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Product Guide
Control and Operation AC800M Minerals Library
Operation AC400 Connect Minerals Library
Operation Siemens PCS7 CEMAT Connect Minerals Library
Version 5.1/4a
Based on
Prep.
Appr.
Doc. kind
Title
Project
ATBPA/W.Vidal
ATBPA/M.Knabenhans
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
BU Minerals Library
12.07.2007
12.07.2007
Doc.
Item
des.
des.
Resp. dept.
CHIND / ATBPA
Document number
3BHS 161554
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en
No. of p.
1
95
Doc. kind
Title
1.
2.
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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en
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2.2.2
3.
4.
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Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
3
95
Control AC800M Minerals Library, which contains the software modules that are used
to configure applications using the AC800M controllers.
Operations AC800M Connect Minerals Library, which provides display elements and
faceplates for monitoring and control of objects, defined by means of the AC800M
Minerals Library.
Operations Process Portal 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.
The documentation for all these elements is included on the installation CD-ROM.
This version runs on System 800xA Version 5.1 with Feature Pack 4.
1.1 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-build, typical, 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 coding of the Control Modules is compliant with the IEC 61131-3 standard.
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.
1.1.1 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.
PCC Bus Light concept created for all devices in BMIStandard. Through this new PCC
Bus Light version we have now the possibility to see the DIS, DIC, AIS and AIC limit that
is causing some fault to the consumer object. In addition it is possible to see in the AIS,
AIC, DIS and DIC faceplate what is the motor that it is connected to.
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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
Type
Function
Data Type
AIS
CM
AISData
AOS
CM
AOSData
DIS
CM
DISData
DOS
CM
DOSData
Doc. kind
Title
Name
Type
Function
Data Type
AIC
CM
AISData
AOC
CM
AOSData
DIC
CM
DISData
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Name
Type
Function
Data Type
Read: IO.<TagName>.Signal.Value
Interlock: IO.<TagName>.Signal.Normal
DOC
CM
DOSData
Type
Function
Data Type
GCC_Com_
M
CM
GCC_ComD
ata
GCC_Com_
S
CM
PCC_Com_
Drive
CM
CM
PCC_ComD
ata
GCC_ComD
ata
Point-to-point communication to
GCC_Com_M via Communication Variable
PCC_Com_
Signal
Point-to-point communication to
GCC_Com_S via Communication Variable
PCC_ComD
ata
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Name
Type
Function
DataTypes
MOT1
CM
MOT1Data
MOT1_VVVF
CM
MOT1VVVFD
ata
MOT2
CM
MOT2Data
MOT2_VVVF
CM
MOT2VVVFD
ata
MOTP
CM
MOTPData
VLV1
CM
VLV1Data
VLVNO1
CM
VLVNO1Data
Doc. kind
Title
Name
Type
Function
Data Type
GROUP
CM
GrpInput
GrpOutput
GrpDrvCon
DriveGroup
CM
DriveGroupD
ata
GrpCycleCtrl
CM
GrpCycle
CntrlData
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Minerals Library version 5.1/4a
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CM
PreBinData
STW
CM
STWData
GroupStep
CM
Not defined
Type
Function
Data Type
PIDCtrl
CM
PIDCtrlData
Type
Function
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Data Type
BU Minerals Library
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PulseCount
CM
PulseCount
Data
Reporting
Count
CM
Reporting
CountData
Type
Function
Data Type
Circuit Breaker
CM
CircuitBreaker
Data
CircuitBreakerA
BBREF542Plus
Composite CM:
Circuit Breaker +
3 AIC (Current,
Voltage, Power) + 1
Counter (Energy)
CircuitBreaker
ABBREF542P
lusData
PFCCtrl
CM
PFCCtrlData
Type
Function
Data Type
MOT1VVVF_ACS8x0
Composite CM:
MOT1_VVVF
MOT1_VVVFData
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
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ACS500, ACS600,
ACS800 or ACS1000
MOT2VVVF_ACS8x0
Composite CM :
MOT2_VVVF
MOT2VVVFData
UMC22
Composite CM
MOT1UMCData
MOT1_MNSIS
MOT2_MNSIS
MOTP_MNSIS
Composite CM
MOT1 + AIC (Current or Power)
MOT2 + AIC (Current or Power)
MOTP + AIC (Current or Power)
MOT1_MNSISData
MOT1_MNSiS_MBTCP
MOT2_MNSIS_MBTCP
MOTP_MNSIS_MBTCP
Composite CM:
MOT1, MOT2, MOTP
MOT1_MNSiS_MBT
CPData
MOT1_UMC100
MOT2_UMC100
MOTP_UMC100
Composite CM:
MOT1, MOT2, MOTP
MOTx_UMC100Data
Type
Function
Data Type
Load
Composite CM
Load
Load :
Enable grouping of MV-Switchgear according Plant
Sections in order to monitor and control their
Energy consumption
Load_DataType
Load Shedding
Load Shedding:
Enable to ensure that the Energy consumption of
the Plant respects certain conditions according
priorities
LoadSheddingData
Power
Demand
Supervision
Composite CM
PowerDemand
Supervision
PowerDemand Supervision:
Enables input of tariff structure and their given
conditions to respect coming from the Energy
supplier
PowerDemandData
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
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BU Minerals Library
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1 DIC (syncPulseAlarm) +
6 AIC Total Power, Total Current,
ActualEnergyInInterval,
ForecastEnergyAtIntervalEnd,
EnergyMovingInterval,PeakPowerExceededTime,
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Industrial IT System 800xA
Minerals Library version 5.1/4a
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BU Minerals Library
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3BHS 161554
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Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
12
95
Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
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BU Minerals Library
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Tag name
Description
Point of Control
indication
Motor status
Call up
Call up
Object
Alarm
List
Object
Event
List
Indication
Change Point of
Control
Seq => Sequence
Cen => Central
Loc => Local
Start motor
Stop motor
Acknowledge Alarm
Extended view
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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 eventing on 2 Process Limit levels (Plo, Phi)
Adjustable Low Pass Filter.
FilteredSignal Rate of change calculation and alarm. The ROC is presented in %
of Total Range per second.
All Substatus 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
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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 Substatus for IO and FF Filed Device will generate error control when quality is
Bad or Uncertain for AOS Control Module
Process Panel status indication and operation
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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.
Doc. kind
Title
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
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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.
Process Panel status indication and operation
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
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3BHS 161554
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The group sequence start / stop module provides the following features:
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BU Minerals Library
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Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
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3BHS 161554
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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
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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.
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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.
Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
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
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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.
1.1.12.4 Start Warning (STW)
Main purpose of Module:
Control for buzzers and flashlights, prior to a remote start of equipment
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.
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Alarm
Interlock
Off
Bad Quality (OPC)
Running
Running, Central
Running, Central,
Interlock Blocked
The control module for a one-direction motor provides the following features:
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Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
Process Panel status indication and operation
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
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The control module for a variable speed drive has basically the same functionality as MOT1,
with the following additions:
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BU Minerals Library
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Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
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3BHS 161554
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The control module for a reversing motor has basically the same functionality as MOT1,
however with the following adaptations:
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The control module for a reversing variable speed motor is a combination of the MOT2 and
MOT1_VVVF modules, with the following features:
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
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BU Minerals Library
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3BHS 161554
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95
Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
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95
The control module for a motorized damper/actuator provides the following features:
Doc. kind
Title
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)
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.
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Doc. kind
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New Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
Process Panel status indication and operation
Alarming during Simulation can be enabled for testing the Interlock, FeedBack,..
Alarming Condition clearly defined by the mean of 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
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The module controls valves with one or two coils and up to two position limit switches. It
provides:
Doc. kind
Title
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)
1 additional interface inputs with MCC; for e.g. Availability
2 position feedback signals with error indication if both are present at the 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.
New Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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en
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36
95
The module controls valves with one or two coils and up to two position limit switches. It
provides:
Doc. kind
Title
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)
1 additional interface inputs with MCC; for e.g. Availability
2 position feedback signals with error indication if both are present at the 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.
New Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
Process Panel status indication and operation
Project
Product Guide
BU Minerals Library
Industrial IT System 800xA
Minerals Library version 5.1/4a
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Lang.
Rev. ind. Pages
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en
O No. of p. 95
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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
Product Guide
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PID module for closed loop control has the following options:
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Product Guide
Industrial IT System 800xA
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BU Minerals Library
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Doc. kind
Title
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).
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Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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41
95
Doc. kind
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Product Guide
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The functions are available on all (or selected) Operator Workplaces or on dedicated
Electrical Workplaces.
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Next to the common basic functions for consumer objects, the following functions are
supported for CircuitBreaker:
Doc. kind
Title
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
User definable Warning 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.
Totalisation and indication of CB Close time (in hours) and number of CB Trip and
Close
Alarming during Simulation can be enabled for testing the Interlock, FeedBack,..
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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en
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95
1.1.18.2 CircuitBreakerABBREF542Plus
Power Distribution Monitoring objects provide a composite Control Module with serial
interface to implement the supervision and operation of power network switchgear
equipment. The example below presents ABB REF542+ with Modbus communication.
The Control Module can easily be adapted to other equipment and communication types.
Central Mode (operator) C indication,
Indication of Switches
Indication of Voltage, Current, Power
The Control Module can easily be adapted to other equipment and communication types.
Next to the common basic functions for group objects, the following functions are
supported:
Doc. kind
Title
Operation modes
Selection of individual Breaker for operation
Open / Close order to operate the breaker
Communication link error
Indication of Breaker status
Indication of Switches
Indication of Voltage, Current, Power
Button to access complete Serial information
Project
Product Guide
BU Minerals Library
Industrial IT System 800xA
Minerals Library version 5.1/4a
Document number
3BHS 161554
Lang.
en
No. of p.
45
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
46
95
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 !
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
47
95
1.1.19.1 Load
The Load Control Module Type enables grouping of MV-Switchgear according Plant
Sections in order to monitor and control their Energy consumption.
Possibility to connect MV-Switchgear into Load for monitoring only and not for
shedding (MV/LV Trafo.Feeder).
All of these Informations are available to the operator through standard interfaces from the BMI Library:
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1.1.19.2
Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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en
No. of p.
49
95
1.1.19.3 Loadshedding
The LoadShedding Control Module Type permit to ensure that the Energy consumption
of the Plant respects certain conditions according priorities.
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.
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
50
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
51
95
1.1.19.4 PowerDemandSupervision
The Powerdemandsupervision Control Module Type enables input of tariff structure and
their given conditions as defined by the Energy supplier
Actual Tarif
conditions
Permanent
conditions
Actual Tarif always shown on the base View
It contains following features :
Doc. kind
Title
Issuing of warnings (90%) and alarms. For example in the case of:
o
TotalCurrent
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
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Missing time-synchronization signal if the Signal is missing for longer then two
times Metering Interval time.
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 !
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
53
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
54
95
PCC
Bus
Group
Motor
Digital Input
Group Drive
Bus
Analog Input
Motor
Digital Input
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.
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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en
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55
95
Group faceplate
Signal faceplate
Doc. kind
Title
Consumer faceplate
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Signal faceplate
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
56
95
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:
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.
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.). Further more the two feed back signals (FB1 and FB2
for example speedswitch) 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 re-set from the operator station only with special user rights.
The Figure below shows the Control Modes and their graphical presentation for the Group and
Consumer Objects. Please note that for better operator guidance the default POC (Central for
Group and Sequence for Drives) is not indicated by a character on the process display.
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
57
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
58
95
Doc. kind
Title
Group off
Gray
Group running
Green filled
Group stopping
Product Guide
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Project
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The group constantly monitors all process objects assigned to it and updates the status in real time. The
faceplate provides additional detailed indication on:
Group Starting
Group in Hold
Tagname of Object in
actual Step
Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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95
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 preformed 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 preselections. 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.
Stopping a group
A group may be stopped in case there is no stop interlock active (e.g. group cant 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.
Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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en
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95
The figure below shows a simplified flow diagram for a Sequential Group Start with route
change over (stopping of all not selected equipment)
NO
All Selected
Equipment Ready
Preselection
Correct
Indication Preselction
Missing or Error
YES
Group Start
Interlock Active
YES
YES
AND
CEN
(on faceplate
only)
NO
Control Mode
SEQ
AND
Start from
Application
Program
AND
Indication Group
Starting
Start Warning
NO
All Selected
Equipment Running
NO
Sequential Start of
Next Preselected
Equipment
Equipment Fault,
Time Out or Hold
Command
YES
YES
YES
NO
NO
Sequential Stop of
Next not
Preselected
Equipment
YES
YES
All Selected
Equipment Run
(Group Run)
NO
Doc. kind
Title
YES
NO
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Status Group
Running
Project
BU Minerals Library
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3BHS 161554
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62
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The figure below shows a simplified flow diagram for a Sequential Group Stop.
YES
Group Stop
Interlock Active
NO
OR
AND
Stop from
Application
Program
NO
NO
Sequential Stop of
Next Equipment
YES
YES
YES
YES
NO
NO
Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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en
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63
95
The figure below shows a simplified flow diagram for an Instant Stop.
Quick Stop
from
Application
Program
OR
Indication Group
Stopping
NO
NO
Stop Command to
all Equipment
YES
YES
YES
NO
YES
NO
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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en
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64
95
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.
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.
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Product Guide
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Minerals Library version 5.1/4a
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3BHS 161554
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The operator is allowed to change the pre-selections when a group has following status:
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Minerals Library version 5.1/4a
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BU Minerals Library
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3BHS 161554
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en
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66
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
67
95
Per system
# of controllers
# of clients (depends on server configuration)
# of remote clients (depends on server configuration)
# of connectivity servers
# of aspect servers
# of Tags (Aspect Object with Faceplate)
# of Aspect Objects
# of concurrently updating data points (OPC items)
The latest platform values should always be checked with the ABB Products group before any
commitment is made.
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
68
95
PP Client
PP Client
PP Client
PP Client
PP Client
PP Client
PP Client
PP Client
PP Client
Aspect Server
Connectivity
Server
200000 Objects
Profibus
S800/S800L
I/O
Doc. kind
Title
Universal
Motor
Controller
Profibus
S800/S800L
I/O
Universal
Motor
Controller
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
S800/S800L
I/O
Universal
Motor
Controller
Lang.
BU Minerals Library
Document number
Profibus
3BHS 161554
en
No. of p.
69
95
Memory Requirements
Execution Time
First Instance
Add. Inst
AC800 PM861
kB
kB
AIS
45.1
6.2
ms
0.24(Indic. only)
0.60(3.0)
AOS
12.2
2.2
DIS
18.4
2.9
DOS
10.3
0.7
MOT1
69.8
11.8
MOT2
71.0
13.1
Notes
MOTP
105.9
18.5
Fast:0.02
ConPu:0.25
Normal:0.75(2)
VLV1
65.6
9.1
0.26(1.5)
MOT1_VVVF
82.3
15.4
0.75(2)
VVVF_Serial
154
36.8
PulseCount
9.2
3.2
ReportingCount
17.2
3.2
PIDCtrl
156
23.0
GrpCycleCtrl
91.2
15.7
Group
42.1
7.7
77
14
REF542+ ModBus
177
39
Load
74.1
LoadShedding
29.7
PowerDemand
133.7
19.3
Only one
instance
needed..
Only one
instance
needed..
MOT2_VVVF
Circuit Breaker
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
2(5)
BU Minerals Library
Document number
0.5
3BHS 161554
Lang.
en
No. of p.
70
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
71
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
72
95
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
73
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
74
95
Project Documentation
<Project>
<Customer>
Configuration Standard
MINERALS (BMI)
C IT Design 00
Product Guide
Minerals Library
OperateIT PP
Reference Manual
Minerals Library Overview
Reference Manual
ControlIT AC800M
Figure 1
Document Organization
Reference Manual
Minerals Library
Process Panel
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
75
95
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.
The license Key (a .SLA file) for the Minerals Library has to be generated in ABB
SoFa and installed in the 800xA system licensing server.
MLP count
Circuit Breaker
Add 20% to the total CLP count to leave a margin for further growth.
1.5.3 ORDERING EXAMPLES
The CD-ROM with the software and documentation should be ordered.
From the Price List for 1.4 Control and Operation; AC800M; Minerals Library 5.1/x:
1 of
Control&Operation;AC800M;MineralsLib5.1/x;SW&DocCD 3BHS205193R03
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
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en
No. of p.
76
95
The above configuration requires the price list items listed below.
From the Price List for 1.4 Control and Operation; AC800M; Minerals Library 5.1/x:
System-wide license for 2000 MLPs (350+550+1100) is calculated as follows:
1 of
20 of
Control;AC800M;MineralsLib5.1/x; BaseLic
3BHS200491R03
Control;AC800M;MineralsLib5.1/x;100CLP;<=5000CLP
3BHS200492R03
Doc. kind
Title
3BHS200491R03
50 of Control;AC800M;MineralsLib5.1/x;100CLP;<=5000CLP
3BHS200492R03
30 of Control;AC800M;MineralsLib5.1/x;100CLP; 5001-20000CLP
3BHS200493R03
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
77
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
78
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
79
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
80
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
81
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
82
95
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)
2.1.7 START WARNING (STW)
Main purpose of Module:
Control for buzzers and flashlights, prior to a remote start of equipment
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.
Doc. kind
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Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
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3BHS 161554
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en
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Alarm
Ready for Start
Off
Bad Quality (OPC)
Running
Running, Central
Running, Central,
Interlock Blocked
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
84
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
85
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
86
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
87
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
88
95
The System 800xA SV5.x Core System is installed, with the AC400 Connect
Option.
The AC400 controllers have the BMI Type Circuit Library installed.
Controllers, with different capacity and different Controller License Points (CLPs).
Operation;AC400Connect;MineralsLib5.1/x;BaseLic
3BHS200501R02
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
Doc. kind
Title
Operation;AC400Connect;MineralsLib5.1/x;SW&Doc CD
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS200505R02
3BHS 161554
Lang.
en
No. of p.
89
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
90
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
91
95
4.2.1 H658 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 H561.
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
92
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
93
95
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
BU Minerals Library
Document number
3BHS 161554
Lang.
en
No. of p.
94
95
REVISION HISTORY
Rev.
ind.
draft
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
Doc. kind
Title
Product Guide
Industrial IT System 800xA
Minerals Library version 5.1/4a
Project
16.01.2006/N.B
08.12.06 / HT
28.06.2007 / MB
11.10.07 / HT
27.08.2008 / NB
24.04.2009 / LK
22.12.2009 / HT
30.09.2010 / CT
16.04.2012 / YM
16.09.2013 / LK
BU Minerals Library
Document number
Date
Dept./Init.
26.07.03 ATBAM/GPC
04.09.03 ATBAM/GPC
08.03.04 ATBAM/GPC
01.06.04 ATBAM/GPC
10.11.04 ATBAM/GPC
27.05.05 ATBAM/HT
3BHS 161554
Lang.
en
No. of p.
95
95