31 Oktober 2012

Installation of DC Systems

Figures 1 through 3 show examples of DC power distribution. Figure 1 shows how a DC power source and distribution panel should be connected to various components of an INFI 90 system. Refer to Notes for Figure 1 for an explanation of Figure 1.Figure 2 shows how to connect and ground a two-line DC source. Figure 3 shows how to connect DC common bus bars on multiple cabinets. Refer to Notes for Figure 3 for an explanation of Figure 3.
Refer to ANSI/NFPA 70, National Electrical Code or CSA Standard C22.1, Canadian Electrical Code for information on conductor size requirements of DC power wiring, equipment grounding conductors and DC grounding conductors. Grounding electrode conductors should be the same size as the largest conductor feeding the applicable source. Minimum conductor sizing should be increased one size for every increment of 30.5 meters (100 feet) greater than 30.5 meters (100 feet). All conductors should be stranded, insulated copper.
DC power requires three insulated conductors that are within the same cord, cable, conduit or raceway. These conductors will be a positive conductor, negative conductor and an equipment grounding conductor. The positive conductor can be any color except those used by the negative and grounding conductor. All power wiring must be checked prior to applying power to any of the Bailey system components. In addition, verify that the wiring for all AC receptacles used to supply power to peripheral INFI 90 equipment is correct.
All PCU cabinets, OIS consoles and OIS driver cabinets have terminal blocks for connecting power. Each powered PCU cabinet has a power entry panel at the top of the cabinet. Power conductors connect to the power entry panel through compression type terminal blocks. The console monitors, printers and engineering work stations have plugs for ordinary grounded AC receptacles. The AC receptacles must share the same ground that the cabinets use. Each unit comes with a 1.8 meters (six feet) line cord that has a standard three­prong plug. Refer to the product instruction that accompanies each unit for more information on connecting power to that particular unit.
Notes for Figure 1
  1. For personnel safety, follow the grounding guidelines contained in this instruction. They comply with Section 10 of the Canadian Electrical Code Part 1 (C22.1) and Article 250 of the National Electrical Code.
  2. The system power source must be dedicated for the INFI 90 system and associated equipment. The AC system power source must not supply power for air conditioning, convenience outlets, lighting, or other plant equipment.
  3. Safety ground conductor size must be equal to or greater than the size of the power conductors connected to the secondary wiring. Increase one (1) wire size for every 30.5 meters (100 feet) of safety conductor length if the length is greater that 30.5 meters (100 feet).
  4. All devices that make up part of the INFI 90 system (i.e., OIS consoles, printers, work stations, etc.), and are in a common area, should be powered from and grounded through the same power distribution panel. Power remote equipment through a dedicated power source. Do not power or ground other systems through the INFI 90 power and grounding system.
  5. Size the breakers according to the load requirements and conductor size.
  6. Connect structural steel within 1.8 meters (6 feet) of the system to the building ground system to insure that the potential difference between the system chassis and nearby structural steel is less than 30 Vrms.
  7. If conductors that carry signals to and from the INFI 90 system pass through conduit, bond and ground the conduit to the local system ground using an equipment grounding conductor.
  8. Do not use conduit as an equipment grounding conductor; use a separate wire that is insulated and properly sized.
  9. Install ground fault detector at the distribution panel if source is floating (ungrounded).<12> Connect the system power source to the local building grounding electrode system. The grounding electrode system must have an impedance of five ohms or less to the earth. Bond the grounding electrode system to the existing building service ground system through a grounding electrode conductor.
  10. Connect the cabinet DC common bus bar to the system dedicated DC common. The dedicated DC common must be bonded to a grounding electrode that is part of the existing local building grounding electrode system. Connect one end of the DC electrode conductor to the isolated DC common bus bar. Exothermically weld the other end of the DC electrode conductor to the electrode. The building grounding electrode and the DC grounding electrode must reference a common ground location. The DC common electrode conductor should be a 4/0 insulated conductor minimum.
  11. Connect the DC common bus bar of additional cabinet assemblies within the same location to the main system cabinet isolated DC common bus bar (in a star pattern).
  12. Ground I/O wiring shields at one end only. Terminate all I/O wiring shields at the side bus bars within the system cabinet, except those shields containing grounded thermocouples or grounded RTD elements. Ground the shields of thermocouples or grounded RTD elements at the sensor.
  13. The INFI­NET/Plant Loop cable that Bailey provides with the system connects all conductors to the system on each end. The system design allows the cable shield to connect to the termination unit at both ends without creating a ground loop. Do not allow the metal connectors on the coax cable to make contact with the cabinet frame.
  14. It is permissible to use a different AC power source for a remote OIS console, printer and associated equipment. The source must satisfy the AC power distribution and system grounding requirements specified by Bailey, and both the OIS console and printer must be grounded to the same power source. All devices that communicate to the remote OIS console through an RS­232­C interface must use an isolating short haul modem (or other isolation device) unless those devices are powered and grounded through the same power source that serves the remote OIS console.
  15. Equipment communicating with the Bailey system via an RS­232­C link must use an isolating device (i.e., an isolating short haul modem) if they are not powered and grounded through the same power source.
    Notes for Figure 3
    1. Every cabinet must be tied to the system safety ground through an equipment grounding conductor. The equipment grounding conductor for nonpowered cabinets must connect to a powered cabinet that has a connection to the safety ground at the power source.
    2. This ground connection is internal to the power entry panel. Bolts are provided to make this connection.
    3. Notice that the DC common bus bars of all nonpowered cabinets connect in a star pattern to the DC bus bar of the cabinet supplying their I/O power. Likewise, all the DC common bus bars in powered cabinets connect in a star pattern to the DC bus bar of the powered cabinet that is closest to the DC grounding electrode (cabinet 4). The DC bus bar of the cabinet that is closest to the DC grounding electrode connects to the DC electrode through a DC grounding electrode conductor.


Angka 1 sampai 3 contoh menunjukkan distribusi listrik DC. Gambar 1 menunjukkan bagaimana kekuatan DC sumber dan panel distribusi harus dihubungkan ke berbagai komponen sistem 90 infi. Mengacu pada Catatan untuk Gambar 1 untuk penjelasanGambar 1 . Gambar 2 menunjukkan bagaimana untuk menghubungkan dan tanah sumber dua baris DC. Gambar 3 menunjukkan bagaimana menghubungkan bar DC bus umum di lemari beberapa. Mengacu pada Catatan untuk Gambar 3 untuk penjelasanGambar 3.
Mengacu pada ANSI / NFPA 70, Kode Listrik Nasional atau CSA Standar C22.1, Kode Listrik Kanada untuk informasi tentang persyaratan ukuran konduktor kabel listrik DC, konduktor peralatan grounding dan konduktor grounding DC. Grounding konduktor elektroda harus ukuran yang sama dengan konduktor terbesar makan sumber berlaku. Sizing konduktor Minimum harus ditingkatkan satu ukuran untuk setiap kenaikan 30,5 meter (100 kaki) lebih besar dari 30,5 meter (100 kaki). Semua konduktor harus terdampar, tembaga terisolasi.
DC listrik membutuhkan tiga konduktor terisolasi yang berada dalam, kabel saluran kabel yang sama, atau raceway. Konduktor ini akan menjadi konduktor positif, negatif dan konduktor konduktor grounding peralatan. Konduktor positif dapat berupa warna kecuali yang digunakan oleh konduktor negatif dan landasan. Semua kabel listrik harus diperiksa sebelum menerapkan kekuatan untuk salah satu komponen sistem Bailey. Selain itu, pastikan bahwa kabel untuk semua wadah AC digunakan untuk memasok daya ke perangkat 90 peralatan infi benar.
Semua lemari SMP, konsol OIS dan lemari sopir OIS memiliki blok terminal untuk menghubungkan daya. Setiap kabinet PCU bertenaga memiliki panel listrik masuk di bagian atas lemari. Konduktor listrik terhubung ke panel listrik masuk melalui terminal blok kompresi jenis. Monitor konsol, printer dan stasiun rekayasa kerja memiliki colokan untuk biasa wadah AC membumi. Wadah AC harus berbagi tanah yang sama yang digunakan lemari. Setiap unit dilengkapi dengan 1,8 meter (enam kaki) kabel saluran yang memiliki konektor threeprong standar. Mengacu pada instruksi yang menyertai produk masing-masing unit untuk informasi lebih lanjut tentang cara menghubungkan kekuatan pada unit tertentu.
Catatan untuk Gambar 1
  1. Untuk keselamatan personel, ikuti panduan landasan yang terkandung dalam instruksi ini. Mereka mematuhi Pasal 10 dari Bagian Kode Canadian Listrik 1 (C22.1) dan Pasal 250 dari Kode Listrik Nasional.
  2. Sumber daya sistem harus didedikasikan untuk sistem 90 infi dan peralatan terkait. Sistem AC sumber daya tidak harus memasok listrik untuk pendingin udara, gerai kenyamanan, pencahayaan, atau peralatan pabrik lainnya.
  3. Keselamatan tanah ukuran konduktor harus sama dengan atau lebih besar dari ukuran konduktor listrik yang terhubung ke kabel sekunder. Kenaikan satu (1) ukuran kawat untuk setiap 30,5 meter (100 kaki) panjang konduktor pengaman jika panjang lebih besar bahwa 30,5 meter (100 kaki).
  4. Semua perangkat yang membentuk bagian dari sistem 90 infi (yaitu, OIS konsol, printer, stasiun kerja, dll), dan di area umum, harus didukung dari dan membumi melalui panel distribusi daya yang sama. Daya peralatan remote melalui sumber daya yang berdedikasi. Jangan daya atau sistem tanah lainnya melalui kekuatan 90 infi dan sistem grounding.
  5. Size pelanggar sesuai dengan persyaratan beban dan ukuran konduktor.
  6. Hubungkan baja struktural dalam 1,8 meter (6 kaki) dari sistem ke sistem tanah bangunan untuk memastikan bahwa perbedaan potensial antara sasis sistem dan baja struktural terdekat kurang dari 30 Vrms.
  7. Jika konduktor yang membawa sinyal ke dan dari lulus 90 sistem infi melalui saluran saluran, obligasi dan tanah ke tanah sistem lokal menggunakan konduktor grounding peralatan.
  8. Jangan gunakan saluran sebagai konduktor grounding peralatan; menggunakan kawat terpisah yang terisolasi dan benar ukuran.
  9. Instal detektor gangguan tanah pada panel distribusi jika sumber mengambang (dibumikan).<12> Hubungkan sumber daya sistem ke sistem grounding bangunan elektroda lokal. Sistem elektroda grounding harus memiliki impedansi dari lima ohm atau kurang ke bumi. Obligasi sistem elektroda pembumian ke sistem pelayanan bangunan tanah yang ada melalui konduktor elektroda grounding.
  10. Hubungkan kabinet DC bar bus umum untuk sistem didedikasikan DC umum. The DC berdedikasi umum harus terikat pada elektroda grounding yang merupakan bagian dari sistem grounding bangunan elektroda lokal yang ada. Sambungkan salah satu ujung konduktor elektroda DC ke bar bus umum terisolasi DC. Exothermically mengelas ujung konduktor elektroda DC ke elektroda. Landasan bangunan elektroda dan elektroda grounding DC harus referensi lokasi kesamaan. Konduktor DC elektroda umum harus minimal konduktor 4/0 terisolasi.
  11. Hubungkan bar DC bus umum majelis kabinet tambahan dalam lokasi yang sama dengan sistem bar kabinet utama terisolasi DC bus umum (dalam pola bintang).
  12. Tanah I / O kabel perisai di salah satu ujung saja. Hentikan semua perisai I / O kabel di bar side bus dalam kabinet sistem, kecuali yang mengandung perisai termokopel didasarkan atau didasarkan elemen RTD. Tanah perisai termokopel atau didasarkan RTD elemen di sensor.
  13. The INFINET / Tanaman kabel Loop yang menyediakan Bailey dengan sistem menghubungkan semua konduktor ke sistem pada setiap ujungnya. Desain sistem memungkinkan perisai kabel untuk menghubungkan ke unit terminasi pada kedua ujungnya tanpa membuat loop tanah. Jangan biarkan konektor logam pada kabel coax untuk melakukan kontak dengan bingkai kabinet.
  14. Hal ini dibolehkan untuk menggunakan sumber listrik AC yang berbeda untuk konsol OIS terpencil, printer dan peralatan yang terkait. Sumber harus memenuhi distribusi listrik AC dan persyaratan grounding sistem ditentukan oleh Bailey, dan kedua konsol OIS dan printer harus didasarkan pada sumber daya yang sama. Semua perangkat yang berkomunikasi dengan konsol OIS jarak jauh melalui antarmuka RS232C harus menggunakan modem jarak mengisolasi singkat (atau perangkat isolasi lainnya) kecuali alat-alat yang didukung dan membumi melalui sumber daya yang sama yang melayani konsol OIS terpencil.
  15. Peralatan berkomunikasi dengan sistem Bailey melalui link RS232C harus menggunakan perangkat mengisolasi (yaitu, modem jarak pendek mengisolasi) jika mereka tidak didukung dan membumi melalui sumber daya yang sama.
    Catatan untuk Gambar 3
    1. Setiap kabinet harus diikat ke tanah sistem keamanan melalui konduktor grounding peralatan. Landasan peralatan konduktor untuk lemari tanpa catu daya harus terhubung ke kabinet bertenaga yang memiliki koneksi ke tanah keselamatan pada sumber listrik.
    2. Ini koneksi tanah bersifat internal ke panel listrik entri. Baut disediakan untuk membuat hubungan ini.
    3. Perhatikan bahwa bar DC bus umum dari semua lemari tanpa catu daya terhubung dalam pola bintang ke bar bus DC dari kabinet memasok I / O kekuasaan mereka. Demikian juga, semua bar DC bus umum di lemari bertenaga terhubung dalam pola bintang ke bar bus DC dari kabinet bertenaga yang paling dekat dengan elektroda grounding DC (kabinet 4). Bus DC bar kabinet yang paling dekat dengan elektroda grounding DC terhubung ke elektroda DC melalui konduktor elektroda grounding DC.

Migration Justification

Hi! Anybody help us on the list of Bailey Infi90 system limitations? we need to come up with a list of Bailey Infi90 system limitations from technical points (not commercial) for migration justification.
Limitations such as; Communication speed, CPU Memory, PID control, ACP etc... 
Thanks in advance..

Could you describe your current system? that might help a little.

The existing Bailey ifi90 has the complete redundent configuration; (NW, PCU, PS)
the modules on the rack shows;
with IEPAS02 etc....
The Console type is OIS42, 
Hope this information will help..

Wow, you have a very old INFI90 system. There have been new enhancements in the communication system and in the speed/capacity of the controllers. Also I can see you still use the old OIS42's which are based in obsolete DEC computers. You can justify an upgrade based in just obsolescence and availability of the hardware which I think is no longer being supplied by ABB(who now owns the Bailey techonology) or DEC (which was bought by Compaq which also was acquired by HP). Critical issues, the way I see it, are the console system and the old power supply system. Next critical issues are controllers and the communication system (NIS/NPM based). So you may think in an upgrade plan replacing first the consoles and the power supply system (which may be replaced by ABB's new MPSIII), and then go for the replacement of the controllers and comm system.

You may choose to go with ABB and migrate your system to a new 800xa system which may use most of the existing application. Also you may consider to go to a different system from a different supplier and reengineer the whole application which might be costly.

I have exactly the same control system in my plant. Last year we upgraded to MPS3 power supply as the old power supply unit is very costly in terms of spares and unreliable during thunderstorm season. As for the OIS, nothing much were able to be done except for the replacement of the old crt to lcd screens. As a backup, PGP from ABB were installed in case all 4 ois fail at the same time. Now i have 1 OIS down which I need to replace the CPU (thx god I still have 1 new left ;) )during the outage next month.

I know this is a thread revival but I was told by an ABB rep that they will be providing support until 2025. So you need to talk to your local rep to get an upgrade path if you want to stick with your infi-90.

ABB formally announced a few years ago that the Harmony/Infi90 system will remain in the "active" phase through at least 2015, transitioning to the "classic" phase through at least 2025, and finally transitioning to the "obsolete" phase. I have also read that ABB attempts to have a minimum classic and obsolete phase duration of at least 7 years. That puts us to 2032 if my math is right.

My understanding of the phases, based on reading and discussions with ABB personnel (not just sales and marketing...) is this:

Active - Fully available including large new complete engineered systems. Ongoing training classes available. R&D monies allocated for new stuff.

Classic - Fully available to maintain and expand existing systems. R&D not spent to add more capabilities, but limited to allow for new parts to be available. This would include development of engineering software applications to run on current computer operating systems.

Obsolete - New modules available as supplier sub component parts are available. Repair/refurbishment when not. No R&D.

Keep in mind that while a system is "active" or "classic", components, such as an MFP12, can be made "obsolete" due to supplier parts availability. However, there is generally a pretty clean direct replacement (BRC300 or 400 in the MFP case.) I know that some items, like Block IO, are not a simple plug and play replacement. The OIS path is also complex. But my experience-based observation is that they have done as good or better than other suppliers in this regard. Again, these are my experienced based observations as a customer.

So, enough advertisement and back to the thread.

Is your MFP12/OIS42 system "old school" as my son would say, or are you running at a huge risk? I would say no based on the discussion above.

Are you in the position to evaluate your options and create/update a 5 and 10 year plan? Obviously so due to your questions.

However, the original line of questioning ("tell me what the CPU memory specifications are on my Infi90 system so I can justify a new one") is quite ridiculous. That may sound harsh, but I'm trying to save your career. Let's face it - every day there is something better. To go before management of a company and tell them that we need a new one because the old one is old is asking for trouble, in most organizations anyway.

Consider this question. The Infi90 has X memory, Y speed, etc. It worked when it was installed, and it works today. Are you saying that it won't work tomorrow because of X and Y? That makes no logical sense. 

What is your real fear? What are your real issues? Write them down, think about them. Ask others on this forum. Then ask the OEM what they can do for you. But consider a 5 and 10 year plan. Then talk to other suppliers and see what they can do for you. At that point you will be informed, and in turn make an informed recommendation to your company.

Not that you are doing this...but it amazes me when someone rips and replaces an Infi90 system when a simple power supply/controller/HMI upgrade (at say 20% of the rip and replace cost) can get them another 15 years of operation. Another variation of a bad decision is to put in a brand X HMI on a Harmony/Infi90 without having the rest of the plan in place. Note that I did not say that putting in a 3rd party HMI is bad. If you put in a brand X HMI, and save $100,000 when compared to ABB (just to pull a number out of the air) that is ok. But if 5 years later you give brand X a no-bid contract to replace all of the controls you have just lost your savings times 10 or more. That is really bad. Think things all of the way through.

What if ABB could, over time to levelize your cash flow if needed, convert one or two controllers at a time from Harmony to 800xA, retaining your Harmony IO. That means that you don't rework any IO, any field cables, any associated drawings, not to mention lost production. What if they could take the Harmony logic drawings and convert that proven control strategy to the new controller such that you don't even need to tune. What is the cost difference to a rip and replace?

If you go that route, it would behoove you to get the ABB costs up front before you commit. The natural behavior of any supplier will be to take some advantage of any possible situation.

apologies for hijacking this thread. I need some help from Bailey INFI 90 experts. I need to know if I can achieve modbus communication from another system to the Bailey INFI 90 system. What will be required on the INFI 90 side?

You have options:

1. Set up an MFC/MFP/BRC (controller) as a Foreign Device Interface (FDI) running with a Modbus master application. The controller will require a termination unit with serial ports. Both RS232 and RS485 are available in this configuration, although if you want redundant ports RS232 is the only option. Redundancy at the controller level is optional as well. The Modbus mapping ends up running in an "NBS" file, executing in the same controller with a traditional "CFG" files. Within the CFG file are function blocks that expose the Modbus reads to individual block numbers. You can write from any block number.

2. If you don't mind the "Microsoft factor" or increased security issues (real or perceived) you can use one of many OPC applications (third party and ABB) that can read/write to the system via an ICT. You will also need one of the many available OPC Modbus drivers and connect the two. Of course this type of interface is open to many additional protocols, not just Modbus.

3. As a variation to item 2, if you have a Process Portal A based HMI on top of the Infi90, this is based on OPC so some of the software mentioned in item 2 is already in place. If the purpose of the interface includes presenting unaltered data on the HMI, you can go direct and bypass the property transfer into the Infi90 controller world. You can, if needed, send a subset of tags to Infi90 and the remainder/all to the HMI.

There are pros and cons to each approach. I highly recommend having a technical discussion with ABB. There are some pretty new (1 yr) products that they have introduced in this space that I have not used yet (I've got all three mentioned above.) Look at all your options before deciding.

Item 2 can be easily tried using evaluation products. As pointed out you will need a modbus OPC server (Kepware has a few of these), Infi 90 OPC server and bridging software to link the two servers together (RoviSys Infi 90 OPC server and BridgeMaster products can be evaluated at no cost).

This is easily accomplished by using a Modbus OPC server and Infi 90 OPC server with bridging software to link the two OPC servers together. The RoviSys OPC90 Server and BridgeMaster software products can be used for the INFI 90 side.

Refer to John's post (25 Jan 2011) and of all three options he outlines, I've found the first one to be the simplest and most reliable. Depending on what Infi90 'tools' you have on hand, you can use a simple DOS program known as GPI02 or the more up-to-date version of it that partners with the 'Composer' Toolset, which is what appears to be the FDI John is talking about. (If you are using the old 'Wintools' or even older SCAD you must use the GPI02, which partners with the .cfg file produced by those.

In both cases a .NBS file is downloaded together with the normal .cfg file to the module running the interface.

I have also worked with OPC interfaces on Conductor NT and although it works OK, you will also need a third party OPC server to connect to the ABB OPC database.

I cannot comment on the OPC with PPB as I haven't worked with OPC on that type of console, however of the two I have used, the GPI02 or FDI which runs a .NBS (a C language simple script that connects your foreign device to special Bailey function codes via an RS232 link) is BY FAR the more reliable of the two options.

Note that the .NBS file can only be saved in your Composer or Wintools project and downloaded (say in the event the module failed and you don't have redundant pair); it cannot be opened and edited. You can only edit the actual script with the GPI02 program or the FDI, then when you download it together with the module configuration (the function codes); the updated .NBS file is then replaced in the module.

ABB would no doubt have a few more options available now, so as John has suggested: you would be well advised to discuss it with them first.

I cannot comment on the OPC with PPB as I haven't worked with OPC on that type of console

I worked at a site that had multiple ABB OPC servers set up to allow communication between DeltaV controllers and ABB PPB and it worked fine. I also set up a couple of OPC servers to allow communication to Matrikon's Alarm Manager and Control Performance Monitor. It is very easy to install but setting up DCOM will do your head in. It's a nightmare to set up if you don't have all servers on the same domain, but you can make it work (I suggest using OPC Tunneler from Matrikon)

I need a little bit guidance regarding saving .NBS file from IMMFP01 using composer. 
Can you please tell me how can I save .NBS file from IMMFP01 on composer? What options of Composer should I use to do so?
Hope you would help me.
Looking forward for your swift response.

Just to reassure Harsha and to add weight to John's comments regarding the various phases from 'active' to obsolete etc., you can simply browse this entire site and look for posts about Bailey Infi90 / ABB Harmony and after a while, one thing will become apparent: You will notice that there is relatively very little posted about these systems! This should tell you something...

Not that I am biased of course :)... 

I've been working with these systems for about 27 years now, since the very early Network 90 and its classic NOIU01 / 02 console, right up to the present, with the 800 xa series and am currently engaged at a power station that uses 'classic' Infi90 (that's INNIS01 INNIS11 / INNPM01/11 and IMMFP02/12 controllers and Symphony power system). We have an ABB (Italy) Power Generation Portal (PGP v 3.2) HMI, which was chosen over PPB or CNT or other HMI products simply because it was the only console available that could use the SODG displays that were used on the former OIS43 consoles. (We still have one of those in service, but is only used as the time synch master and for a backup if the entire PGP has to be taken off line).

I have worked with other DCS products and a number of 'generic' HMI's and still maintain that nothing even comes close to the Bailey / ABB systems in terms of their ability to be easily upgraded - backward compatibility and support of what would otherwise be very 'old' system components. The actual DCS hardware is VERY reliable and I've worked with systems that have been 'online' continuously for more than 20 years without a single glitch over that period!

From what you've said about your system (and to back up John's comments), you really only need to concern yourself at this stage with the HMI's and maybe the cabinet power systems, the rest of it should keep your plant running for many more years yet!

Since you are upgrading OIS4xx consoles, you should consider the PGP as a replacement as the SODG displays from your OIS42 will go straight into this console with minor tidying up required. Any other HMI will require the graphics to be built 'from scratch' again and if your system is a large one (such as ours with over 2000 displays), that could mean months even YEARS of extra work!

Seems you are closely involved in the Harmony system. Maybe you can tell me: how does the recent launch and promotion of "Symphony Plus" fit into this ABB strategy? What is new about this? Is it still Bailey?

Symphony Plus (S+) is simply the next moniker in the Bailey Net90-Infi90-Symphony/Harmony naming scheme. As with all name changes there are some commensurate new products released, and this time around is no different in that regard. However, anyone that has this DCS "line" should realize that this new investment brings our trusted friend back for many years to come. The previously promised 2015 transfer from active to classic with support to 2025 is now indefinite. I suppose that promise was broken in a good way. Thus one can argue that this is the most important name change yet (realizing of course that the name is just skin deep, the real importance is the investment and continued commitment.)

As to the pieces and parts, starting at the HMI level, S+ adds "S+ Operations" (PGP - Power Generation Portal) as an alternative to the 800xA based PPA system. Both are available. As with any decision, there are pros and cons to both. 

Moving to communications, the current NIS/NPM remain, but new models released over the last 2 years or so have significant capability improvements. But as is often the case ABB does a best in class job of letting you replace such things in pairs as long as firmware throughout the loop is at an appropriate level. For those that are running out of parts of old parts, if they become unobtainable, this is a good way to kick some free one pair at a time if you can't fund a wholesale upgrade.

There is a new processor with S+, the BRC410 I believe, with a built in Ethernet port. The initial function is for Modbus, but it does provide an open door for more, N'est-ce pas? I wonder what else they can do with that port... Moving from MFC/MFP or older BRC's to the current can be done in pairs like discussed above.

For interfaces to computers, the IET800 is the long awaited Ethernet CIU.

At the IO level, rack IO (all models I think are now upgraded to surface mount) are still available and viable, as well as S800 IO.

At the power supply level, the MPSIII is current.

Composer 5.1 is the new release with S+, and I believe is Windows 7 32 bit compatible. 

As you can see I'm pretty darn happy with our stuff, some installed in 1983 and the latest installed in 2008, and some to be installed soon.

It's pretty cool to have a cabinet with many 1983 based rack IO modules, a 1997 MPSII power supply, some 1999 MFP02's, some BRCs, remote S800 IO, on Composer 5.0 and a PPA HMI, all circa 2007.

Here are some links to some official info:
http://www.abb.com/cawp/seitp202/a223fcb054afb121c125788e0047e181.a spx

"S+ Operations" seems to me the greatest novelty though? What are the pros and cons you mention? What about 800xA in power? I thought they wanted to migrate all?

> "S+ Operations" seems to me the
> greatest novelty though? What are the
> pros and cons you mention?

Since S+ Operations (aka PGP) is new to me, I have not done any detailed comparison. My understanding is that ABB needed a lower cost HMI solution (compared to the 800xA PPA HMI) for Harmony applications, and this could help in that regard, even with the PPA system projects reaching a pretty good level of optimization and loaded on hardware now being deployed in a significantly smaller footprint by means of using virtual servers. If I were to do such a comparison, I would visit sites to compare features of both systems along with end user satisfaction. Another concern for me is that a lower cost solution often means less of the good stuff that I am used to (but that does not have to be the case).

From a technical standpoint, my understanding is that the S+ Operations is close to the OIS architecture, with each computer (Windows based) capable of acting as a server with its own ICT's. One of the pros is reliability when you have multiple independent servers. One of the cons is keeping the databases and files synchronized between them. The PPA Harmony Connect uses pretty much the same interface computer software (SQL server based database) as Process Portal B and Conductor NT from what I hear. One of the pros here is one database and one set of files to manage. One of the cons is that many feel that the system is "too complex". 

>What about 800xA in power? I thought they wanted to migrate all?

What we want and what we get are often not in alignment, and ABB has lost a lot of HMI business to "third parties". Having attended the recent Automation and Power World conference in April, I can say that there is no shortage of 800xA PPA HMI's on top of Harmony systems in Power and other industries. However, there may be as many or more that have gone another direction. More than likely, for the systems that have not yet done an HMI upgrade, S+ Operations will provide ABB another tool to retain a higher percentage of their installed base than with PPA alone. Those two HMI options coupled with the fact that the controls hardware (processors, communications, IO's) are NOT obsolete (in spite of some of the innuendo from others) means that customers can avoid the "rip and replace" method of upgrades.

For those that start small with a third party HMI upgrade, thinking that they are saving money, tend to not think 5 to 10 years down the road when they (or their successor) hands a blank check to someone to finish the job and replace the PCU cabinets that they are convinced are obsolete. Such a waste. I suppose that company executives and boards of directors are not the only ones subject to a "quarter mentality".

In case it could be interesting someone... we have developed applications allowing ABB legacy consoles migration to the new 800xA (VB and PG2 new graphic builder). The migration is 100% guaranteed error free and can be done ON-LINE. We support all legacy consoles versions for MCS, OIS, PCV, CONDUCTOR and PPB. Every dynamic symbols and graphic are perfectly replicated. The migration include taglist, alarm management and historical trend replication. Additional options such as operator keyboard, advanced Harmony popup, Navigation Display Panels, and improved 3D replication is also available.We have many successful major systems completed in North/South America, Europe and Asia...


30 Oktober 2012

INFI90 MFP02 Fault

We are using INFI90 DCS in a power plant and we got 4 MFP02 processor modules. These modules goes to fault mode after working for a while.
This fault occurs like written below:

Power LED must be normally green but when fault occurs Power LED goes to blinking mode.

MFP02 LED 7 and 8 also turns red. Except these 2 of them there is no Fault LED indication in front panel.

All MFP02 modules have same fault at same time.

We tried to run modules after clearing the memory and downloading the program of modules and we got same fault.

We tried to run modules after loading only configuration and resetting the module and we got same fault.

We checked all electrical connections and we have no abnormality in connections.

We tried to run modules from configuration mode when the module memories are empty and we got same fault.

These faults are not periodically, sometimes it takes 10 mins to go faulty mode or sometimes it takes 1 hour.

I need help about this issue urgently.

Best Regards,

The status LED is a two-color (red and green) LED. It shows the MFP module operating condition. There are four possible operating conditions:

Off: No power is being supplied to the MFP module. The status LED is momentarily off when the microprocessor initializes on start-up.
Solid Green: The MFP module is in execute mode.

Flashing Green: The MFP module is in execute mode but there is an NVRAM checksum error, or the MFP module is in configure or error mode.
Solid Red: The MFP module diagnostics have detected a hardware failure, configuration problem, etc. and have stopped the module.
Additionally, LEDs 1 through 8 will illuminate in a certain combination to display the error code.

LED's 7 & 8 both Red indicate a Primary module, so based on your stated conditions I can only assume that the module is in Configure mode. Why is another story !

Sounds like you might be experiencing a Power Fail Interrupt (PFI). Do you have any communication modules (LIM/BIM, NIS/NPM) or ICT modules? During a PFI those would most likely red light also.

Check all bus voltages (5/15/-15/24) and reply back with values. Since the problem is intermittent, you should probably install a recorder to find out what bus(ses) you are having a problem with.

What type of power supply system and what power supply modules do you have?

How old are the power supplies?

we are now having the same problem MFP02. We think is about 5 V p-p voltage drop. It must be just like john's say PFI.

Our plant 15 years old

Measure the 5V bus value in the PCU cabinet. Use DC Common as the reference. The safest place to do so on an MPSII based system is on the front of the IPMON module - less chance of inducing a short.

The next discussion is based on the MPSII power system, there might be some differences with other systems but you should be able to figure that out.

If less than 5V, at the next opportunity to shut the cabinet down, (1) remove the large cables that connect the power supply with the vertical power bus bar, (2) cut the heat shrink cable off, filling crimped connector with solder, and reapplying heat shrink insulation, (3) reinstalling making sure that you have the proper tooth washers and appropriate torque. As an option to (1) and (2) you can procure new cables from ABB, they are available.

There was at one point in time a bad batch of cables with out of specification crimping, resulting in an abnormally high voltage drop. Loose connections due to vibration over time can also result in a voltage drop that can result in a PFI. 

We've got a couple of hundred PCU cabinets and check the various voltages every couple of years, taking corrective action as needed. I can say that in the 10-15 year time frame these things need some attention, even if it is tightening connections. The only problems that we have found have been with the 5V bus, but we still check +15, -15, and 24 also.

Another thing to consider is refreshing the capacitors in the power supply modules. New power supply modules for the MPSII systems are still available from ABB. You can also have your supplies refurbished.

We have had some PFI's occur due to faulty IPSYS01 power supplies, even though they are in a 2N configuration. Running power supplies to end of life can be a matter of saving money now, but causing loss of production later. I believe that the ABB MPSII manual states that an expected life of an IPSYS01 power supply module is 7 or 8 years.

We had found temporary solution for voltage drop at 5V. I had supplied 5V 55A externally. After this operation nvrams aren't been erased and blinking green (while system working) matter isn't happen.

But differently from these problems now I am having another problem; while system working normally then suddenly some of the relays opens and closes haphazardly this continue until restart. Some time this occurs after restart, some times 7 hours later, some times 3 month later. What could cause to this? Do you have any idea?


ABB Industrial IT

IndustrialIT System 800xA
Harmony/INFI90 System
Extending Return-on-Investment
Harmony Systems: system hardware software releases increase operating efficiency extend life installed systems. products programs make decision evolve existing systems straightforward easy.
Achieving Extended Automation
scope with System 800xA: Personalized User Workplaces: Reduced time decision action achieved with 800xA Process Portal personalized workplaces. Information workplace layouts optimized maintenance, engineering, management, operating personnel preferences needs. Wide-ranging control functionality: Applicable control safety applications, 800M Control meet plant automation needs. 800M integration with Harmony systems made easy through INFI90 Function Code (FC) Library peerto-peer communications with Harmony controllers. Device Management: Device Management features lower lifecycle costs through significant savings design, implementation, operation field equipment. Asset Optimization: Significantly increase process uptime reduce maintenance costs through optimized remediation work processes early detection asset performance problems. Information Management: Improve visibility integrated information results effective decision-making.
Lowering System Lifecycle Costs
successful today's highly competitive business markets, companies drive their production facilities toward Operational Excellence (OpX) with defined goals maximizing Return Assets (RONA), lowering Total Cost Ownership (TCO), sharing best practices throughout enterprise, driving profitable, sustainable growth. Achieving these goals require more than what traditional Distributed Control System (DCS) offer. requires plant automation system that improve:
Plant effectiveness ability combine right decisions with optimized work processes Plant agility ability make `on-the-fly' adjustments business opportunities present themselves with same proficiency when performing routine Performance visualization ability provide users with realtime performance feedback
general, only achieved extending reach plant automation systems synchronize process operations within common environment operations, engineering, information. delivers this extended automation scope combining SYMPHONY Harmony system with Industrial Extended AutomationSystem 800xA's best-in-class productivity enhancement software. System 800xA Asset Optimization, Information Management, Process Portal personalized workplaces optimize productivity substantial cost savings. Where others promote "rip-and-replace" migration strategies, delivers true system evolution allowing Harmony owners build their strong foundation providing flexibility implement these functions incremental stepwise fashion.
Risk through System Evolution: Evolution programs ensure that automation systems continually optimized support customer business goals.
Harmony System
SYMPHONY Harmony proven process control system used demanding applications various industries. wide range Harmony references includes power generation, chemical, pharmaceutical, pulp paper, water wastewater, petrochemical, metals mining, food beverage, cement, sugar industries. These system owners first acquired their distributed control system because offered best solutions that helped them successful competitive. Whether ease engineering, system scalability, powerful control applications ergonomically designed user interfaces, system company's needs effective efficient manner. markets business conditions constantly changing, requiring faster turnarounds, greater customization, smaller sizes, lower overall costs. today's faced paced economy, companies under more pressure than ever their operation profitably achieve greater results with fewer resources. With reduced capital spending, system owners need perform smarter better substantial cost savings. business challenge they face squeeze most productivity from installed system adding functions features, extending useful life applications within reducing maintenance costs while improving overall reliability. addresses these challenges providing capabilities that enable Symphony Harmony system owners achieve Operational Excellence. Symphony Harmony system products enhanced improve their cost/performance curves make them more reliable while incorporating proven, technology enable step change benefits. While greenfield automation system installation readily take advantage latest capabilities, existing system installation faces many modernization challenges. These include:
24/7 production, short non-existent downtime Upgrades must performed without jeopardizing operation Maintenance budgets rather than large capital project funding Site made significant investments
plant mill
Control applications User interfaces Training plant personnel Standard Operating Procedures (SOP) based automation system Validation (for regulated industries) Hardware Software Other intellectual property Therefore, changes existing system must limited specific area interest, risk averse, protect owner's investments hardware, software, intellectual property. short, there must solid, measurable Return-onInvestment (ROI).
IndustrialIT System 800xA ABB's answer these issues founded evolution strategy. Evolution ABB's deliver continuous improvement installed systems; allowing system owners meet automation system business objectives incremental affording lowest risk best ROI. migration, "rip-and-replace"; well thought plan, allowing system owners adapt capabilities their pace, according their need. From product point view, this strategy business usual ABB. pledge Evolution through Enhancement (Figure extended life Return-on-Investment installed Harmony systems. Other vendors talk about investment protection, ABB's proven programs truly unique industry. told, from introduction Network 1980, through each evolutionary steps INFI 90®, INFI OPEN, SYMPHONYHarmony, this family systems represents largest contiguous installed base process automation system world. System 800xA represents most recent step on-going system evolution process. purpose this document summarize many opportunities available Harmony system owner enhancing value extending useful functionality their system. following pages details enhancements available Harmony foundation (see section "Extending Return-onInvestment Harmony Systems"); well opportunities available build extended automation scope from Harmony foundation (see section "Achieving Extended Automation Scope with System 800xA").
Harmony System
Extending Return-on-Investment Harmony Systems
continues traditional functionality Harmony system. This resulted variety functions technology updates Harmony products including Rack modules, Bridge Controllers, communication modules, Composer system configuration tools, operator consoles. following sections summarize most recent enhancements Harmony system.
Figure Evolution through Enhancement
IndustrialIT System 800xA
Harmony Control, I/O, Communications
Harmony Rack modules (Figure redesigned with modern board components surface mount technology, form, fit, functional equivalents Network INFI INFI OPEN modules. This provides backward compatibility ensure long lifecycle Harmony systems.
Figure Harmony Rack Modules
Harmony Rack Controllers. Harmony Rack controllers have remained state-of-theart through annual software hardware enhancement releases. Following ABB's commitment Evolution through Enhancement, system's flagship controllers, Harmony Bridge Controller (BRC) family, preserve existing system control logic configuration including support existing function code executions, custom user programs, foreign device interfaces. This provides predictable risk-free evolution system's control execution environment. BRC300 BRC400 (Figure represent latest additions family.
Harmony System
Harmony Controller Features
Form, functional equivalent Harmony rack controllers Deploys advanced Reduced Instruction Computer (RISC) microprocessor technology Motorola 32-bit Coldfire Retains Harmony controller (BRC, MFP, etc.) hardware software architecture Enhanced controller reliability Provides approximately (2x) function code execution rate BRC100, (4x) MFPxx, (8x) MFCxx Extended user configuration memory; 30,000 function blocks (BRC400 version) Preserves existing control logic configurations, providing predictable risk-free evolution:
Function code execution Custom user programs Foreign device interfaces Fast fail-over redundancy
High availability fault tolerance redundant pair configuration Controller configuration supported Composer engineering tool Supports Harmony systems, simultaneously providing support installed systems expansions:
Rack Block S800 (System 800xA)
Support Module Controlway communications
Figure Bridge Controller Family (BRC300, BRC400)
Harmony Rack I/O. Harmony Rack family includes wide variety input, output, signal conditioning modules. Module types, ranging from standard analog digital specialty such turbine control, Sequence Events (SOE), combined provide comprehensive functionality meet market industrial requirements. Additionally, Harmony remote capabilities have been enhanced with addition S800 (see section "S800 Harmony" details).
IndustrialIT System 800xA Another example ABB's continuing commitment protect investments made Harmony system assets found recent introduction Rack Remote alternative. Needed protect more than year investments made rack remote IMRIO02 module, this alternative minimizes change impact existing hardware architectures. Specifically, Rack Remote alternative leverages newer H-Net technology remote communications requires minimal change Remote interface block 146). Rack Remote alternative supports multiple links mixed with other Harmony types: Rack, Block, S800 I/O. Rack Remote alternative supports multiple links mixed with other Harmony types: Rack, Block, S800 I/O. Rack Remote architecture summarized Figure
Existing Fiber Optic Cables
Figure Harmony Rack Remote solution using H-Net
Harmony Communications. communication modules ensure long term viability installed systems. flagship Communication products, INNIS21/INNPM22 modules provide significant increases performance capacity compared previous generations. Additionally, INFI-NET Computer Interface INFI-NET INFI-NET Local Remote Bridge modules available. these communication modules form, fit, functional replacements their predecessors.
Harmony System
Composer Engineering Tools Harmony
Composer comprehensive engineering maintenance tools Harmony systems. provides configuration support controller INFI-NET (Cnet) communication options. working environment provided Composer simplifies configuration maintenance Harmony systems. base product contains functionality necessary create maintain control system configurations. addition, includes applications that support graphic configuration database management current operator console offerings. Composer's multiuser client server architecture allows configuration information accessed, created, modified simultaneously different users. Composer's project explorer provides user with ability organize, navigate, manage Harmony system configuration documents. Once documents located, Composer's explorer used launch editors which used develop Harmony configurations. Composer tools include:
Monitor: Provides ability view control configurations with live data from Windows based browser application network (Figure Maintenance Tools: Provides users with ability trouble shoot, perform diagnostics, maintain operating Harmony system Configuration Viewer: Offers users option view files view tune configurations controller without requiring Composer software projects Tools: Suite add-on applications that extends capabilities Composer reduces amount time required engineer configure Harmony system. Applications include Control Logic Editor, Revision Manager, Automatic Drawing Generator, Advanced Trend (runtime monitoring tuning) Data Manager (BDM): family engineering tools used creating, editing, managing, downloading, debugging batch, sequential, user defined function code configurations. discussed further section "System 800xA Production Management Harmony"
learn more about Composer Engineering Tools, please refer Composer Data Sheet, 3BUA000304Rxxxx.
Figure Composer View Monitor Mode
Operator Consoles Harmony operator console evolution dates back early 1980s with
introduction Operator Interface Unit (OIU). Since then, supported console enhancements graceful evolution newer technology through database process graphics compatibility conversion services. current console portfolio includes Conductor 800xA Process Portal (see section "System 800xA Process Portal Harmony Systems" operator console details). 3BUS094398
IndustrialIT System 800xA
Achieving Extended Automation Scope with System 800xA
Easy integration System 800xA's productivity enhancing applications, such Asset Optimization, allows Harmony system owners into their assets' unused productivity achieve sustainable competitive advantage (Figure Through incremental, stepwise evolution process, productivity gains realized substantial cost savings. following sections discuss 800xA Operations, Device Management, Asset Optimization, 800M Control I/O, Information Management solutions available Harmony system owners.
Remote Process Portal Clients
800xA Process Portal Workplaces
System Servers
Client Server Network (TCP/IP) INFINET
Control Network (TCP/IP)
Process Automation
Process Automation
800M SIL3
Controlway H-Net Rack
Additional 800Ms
Variable Speed Drives
S800 S900
Fieldbus High Speed Linking Devices HSE/H1, DP/PA)
Figure Extending Harmony Functionality with System 800xA
Harmony System
System 800xA Process Portal Harmony Systems
System 800xA Process Portal, industry's most comprehensive operations software automation, offers intuitive, easy-to-use system interface. Providing direct access relevant information through contextual navigation, 800xA Process Portal facilitates timely informed decision-making. Unique System 800xA Process Portal ability gather information from multiple plant sources transform into relevant information diverse users such maintenance technicians, process engineers, production managers plant operators (Figure
Engineering Management
Maintenance Operations
Energy Efficiency Material Efficiency Personnel Efficiency Uptime Efficiency
Production Variance Product Concentration
Planned Actual
Figure Personalized User Workplaces
enabling technology this data access, storage, management ABB's patented Aspect Objectframework. Aspect Objects relate plant data; aspects, specific plant assets; objects. example, aspects informational items associated with objects, such definitions, engineering drawings, process graphics, reports, trends, etc., that assigned each object system. Aspect Object navigation presents entire production facility consistent, easy-to-view fashion. This allows single window environment include smart field devices, asset optimization functions, information management, batch management, safety systems, manufacturing execution system (MES) applications. System 800xA Process Portal features include:
Workplaces Focused Information Access: Workplace layouts adjusted optimized user preferences needs with individualized menus, toolbar contents, display locations. Operator, maintenance, engineering, management personnel ease perform their responsibilities efficiently using Windows management functions, such safe areas pinning stacking priorities, thus minimizing operation errors.
IndustrialIT System 800xA
Flexible Navigation Fast Information Access: Familiar browser tools provide quick access displays information. Favorites, history lists, shortcuts, buttons provide navigation through process production facility quickly accurately. right mouse button provides access additional details (Figure Data Informed Decision-Making: extends automation reach integrating information from wide range applications, other automation systems, business systems into System 800xA common displays. This single window provides users much broader view facility from which make more informed decisions (Figure Operator Functionality Reliable Control: System 800xA Process Portal provides complete operator functions that includes realistic process graphics with standard faceplates, superior trending capabilities, intelligent alarm event handling, production reporting, remote messaging (Figure 10).
Figure Intuitive flexible contextual navigation
Figure Integrated data informed decision-making
Figure Comprehensive operator functionality reliable control
These personalized workplaces coexist with existing Harmony operator consoles. This provides option immediately gain added benefits from System 800xA Process Portal functionality without completely evolving existing Harmony operator consoles. However, Process Portal also offers extended operations environment with comprenhensive process information system operator. does this while preserving Harmony system data, standard Harmony displays, operator functions.
Harmony System following paragraphs describe unique Harmony Process Portal features. those requiring more details regarding general Process Portal functionality, please refer Industrial System 800xA Operations Overview document (#3BSE 034823). Preserving Harmony Configuration. Harmony Composer engineering tool provides basis 800xA Process Portal configuration. simple importing process from Composer sets Harmony configuration data standard Harmony informational views within Process Portal. Preserving Harmony Process Graphics. provides options existing Harmony process graphics. service provided convert existing graphics those users need maintain current operator process visuals navigation. Optionally, refresh current visuals with latest graphics technology thereby providing operators with enhanced view process. Harmony Standard Informational Views. Harmony importing process automatically creates control faceplates, trend displays, block details, module status, operating parameters, other Harmony specific, standard informational aspect views (Figure 11).
Figure Process graphics with contextual navigation Harmony control information
IndustrialIT System 800xA following Process Portal aspects easily modified meet operational requirement.
Figure Control faceplate views: Normal Extended Faceplates.
Faceplates include several views; from normal standard control point display view detailed control. Harmony Point Displays (Figure expanded faceplates that include trend elements that display trace process value state. Point displays occupy extended slot faceplate control those types. These faceplates automatically configured during data conversion process. Each Harmony types listed below (unless noted) associated faceplate extended point display. Device Driver (DD) Multi-State Device Driver (MSDD) Remote Control Memory (RCM) Report Trigger Remote Manual Constant (RMSC) Remote Motor Control Block (RMCB) Station Analog Enhanced Analog Enhanced Analog Digital Enhanced Digital Enhanced Digital display only) display only) display only) display only)
Details. Block Details aspect (Figure inspects function blocks within selected controller. Grouped within series tabs, Block Details aspect displays block's specifications with tuning options, outputs, additional related function code information. Tabs include:
Specifications Specification data (i.e. references another function block output, tunable non-tunable parameters) Outputs Current output value(s) block Description Description Address Enter block address NextBlock Jump next block address module
Harmony System
Figure Block details view
Figure Module Status View Module
Details. Module Details aspect (Figure provides detailed information about operational status selected Harmony module. Detailed information available through following navigation tabs:
General displays Type, Revision (firmware), Description, Mode, Collection Time, Status Bytes Status displays list status error messages that apply selected module time last scan Problems displays list problem report messages that apply selected module time last scan
Parameters. Operating Parameters aspect allows interaction with Harmony including examination parameters, tagging, inhibiting, value substitution (Figure 15). Tables summarize operating parameters included within General Harmony Tabs respectively. important feature operating parameters aspect Manual Inhibit option General tab. This used disable event reporting same
IndustrialIT System 800xA automatic inhibit. Substitute Value used enter substitute value tag. When substitution applied, "scan" automatically turned value controller unchanged. substitute value only performed Operator Workplace level. Only operators with proper, user selected security level access this function. feature available controllable types that support tagging. tagging method used place service (for maintenance other purposes) that prevents from being back into service unauthorized users. Typically only limited number users permitted implement this feature. pages defined each object type display operational data. This also allows user change state object (such tags), utilize manual inhibiting alarms, substitute values.
Figure Operating Parameters view
Type Description Security group Alarm status Quality inhibition Inhibit Inhibit Value Overall Inhibit Auto Inhibited Manual Inhibit Manual Inhibited Time stamp
type (Harmony station) Information entered during configuration that further describes function Security group that belongs Selected reporting alarm. This single overall alarm status indication Information reported from system about quality Information about inhibit status tag. inhibit disables event reporting that causes inhibit when inhibit value reached Value during configuration that causes inhibit Indicates that inhibited Selected automatically inhibited another system Enable manually inhibit event reporting Time when manually inhibited
Table Operating Parameters General
Harmony System
Loop Node Module Block
Loop number from that identifies communication network (loop) Harmony control unit Node number from that identifies interconnection point communication network Module number from that identifies device within Harmony control unit Function block location from 31,998 that identifies location specific function block Harmony configuration (controller) Selected disestablished Cnet-to-computer interface. becomes disestablished when substitute value been entered Value manually substituted Enable have system ignore Time when suspended (manually substituted) Number exception reports processed this tag. Time when specification data received from controller
Table Operating Parameters Harmony
Substituted Value Suspended Suspended Time stamp Exception Count Spec Time Stamp
Figure System Status Viewer System
Status. System Status Viewer (Figure used monitor status Harmony system applications. description field display following messages:
Alarm State (Normal Alarm) This displays normal long there other errors. status offline other errors exist, then displays alarm Status (Online Offline) Indicates that Online Offline CommErr Indicates that there some kind communication error InternalErr This internal error configuration
"View Monitor." Harmony Composer Configuration View Monitor function integrated with 800xA Process Portal. With right-click graphic tag, associated Control Logic Diagram viewed with live data monitoring. This "view only" function that maintains high security integrity control logic configuration. Events. Harmony's Sequence Events (SOE) system enables plant personnel closely monitor critical digital points where sequence changes state points groups points critical, must accurate possible.
IndustrialIT System 800xA systems allow collection precise state transition event data originating Sequence Events Recorder (SER), Distributed system within control system. Harmony system, digital state transitions recorded time stamped millisecond resolution time occurrence. reports (Figures created automatically, based triggered value property. Report action parameters configured. These parameters include: Time Limit, Isolated Priority, Attempts, System Messages, Report Templates, Export Paths. This feature allows flexibility configure specific reports based specific events. reports saved reviewed later, and/or printed Client system that Microsoft Excel installed. When integrated with 800xA Information Management, reports archived long-term storage.
Figure Report
Figure Report Trigger Point Display
Harmony System
S800 Harmony
Harmony remote capabilities expanded with S800 I/O. facilitate local mounting sensors plant, S800 family designed with small, modular form factor footprint. S800 provides options signal types ranging from basic analog digital inputs outputs pulse counters intrinsically-safe applications. S800 supports Sequence Events functionality with millisecond accuracy event timestamping source. communicates with Harmony Bridge Controller Hnet communications Harmony IOR-800 module (Figure 19). Redundant communication provides fault tolerant connection S800 I/O. Standard Composer tools configure Harmony IOR-800 Interface module S800 I/O, their individual channels. single Harmony Bridge Controller simultaneously supports both Rack S800 simple expansions ease system evolution.
Figure Interface Module S800 Modules
800M Control
Through their modular design, 800M controllers associated options contribute lower costs, higher engineering quality, higher operating efficiency. Equally effective small hybrid systems large, integrated automation applications, modularity subsystem results higher return assets providing flexibility choose specific functions required meet automation need. Designed plant automation SIL2 SIL3 safety applications, 800M controller family provides Harmony system owners with opportunity expand their automation system capabilities. Additionally, 800M controller associated modules support industry standard interfaces, network protocols, fieldbuses allowing wide range devices systems accessed their resident information used produce tighter more reliable control solutions. learn more about 800M controller subsystems, please refer System 800xA Control Overview document, 3BSE047351. Harmony system owners take advantage powerful flexible capabilities 800M controllers while protecting investments they have made their existing control assets. Whether replacing aging PLCs evolving existing
IndustrialIT System 800xA process control area with fieldbus devices, ABB's control evolution products minimize production risk while providing incremental stepwise evolution paths. These products include:
Gateway HPG800. HPG800 rack module addresses needs those system owners want extend their Harmony systems using 800M controllers. high performance, high capacity rack module that provides high speed, robust, real-time, peer-to-peer communication interface between Harmony 800M controllers. HPG800 communicates with Harmony controllers over Controlway INFINET standard function blocks. Harmony Gateway Software (HGS) maps INFI function blocks MODBUS points communicates those points over Ethernet port using MODBUS protocol. module provides physical MODBUS interface 800M. architecture communication paths interface shown Figure while module's features summarized Figure
Composer Harmony Consoles Harmony Connectivity Server(s) Function Designer Aspect Server(s) 800xA Process Portal
800xA CNET
ODBUS aster"
Exception Reports: AOL, DOL, etc. Control-Way Signals: AIB, DIB, etc.
ODBUS Slave"
Harmony Gateway Software
ODBUS Ethernet
Switch Connect Redundant 800M Controllers
Figure HPG800 connects Harmony controllers 800M controllers
Harmony System
Harmony Gateway (HPG800) Features
Communicates with 800M controllers Communicates with other Harmony INFI controllers Controlway standard function codes Bi-directional communication 4,000 MODBUS points less Ethernet port using MODBUS protocol Deploys adva nced RISC microprocessor technology Motorola 32-bit Coldfire with megabytes onboard DRAM High availability fault tolerance redundant pair configuration Configuration supported Composer Engineering Tool (version 5.0, later) Ability interface third-party PLC's devices MODBUS
learn more about HPG800 peer-to-peer rack module, please refer 3BUS094832.
800M. INFI90FCLib 800M evolutionary library that contains INFI Function Codes. purpose INFI Function Block library allow Harmony system owners protect intellectual property embedded within their existing controllers. Specifically, library designed make evolution Harmony control applications 800M straightforward simple. INFI90FCLib does this providing equivalent function block 800M function codes from Harmony. Table lists 61131-3 Function Block Types (FBTs) provided INFI90FCLib.
IndustrialIT System 800xA
800M FnGen LeadLag PulsePosn PulseRate Sqroot RateLimiter XferReal HiLowComp Sum2Real ErrPID DeltaPID BasicStation TSTQ TRIP SRMem TimerBool XferDint DelayReal XferBool Blink DSum REMSET TSTALM Station Exec UpDnCount ElapTimer ExExec MODST RedAI
800M RedDI SLSEL Rung5 Rung10 Rung20 JumpMCR RecipeBool RecipeReal MuxBool MuxReal DeviceDriver SeqMon DevMon DMuxReal MSDD MULTIMON SEQMGR RMCB SeqMstrSlv SeqMstrSlv TexSel APID SeqGen MovAvg Integrator POLY INPOL TRIG EXP1 POWER Log1 DAANG DADIG
Table INFI90FCLib 2.0-0 List FBT's
Table depicts standard 800M system functions that provide equal superior functionality those provided INFI function codes. When following INFI function codes applied, corresponding 800M system functions used with equal better results going forward.
Harmony System
INFI Name 800M System Function LIMIT HISEL LOSEL SUM4 MULT real variable limit(real) max(real) min(real) add(real) mul(real) div(real) not(bool)
INFI Name 800M System Function AND2 AND4 ON/OFF A-INT TREND ETREND boolean variable dint variable required 800M (bool) (bool)
Table 800xA System Functions INFI FC's
Function Designer used configure maintain INFI90FCLib control configurations. Function Diagrams (FD) provide same "look feel" graphical documentation Composer's Control Logic Diagrams (CLD) have done INFI based control logic within Harmony. Figure compares with converted counterpart. preserving "look feel" control logic documentation, engineering re-training minimized. Also, providing automated conversion service, engineering costs further reduced protecting investments system owners have made their documentation assets.
Figure (left) Conversion Function Diagram (right)
INFI90FCLib features include: 1-for-1 each INFI90 Function Code 800M Function Block Based same field proven field tested function code algorithms Inputs, outputs, parameters provide same behavior re-tuning converted loops required Same operator faceplates those used with 800xA Harmony Same graphical "look feel" within 800M's engineering tool Function Designer Function Designer standard loop templates provided Basic Loop Basic Cascade Loop Basic Valve Control Loop Compatible with 800M's other 61131-3 control languages (Sequential Function Charts, Ladder Diagrams, Structured Text, Instruction Lists)
IndustrialIT System 800xA read more about 800M's INFI evolutionary library, please refer INFI90 Function Code Library 800M Application Overview, 3BUS094839.
Harmony Termination Unit (TU) prefabricated cables. minimize risk costs re-terminating field wires, created family cables that preserves investments made standard Harmony field wiring terminations. These prefabricated cables allow module upgrade S800 without ever touching field wires. cables used place traditional NKTU cables. They connect existing S800 modules standard cable plug-ins. S800 cables exist Digital I/O, 4-20 mADC Analog I/O, (ASM01, ASM02, ASM03) termination units. Similar solutions exist Harmony Block bases (AIN, AOT, DIN, DOT).
Whether replacing aging PLCs incrementally upgrading older Network INFI based controllers, especially AMM, LMM, COM, modules, these control evolution products allow seamless evolution 800M S800 without costs risks associated with "rip-and-replace" controller upgrade methods (summarized Table
Traditional "Rip Replace" Upgrades Re-engineering translation control applications algorithms result process control behaviors Long commissioning start-up periods (re-configuration re-tuning loops) Create documentation Results Greater loss production Increased risk Higher project costs INFI90FCLib 800M upgrades Minimal engineering required Process control same before Minimal commissioning start-up re-tuning loops) Documentation converted enhanced Results Minimal loss production Minimal risk Lower project costs
Table avoiding high project costs production risks, control evolution upgrades cost less than "rip-and-replace" alternatives
System 800xA Device Management Harmony
System 800xA's Device Management features (Figure lower lifecycle costs through significant savings design, implementation, operation field equipment. harnessing untapped potential from substantial installed base HART® devices conforms with Advisory Group analysis that: "Users employ many their HART field devices with generation automation architectures, making migration process automation system more economical while increasing availability intelligent data that long been under utilized."
Figure System 800xA's Device Management
Harmony System Digital information from HART devices accessed System 800xA Fieldbus Management tools that physically connect HART multiplexer units. These multiplexers receive HART device data cable connections from standard Harmony Termination Units (Figure 24). ABB's HART solution supports device parameterization remote monitoring signal status process variables. also supports diagnostic information through device specific Device Type Managers (DTMs), which supplied respective device manufacturers. addition, tight integration HART devices within Harmony enables improved device maintainability through asset monitoring optimization.
Figure Simple Cable Connections Provide Access System's Smart Device's HART Data
Foundation Fieldbus Profibus interfaces available through System 800xA 800M controller. more details, please refer System 800xA Device Management Overview, 3BDD013081. With access installed HART field device information, Harmony system owners System 800xA Asset Optimization take full advantage System 800xA's Asset Optimization features. application (Figure exploits wealth field resident information accessible through Harmony
HART Fieldbus higher-level systems access document equipment conditions real-time. addition field devices, System 800xA asset monitoring features inspect health status operations network, including networking equipment such PCs, routers, printers, etc. These functions enable personnel implement proactive predictive maintenance services. Additionally, software seamlessly integrates plant maintenance calibration management systems greatly reduce time repair through streamlined work processes.
IndustrialIT System 800xA System 800xA Asset Optimization highlights include:
Asset Optimization: Provides higher return plant assets through optimized remediation work processes early detection failure single environment engineering, operations, notification. Monitoring Maintenance Conditions Automatic Alarms: Real-time monitoring asset Performance Indicators (KPI's) facilitates fast, reliable implementation corrective actions. Adoption Predictive Proactive Maintenance Strategies: Collects, aggregates, analyzes real-time plant asset information provide advanced warning degrading performance impending failure. Reporting Plant Asset Health Status: Reporting features provide visualization current health conditions. Analysis features provide ability drill down root cause failure. Time Repair through Optimized Work Processes: Integration disparate Computerized Maintenance Management System (CMMS) data, calibration system data, condition monitoring system data, control system asset data provides users single application view, leading quick efficient assessment maintenance needs status.
Figure Asset Optimization
Additionally, 800xA Asset Optimization reviews health condition Harmony control network. provides detailed information Harmony Process Control units, controllers, bridges, modules system, module/loop faults overall performance (Figure 26). 800xA Asset Monitoring leverages diagnostic information resident system's traditional diagnostic views Harmony Control Network individual system nodes (PCU). These displays provide information about current Harmony equipment sub-conditions, severity, asset monitor status, fault report availability, work order availability when integrated with plant's CMMS system.
Harmony System
Traditional Diagnostics View
Harmony Performance Statistics
800xA Harmony Asset Monitor Views
Harmony Loop Topology
Harmony Loop Asset Monitor Display
Harmony Exception Report Statistics
Harmony Asset Monitor Alarm List
Harmony Network Event Error Counters
Harmony Node (PCU) Topology
Harmony Node (PCU) Asset Monitor Display
Figure Harmony Control Network Health Status Reporting
more details, please refer System 800xA Asset Optimization Overview, 3BUS094382 System 800xA Asset Optimization Advanced Harmony Control System Monitoring Datasheet, 3BUS094351.
System 800xA Production Management Harmony
800xA Production Management suite automates, monitors, controls, documents compliant with cGMP (current Good Manufacturing Practices) manufacturing processes. This enables users achieve operational excellence real-time manufacturing execution, quality, performance management. ABB's production management capabilities built S88, 61512, 61131-3 standards.
IndustrialIT System 800xA
800xA Production Management provides batch production management solutions, delivering unsurpassed batch-to-batch consistency, quality, productivity. These measurable results achieved through unmatched level scope batch control integrated with scheduling, electronic batch records, inventory management, quality control, HSI, history, controllers.Whether process manual, automated both, 800xA Production Management offers solutions stand-alone environments integrated operation with MES, etc. Batch Management component 800xA Production Management powerful application software package configuring, scheduling, managing batch operations. such, 800xA Batch Management provides:
Real-time resource management Flexible on/off-line recipe management Batch data collection history integrated
with 800xA Information Management
800xA Batch Management server supervises execution control recipe procedures. server sends formulation data issues commands equipment phase logic PHASEX function block running Harmony controllers. PHASEX block executes equipment phase logic communicates status information batch server. more details, please refer 800xA System Batch Management Overview, 3BUS092077. Batch Data Manager Tools (from Composer Phase Logic). Batch data manager (BDM) family engineering tools creating, editing, managing, downloading, debugging batch equipment phase logic Harmony systems. heart Batch 90programming language which enables engineer create equipment phase logic using clear, concise, natural syntax control statements. Batch layers regulatory discrete device control function code logic Harmony. Equipment phase logic change controller points, turn discrete devices off, change modes, other equipment supervisory operations written Batch PHASEX function code provides programmatic interface between Batch regulatory discrete control configured using INFI function blocks.
Harmony System
System 800xA Information Management Harmony
achieve sustainable competitive advantage, manufacturing non-manufacturing businesses must able adapt quickly market changes. This makes timely collection distribution reliable information plant's decision-makers critical. System 800xA Information Management provides ability collect securely store present business well process data from plant data sources. This data analyzed transformed into useful information, then presented personnel (e.g. Plant Manager's Workplace, Figure improve operations efficiency profitability. System 800xA Information Management features include:
Information Presentation: Desktop displays provide concise, enterprise-wide system process information familiar office presentation format without requiring personnel leave their office workplaces. discrete ticker continuously shows business Performance Indicators (KPIs), providing fingertip, real-time, historical information planned versus actual production status. ticker information supplemented with trend display when more detailed information status required. System Actions: Versatile scheduling options provide automatic triggers system actions such process data collection, running calculations process data, report generation, historical information archiving, history data consolidation provide single, plant-wide history repository, well system back-up functions. Scheduled actions based cyclic scheduling event-driven, time based, performed demand, requiring minimal effort perform repetitive system activities.
Report Generation Distribution: variety reporting software supported including Microsoft® Excel Crystal Report very familiar, easy-touse formats. Standard report templates included, which offer quick report setup. These reports fulfill plant regulatory agency documentation requirements well provide powerful tools decision-making planning improved operations performance. Historical Data Storage Access: Fault tolerant distributed data configurations provide dependable data information availability. information also protected user access restrictions offline storage. Users confident that electronic record keeping requirements being that their decisions based upon reliable information.
IndustrialIT System 800xA
Energy Efficiency Material Efficiency Personnel Efficiency Uptime Efficiency
Production Variance Product Concentration
Planned Actual
Figure Manager's Desktop Information Workplace
Information Management integrated with Harmony, ensuring that process data events securely collected, stored, archived. Plant users then able access, analyze, report, document Harmony data improve plant operations. more details, please refer System 800xA Information Management Overview, 3BUS092079. Smart Client provides Harmony users with browser-based thin client displaying cpmPlus Smart Client Harmony information from System 800xA (Figure 28). cpmPlus Smart Client true
thin client that seamlessly retrieves data from ABB's System 800xA connected third-party systems. Displays available inside outside plant facility, long connection plant exists (i.e. VPN). cpmPlus Smart Client utilizes extended automation capabilities System 800xA technology provide intelligent data access viewing functions assist levels personnel making quick, informed decisions taking appropriate action, thereby improving performance. Major benefits cpmPlus Smart Client include:
duplicate engineering using existing data definitions. information defined System 800xA, including upper lower limits, seamlessly available inside cpmPlus Smart Client.
Harmony System
display configuration requires programming. Displays configured using drag-and-drop display components information from System 800xA property browser. additional costs based count. Information from connected System 800xA's available.
These benefits allow companies lower their overall cost ownership leverage advantages ABB's System 800xA extended automation environment. feature cpmPlus Smart Client includes:
client based graphical displays statistical process control Excel Interface Event Reporting
Trending Alarm
Figure Using Smart Client, information from System 800xA Harmony connected third-party data sources readily available users' easily customized allow access precise data needed make better decisions
more details, please refer cpmPlus Smart Client brochure, 3BTG6000PM1002.
IndustrialIT System 800xA
Lowering System Lifecycle Costs Risk through System Evolution
stated earlier, long-standing commitment system owners that ensures future advances system technologies will enhance rather than compromise their current system investments. over years, ABB's evolution policies have allowed system owners maximize useful life both their control systems intellectual assets built upon them. Through stepwise their system evolution solutions, risk associated with system change mitigated; minimizing process/ system down-time protecting owner's long-term investments control applications, process graphics, historical data. Working side-by-side with Harmony system owners guided owner's business goals, assists development evolution path pace. Regardless whether initial investment made years ago, installed automation system still vital sustainable part business manufacturing strategy that enhanced extended years come that presents lowest lifecycle costs lowest risk.
Four-Point Evolution Strategy
Superior products cornerstone ABB's evolution strategy; however, simply incorporating products into existing system will ensure success provide desired results. ABB's evolution commitment consists four-point strategy that represents comprehensive solution provides roadmap successful system evolution. This four-point strategy includes: Product Planning Process ABB's system planning development strategy fundamental features capabilities must adapted seamlessly with minimum impact existing applications. development process involves rigid guidelines ensure compatibility differing versions models system components. Each step natural progression current system offering never behaves like plug-in adaptation someone else's product. example, application code runs when first developed controllers seamlessly coexist same control network previous generation controllers. order fulfill individually tailored upgrade path, system enhancements provide unique blend flexibility scalability. ability match hardware software different generations major strength. services solutions that preserve system owner's investments. This ensures continued base control hardware infrastructure protects intellectual asset investment made software applications. example:
Graphics: Save time expense re-engineering intensive user/operator retraining History data preservation restores existing historical data transferred directly history platform Wiring: Eliminates need field re-wiring reduces time costs re-testing when existing replaced with product applications: Preservation field proven control configurations documentation minimizes production risk project engineering costs
Database: Field
Harmony System Customer Evolution Planning Process successful evolution program begins with solid plan driven owner's business goals. Good planning critical incremental, stepwise evolution minimize negative production impact actual upgrade process. simplify improve yearly budgeting process facilitate better system upgrades planned plant shutdowns. Individualized planning essential. Different industries invariably have different strategies business issues going forward. ABB, account managers technical experts work with system owners individually address their unique needs. collaborative relationship results best strategies each individual site. After comprehensive audit existing system, with understanding business drivers, will:
year plan reviewed revised necessary. ABB's incremental approach supports flexibility; allowing changes plan required over time. target which facilities greatest risk production loss those that have greatest potential increased production. each phase identified, will provide value assessments Return-on-Investment support consideration order facilitate successful project appropriation requests. long-term plan periodically; update required reflect changing business needs solutions. This approach takes guessing budgeting process. part this planning process, specific projects identified implemented.
Customer Evolution Programs promotes proactive approach hardware software upgrades; working with system owners stay current avoid hitting brick wall obsolescence through stepwise, incremental upgrades. This philosophy allows system owners continuously improve productivity technologies automation product offerings become available. evolution programs provide financial flexibility move from existing automation system products new, higher performance human system interfaces, system engineering tools, controllers, control networks, information management functional area time. ABB's Automation Sentinel software management program assists system owners actively managing their lifecycle costs control system software. With this program, they keep control software up-to-date maintain flexible path forward system software technology. Automation Sentinel helps manage software assets with timely delivery latest software releases, thus providing subscribers:
Better Lower
productivity through enhanced software functionality support cost simpler software management through known annual subscription fees stay current with latest industry standards Access most current system documentation Evolution higher levels human system interface, control, information management, connectivity
IndustrialIT System 800xA Automation Sentinel program deliverables summarized below Table Licenses versions installed software products Software maintenance updates Software licenses evolution equivalent functions newer technology products, including System 800xA Extended support System 800xA software version. seven years Technical phone support assist with system software updates On-line website access downloads: updates notes updates bulletins manuals Software security management: security patch validation status party virus scanner qualification System 800xA computer hardware qualification replacement models available Device Library management updates 800xA systems: Fieldbus Auto notification email: updates release information
Table Automation Sentinel deliverables
Solutions Delivery Delivery sound system solutions based evolution plans another important process evolution value chain. ABB's system engineers highly trained, skilled, equipped with tools resources right. These resources know what installed, know what needed meet future goals, have know deliver project begins with comprehensive review requirements formulated long-term plan. engineers work closely with system owner formulate project plan that achieves desired results. Based this collaborative effort, engineers design solution that delivers results, protects system investments, presents lowest risk possible during installation.
Harmony System
With today's economic restraints putting pressure capital spending, system owners need perform smarter better substantial cost savings. business challenge they face squeeze most productivity from their installed system through functions features, extend useful life applications within reduce maintenance costs while improving overall reliability. delivers extended automation scope that enables system owners successful today's highly competitive business markets evolving their existing Symphony Harmony system with Industrial Extended Automation System 800xA's best-in-class productivity enhancement software. Learn more about evolution Symphony Harmony systems System 800xA Extended Automation www.abb.com/controlsystems.
Open Control Systems Sweden Phone: Fax: E-Mail: processautomation@se.abb.com www.abb.com/controlsystems Industry Open Control Systems Singapore Phone: 6776 5711 Fax: 6778 0222 E-Mail: processautomation@sg.abb.com www.abb.com/controlsystems
Inc. Open Control Systems Wickliffe, Ohio, Phone: 8500 Fax: 8756 E-Mail: www.abb.com/controlsystems Automation GmbH Open Control Systems Mannheim, Germany Phone: 1805 Fax: 1805 E-Mail: www.abb.de/controlsystems
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