blocks will be used as SW representation of valves, motors and
measurements.
– Entering names of Control Modules according to the Tag List and connecting I/O Signals
according to the I/O List.
Configuring Application
– Checking and modifying the necessary Control Module Parameters according to the Tag List,
e.g. Name, Limits, AE Class etc.
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration Application - Create Diagrams & Tag Objects Considerations
Cycle Times Diagram Size
Up to 32 Applications can be assigned to one Controller Applications can host up to 128 Diagrams
Up to 32 Tasks be run per Controller In order to maintain responsiveness following limits are
Tasks can be assigned to one Application only enforced. System variable value cause warning where max
values are prevented to be exceeded.
Best practice is to have about 3-10 applications per controller
with 3 tasks each (fast, medium, slow)
Note: Controller tuning gets easy, when the different task
interval times are multiples of the fastest tasks interval time
It is recommended to either configure one Diagram:
a) per Unit (10 to 70 Tags)
It keep process separation easy
b) one Diagram per Control Loop (1 to 5 Tags)
May be suitable if such loops can be auto generate by
BDM2
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration Application - Create Diagrams & Tag Objects
Ways how to Create Diagrams and Tags
a) Interactively in CBM
b) Auto Generate: BDM2 CBDiagramCreation
The sheet is optimized to create Diagrams for Units and
place Tag process objects on pages and connect I/O
signals to the process objects
After generation of tags the unit logic is implemented
interactively e.g., with SFCs
c) Auto Generate: BDM2
CBDiagramDuplicationAndModification
This sheet is optimized to duplicate diagrams where in the
duplicate a simple replacement of strings for tags,
variables and signals is needed
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration Application - Create Diagrams & Tag Objects
Ways how to Create Diagrams and Tags
a) Interactively in CBM
b) Auto Generate: BDM2 CBDiagramCreation
The sheet is optimized to create Diagrams for Units and
place Tag process objects on pages and connect I/O
signals to the process objects
c) Auto Generate: BDM2
CBDiagramDuplicationAndModification
This sheet is optimized to duplicate diagrams where in the
duplicate a simple replacement of strings for tags,
variables and signals is needed 1.Selec
t
source
2. Name
New
Diagram
3.
Replace
strings
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration Application – Block Parametrization
BDM2 and Diagrams allow modification of parameters of
Blocks.
1. Define which parameters of which block types are needed
Done in BDM2 CBParametrization template with + Create
Header. Typical parameter to configure in bulk is the AEClass
parameter. All visible ports of a block instance can be
selected.
2. Reading applications and diagrams in reads the currently
configured values
3. Values can be updated and written to the Diagrams for
update
Note: visible and invisible ports can be read and written but
only visible ports can be selected
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration - Overview
Software Configuration can start in two streams:
a) Application
Configuration of the Applications, Diagrams and Tags as
per the specification
b) HMI
Engineering of the HMI starts with creation of the
functional structure. Next the Alarm and event lists and
bands are being configured and the Process Graphics with
Statics and Dynamic content. Once the alarm bands and
lists are available the Operator workplace and its menus
and options can be done
c) Software Binding
After the Applications are done the HMI and Application
can be correlated and logs and trends can be configured
d) Software Test & Factory Acceptance Test
The AC800M Soft Controller option allows software test
and FAT to be done in an office environment or clouds with
remote dial in capabilities.
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration HMI – Functional Structure
Functional structure follows the plant process hierarchy plant
HMI displays are added to the different hierarchies as Process
Graphics as well as Trends and Alarm and Event lists
Structuring objects are build based on types in the plant and
mill folder
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration HMI – Process Graphics Static
Static content in the Process Graphics can be created with the
build in libraries
Libraries contain typical elements for the process industries
market
The pipes connect wo points with vertical and horizontal lines
automatically
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration HMI – Process Graphics Dynamic Content
Graphic Elements that are to be bound to a tag running in the
controller can be created:
A) In offline mode
1.Select the object type to be placed (consider the filter
field)
2.Select the element to be placed
3.Drag and drop the element to the display
4.Set the object name in the element property to the target
Tag Name
5.Save Graphics Display
B) In online mode
1.Select the object to be placed (consider the filter field)
2.Select the element to be placed
3.Drag and drop the element to the display
Note: it is suggested to work in offline more as mostly the
tag objects are not available to the technicians
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration HMI – Alarm and Events List and Band
Process areas and Units have been assigned to AE Class as
per the tag list.
Next in the Functional Structure Alarm and Event lists are
being created and the filter is to be set for the AE Class
attributes.
In the Example the following filters are to be set:
– Preparation Area AE Class 100-500
– Preparation Tank 1 AE Class 100
– Preparation Tank 2 AE Class 200
– Preparation Tank 3 AE Class 300
– Preparation Tank 4 AE Class 400
– Preparation Tank 5 AE Class 500
– Reactor Area AE Class 600 - …
Simple configuration of columns and colors can be done by
making the configuration local to the object and not
referencing to a library object.
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration HMI – Alarm and Events Band
The Workplace Object has an Aspect “Alarm Band Process”
Here multiple button of the Alarm Band can be configured in
size and position, where each points to a Alarm and Even list
for the filter conditions
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration HMI – Workplace
Note: It is not suggested to modify Workplaces delivered with
the product as such may be overwritten at update and
upgrades
Copy a product workplace e.g., Operator W-12 Tab 1920x1080
for a dual screen workplace with tabbed navigation
How to configure the Alarm Band is show in the Alarm and
Event page section
The Startup screen is configured in the aspects
1_ScreenLayout and 2_ScreenLayout
In the user structure the default workplace profile values and
plant explorer settings are configured
Name of aspect in
Name of object in Functional Structure Functional Structure
where aspect for displaying is located for displaying
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration HMI – Workplace tabbed Navigation
In the workplace the Tab Grouping aspect is already
integrated in the workplace via the Panel Layout and
Application Bar
The tabbed Navigation Aspect configures:
– Tab style appearance and status indications
– which path to be used in functional structure
– On which level the first object is
– How many levels are shown
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration - Overview
Software Configuration can start in two streams:
a) Application
Configuration of the Applications, Diagrams and Tags as
per the specification
b) HMI
Engineering of the HMI starts with creation of the
functional structure. Next the Alarm and event lists and
bands are being configured and the Process Graphics with
Statics and Dynamic content. Once the alarm bands and
lists are available the Operator workplace and its menus
and options can be done
c) Software Binding
After the Applications are done the HMI and Application
can be correlated and logs and trends can be configured
d) Software Test & Factory Acceptance Test
The AC800M Soft Controller option allows software test
and FAT to be done in an office environment or clouds with
remote dial in capabilities.
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration – Software binding
All Graphic displays need to resolve references
– Open Graphic Display in Editor
– Open Data Reference tool
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration – Configure Logs
Three different approaches are possible:
1) Configure logs at Object types and auto instantiate
Done if history performance is off no concern. Log template
aspects are configured on the object to auto instantiate. All
objects of such type will automatically have a log aspect on
the instances and collect data.
2) Configure logs at Object types and bulk instantiate
Done if history performance is constraint. Log template
aspects are configured on the object without auto instantiate.
Log template aspect can added via BDM2 by simply adding a
log configuration aspect.
3) Configure logs on instances
Fully flexible solutions are possible, where high flexibility to
determine logged properties is required. Configuration can be
performed via a BDM2 template for detailed log configuration
Note: All approaches rely on Log configuration templates
configured in Library Structure
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration – Configure Trends
Trends for single objects can be put on the object type and do
not need any further configuration
Trends showing multiple traces from different object would be
positioned into the function structure
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration - Overview
Software Configuration can start in two streams:
a) Application
Configuration of the Applications, Diagrams and Tags as
per the specification
b) HMI
Engineering of the HMI starts with creation of the
functional structure. Next the Alarm and event lists and
bands are being configured and the Process Graphics with
Statics and Dynamic content. Once the alarm bands and
lists are available the Operator workplace and its menus
and options can be done
c) Software Binding
After the Applications are done the HMI and Application
can be correlated and logs and trends can be configured
d) Software Test & Factory Acceptance Test
The AC800M Soft Controller option allows software test
and FAT to be done in an office environment or clouds with
remote dial in capabilities.
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration – Software Test / Factory Acceptance test
Software test can be performed on Soft Controller
a) up to 10 controller can be emulated on one PC
b) If the HW simulation flag is et on the controller any
controller configuration can be loaded into a
SoftController
c) If inter controller communication shall be tested the
controllers System Identification needs to be set to the
SoftController address as well as the IP address on the
Ethernet port
d) Please also change the OPC Server addresses to the
SoftController IP address
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Engineering Efficiency in System 800xA Version 6.1
Software Configuration – Software Test / Factory Acceptance test
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Engineering Efficiency in System 800xA Version 6.1
Late Binding
Power of Signals
The new Signal Concept in 800xA allows to
configure and test Software and application
in parallel
Late Binding consider the steps
1.Merge the configuration into one system
using Export Import
2.Check the Signal mapping of Hardware and
Software for errors
3.Download integrated configuration
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Engineering Efficiency in System 800xA Version 6.1
Late Binding – Export Import
Export Import Hardware
Configuration
From 800xA 6.1 onwards some
Communication Interfaces can be
independently exported and imported
To merge a Modulebus configuration into an
existing controller:
1.Export the controller
2.Import the controller with the Modulebus in
parallel to the one designed for the
Software
3.Drag and drop the Modulebus I/O units
from the Hardware controller to the
Software one
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Engineering Efficiency in System 800xA Version 6.1
Late Binding – Signals
Signal Binding
Application Signals and Hardware Signals will
be automatically being bind at download of
the controller based on name, direction and
data type
The Signal Overview on Application,
Controller and Project level can help to
determine configuration errors
– Duplicated I/O Signal names
– Open I/O Signals on Application or
Hardware
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Engineering Efficiency in System 800xA Version 6.1
Key Learning
– Parallel execution is a key success factor
enabling for cost effective configuration
– Stop binding Field device electrically, bind
by software signals
– Prevent late changes and unplanned work
by thorough preparation
– Standardize where possible allowing only
as much as necessary customization
– You know how you can share work
effectively between team members
– You know that different talents can be used
for different task
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