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Automation Training Course

Automation Training Course


Advant OCS/AC400

© ABB Group
April 7, 2009 | Slide 1
ABB MMACS System Overview

• 4 Advant Controller 450 (AC450)


• 4 Advant Controller 70 (AC70)
• 6 Advant Operator Station 520 (AS520)
• S800 I/O Stations
• S800 I/O Modules
• 1 redundant Master Bus 300 ship’s network (MB300)
• 1 TCP/IP ship’s network
• redundant Advant Fieldbus 100 networks
• MODBUS communications
• Color Hardcopy printer
• Alarm and event printers

© ABB Group
April 7, 2009 | Slide 2
ABB MMACS System Overview
AS520-OS AS520-OS AS520-OS AS520-OS AS520-OS AS520-OS

MASTERBUS300
AC450 AC450 AC450 AC450

AC70 AC70 AC70 AC70

S800 S800 S800 S800

ADVANT FIELDBUS100

© ABB Group
April 7, 2009 | Slide 3
AC450 Controller Maintenance
Visual Inspection
Inspect the Advant Controller and the I/O cabinets at regular intervals determined by
environmental factors such as vibration, high ambient temperatures, and so on.

Safety
Check that all screwed joints and connections within the cabinets are tightened effectively.
Ensure that wiring, circuit boards and other electrical components are undamaged.
Pay particular attention to overheating, damaged insulation or signs of wear.

Cleanliness
Remove dust and any other soil from the cabinet with a vacuum cleaner. Use a lint-free cloth,
dampened with methylated spirits to remove stubborn dirt.

Air Filter
The fan unit located beneath the controller subrack (Advant Controller 450) always includes an
air filter. Wash the air filter included with the equipment in warm water with a mild detergent at
regular intervals determined by environmental conditions. Replace the filter after three such
washings. The new filter must be an approved spare part.

© ABB Group
April 7, 2009 | Slide 4
AC450 Controller Maintenance
Backup Batteries
Replace the rechargeable battery package mounted inside the controller cabinet on the
righthand side after every three years of service.
Also replace it after each complete discharge (the memory contents are lost), which
introduces the risk of battery cell damage.

Forced Cooling
The fan unit incorporates transducers which are activated by failure of the cooling
system. This condition is indicated in the data base (Station Element) and the system
status display in the central operator station.

Hardware Indicators
Most of the replaceable hardware modules are equipped with LED indicators.
• A green LED indicating running.
• A red LED indicating fault.
Some modules provide additional yellow LEDs for increased maintainability, for example
send and receive information on communication modules.

© ABB Group
April 7, 2009 | Slide 5
AC450 Controller Maintenance

Diagnostics and Fault Announcement


Both hardware and software in an Advant Controller 450
are provided with supervision against system fault.

The Controller and I/O Cabinet


• LED indicators on circuit boards:
– Green LED, RUN, indicates normal function.
– Yellow LED indicates an active signal, for example,
status of digital input (DI) or digital output (DO).
– Red LED, FAULT, indicates malfunction.

• Character display on processor module front:


– Show working mode, error or halt code.

© ABB Group
April 7, 2009 | Slide 6
AC450 Controller Maintenance

RC527 FAN UNIT


• High performance, three fans
• Uses redundant power supplies +24 VA and +24 VB
• Each fan separately fused
• Fan rotating speed supervision

© ABB Group
April 7, 2009 | Slide 7
AC450 Controller Maintenance

SA1xx POWER SUPPLY UNIT


Power supply units for a.c. to d.c. conversion
• Variants for different mains supply
• Unstabilized d.c. output
• Variants for different output voltage and load
• Provides galvanic isolation
• Rack or wall installation.

© ABB Group
April 7, 2009 | Slide 8
AC450 Controller Maintenance
SB511 Back-up Power Supply 24 – 48 Vdc
SB511 is a battery charger which works together with one single battery
package, for example, SB522. Use these two modules for current
supply of processor module RAM in the event of mains supply drop out.
The mains supply input provides fusing and other adequate protection.
Recharging takes approximately 10 hours after power-up battery replacement,
or trickle charging.
During recharging, a LED FC on module front lights up.
Diagnostic functions continuously supervise the operation. Error and other statuses are
indicated by module front LEDs. The information is available on the backplane
for further processing by the system status functions.
At installation, insert the module in the subrack first. Then connect the power supply (X9)!

© ABB Group
April 7, 2009 | Slide 9
AC450 Controller Maintenance
SB522 – Battery Unit
• Rechargeable 12 V, 4 Ah NiCd battery
• Charging and discharging via the battery charger
• Fits Battery Charger SB510, SB511
• Used for backup current supply of RAM.

SB522 includes 10 NiCd cells size D organized in two lines.


The battery package as well as the connecting device are semi-protected.
There is a built-in non-replaceable fuse to protect against shorts and results such as fire.
Store SB522 in a charged or discharged condition without considerable influence to
useful life.
To be installed vertically in a well-ventilated place.

© ABB Group
April 7, 2009 | Slide 10
AC450 Controller Maintenance
Advant Controller 450 – System Status Display
The appearance of the System Status Display in an Advant Station 500 Series operator
station is shown as follow:

© ABB Group
April 7, 2009 | Slide 11
AC450 Controller Maintenance
Advant Controller 450 – System Status Display:

1) (POW SUPP ST) 24 V supply A/B faulty


Supervision of the 24 V power supply for the subrack containing the processor module.
(only relevant when two redundant branches A and B are installed).
Check of Power Supply

2) (POW SUPP ST) Voltage Regulator faulty


Supervision of redundant 5 V regulators in the subrack containing the processor module
Check of Power Supply

3) (POW SUPP ST) Voltage Regulator faulty


Supervision of particular 5 V regulator in the subrack containing the processor module.
(only relevant when redundant 5 V regulators are installed).
Replace the regulator pointed out. Check of Power Supply

4) (POW SUPP ST) Backup Battery faulty


Supervision of the battery charge and the battery condition.
Replace the Battery Unit SB522. Check of Power Supply

5) (POW SUPP ST) Battery Charger faulty


Supervision of the backup power supply of RAM.
Check of Backup Power Supply

© ABB Group
April 7, 2009 | Slide 12
AC450 Controller Maintenance
Advant Controller 450 – System Status Display:

6) (DEV ST) Error in CPU


Supervision of redundant processor modules
Replace the pointed out processor module
Fault finding in case of a single processor module or stop of both modules when redundant.
Check of Backup Power Supply

7) (PROGRAM CARD) Memory error/Missing card/Wrong card <pos.>


Supervision of program card including system software (check sum)
Install or replace program card (PCMCIA)
Replace processor module PM511

8) (PROGRAM CARD) Memory error/Missing card/Wrong card <pos.>


Supervision of program card including system software (check sum)
Install or replace program card (PCMCIA)
Replace program card interface MB510

9) (POW SUPP ST) 24 V I/O supply A/B faulty


Supervision of the 24 V power supply for one or several I/O subracks (collecting alarm).
Each branch A/B is supervised if redundant branches are installed.
Check of Power Supply

© ABB Group
April 7, 2009 | Slide 13
AC450 Controller Maintenance
Advant Controller 450 – System Status Display:

10) (POW SUPP ST) 24 V I/O supply A/B faulty


Supervision of the 24 V power supply for one or several I/O subracks (collecting alarm)
Each branch A/B is supervised if redundant branches are installed.
Check of Backup Power Supply

11) (POW SUPP ST) I/O voltage regulator faulty


Supervision of redundant 5V regulators in one or several I/O subrack (collecting alarm)
Check of Backup Power Supply

12) ( - ) Fan for CPU faulty


Supervision of the fan unit in the controller subrack. Note! The Fan Unit requires 24Vdc
(24VA and/or 24VB) for reporting FAN ERR (active fault signal)
Check function in cabinet.
Check fuses in the fan unit RC527
Check electrical signal
Replace fan unit

13) (P) Fan for I/O faulty


Supervision of fans in all I/O subracks (collecting signal)
Check function in cabinet.
Check fuses in the fan unit RC527
Check electrical signal
Replace fan unit
© ABB Group
April 7, 2009 | Slide 14
AC450 Controller Maintenance
Advant Controller 450 – System Status Display:
14) (S100 BUS EXT STATUS) Bus extender error
Supervision of S100 I/O Bus Extenders
Check the communication link with respect to damage, loose connector, broken wire, etc.
Replace the faulty bus extender DSBC 174 or DSBC 176
15) ( - ) User defined error 1
Supervision of application defined function
Check application function in the cabinet
16) ( - ) User defined error 1
Supervision of function in application program (AMPL)
Check application program
17) N/A
18) (RS 232) CI531 missing
Supervision of printer and its communication
Check the communication link with respect to damage, loose connector, broken wire, and so on.
Check the printer
Replace hardware modules; Modems, Printer, CI531 one at a time
19) (RS 232) CI531 missing
Supervision of the communication with an external computer using V.24/RS-232-C and EXCOM
Check the communication link with respect to damage, loose connector, broken wire, and so on.
Check the computer
Replace hardware modules; Modems, Printer, CI531 one at a time
© ABB Group
April 7, 2009 | Slide 15
Common properties:
Display elements, Object Displays, Dialogs,
Process Displays

© ABB Group
April 7, 2009 | Slide 16
© ABB Group
April 7, 2009 | Slide 17
User Interface

AdvaCommand software provides the operator


interface to monitor and control plant processes
using the Advant OCS. The AdvaCommand basic
software contains the following:

• AdvaCommand User Interface


• AdvaCommand Event and Alarm
• AdvaCommand System Status

© ABB Group
April 7, 2009 | Slide 18
Advant Station 500 Series Operator Stations

The complete
operator station for
process automation

© ABB Group
April 7, 2009 | Slide 19
Advant Station 500 Series Operator Stations

Single window
capabilities
Process supervision
& control

Engineering
tools

© ABB Group
April 7, 2009 | Slide 20
Advant Station 500 Series Operator Stations

Main Features
• Intuitive user interface
• Process supervision and control
• Single-window capabilities
• Graphical display builder
• On-line configuration of controllers
• Safety backup of all nodes on the control network

© ABB Group
April 7, 2009 | Slide 21
Advant Station 500 Series Operator Stations

Intuitive User Interface

• Full graphics with


high resolution

• Windowing
capabilities

© ABB Group
April 7, 2009 | Slide 22
Advant Station 500 Series Operator Stations

Windowing
• Basic Display
– gives overview
– covers the whole
display area
• Overlapping Displays
– gives detail
– on top of current
displays
– can be moved,
resized and closed

© ABB Group
April 7, 2009 | Slide 23
Advant Station 500 Series Operator Stations

Intuitive User Interface


• “Point-and-click”
operation
• Dialog boxes
• Pull-down menus

© ABB Group
April 7, 2009 | Slide 24
Process Supervision and Control

• Presentation
• Manual control
• Event and alarm handling
• Self diagnostics
• Status lists
• Process Sectioning

© ABB Group
April 7, 2009 | Slide 25
AdvaCommand User Interface
Screen Layout
Icons for system Date and time Fixed display area
functions

Alarm line
Display name
and description

Display area

Object close-up
area
Dynamic keys
Dialog line
Message line

© ABB Group
April 7, 2009 | Slide 26
AdvaCommand User Interface
Trend curves

• Access to logged
variables throughout
the system
• TTD logs
• AdvaInform History
• Object selection
from trend displays

© ABB Group
April 7, 2009 | Slide 27
AdvaCommand User Interface
Manual Control

Selected object
corresponding dialog
and
object close-up

© ABB Group
April 7, 2009 | Slide 28
AdvaCommand User Interface
Object Display

• Automatically
created
• No extra
configuration
• Available for all
objects in the
system
• Controller objects
• One layout for every
object type

© ABB Group
April 7, 2009 | Slide 29
AdvaCommand User Interface
Object Trend

• Automatically
created
• No extra
configuration
• Available for all
variables logged in
the controllers

© ABB Group
April 7, 2009 | Slide 30
AdvaCommand Event and Alarm
Operation by exception
• Status in process
displays
• Status in object displays
and closeups
• Alarm bar showing latest
alarm
• Alarm and event lists
• Direct object selection
• Operator
acknowledgment
• External alarms
• Alarm grouping

© ABB Group
April 7, 2009 | Slide 31
AdvaCommand System Status
Continuous diagnosis of the control system

• List of control system


alarms
• Control network
overview
• Status for individual
nodes
– I/O boards
– Communication
– Other hardware
components

© ABB Group
April 7, 2009 | Slide 32
AdvaCommand Status List
Instant status reports of the process
Flexible search keys

List presentation

© ABB Group
April 7, 2009 | Slide 33
AdvaCommand Process Sectioning

• Operator
authority
definition
• Alarm and event
processing
• Storage
• Display
• Printing
• External alarms

© ABB Group
April 7, 2009 | Slide 34
AdvaBuild Display Builder
WYSIWYG (What You See Is What You Get)

Object list
Dynamic
display
elements

Graphics palette
with drawing tools Color
palette
© ABB Group
April 7, 2009 | Slide 35
AdvaBuild On-line Builder
Facilitates commissioning and maintenance

Live process
values
On-line
configuration of
controllers through
a window

© ABB Group
April 7, 2009 | Slide 36
AdvaBuild Central Backup
Safety backups of controller application software

Cyclic backup
using timer

Status indication Time of last backup

© ABB Group
April 7, 2009 | Slide 37
Hardware Platform & System Software

• HP Workstations
– High performance
processor
– High resolution graphical
user interface
• Real-Time Accelerator
• System software
– UNIX, OSF/Motif, SQL,
X Window System,
TCP/IP

© ABB Group
April 7, 2009 | Slide 38
Real-Time Accelerator

• Co-processor board in the workstation


• High performance CPU ensures real-time behavior
• Includes two MasterBus 300 channels for
redundant connection to control network

© ABB Group
April 7, 2009 | Slide 39
Function Keyboard
Security
key Alpha numerical (QWERTY)

Del ! @ # $ % ^ & * ( ) _ + + - Clear


BS Line Line Line F1 F2 F3 F4
ESC 1 2 3 4 5 6 7 8 9 0 - =
Q W E R T Y U I O P { } | +
Char
-
Char
Clear
Display
Tab F5 F6 F7 F8
[ ] \
Caps CTRL A S D F G H J K L : ” Menu Prev
F9 F10 F11 F12
; ’
Z X C V B N M < > ? Select Next
User
Shift Shift
System
, . /
Print
Alt Alt
Enter

System Status Status Display Object


Dialog
Status 1 2 3 4 List List Req Req
Menu

System Display Event Alarm Prev Dialog


List 5 6 7 8 Menu List List Man Auto E1 E2 Dialog Object Exit 7 8 9 BS

System
Config 9 10 11 12 4 5 6 ,

+
? 13 14 15 16 D1 D2 D3 D4 D5 Object 1 2 3

17 18 19 20 D6 D7 D8 D9 D10 - 0 .
- Send

Display System Dynamic Direct Object & Numerical


selection functions keys dialog dialog control

© ABB Group
April 7, 2009 | Slide 40
Trackballs

OFF ON
Analog Control

• Two models
Acknowledge Send – Basic version with
Select Select
four buttons
– Enhanced trackball
with six buttons and
analog adjuster

© ABB Group
April 7, 2009 | Slide 41
Operator Station functions

User Interface
Event and Alarm
AdvaCommand System Status
operator interaction Process Sectioning
Status List
AdvaBuild
engineering Display Builder
Central Backup
On-line Builder

© ABB Group
April 7, 2009 | Slide 42
Summary

• Intuitive user interface


– Graphics, Windowing, Powerful dialogs & menus
• Process supervision and control
– Presentation, Manual control . . .
• Single-window capabilities
– X Windows
• Graphical display builder
– WYSIWYG, powerful menus & palettes, import
• On-line configuration of controllers
• Safety backup of all controllers on the control network

© ABB Group
April 7, 2009 | Slide 43
Keyboard, Mouse and Trackball

© ABB Group
April 7, 2009 | Slide 44
MOTCON
MIN Dialog

MAX Dialog

© ABB Group
April 7, 2009 | Slide 45
MOTCON

© ABB Group
April 7, 2009 | Slide 46
MOTCON

© ABB Group
April 7, 2009 | Slide 47
PIDCON

© ABB Group
April 7, 2009 | Slide 48
MIN Dialog

PIDCON

MAX Dialog

© ABB Group
April 7, 2009 | Slide 49
PIDCON

© ABB Group
April 7, 2009 | Slide 50
VALVECON

MIN Dialog

© ABB Group
April 7, 2009 | Slide 51
VALVECON

© ABB Group
April 7, 2009 | Slide 52
© ABB Group
April 7, 2009 | Slide 53
Keyboard Operation

© ABB Group
April 7, 2009 | Slide 54
Methods for Display Access
• From a Display Menu using cursor positioning.
• By using user-defined Direct Selection keys.
• By using the Dynamic Function keys.
• By using the Previous Display key.
• By using the paging keys.
• By using the Display Request key and entering the display
name.
• By using the Object to Display key.
• By using Display Links in Process Displays.
• By using System-defined keys.

© ABB Group
April 7, 2009 | Slide 55
Methods for selection of Process Objects

Mark and Select Process Object!!!

• Position cursor on the object symbol in the display and press the
select key or click with the select mouse button.
• Enter the object name.
• Position cursor on the object name presented on the latest
unacknowledged alarm line and press the select key or click with the
select mouse button.
• Position cursor on the object name in the Alarm List and press the
select key.
• Use the Prev Object key.

© ABB Group
April 7, 2009 | Slide 56
Event and Alarm Handling

© ABB Group
April 7, 2009 | Slide 57
System Status

© ABB Group
April 7, 2009 | Slide 58
Pop-up menu

© ABB Group
April 7, 2009 | Slide 59
© ABB Group
April 7, 2009 | Slide 60