abb 800xa minerals library guide

8/19/2019 ABB 800xA Minerals Library Guide

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Doc. kind Product Guide Project BU Minerals LibraryTitle Industrial IT System 800xA

Minerals Library version 5.1/4aDocument number

Lang. Rev. ind. Pages 2

ABB Switzerland Ltd 3BHS 161554 en O No. of p. 95

1. SYSTEM 800XA CONTROL AND OPERATION AC800M MINERALSLIBRARY ................................................................................................................... 4

1.1 Control AC800M Minerals Library................................................................. 41.1.1 Basic Objects.................................................................................. 41.1.2 Communication Objects .................................................................. 61.1.3 Consumer Objects .......................................................................... 61.1.4 Group Objects ................................................................................ 71.1.5 Loop Objects .................................................................................. 8

1.1.6 Report Objects................................................................................ 81.1.7 Power Monitoring Objects ............................................................... 91.1.8 Composite Object Templates .......................................................... 91.1.9 Energy Management .................................................................... 101.1.10 Support for Process Panel 800 ..................................................... 121.1.11 Basic Objects................................................................................ 141.1.12 Group Objects .............................................................................. 191.1.13 Consumer Objects ........................................................................ 251.1.14 Loop Objects ................................................................................ 391.1.15 Reporting Objects ......................................................................... 411.1.16 Composite Object Templates ........................................................ 42

421.1.17 Electrical Control – Energy Management ...................................... 431.1.18 Power Distribution Monitoring ....................................................... 431.1.19 Energy Management .................................................................... 46

1.2 Some Implementation Concepts................................................................. 541.2.1 Look and feel ................................................................................ 541.2.2 PCC (Priority Command Connection) ........................................... 551.2.3 Point of Control (POC) .................................................................. 57

1.3 Technical and Performance Data ............................................................... 671.3.1 System Performance and Capacity ............................................... 671.3.2 System Example ........................................................................... 69Memory Space Requirements and Execution Times ..................................... 69

1.3.3 Performance Data ........................................................................ 711.4 Related Documents .................................................................................... 751.5 Licenses and Ordering Minerals AC800M Control and Operation............... 76

1.5.1 Minerals Library License ............................................................... 761.5.2 Minerals License Point .................................................................. 761.5.3 Ordering Examples ....................................................................... 76

2. SYSTEM 800XA OPERATIONS AC400 CONNECT MINERALS LIBRARY ........... 78

2.1 Functional Description ................................................................................ 782.1.1 Analog Input (AI, AiandUnit, AIBar)............................................... 782.1.2 Analog Output (AO, AoandUnit) .................................................... 792.1.3 Digital Input (DI) ............................................................................ 80

2.1.4 Digital Output (DO, DOTxt) ........................................................... 812.1.5 Group Sequence Start / Stop Controller (GROUP) ....................... 822.1.6 Pre-Selection (PREBIN) ............................................................... 832.1.7 Start Warning (STW) .................................................................... 832.1.8 Motor Controller (Motor) .............................................................. 842.1.9 Damper/ Actuator Controller (MOTP) ............................................ 852.1.10 Valve Control (Valve) .................................................................... 862.1.11 PI Controller (PIControl) ............................................................... 872.1.12 PID Controller (PIDControl) .......................................................... 88

2.2 Licenses and ordering PPA AC400 Minerals Connect ................................ 892.2.1 Tag ............................................................................................... 89


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2.2.2 Ordering Example ......................................................................... 89

3. MINERALS OPERATIONS FOR SIEMENS PCS7 CEMAT ..................................... 90

4. SUPPORT AND TRAINING ..................................................................................... 91

4.1 Minerals Support ........................................................................................ 914.1.1 Design Review.............................................................................. 914.1.2 Life Cycle Services ....................................................................... 91

4.2 Minerals Training ........................................................................................ 91

4.2.1 H658 IndustrialIT 800xA Applications for Minerals – Engineering with EBase and Control Builder M............................. 92

4.2.2 H651 IndustrialIT 800xA Applications for Minerals – Configuration and Operation ......................................................... 93

4.2.3 H652 Industrial IT 800xA Applications for Minerals – Operation...................................................................................... 94

REVISION HISTORY ...................................................................................................... 95


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1. SYSTEM 800XA CONTROL AND OPERATION AC800M MINERALS LIBRARY

The IndustrialIT System 800xA Minerals Library comprises of

· Control AC800M Minerals Library, which contains the software modules that are usedto configure applications using the AC800M controllers.

· Operations AC800M Connect Minerals Library, which provides display elements andfaceplates for monitoring and control of objects, defined by means of the AC800M

Minerals Library.· Operations Process Portal AC400 Connect Minerals Library, which provides display

elements and faceplates for monitoring and control of objects defined by means of the AC400 BMI Type Circuit Library.

The documentation for all these elements is included on the installation CD-ROM.

This version runs on System 800xA Version 5.1 with Feature Pack 4.

1.1 Control AC800M Minerals Library

Control AC800M Minerals Library contains controller software modules that are used toconfigure applications (main focus being in Minerals Industry) using the AC800M

controllers. A set of purpose-build, typical, software modules has been developed, supporting theprocess requirements for these applications. These software modules are developed withthe ABB Control Builder M Professional programming tool, as Control Module Types(CM). The coding of the Control Modules is compliant with the IEC 61131-3 standard.

These software modules comprise the Minerals Library, and are grouped in eight differentobject categories:

· Basic Objects

· Communication Objects

· Consumer Objects

· Dosing Objects· Group Objects (sequencing)

· Loop Objects

· Power Monitoring Object

· Report Objects

· Energy Management

A separate Reference Manual is available for each object category providing moredetails.

1.1.1 BASIC OBJECTS

The Basic Objects (AI, AO, DI, DO) provide access and control for process IO-signals andcalculated IO-signals.

Basic functions such as blocking and forcing of signals, control of output and limit levelchanges are integrated in these objects.

PCC Bus Light concept created for all devices in BMIStandard. Through this new PCCBus Light version we have now the possibility to see the DIS, DIC, AIS and AIC limit thatis causing some fault to the consumer object. In addition it is possible to see in the AIS, AIC, DIS and DIC faceplate what is the motor that it is connected to.


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A detailed description of the basic objects and their interfaces is given in the referencemanual Basic Objects.

Reference Table: Basic Objects for process IO-signals

Name Type Function Data Type

AIS CM Analog input module for 1 process signal. The

functions are blocking & forcing of input value, 4limit levels, 3 alarm priorities, alarm delay, alarmblocking, alarm disabling/enabling.

Write: use AIC control moduleRead: IO..FilteredSignal.ValueInterlock: IO...Normal

AISData

AOS CM Analog output module for 1 process signal. Thefunctions are manual / auto mode, tracking of modeand output changes, 2 output limits.

Write: IO..AutoValueTogether with IO..SetAutoRead: IO..Signal.Value

AOSData

DIS CM Digital input module for 1 process signal. Thefunctions are blocking and forcing of input value, 3alarm priorities, alarm delay, alarm blocking, alarmdisabling/enabling from application software.

Write: use DIC control moduleRead: IO..Signal.ValueInterlock: IO..Signal.Normal

DISData

DOS CM Digital output module for 1 process signal. Thefunctions are manual / auto mode, tracking of modeand output changes.

Write: IO..AutoValue

Together with IO..SetAutoRead: IO..Signal.Value

DOSData

Reference Table: Basic Objects for calculated IO-signals


AIC CM Analog input module for 1 calculated signal. Thefunctions are the same as for the AIS. AIC uses thesame data type as AIS.

Write: IO..Signal.IOValueRead: IO.. FilteredSignal.ValueInterlock: IO...Normal

AISData

AOC CM Analog output module for 1 calculated signal. Thefunctions are the same as for the AOS. AOC usesthe same data type as AOS.

Write: IO..AutoValueTogether with IO..SetAutoRead: IO..Signal.Value

AOSData

DIC CM Digital input module for 1 calculated signal. Thefunctions are the same as for the DIS. DIC uses thesame data type as DIS.

Write: IO..SigHW.IOValue

DISData


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Read: IO..Signal.ValueInterlock: IO..Signal.Normal

DOC CM Digital output module for 1 calculated signal. Thefunctions are the same as for the DOS. DOC usesthe same data type as DOS.

Write: IO..AutoValue

Together with IO..SetAutoRead: IO..Signal.Value

DOSData

1.1.2 COMMUNICATION OBJECTS

Communications objects establish and supervise the communication between two AC800M controllers or between different applications or diagrams.

A detail description of the objects and their interfaces is given in the moduledescription Communication Objects.

Reference Table: Communication Objects


GCC_Com_ M

CM The GCC_Com_M extends the group drive bus toanother diagram and/or application

· Point-to-point communication toGCC_Com_S via Communication Variable

GCC_ComData

GCC_Com_ S

CM The GCC_Com_S extends the group drive bus toanother diagram and/or application

· Point-to-point communication toGCC_Com_M via Communication Variable

GCC_ComData

PCC_Com_ Drive

CM The PCC_Com_Drive is used to connect the PCC

bus if the Signal and Drive are located in differentdiagrams and/or applications:

· Point-to-Point Communication via oneCommunication Variable transferred to thePCC_Com_Signal Block

PCC_ComD

ata

PCC_Com_ Signal

CM The PCC_Com_Signal is used to connect the PCCbus if the Signal and Drive are located in differentdiagrams and /or applications:

· Point-to-Point Communication via oneCommunication Variable transferred to thePCC_Com_Drive Block

PCC_ComData

1.1.3 CONSUMER OBJECTS

Consumer objects provide access and control for the physical devices (consumers) inthe plant.

Basic functions such as operator orders, detailed interlock and alarm indication,tracking of mode and status changes, are integrated in these objects.

A detailed description of the consumer objects and their interfaces is given in thereference manual Consumer Objects.

Reference Table: Consumer Objects


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Name Type Function DataTypes

MOT1 CM The Control Module Type MOT1 is used to control amotor with one direction (one speed) in a drivegroup or standalone.

MOT1Data

MOT1_VVVF CM The Control Module Type MOT1_VVVF is used tocontrol a motor w ith one direction and variablespeed in a drive group or standalone.

MOT1VVVFData

MOT2 CM The Control Module Type MOT2 is used to control amotor with two directions (two speeds) in a drivegroup or standalone.

MOT2Data

MOT2_VVVF CM The Control Module Type MOT2_VVVF isused to control a motor with two d irectionand variable speed in a drive group or standalone.

MOT2VVVFData

MOTP CM The Control Module Type MOTP is used to controla motorized valve or damper with or withoutanalog position feedback in a drive group or standalone.

MOTPData

VLV1 CM The Control Module Type VLV1 is used to control anormally-closed one-way valve with one or twocoils in a drive group or standalone. Up to twoposition limit switches (open and closed) can besupervised.

VLV1Data

VLVNO1 CM The Control Module Type VLV1 is used to control anormally open one-way valve with one or twocoils in a drive group or standalone. Up to twoposition limit switches (open and closed) can besupervised.

VLVNO1Data

1.1.4 GROUP OBJECTS

The Group Objects provide access and control for a process group or process grouprelated features.

Basic functions such as operator orders, detailed interlock and alarm indication,tracking of mode and status changes, pre-selection of group members and startupwarnings are integrated in these objects.

A detail description of the group objects and their interfaces is given in the referencemanual Group Objects.

Reference Table: Group Objects


GROUP CM Group sequence. The functions are starting,stopping of group members in a sequential order,summary status indication of all pre-selected groupmembers (ready, run, off), 4 start and 4 stopinterlocks, emergency quick stop.

GrpInputGrpOutputGrpDrvCon

DriveGroup CM Technological group can handle auxiliaryequipment and main drives like one system

DriveGroupData

GrpCycleCtrl CM Cycle controller for the group. This control modulecan be used for cyclic activation and deactivation of group members by means of a script (e.g. silo

GrpCycleCntrlData


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aeration, cool down lubrication etc.). SeveralGrpCycleCtrl objects can be added to one GROUP.

PREBIN CM Pre-selection module. The function is to activate or deactivate one or a set of group members such asconsumer objects or loops during the group startup.

PreBinData

STW CM Start Warning module. The function is to provide astart up warning for an individual consumer object

or a group.

STWData

GroupStep CM The GroupStep module can be used to:

· Start / Stop equipment not controlled by aconsumer object or loop. (e.g. valverepresented by a DOS)

· Start / Stop consumer objects located inanother controller.

· Start / Stop consumer objects controlled bymore than 2 groups.

Not defined

1.1.5 LOOP OBJECTS

Loop objects provide access and control for analog open and closed control loops.

Basic functions such as operator orders, detailed alarm indication, tracking of modeand status changes, are integrated in these objects.

A detailed description of the loop objects and their interfaces is given in the referencemanual Loop Objects.

Reference Table: Loop Objects


PIDCtrl CM State-of-the-art PID Closed loop controller with feed

forward, anti wind up and gain scheduling functions.

PIDCtrlData

1.1.6 REPORT OBJECTS

Report objects provide access to counter values or summarize Analog Values over time (integrator). They provide a focused historical archiving for detailedinformation.

The different counter types provide total following functions:

· Total and shift value summation

·

Reset counter value from controller or from the Operator Station(via the faceplate)

· Adjustment (positive & negative) of counter value and constant from theOperator Station (via the faceplate)

· Operator Station Interface (graphic element and faceplate)

A detailed description of the report objects and their interfaces is given in the moduledescription Report Objects.

Reference Table: Report Objects



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PulseCount CM Pulse Counter is used to count pulses and sumthem up for production data reports.

PulseCountData

ReportingCount

CM The ReportingCount is giving all featuringfrom PulseCount and additionally a focusedhistorical archiving for detailed information

ReportingCountData

1.1.7 POWER MONITORING OBJECTS

Power monitoring objects are intended for supervision and control of power distributionequipment such as switchgear, and protection relays using serial connectivity (e.g.Profibus or Modbus). The objects are designed as composite control modulescontaining one module for the communication. This module can be modified to adaptto the requirements of the equipment.

A detail description of the objects and their interfaces is given in the moduledescription Power Monitoring Objects.

The Control Module Types for Power Distribution Monitoring objects and their corresponding Structured Data Types are located in the library BMIEnergy 1.0-0 for

Control Builder Professional.Reference Table: Power Monitoring Objects


Circuit Breaker CM Control an IED Control Device withup to 2 Breakers with Isolator andEarth Switch in a drive group or standalone

CircuitBreaker Data

CircuitBreakerABBREF542Plus

Composite CM:

Circuit Breaker +3 AIC (Current,

Voltage, Power) + 1Counter (Energy)

Interface to an ABB REF542+connected via ModBus

CircuitBreaker ABBREF542PlusData

PFCCtrl CM Power Factor Correction Controller with up to 8 Circuit Breaker (Steps)

PFCCtrlData

1.1.8 COMPOSITE OBJECT TEMPLATES

The library contains a so called wrapper framework to compose project specificconsumer objects having serial communication interface (Profibus, Modbus, etc.)between control system and device. The intention is to provide samples of how toimplement project specific serial devices. The samples included in the library shall beused as templates, i.e. copied and adapted to the project specific requirements if required.

The Control Module Types and their corresponding Structured Data Types are locatedin a dedicated Library per Interface like BMI_MNSIS, BMI_MNSiS_MBTCP,BMI_UMC22, BMI_UMC100 and BMI_ACS8x0.

Reference Table: Serial Communication Objects


MOT1VVVF_ACS8x0 Composite CM:

MOT1_VVVF

ABB Drive system withProfibusDP interface

MOT1_VVVFData


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ACS500, ACS600, ACS800 or ACS1000

MOT2VVVF_ACS8x0 Composite CM :

MOT2_VVVF

ABB Drive system withProfibusDP interface

ACS500, ACS600, ACS800 or ACS1000

MOT2VVVFData

UMC22 Composite CM ABB UMC22 MCC device MOT1UMCData

MOT1_MNSIS

MOT2_MNSIS

MOTP_MNSIS

Composite CM

MOT1 + AIC (Current or Power)

MOT2 + AIC (Current or Power)

MOTP + AIC (Current or Power)

ABB MNS iS MCC withProfibusDP Interface

MOT1_MNSISData

MOT1_MNSiS_MBTCP

MOT2_MNSIS_MBTCP

MOTP_MNSIS_MBTCP

Composite CM:

MOT1, MOT2, MOTP

ABB MNS iS MCC withModbus over TCP/IPInterface

MOT1_MNSiS_MBTCPData

MOT1_UMC100

MOT2_UMC100

MOTP_UMC100

Composite CM:

MOT1, MOT2, MOTP

ABB UMC100 withPROFIBUS Interface

MOTx_UMC100Data

1.1.9 ENERGY MANAGEMENT

Energy Management functions are licensed as an option to Minerals Control Library.

Energy Management Objects are intended for supervision of the electrical feeders,monitoring and controlling of loads with the target to ensure that the Energyconsumption of the Plant respects given conditions.

The Control Module Types for Energy Management objects and their correspondingStructured Data Types are located in the library BMI EnergyMgmt 1.0-0. for ControlBuilder Professional.

Reference Table: Examples of Energy Management ObjectsName Type Function Data Type

Load Composite CM

Load

Load :Enable grouping of MV-Switchgear according PlantSections in order to monitor and control their Energy consumption

Composed from : Load +3 DIC (Warning, Interlock,Tripping) +1 Reporting_Counter (EnergyCost)

Load_DataType

LoadShedding

Load Shedding Load Shedding:Enable to ensure that the Energy consumption of the Plant respects certain conditions accordingpriorities

LoadSheddingData

Power DemandSupervision

Composite CM

PowerDemandSupervision

PowerDemand Supervision:Enables input of tariff structure and their givenconditions to respect coming from the Energysupplier

Composed from : PowerDemandSupervision +8 Tariffs / each Tariff composed from 8 TariffSet +

PowerDemandData


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1 DIC (syncPulseAlarm) +

6 AIC Total Power, Total Current, ActualEnergyInInterval,ForecastEnergyAtIntervalEnd,EnergyMovingInterval,PeakPowerExceededTime,


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1.1.10 SUPPORT FOR PROCESS PANEL 800

BMI standard symbol library for Process Panel P800 is included in the MineralsControl and Operation Library.

The Process Panel 800 Object types provide access and control for the followingstandard control modules:

· MOT1· MOT2

· MOTP

· MOT1VVVF

· MOT2VVVF

· VLV1

· VLVNO1

· GROUP

· PREBIN

· AIS· AIC

· AOS

· AOC

· DIS

· DIC

· DOS

· DOC

All Process Panel objects have the following common basic functions:

·Manual control from the Process Panel (via commands and input fields)· Status and operation indication

· Mode selection from the Process Panel (via commands)

· Data exchange through a single access variable

For more info consult the documentation: Process Panel Reference Manual 3BHS240189

Control – AC800M – Minerals Library

Operation – Process Panel - AC800M Connect – Minerals Library


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· Operations AC800M Minerals Library

Operations AC800M Minerals Library integrates the Control AC800M Minerals Librarywith the Process Portal. The AC800M Connect Minerals Library provides displayelements and faceplates on the Process Portal, for monitoring and control of objectsdefined by means of the AC800M Minerals Library.

The figure below shows examples of the display elements with status indication of equipment as presented on the process displays.

See as well chapter 1.2.1 Look and feel.


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Example of a motor Faceplate (Extended View)

1.1.11 BASIC OBJECTS

1.1.11.1 Analog Input (AIS, AISandunit, AISbar)

Main purpose of Module: Analog Input Interface

Tag nameDescr i t ion

Point of Controlindication

Motor statusIndication

Start motor

Stop motor

Acknowledge Alarm Extended view

Change Point of Control

Seq => SequenceCen => Central

Loc => Local

Call up

Object

AlarmList

Call up

Object

EventList


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The analog input module for 1 IO-signal provides the following features:

· Blocking and forcing of input value generating event (even on new forced values)

· Threshold detection and alarming on 4 alarm limit levels (L2,L1,H1,H2)

· Threshold detection and eventing on 2 Process Limit levels (Plo, Phi)

· Adjustable Low Pass Filter.

· FilteredSignal Rate of change calculation and alarm. The ROC is presented in %of Total Range per second.

· All Substatus for DP, PA and FF Field Devices will generate error control whenquality is Bad or Uncertain for AIS Control Module.

· Common or Individual alarm delay for all 6 limits.

· Alarm blocking (from faceplate). All alarm limit levels will be blocked.

· Alarm disabling/enabling of each alarm limit individually (from application program /Faceplate); generating events when blocked.

· Trend for Signal Value, Filtered Value and Rate of Change

· Signal Error Pre-Warning with adjustable alarm delay

· Process Panel status indication and operation


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1.1.11.2 Analog Output (AOS, AOSandUnit)

Main purpose of Module: Analog Output Interface

The analog output module for 1 IO signal provides the following features:

· Automatic control from a superior application

· Manual control from the Operator Station (via the faceplate)

· Tracking of mode and output changes

· Output limitation high/low

· On-Line trend with actual output value shown in the faceplate.

· All Substatus for IO and FF Filed Device will generate error control when quality isBad or Uncertain for AOS Control Module



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1.1.11.3 DIGITAL INPUT (DIS)

Main purpose of Module: Digital Input Interface

The digital input module for 1 IO signal provides the following features:

· Blocking and forcing of input value generating event (even on new forced values)

· Alarming if input value differs from pre-defined (healthy; normal position) state

· Warning time to be used to generate a pre warning alarm or event before themain alarm (failure) occurs.

· Ready Delay time to hold the alarm position in order to prevent noisy signals toclear and re-activate the alarm very often.

· Alarm delay

· Alarm blocking (from faceplate). All alarm limit levels will be blocked.

· Alarm disabling/enabling (from application program)

· On-Line trend with actual input value

· Process Panel status indication


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1.1.11.4 DIGITAL OUTPUT (DOS, DOSTXT)

Main purpose of Module: Digital Output Interface

The digital output module for 1 IO signal provides the following features:

· Automatic control from a superior application

· Manual control from the Operator Station (via the faceplate)· Manual control from the Process Panel

· Tracking of mode and output changes

· On-Line trend with actual output value shown in the faceplate.



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1.1.12 GROUP OBJECTS

1.1.12.1 Group Sequence Start / Stop Controller (Group01)

Main purpose of Module: Sequence controller for starting / stopping a drive group

Group Off

Group Starting

Group on Hold

Group Running

Group Stopping

The group sequence start / stop module provides the following features:

· Starting / stopping of group members (up to 999 motors, valves, etc) in asequential order with Supervision of First Step in Hold, First Step Not Off on

Faceplate.· Consumer objects have 4 different Point of Control (POC): SEQ, CEN, LOC, and

Out Of Service.

· Modularity on Group control : Settings of the Consumer POC when Group starts(immediate, only on Step, never)

· Summary status indication of all pre-selected members (Ready, run, off)

· Alarming when exceeding maximum start-up / shut-down time

· 1 Safety interlock, 1 Chain Auto interlock, 4 start and 4 stop interlocks

· Emergency quick stop


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· Hold function. Interrupts start-up respectively shut-down sequence

· Show Tag function. Displays the tag numbers of the group members on theprocess display (adjacent to the graphic symbol of the members)

· Show Mem function. Emphasizes the group members on the process displayand indicates the start step number of each member.

· Simulation mode (Analog value, motor feedback….), to simulate feedback signalsof all group members.

· Auto Mode, starting and stopping the group with a delays from IA Interlock

· Unconditional Start, the operator or maintenance user is enabled to start the groupdisregarding any preselected Drives that are not Ready for Start (Start Interlock, ICinterlock, Presel Missing still active).

· Remaining Time Indication for the step shown in the Group faceplate and in theConsumer Objects as well


· Indication of TagName on the Group Faceplate for Consumers / StepOneGroup/ StepTwoGroup and PID in case of:

§ Consumer not ready for start§

Group in Hold§ Actual Starting / Stopping Step

· A Link button to access the faceplate of the indicated object


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· indication of 4 start and 4 stop interlocks

· In the case that sub-ordinate object is causing an interlock then the actual Tagname of the faulty object is dynamically propagated into the Group for theoperator quickly to see the reason for a problem


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1.1.12.2 Group Sequence Cyclic Controller (GrpCycleCtrl)

Main purpose of Module: Sequence controller for a cyclic activation of equipment

The module handles sequential and cyclic activation and de-activation of devices. Typically

used to control silo aeration valves when silos containing fine bulk materials are discharged.The module provides:

· Program selector with 3 programs selectable from faceplate or application

· 1 Safety interlock, 1 Chain Auto interlock, 2 start interlocks, 1 Previous drive

· Consumer objects have 4 different Point of Control (POC): SEQ, CEN, LOC, andOut Of Service.

· 2 External Alarm inputs and 2 External Warning inputs

· Sequence cycle time supervision, Alarming when exceeding maximum start-up /shut-down time

· Continuous execution or execution during a defined number of cycles

· Next step control from faceplate or application

· Modularity on Group control : Settings of the Consumer POC when Group starts(immediate, only on Step, never)

· 2 stepping modes (ByTime, ByTime and condition)

· 2 restart modes (step 1, last step)

· Automatic step over if all drives of a step are out of service or not selected

· Ready for start summary of all drives included in the selected program.


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· Show Mem function. Emphasizes the group members on the process displayand indicates the start step number of each member.

· Simulation mode (Analog value, motor feedback….), to simulate feedback signalsof all group members.


· In the case that sub-ordinate object is causing an interlock then the actual Tag

name of the faulty object is dynamically propagated into the Group for theoperator quickly to see the reason for a problem


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1.1.12.3 Pre-Selection (PREBIN)

Main purpose of Module: Routing control

PREBIN has no faceplate. Clicking on the push button symbol toggles the state. In casestand-by preselection is configured, an additional button is provided for each pre-selection todefine the current stand-by selection.

The pre-selection module allows the operator to select or de-select a single device or a setof devices within a group. By e.g. pressing “Silo1” all objects belonging to the route to silo 1are pre-selected. This does however, not cause a start-up of equipment, it is just a selection.When initiating a group sequence start, selected devices will start up in a sequential order;de-selected devices will shut down in a sequential order (provided they were in a runningstate).In case stand-by pre-selection is active, a pre-selected and running drive will initiate a

switchover (group start) when tripping, automatically starting up the stand-by pre-selecteddrives.

1.1.12.4 Start Warning (STW)

Main purpose of Module:

Control for buzzers and flashlights, prior to a remote start of equipment

STW has no stand-alone graphic element and no faceplate. It is tightly integrated with motor and group control. See Group control graphic element.

The start warning module is integrated with the consumer objects (e.g. MOT1, MOT2,MOTP, etc.). When a start command for a motor is initiated, the start warning module firsttriggers the buzzers and/or flashlights before it returns the actual start release for the motor.Different buzzers and flashlights can be assigned to appropriate start warning modules,which in turn are assigned to appropriate consumers.


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1.1.13 CONSUMER OBJECTS

1.1.13.1 Motor Controller – non reversing (MOT1)

Main purpose of Module: Controller for a motor with one direction (one speed)

Alarm

Interlock

Off

Bad Quality (OPC)

Running

Running, Central

Running, Central,Interlock Blocked

The control module for a one-direction motor provides the following features:

· Tight group sequence control integration (start/stop or open/close) from thecorresponding drive group. Sequence order within a group can be configured bysimply entering the step number parameter (1..999). Could be simulated fromthe group, with or without any alarms.

· Tight integration of object control and start warning in order to automaticallyactuate audible and/or visible warning devices prior to starting up.

· Out of service function. Enables the operator to take single motors out of control(No Action from the group, Faceplate neither LCB)

· Motor current indication and high limit warning supervision

· User definable Warning indication

· 3 additional interface inputs with MCC; for e.g. Overtemp, Overload & Availability

· 2 functional back process inputs with feedback time supervision for e.g. speed,pressure or flow supervision. Pulsed feedback supported as well with actual Periodtime shown on the Faceplate.

· 1 Safety interlock, 1 Chain Auto Interlock, 4 Process interlocks, 1 Previous drive

· 2 of the in total 4 Process (run) interlocks, can be configured as pure startinterlocks

· Totalisation and indication of run time (in hours) and number of starts


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· Operator Station Interface (graphic element and faceplate) including detailed alarmand interlock indications, separated between the object and its TagName


· Alarming during Simulation can be enabled for testing the Interlock, Feedback

· Alarming Condition defined by a Project Constant :

For Standard BMI Library, the consumer object alarming is enabled on:

§ Start order given, or

§ Consumer object in Auto mode

For Non Standard BMI Library, the consumer object alarming is enabled on:

§ GroupStart and Motor Preselect (or StandBy), or

§ POC is in Cen and Motor is started, or

§ Otherwise Not Ready Treatment is shown


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1.1.13.2 Variable Speed Drive Controller (MOT1_VVVF)

Main purpose of Module: Controller for a variable speed drive motor

The control module for a variable speed drive has basically the same functionality as MOT1,with the following additions:

· Tight group sequence control integration (start/stop or open/close) from thecorresponding drive group. Sequence order within a group can be configured bysimply entering the step number parameter (1...999). Could be simulated fromthe group, with or without any alarms.





· Motor speed indication

· Speed set point coming from the corresponding drive group (Automatic) or from theOperator Station / Process Panel (Manual)

· Speed set point low and high limitation





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· Totalisation and indication of run time (in hours) and number of starts




· Alarming during Simulation can be enabled for testing the Interlock, Feedback, etc.

· Alarming Condition defined by a Project Constant:









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1.1.13.3 Motor Controller – reversing (MOT2)

Main purpose of Module: Controller for a motor with two directions (or two speeds)

The control module for a reversing motor has basically the same functionality as MOT1,

however with the following adaptations:

· Tight group sequence control integration (start/stop or open/close) from thecorresponding drive group. Sequence order within a group can be configured bysimply entering the step number parameter (1..999). Could be simulated fromthe group, with or without any alarms.







· 2 feedback run signals (one feedback for each direction)




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· All interlocks, except equipment interlocks, are direction related

· Totalisation and indication of run time (in hours) and number of starts.

· New Remaining Time Indication for the step shown in the Group faceplate and inthe Consumer Objects as well



· Alarming during Simulation can be enabled for testing the Interlock, FeedBack,..

· Alarming Condition clearly defined by the mean of Project Constant :





§ GroupStart and Motor Pre-selection (or StandBy), or




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1.1.13.4 Variable Speed Drive Controller – reversing (MOT2_VVVF)

Main Purpose of Module: Controller for a variable speed motor with two directions

The control module for a reversing variable speed motor is a combination of the MOT2 andMOT1_VVVF modules, with the following features:

· Tight group sequence control integration (start/stop or open/close) from thecorresponding drive group. Sequence order within a group can be configuredby simply entering the step number parameter (1..999). Could be simulatedfrom the group, with or without any alarms.





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· Speed set point and limitation from the corresponding drive group (Automatic) or fromthe Operator Station / Process Panel (Manual) separately for X and Y direction



· 2 feedback run signals (one feedback for each direction)· 1 Safety interlock, 1 Chain Auto Interlock, 4 Process interlocks, 1 Previous drive


· All interlocks, except equipment interlocks, are direction related

· Totalisation and indication of run time (in hours) and number of starts.


· Supervision of the Actual Speed feedback during Start and Stop as configurablecondition for alarming and feedback to the drive group






§ GroupStart and Motor Pre-selection (or StandBy), or




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1.1.13.5 Damper/ Actuator Controller (MOTP)

Main purpose of Module:

Controller for a motorized damper with or without analog position feedback

The control module for a motorized damper/actuator provides the following features:

· Tight group sequence control integration (start/stop or open/close) from the correspondingdrive group. Sequence order within a group can be configured by simply enteringthe step number parameter (1..999). Could be simulated from the group, with or without any alarms.

· Tight integration of object control and start warning in order to automatically actuateaudible and/or visible warning devices prior to starting up.

· Out of service function. Enables the operator to take single motors out of control (No Action from the group, Faceplate neither LCB)

· 2 additional interface inputs with MCC; for e.g. Overload & Availability

· 2 position feedback signals with error indication if both are present at the same time

· 2 running feedback signals

· 1 Safety interlock, 1 Chain Auto Interlock, 1 Process interlock

· 1 Force interlock

· All interlocks are direction related

· Automatic position control either with internal or external set point, Analog or Digital

· Position set point low and high limitation.


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· New Remaining Time Indication for the step shown in the Group faceplate and in theConsumer Objects as well




· Alarming Condition clearly defined by the mean of Project Constant :









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1.1.13.6 Normally-closed Control (VLV1)

Main purpose of Module: Controller for a normally-closed one-way valve or actuator

The module controls valves with one or two coils and up to two position limit switches. Itprovides:




· 1 additional interface inputs with MCC; for e.g. Availability

· 2 position feedback signals with error indication if both are present at the same time.Timer delay.

· 1 Safety interlock, 1 Chain Auto Interlock, 2 Process interlocks, 1 Previous drive.

· One or two-coil, energized till Feedback or steadily features enabled.




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For Standard BMI Library, the consumer object alarming is enabled on :



For Non Standard BMI Library, the consumer object alarming is enabled on :§ GroupStart and Motor Preselect (or StandBy), or




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1.1.13.7 Normally-open valve Control (VLVNO1)

Main purpose of Module: Controller for a normally-open one-way valve or actuator

The module controls valves with one or two coils and up to two position limit switches. It

provides:




· 1 additional interface inputs with MCC; for e.g. Availability

· 2 position feedback signals with error indication if both are present at the same time.Timer delay.

· 1 Safety interlock, 1 Chain Auto Interlock, 2 Process interlocks, 1 Previous drive.

· One or two-coil, energized till Feedback or steadily features enabled.





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For Standard BMI Library, the consumer object alarming is enabled on :



For Non Standard BMI Library, the consumer object alarming is enabled on :

§

GroupStart and Motor Preselect (or StandBy), or § POC is in Cen and Motor is started, or



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· Auto tuning of control parameters P, I and D

· Gain scheduling

· Feed forward control

· Anti wind up

· 2 external set point references, that can be written from the application

·

2 external controller output references, that can be written from the application· Limit supervision of measured value and deviation, with integrated alarm annunciation

· Alarm and event handling with 3 alarm priorities

· Set point high and low limitation

· Controller output high and low limitation

· Event logging for control mode changes and set point changes

· Tracking and balancing modes

· FF State Machine possibility to set Cascade Mode position automatically whenrequested from the faceplate or from the FF Function Block.

· Status of MV, ActuatorPos and OUTP signals. All Sub-status for DP, PA and FF FieldDevices will generate error control when quality is Bad or Uncertain for MV and OUTP

· Threshold detection and event treatment on 2 Process Limit levels (Plo, Phi)

· Alarm disabling/enabling of each alarm limit individually (from application program /Faceplate); generating events when blocked (same for MV).


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1.1.15 REPORTING OBJECTS

Main purpose of Module: Report objects provide access to counter values.

Counters Control Module Type supports the following functions:

· Total and shift value Summation

· Reset counter value from controller or from the Operator Station (via the faceplate)

· Adjustment (positive & negative) of counter value and constant from the Operator Station (via the faceplate)

· Operator Station Interface (graphic element and faceplate)

4 different modes can be used as:· Pulse Counter (used to count pulses and multiply them with a factor)

· Integrator (used to integrate an Analog Input signal in case no pulse is available)

· Accumulator with external pulse (used when getting counter values from serialinterfaces)

· Delta Accumulator (used when getting counter values from serial interfaces)

And additionally a focused historical archiving for detailed information is also available:

· Actual Shift / Last Shift

· Actual Day / Last Day

· Actual Month / Last Month

Such as on kWh consumption for Cement Mills, Tons of material used for production, running timeof production critical equipment:


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1.1.16 COMPOSITE OBJECT TEMPLATES

Main purpose of composite objects is to provide serial communication interface andmethods to retrieve and present the extensive amount of information provided by the“intelligent” devices.

The library contains a so called Serial Object Framework in form of a composite Control Modulefor implementing serial (fieldbus, etc.) connected equipment. The modularity of the ControlModule allows equipment specific adaptation of the communication part to be used with the

standard object (MOTx, VLVx, CircuitBreaker, etc.) functions.

Serially connected, usually intelligent devices have the ability of providing much moreinformation of their functional status. The faceplate with its limited space is not seen as asuitable media to present all the additional information, most of which is not process operationrelated.

Therefore configurable link buttons have been provided in the Faceplate “Extebded Info” Area toallow direct access to additional aspects of the serial object from the Operator Station.


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1.1.17 ELECTRICAL CONTROL – ENERGY MANAGEMENT

The Electrical Control functionality is implemented in the 800xA Minerals Library using thesame basic software and system functions as process control. The equipment interfacesand the electrical control applications can be located in dedicated controllers or they canco-exist with the process control applications hence allowing a cost optimizedimplementation for small electrical rooms and sub stations.

The Electrical Control functionality contains following main categories of functions

· Supervision and visualization of Power Distribution network(s) – “single linediagram”. The information can be provided on the Operator Workplace terminal or on dedicated Electrical Workplace terminals or both.

· Energy Management functions (Optionally available) This functionality is based ona specific Library which is an extension to the Minerals Control library.

1.1.18 POWER DISTRIBUTION MONITORING

The Power Distribution Monitoring objects provide access and control for supervision andcontrol of power distribution equipment such as switchgear, and protection relays usingserial connectivity (e.g. ProfibusDP, Modbus or IEC61850).

The functional scope of the Power Distribution Network Monitoring contains

- the connectivity to the power distribution feeders and protection relays

- implementation of the feeder objects into system 800xA

- operating faceplates and the associated functionality of the objects

- graphical display (single line display) of the power network

- indication of the main measured values of each feeder

- access to detailed status data of each equipment (scope of data dependenton each device and used communication)

The functions are available on all (or selected) Operator Workplaces or on dedicatedElectrical Workplaces.


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1.1.18.1 Circuit Breaker

The Control Module Type CircuitBreaker is used to control a motorized Circuit Breaker with up to 1 CB and 2 Isolators, in a drive group or standalone.

Next to the common basic functions for consumer objects, the following functions aresupported for CircuitBreaker:

· Operation modes

· Selection of individual Breaker for operation

· Open / Close order to operate the breaker

· Indication of Breaker status

· Indication of Switches

· Current, Voltage and Power indication


· 3 additional interface inputs for each CB; for e.g. Trip, General Alarm & Ready

· 2 functional back process inputs with feedback time supervision; for e.g. CB, Isolator or Earth Switch ( ESW) Pos.Closed, Pos.Open

· 3 Process interlocks for the CB and 2 per Isolator.

· Totalisation and indication of CB Close time (in hours) and number of CB Trip andClose



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1.1.18.2 CircuitBreakerABBREF542Plus

Power Distribution Monitoring objects provide a composite Control Module with serialinterface to implement the supervision and operation of power network switchgear equipment. The example below presents ABB REF542+ with Modbus communication.

The Control Module can easily be adapted to other equipment and communication types.

Central Mode (operator) – C indication,

Indication of SwitchesIndication of Voltage, Current, Power

Central Mode (operator) – C indication,Indication of Breaker statusIndication of Voltage, Current, Power

The Control Module can easily be adapted to other equipment and communication types.Next to the common basic functions for group objects, the following functions aresupported:

· Operation modes

· Selection of individual Breaker for operation

· Open / Close order to operate the breaker

· Communication link error

· Indication of Breaker status

· Indication of Switches

· Indication of Voltage, Current, Power

· Button to access complete Serial information


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1.1.19 ENERGY MANAGEMENT

The Energy Management System consists of three major modules communicatingtogether:

· Power Demand Supervision

· Load Shedding Control (optional automatic switching-off)

· Load (Definition of a set of Circuit Breakers)

The Energy Management objects provide access and

control for supervision of the electrical feeders, monitoringand controlling of loads with the target to ensure that theEnergy consumption of the Plant respects given conditions.


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This is an Example where at 19:42 a load was switched on

o Forecast Energy At Interval End

o Actual Energy In Interval

o Energy Moving Interval

o Warning Level (90% pf alarm Level)

o Alarm Level

For this example, the ForeCast Energy At Interval End shows nicely that is based on the ActualEnergyInInterval and the TotalPower. It calculates how much Energy will be used at the end of theMetering Interval if the actual Power is steady till then.This is the fastest method as shown on the trends : the light blue curves is the first to cross the WarningLevel !


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1.1.19.1 Load

The Load Control Module Type enables grouping of MV-Switchgear according PlantSections in order to monitor and control their Energy consumption.

It contains following features :

· Communication between LoadShedding Module and the connected MV-Switchgear (up to 8 MV-Switchgear, otherwise please use the corresponding Function Blockincluded in the EnergyMgmt Library “Loads_CB_Compacting” (§3.4 Function Block)

· Possibility to connect MV-Switchgear into Load for monitoring only and not for shedding (MV/LV Trafo.Feeder).

· Calculation of total momentary load (active and reactive power)

· Calculation of momentary total load factor (utilization factor)

· Issuing of warnings and alarms. For example in the case of:

o Locking off of loadso Disconnection of loads

All of these Informations are available to the operator through standard interfaces from the BMI Library:

· Faceplate (see extended Faceplate §3.3.3.2)

· Multi-Trends (see extended Faceplate §3.3.3.2)

· Graphical Elements (see §3.3.1)

The Load Object is moreover extended by graphical Elements of

· DIS for direct access to Eventing / Alarming

· Counter for direct access to Cost Supervision


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1.1.19.2


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1.1.19.3 Loadshedding

The LoadShedding Control Module Type permit to ensure that the Energy consumptionof the Plant respects certain conditions according priorities.


· Communication between PowerDemand Module and the Loads

· Locking / releasing of loads according to the load situation within the metering period.

· Disconnection (load shedding) of loads according to the load situation within themetering period.

· Operating modes Eventing & Selection: Manual / Auto / Ext

· Consideration of certain priorities for disconnection of loads

.


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1.1.19.4 PowerDemandSupervision

The Powerdemandsupervision Control Module Type enables input of tariff structure andtheir given conditions as defined by the Energy supplier

Actual Tarif always shown on the base View


· Consideration of a certain tariff structure given by the energy supplier up to 8 differenttariffs each of them including up to 8 different TariffSets

· Supervision of time synchronisation for metering period.

· Calculation of total energy consumption over metering period

· Calculation of total energy consumption forecast at end of metering period

· Calculation of momentary total power factor and limit supervision

· Issuing of warnings (90%) and alarms. For example in the case of:




o Peak Power Exceeded Time

o TotalCurrent

Actual Tarif

conditions

Permanent

conditions


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· As well as Issuing of warnings (90%) and alarms in case of :

o Missing time-synchronization signal if the Signal is missing for longer then twotimes Metering Interval time.

o Impending change of tariff interval

This is an Example where at 19:42 a load was switched on




o Warning Level (90% pf alarm Level)

o Alarm Level

On this exemple, the ForeCast Energy At Interval End shows nicely that is based on the

ActualEnergyInInterval and the TotalPower. It calculates how much Energy will be used at the end of theMetering Interval if the actual Power is steady till then.This is the fastest method as shown on the trends : the light blue curves is the first to cross the WarningLevel !


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1.2 Some Implementation Concepts

1.2.1 LOOK AND FEEL

The library contains several possibilities to adapt its behavior both visually andfunctionally. The customization possibilities are described more closely in the referencedocumentation (Minerals Library Overview).

Below is an example of color coding in form of 6 predefined look and feel setup that canbe switched online. They can be as well extended and further customized.

1. Minerals Standard: Keeps the BU Minerals 4.1 look and feel

2. Holcim Standard: Holcim standard requirements regarding color and shapes

3. Hybrid Standard: The new BU Minerals style as an option for customers

4. Standard Type 4: Minerals Classic with red cross in case of not ready

5. VALE Standard: VALE Standard requirements regarding color and shapes

6. ASM: Alarm Status Monitor


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1.2.2 PCC (PRIORITY COMMAND CONNECTION)

PCC is a normally used structure of the application program to implement logicalconnections between various application objects. It uses structured variables and henceincreases both the engineering easiness (one logical connection) and informationexchange (multivariable connection) between application objects.

This overview shows the structure of PCC.

Through the PCC Bus it is possible to see the DIS, DIC, AIS and AIC limit that is causingsome fault to the consumer object on the Group and Motor Faceplates. The tag name of the alarming input signal is shown on the faceplate of the consumer. In the same way youwill find the link from DIS, DIC, AIS and AIC faceplate to the consumer tag name.

Alarms can be acknowledged at any Faceplate, i.e. the acknowledgement given on theGroup level will be propagated through the Motor down to the Signal level.

Group

Motor

Motor

Digital Input

Analog Input

Digital Input

PCC

Bus

Group DriveBus


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Examples of the use of PCC:

Forwarding of Warning thru PCC:

Forwarding of Failure thru PCC:

Group faceplate Consumer faceplate Signal faceplate

Group faceplate Consumer faceplate Signal faceplate


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1.2.3 POINT OF CONTROL (POC)

Group and consumer objects have four different Point of Control (modes):

- SEQuence

- CENtral

- LOCal

- Out of Service.

All POC are selectable from the operator workplace. The point of control defines from where theobject will be controlled. In order to control an object the corresponding POC must be selectedbefore giving any command to the object. For safety reason, stopping an object or closing a gateis always possible, no matter which control mode has been chosen.

Sequence: The object is controlled by a superior application program e.g. from a drive groupsequence. Sequence mode can be set from the operator station or by the application program.

Central: The object is controlled by the operator station by means of the start/stop or open/closepush buttons on the faceplate. Start/stop or open/close from a superior application program isalso possible in this mode. The Central mode can be set from the operator workplace only.

Consumer Objects in POC Sequence and Central have two sub-modes:

Man (default): An object is controlled by a rising edge start / stop command, either released from theoperator station or from the superior application program.

Auto:

An object is controlled by an input IA (IA =1 starts the motor, IA=0 stops the motor). Typical useof the auto mode is on/off control by thermostats, level switches, etc.In Central Auto and Sequence Auto mode the operator cannot control the objectany more from the operator station. Stopping a motor and closing a gate is alwayspossible.

Local:

The object is controlled from the field via the pushbuttons on the local control box (LCB). Tooperate a drive locally, the drives need the local release from the CCR operator. The point of control has to be changed in the CCR and can be set for a complete drive group or for everyobject individually.

The interlocks are de-activated in this mode except the safety interlock IC (Rope Switches,Bearing/Winding Temp., Vibrations etc.). Further more the two feed back signals (FB1 and FB2 –for example speedswitch) are also de-activated while pressing and holding the start/open pushbutton. Typically, the Local mode is for maintenance purposes.

Note: Alarms are disabled when an object is in Local mode (no alarm acknowledgment on theoperator station necessary when object is operated from the field).

Out of Service: The object is not in service and cannot be started from any location. It also meansthat the object will be skipped when running a superior group sequence. Out of Service mode canbe set and re-set from the operator station only with special user rights.

The Figure below shows the Control Modes and their graphical presentation for the Group andConsumer Objects. Please note that for better operator guidance the default POC (Central for Group and Sequence for Drives) is not indicated by a character on the process display.


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Group Sequence Start / Stop

For Group Control the ABB BU Minerals Library applications provide state of the art functionalityfor sequence start, stop, route and monitoring of all process objects in the plant.

Group Status Indications and monitor ingThe figure below shows all possible status indications of the group as presented in the processdisplay.

Light blue filled, whitearrow up / Green filled

Green arrow down flashing

Green filled with thick orange frame

Green filled

Green arrow up and Start warningflashing

Gray

Group starting / Startwarning

Group running

Group off

Group running / restart requiredas pre-selection has changed

Group stopping

Group running with warning insome of connected e ui ment

Light blue half filled with thick red frame

Light blue half filled

Gray / red arrow up

Green filled / red arrow down

Group failure and in hold (not off but as well not fully running) – not ready for start

Group in hold, ready to restart

Group off, start interlock active

Group run, stop interlock active

Group not ready for start becauseof Failure in at least one of theconnected consumers

Gray with thick red frame


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The group constantly monitors all process objects assigned to it and updates the status in real time. Thefaceplate provides additional detailed indication on:

· Tag Name of the Object not ready for start or in hold

· Interlock text for group start and stop interlocks

· Actual step and tag during Start-up and stopping

· Indication of pre-selection missing or error

Example of Group Faceplate indicating

Group not Ready for Start

Tagname of Object notReady for Start

Group Starting

Tagname of Object inactual Step

Group in Hold

Tagname of first objectin Hold


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Starting a group

A group may be started, if all pre-selected equipment assigned to the group is ready for start, thepre-selection is set correctly and no group start interlock is active. Initial starting is possible fromstatus “Off / Ready for Start”. A group restart can be preformed from the status: “Stopping”,“Hold” or “Running”.

Before starting the group, the pre-selections such as selecting alternative routing, standby units,

set points, etc., may be adjusted. The new settings are indicated in the process display and thefaceplate.

Pressing the “start” button in the faceplate the foll