System 800xA Control AC 800M Binary and Analog Handling

670 Pages·2013·8.02 MB·English

System 800xA Control
AC 800M
Binary and Analog Handling
System Version 5.1

Power and productivity
for a better worldTM

System 800xA Control
AC 800M
Binary and Analog Handling
System Version 5.1
NOTICE
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support all of the features of the described or referenced standard. In order to determine
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TRADEMARKS
All rights to copyrights, registered trademarks, and trademarks reside with their respec-
tive owners.
Copyright © 2003-2013 by ABB. 
All rights reserved.
Release: February 2013
Document number: 3BSE035981-510 A
Table of Contents
About This User Manual
General............................................................................................................................15
User Manual Conventions...............................................................................................16
Feature Pack.........................................................................................................16
Warning, Caution, Information, and Tip Icons....................................................17
Terminology.....................................................................................................................17
Released User Manuals and Release Notes.....................................................................18

SIL Certified Applications
Introduction.....................................................................................................................19
SIL Information Can Be Disregarded by Non-SIL Users....................................19
SIL Applications..............................................................................................................20
Setting SIL-Levels................................................................................................21
Restricted SIL-Level............................................................................................23
Non-SIL parameters.............................................................................................24
High Integrity Controllers...............................................................................................24
Section 1 - Introduction
Extended Control Software.............................................................................................27
Libraries and Types.........................................................................................................28
SIL applications...............................................................................................................29
Process Graphics 2 (PG2)................................................................................................29
Section 2 - Libraries
Introduction.....................................................................................................................31
Libraries and Types..............................................................................................32
3BSE035981-510 A 5
Table of Contents
Advantages of Using Libraries and Types......................................................................38
Type Solutions.....................................................................................................38
Libraries ............................................................................................................39
Building Complex Solutions With Types........................................................................40
Library Management.......................................................................................................44
Tips and Recommendations.................................................................................45
Reserved Names...................................................................................................48
Parameter Keywords............................................................................................48
Library Version Handling....................................................................................50
Updating a Library without increasing the Library Major Version.....................55
Library Command Summary...........................................................................................57
Section 3 - Standard Libraries
Introduction.....................................................................................................................61

Ready-Made Objects, Templates and Building Stones........................................61
Standard Library Types........................................................................................63
Where to Find Information About Standard Library Types.................................63
Common Properties.............................................................................................64
Library Overview............................................................................................................66
SIL Certified Types..............................................................................................66
SupportLib...........................................................................................................67
Icon Library.........................................................................................................67
BasicGraphicLib..................................................................................................67
Basic Library........................................................................................................68
Alarm and Event Library.....................................................................................68
Signal Libraries....................................................................................................68
Process Object Libraries......................................................................................70
Synchronized Control Library.............................................................................70
Control Libraries..................................................................................................71
Supervision Libraries...........................................................................................73
Communication Libraries....................................................................................74
Batch Library.......................................................................................................75
VMT Library (High Integrity Controllers Only).................................................75
6 3BSE035981-510 A
Table of Contents
Hardware Overview.........................................................................................................76
Basic Hardware....................................................................................................76
PROFIBUS...........................................................................................................76
PROFIBUS Devices.............................................................................................77
PROFINET IO......................................................................................................78
PROFINET IO Devices........................................................................................79
FOUNDATION Fieldbus HSE.............................................................................79
Master Bus 300....................................................................................................79
INSUM .............................................................................................................79
DriveBus .............................................................................................................80
MODBUS TCP....................................................................................................80
IEC 61850............................................................................................................80
AF 100 .............................................................................................................80
MOD5 .............................................................................................................80

EtherNet/IP and DeviceNet..................................................................................80
S200 I/O System..................................................................................................81
Satt Rack I/O System...........................................................................................81
S800 I/O System..................................................................................................81
Serial Communication..........................................................................................83
Self-defined UDP Communication......................................................................84
Self-defined TCP Communication.......................................................................84
Printer and Modem...............................................................................................84
FOUNDATION Fieldbus H1................................................................................84
Templates.........................................................................................................................85
Execution of Copied Complex Types...................................................................92
Section 4 - Analog Process Control
Introduction.....................................................................................................................99
Concept..........................................................................................................................100
Control Libraries Overview................................................................................100
Functions and Other Libraries Used for Analog Control...................................103
ControlConnection.............................................................................................103
Controller Types.................................................................................................112
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Table of Contents
Basic Controller Principles................................................................................115
Controller Algorithms........................................................................................117
Hysteresis vs Dead Zone....................................................................................123
Fuzzy Control....................................................................................................127
Controller Modes...............................................................................................134
Faceplates..........................................................................................................134
Design...........................................................................................................................138
General Design Issues........................................................................................138
Control Strategies...............................................................................................141
Remarks on the Design of Control Loops.........................................................143
Controller Types.................................................................................................144
Industrial Controller Types................................................................................151
Signal Handling.................................................................................................154
Getting Started with ControlConnection.......................................................................154

What is ControlConnection?..............................................................................154
Dealing with Data Flow Directions...................................................................155
Open the Gates to ControlConnection...............................................................159
Creating a Control Module with ControlConnection (CC template).................161
What next?.........................................................................................................175
Advanced Functions......................................................................................................183
Anti-Integrator Wind-Up Function....................................................................184
Bumpless Transfer.............................................................................................185
Deviation Alarms...............................................................................................190
Feedforward.......................................................................................................192
Autotuning.........................................................................................................193
Adaptive Control................................................................................................200
Gain Scheduling.................................................................................................204
Gain Scheduling versus Adaptation...................................................................206
Additional Control Functions............................................................................208
Input and Output Signal Handling.....................................................................215
Supervision........................................................................................................226
Calculation.........................................................................................................229
8 3BSE035981-510 A
Table of Contents
Signal Handling..................................................................................................231
Time Average.....................................................................................................234
Branch Objects...................................................................................................240
Selector Objects.................................................................................................244
Limiter Objects...................................................................................................250
Conversion..........................................................................................................253
Miscellaneous Objects.......................................................................................256
Control Loop Solutions.................................................................................................257
Introduction........................................................................................................257
Concept ...........................................................................................................257
Design ...........................................................................................................257
Example ...........................................................................................................266
Basic Control Loop Examples.......................................................................................278
Signal Selection Example..................................................................................280

Common Range Example..................................................................................282
Split Range Examples........................................................................................283
Level Detection Example...................................................................................285
Application Examples...................................................................................................287
Simple Loop Examples......................................................................................290
Cascade Loop Examples....................................................................................292
Fuzzy Control Loop Examples...........................................................................295
Section 5 - Binary Process Control
Introduction...................................................................................................................297
Concept..........................................................................................................................298
Process Object Libraries Overview....................................................................299
Process Object Template Concept (Core Objects).............................................306
Core Object Functions and Parameters (UniCore and BiCore).........................310
Control Module Icons........................................................................................327
Faceplates...........................................................................................................328
Interaction Windows..........................................................................................331
Interaction Parameters........................................................................................332
Design............................................................................................................................333
33BBSSEE003355998811--551100 AA 99
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Choose the Correct Type....................................................................................334
Use Standard Library Types...............................................................................336
Use Standard Library Types to Create Self-defined Types................................336
Group Start Interface..........................................................................................337
Voting Interface..................................................................................................338
Alarm Handling.................................................................................................339
Generic Uni- and Bi-Directional Control..........................................................341
Motor and Valve Control...................................................................................345
Examples.......................................................................................................................352
Create a Library and Insert a Copy of a Type....................................................352
Add Functions to Self-defined Types.................................................................357
Connect Faceplate Elements..............................................................................361
Edit a Faceplate..................................................................................................364
Connect to a Control Panel in Panel Mode........................................................374

Advanced Functions......................................................................................................378
Level Detection, Commands and Alarm Texts..................................................378
ABB Drives Control...........................................................................................381
INSUM Control.................................................................................................401
Section 6 - Synchronized Control
Introduction...................................................................................................................419
Sequence Start Library..................................................................................................422
Overview ..........................................................................................................422
Sequence Start Concept.....................................................................................422
Sequence Start Objects......................................................................................423
SFC Viewer Link...............................................................................................424
Group Start Library.......................................................................................................427
Group Start Concept..........................................................................................428
Group Start Configuration.................................................................................428
Example for Template Configuration................................................................429
Group Start Objects...........................................................................................431
Section 7 - Surveillance
10 3BSE035981-510 A