abb process automation, thwe lin han freelance … · the easy-to-use process control system abb...

FreelanceThe easy-to-useprocess control system

ABB Process Automation, Thwe Lin Han

© ABB / PA / Control Systems© ABB GroupMay 23, 2013 | Slide 2

ABB SystemsOfferings

• System 800xA• Operator Effectiveness• Automation and Power Integration• Integrated Safety• Enterprise Asset Management

ExtendedAutomation

• Freelance DCS• A full fledge easy to use Distributed Control

System• Compact Product Suite• A comprehensive suite of best-in-class control

products

EssentialAutomation

© ABB / PA / Control Systems© ABB GroupMay 23, 2013 | Slide 3

ABB Essential AutomationOfferings

• Ease of Use• Reliable• Scalable• Value for Money

FreelanceSystem

• A comprehensive suite of best-in-class controlproducts

• Flexibility of choice• Can be used in combination or standalone

CompactProduct

Suite

© ABB / PA / Control Systems

ABB Control SystemsExtended Automation & Essential Automation


What is Freelance?

Control Builder F DigiVis

+ I/O’s

AC 700F AC 800F

May 23, 2013 | Slide 5

Freelance is a Distributed Control System made up of these components

Engineering Tool ControllerOperator Station Controller


One common SW setupfor whole DCS

§ Engineering Tool

§ Operator Interface

§ Controller Emulator

à All on one PC

What’s special about Freelance?Smallest footprint HW and SW wise

May 23, 2013 | Slide 6

§ Installation in less than 5 minutes

§ Standard Office PC can be used(could run on your notebook)

§ Just Windows, no 3rd party SWneeded

§ Train yourself with Quick StartDVD (Computer Based Training)

Software Hardware


FreelanceFocus on Ease of Use

May 23, 2013 | Slide 7

Easeof Use

Pre-engineered

Easyto handle

Easyto extend

Easyto learn


SFC DisplayEvent listSystem Display (Module Diagnostics)

Example for Pre-Engineered in Freelance

May 23, 2013 | Slide 8

Group DisplayAlarm Line & Tool BarAutomatic Context Menu with aspects viewsFaceplate (Access on Tags)Overview Display (Table of Contents)Trend Display (Data Historian) DigiVisAC 700FAC 800Fpre-engineered

Automation market

Minimum EngineeringMaximum Automation


FreelanceScalable Architecture

May 23, 2013 | Slide 9

AC 700FController

with direct I/O

Profibus

Modbus

Engineering:Control Builder F

Industrial Ethernet(optionally redundant)

1 PC - optional Dual Screen

Operator Station:DigiVis

Start with just 16 I/O !!

AC 700FController

Add more controllersAdd Panel 800

Panel 800



May 23, 2013 | Slide 10

EngineeringStation:

Control Builder F

OperatorStations:

DigiVis

Operator Stations:Extended Operator

Workplace

AC 700FController

with direct I/O

Profibus

Modbus

Panel800

AC 700FController

Industrial Ethernet(optionally redundant)

Add moreOperatorStations

FieldDevices

UniversalMotorcontroller

Profibus

AC 800FController

FoundationFieldbus

AC 800FController,redundant

S800 I/OS800L I/O

S900I/O

Add Redundancy



May 23, 2013 | Slide 11


Start with Freelance

§ As small as 16 I/Os + 1 OS/ES(all in one PC)


May 23, 2013 | Slide 12

Grow easily later by adding...§ ... I/Os to existing Controller§ ... another DigiVis Operator Station§ ... another Controller§ ... Fieldbus§ ... Batch, Information Management§ ... Extended Operator Workplace


EngineeringControl Builder F – One tool for all

May 23, 2013 | Slide 13

§ Graphics configuration for operatorstation (DigiVis)

§ IEC 61131-3 programminglanguages

§ Graphic macro library with morethan 200 symbols

§ Function block library

§ Hardware and softwareconfiguration

§ Integrated fieldbus management

§ Online downloads andcommissioning

§ Cross-referencing of signalssystem wide

Software Hardware


Choose your IEC 61131-3 language

§ Function block library

§ More than 220 tested functionblocks with faceplates

§ Sequential Function Chart

§ Instruction List

§ Ladder Diagram

Control Builder FProgramming Languages

May 23, 2013 | Slide 14

§ Structured Text

§ Function Block Diagram

Why is that good?

§ Each language has it’s strengths.

§ Different editors are preferred by different users.

§ User can choose preferred language.


Pre-engineered visualizationcomponents§ Faceplates§ System display for hardware

diagnostics§ Extended hardware troubleshooting§ Event list, alarm line, trend displays

and automatically generatedSFC displays

Freelance Engineering ToolControl Builder F

May 23, 2013 | Slide 15

§ Configure intelligent field devicesand I/O’s

§ Fieldbus management fullyintegrated

§ Ready-made controller-to-controllercommunication


Fieldbus Management in Freelance

May 23, 2013 | Slide 16

§ Built-in Fieldbus support for§ PROFIBUS§ Fieldbus FOUNDATION§ HART§ MODBUS and others

§ Covers bus and deviceconfiguration

§ Setting fieldbus topology andparameters

§ E.g. transmission ratesand addresses

§ Scan bus for new devices§ Easy configuration and

diagnostics of field devices withFDT-technology


Device Type Manager (DTM)

§ Configuration andmanagement tool for fielddevices

§ Provide state-of-the-artgraphical user interface

§ Contains all graphical userdialogs, device configuration,diagnosis and maintenance

§ Operate on many controlsystems or asset managementtools without extra effort

Device Type Manager (DTM)Solves problem of intelligent field device engineering

May 23, 2013 | Slide 17

Fieldbus management


§ Open, standardized interface§ Supported by major intelligent

device vendors§ Proven by end users§ FDT enables device vendor to write

applications (DTM’s) fitting best totheir device

§ Efficient fieldbus and devicemanagement§ Similar device types (e.g.

Pressure) are presented inengineering tool with samestyle, reducing engineeringeffort

§ Free choice of device and systemsfor users

§ Consistent engineering data§ Support of full device functionality§ Plug and play

FDT/DTMBenefits and Opportunities

May 23, 2013 | Slide 18

© ABB / PA / Control SystemsMay 23, 2013 | Slide 19

§ GSD-File

What if a DTM is not available?

Slave TemplateSlave with structuredI/O and parameters

Slave BusParameter Set

§ I/O-Data description

§ Parameter description

§ User Dialogs

Fieldbus management


§ Easy Operation & Diagnosticsof entire system

§ Redundancy with 2 DigiVisStations

§ Offers many visualizationoptions:§ Dual monitor operation§ Free graphic displays

§ Standard graphic elements§ Bitmaps, 3D macro library

§ Clearly structuredfaceplates for operatorinterventions includinggroup displays

§ Trend displays includinghistorian

FreelanceOperator Interface: DigiVis

May 23, 2013 | Slide 20


Operator Interface: DigiVisMore visualization options

May 23, 2013 | Slide 21

Automatically generatedsystem displays for

§ Hardware diagnostics

§ Alarm pages for specific plantareas

§ Sequence control displays

§ Shift logs

§ Event logs

§ Excel reports

§ Data archiving


§ It’s a predefined display

§ It allows for diagnosticinformation about thecontroller hardware andconnected field devices

BenefitsSystem Display and Extended Diagnostics

May 23, 2013 | Slide 22

Mismatch between configuredand existing module

Some problemdown that module


FreelanceController – AC 800F

May 23, 2013 | Slide 23

Two versions

§ PM 802F:Typical up to 400 I/Os

§ PM 803F:Typical up to 1.000 I/Os

Redundancy for high availability

Fieldbus support

§ Profibus

§ Foundation Fieldbus

§ HART

§ Modbus Master and Slave

§ CAN for Freelance Rack I/O

§ Hot swap of Fieldbus modules

AC 800F coated (G3 compliant)hardware components available

AC 800F Controller


FreelanceController – AC 700F

May 23, 2013 | Slide 24

§ I/O scan time of 2ms possible§ CPU capacity for 300 I/O’s§ Temperature Range: 0...60 °C§ Monitoring of channels:

§ Short circuit & line break§ CPU PM 783F:

§ Front panel display foreasy diagnostics

§ 1 Ethernet port (10 /100Mbit)

§ 1 Profibus Master§ 1 RS-232 / 485 port -

Modbus§ 1 RS-232 port - extended

diagnostic§ AC 700F attracts PLC users to

use DCS

AC 700F Controller


§ Full range of signal typesincluding AI, AO, DI, DO, Temp,Pulse, Frequency, Relay

§ Inputs & Outputs mixed in onemodule!

§ Easy integration of up to 8direct I/O modules percontroller

§ Terminal units available as

§ Spring type or

§ Screw type

FreelanceS700 - Direct I/Os for AC 700F

May 23, 2013 | Slide 25

S700 – High density I/O modules


FreelanceProfibus Remote I/O S700

May 23, 2013 | Slide 26


§ Inputs & Outputs mixed in onemodule

§ 14 different I/O modules

§ 7 Digital

§ 6 Analog

§ 1 Analog + Digital

§ DC 705F – FBP Interfacemodule is a DC module

§ 8 DI + 8 DC I/O Channels

§ Easy Configuration usingTemplates

S700 – CompactProfibus Remote I/O



§ HART® functionality

§ 0° ... +55°C (+32°F…+131° F)ambience temperature

§ All Hardware components G3Compliant

§ Hot swap of modules

§ Redundancy also on I/Omodule level

§ Flexible configuration andinstallation


May 23, 2013 | Slide 27

S800 - Process I/O forGeneral Purpose


§ Remote I/O for mounting inATEX Zones 1 and 2applications + signals fromZone 0 / 1 / 2

§ -20° ... +70°C (-4° … +158° F)ambience temperature

§ Full range of signal typesincluding AI, AO, DI, DO, Temp,Pulse, Frequency

§ HART® functionality§ Hot swap of modules,

communication interfaces andpower supply

§ All S900 Hardwarecomponents G3 Compliant

§ Hot configuration in run, fullonline configuration capabilities


May 23, 2013 | Slide 28

S900 - Intrinsic Safety forhazardous environments

CB220 - Compact Box


Class G1: Mild§ Corrosion is NOT a factor in

determining equipmentreliability

Class G2: Moderate§ Corrosion is measurableClass G3: Harsh§ It is probable that corrosion

will occurClass GX: Severe§ Only specially designed and

packaged equipment will resist

What does coated and G3 compliant mean?Classification of environmental corrosion

May 23, 2013 | Slide 29

This doesn't happen toG3 compliant modules!


§ Intuitive auto router in FunctionBlock Diagram (FBD) editor

§ multiple programs simultaneouslyopen

§ Optimized for efficientEngineering, fewer clicks withauto-accept!

§ 100% compatible with formerversions

§ Even 18 years old Controllersstill supported

§ Installation in 5 minutes

The new Freelance Engineering ToolControl Builder F in version 2013


AC 900FAC 800FAC 700F

§ Release planned for Q2 2013 as part of Freelance 2013§ Complementing Freelance controller portfolio§ More connectivity and more power§ Attractively priced

The New Freelance Controller coming soonMore Power, more Speed, more Connectivity …


New Ethernet basedprotocols:IEC 60870-5-104Modbus TCP

Available forDCP 02/10Field ControllerAC 700FAC 800FAC 900F

New protocols


§ Simple protocol based on standard Ethernet§ Reduced installation effort by standard Ethernet networks§ Can be connected directly via internet (for remote stations,

distributed devices, web applications)§ High transfer rates up to 100Mb/s§ Can be master and slave

• Transfer rates in10baseTnetworks: up to360,000 registersper second

• Transfer rates in100baseTnetworks: up to3,600,000registers persecond

New protocols: Modbus TCP


§ Telecontrol protocol connects Freelance with RTUs andSubstations

§ Reduced installation effort by standard ethernet networks§ Higher transfer rates§ New functions compared to serial Telecontrol:

§ Redundancy / Time sync / Module diagnostics

New protocols: IEC 60870-5-104


§ F: More power than existing ControllersF: high speed 100Mb/s

§ B: Up to 1,500 I/O supported including 10 directI/O modules

§ F: Station RedundancyF: Hot plug Profibus MasterB: highest availability – no single point offailure

§ F: SD Card Support for application & firmwareupdate

§ B: no PC needed.. easy startup / easy backup /easy replacement

§ F: Modbus TCP Master/SlaveF: IEC 60870-5-104 telecontrol protocol onEthernet

§ B: more connectivity and more flexibility

§ F: G3 compliant by default for all AC 900F§ B: withstands aggressive environments

The New Freelance ControllerFeatures and benefits

§ AC 900F with direct IOs


AC 900FLayout and Interfaces

2 slots forcommunication

modules

4 x Ethernet10/100MB

2x seriallines

Modbus

Up to 10direct IOmodules

Power24V

Display (optional)

Switches/Buttons:ResetToggleOn/off

LEDs:PowerErrorRun/StopPrim/SecBattery

Battery (below display device)

1x Diag/Radio-Clock


AC 900F with direct IOs

§ Redundancy: highestavailability – no single point offailure

§ SD Card Support forapplication & firmware update

§ Display for diagnosis andmaintenance

§ more connectivity§ 2 x Profibus module with

Line redundancy§ 4x Ethernet und 2x Serial§ Modbus TCP via Ethernet§ IEC 60870-5-104

telecontrol protocol onEthernet

§ Up to 10 direct IOs§ New IO types

The new ControllerAC 900F


§ Up to 1.500 IO for typical Process Industry application

§ Up to 320 via direct IO (10 modules)

§ Profibus for more

IO ConnectivityNon Redundant Configuration

S800/S900S800/S900

Hart DeviceHart Device

PA DevicePA Device

DrivesDrives

S700S700Direct IO

Remote IO


§ Station Redundancy:§ 2 CPUs§ High-speed Red. Link§ Profibus Master module§ Direct IOs for non-red. controller

The New Freelance ControllerStation Redundancy

Red. Link (100 Mb/s)

MODBUS TCP

System Bus (100Mb/s)

S800/S900S800/S900

Hart DeviceHart Device

S700S700

PA DevicePA Device

DrivesDrives


SD Card Support§ Load / Save configuration without PC

§ also available for AC 700Fwith Freelance 2013

§ Backup existing configuration§ Firmware update possible§ „Restore“ via Display interface

The New Freelance ControllerDetails

Termination box/converter CableIntelligent Profibus Y-Link already built in

à no need for RLM01!

Line A

Line B


Name IOstypical

Perfor-mance

Ethernetports

Fieldbusslots

Intro.year

AC 700F 250 100% 1 1 2008

AC 800FPM 802F

400 200% 2 4 2000

AC 800FPM 803F

1,000 200% 2 4 2003

AC 900FStandard

1,500 300% 4 2 + serial 2013

AC 900FLight

2014

AC 900FPremium

2014

Freelance Controller FamilyMore connectivity and more power


Hardware comparison

Parameter AC 700F AC 800F AC 900F

CPU Redudancy - þ þ

SD card support þ - þ

Profibus Master modules 1 4 2 (with portredundancy)

CAN Bus modules - 1 -

FF HSE modules - 4 -

Modbus RTU ports 1 8 2

Modbus TCP ports 1 2 4

IEC 60870-5-101 ports 1 8 2

IEC 60870-5-104 ports 1 2 4

Direct IOs þ 8 modules - þ 10 modules

Typically IOs per controller upto

250 400/1,000 1,500

Ambience temperature 0-60 °C 0 – 60 °C 0 – 60 °C

G3 compliant - optional standard

…with Freelance 2013


Module Type Input Range Output RangeAX 721F 4 AI + 4 AO,

12 Bit+Sign0...10 V, -10...+10 V, 0/4...20mA, Pt100/1000, Ni1000, DI

-10...+10 V,0/4...20 mA

DI 724F 32 DI, 24 VDC

24V DC, 1-wire

DA 701F 16 DI, 8 DC, 4AI, 2 AO

0...10 V, -10...+10 V, 0/4...20mA, Pt100/1000, Ni1000, DI

-10...+10 V,0/4...20 mA

§ Three Remote IO modules now also as direct IOs withinAC 900F and AC 700F§ AX 721F§ DI 724F§ DA 701F super flexible… DI, DO, AI, AO

§ More flexibility with S700!

IO UpdateS700


IO UpdateS800 High Density I/O modules

§ DI818 / DO818 - 32 channel 24V§ TU818 (Screw Terminations)§ TU819 (2-25 pin D-sub)

§ DI828 - 16 channel 120V /DO828 - 16 channel Relay§ TU851 (Screw Terminations)§ TU852 and TU854 redundant

MTUs w/25 pin D-subs

Approximately 20% spacesavings in typical project

(approx. 70% digital signals)


§ New CI920AS and CI920AB forintrinsically safe (IS) installations

§ Higher Reliability§ Up to 15 slaves per segment

behind the Fieldbus isolatingrepeater(instead of 10)

§ No line lengths limitationsbesides PROFIBUS standard.

§ Must be used together withnew IS Profibus connectorBP914S!

§ Don‘t mix old interfaceswith new connectors &vice versa!

IO UpdateS900: New Profibus Communications interfaces

Non-hazardous areaHazardous area

BP914S

BP914S


AC 700F§ SD Card for Application &

Firmware update§ Profibus module with Line

redundancy§ High performance Profibus

master§ New direct IO Types§ Faster than before

AC 700F and AC 800F§ Modbus via Ethernet

(Modbus TCP/IP)§ IEC 60870-5-104 telecontrol

protocol on Ethernet

Why Upgrade to Freelance 2013Benefits for the huge installed base

AC 700F

AC 800F


On which version is your Freelance System?

Automation Sentinel Maintain PlusThe way to make your DCS fit for the future !

Newest VersionFormer Versions

V1 V2 V3 V4 V5 V6 V7 V8 V2013V9


Why to subscribe to Automation Sentinel Maintain PlusMy System is on Version 9 – What would be available?

1 2 3 4 5 6 7 8

2013§ New Controller : AC 900F§ Redundancy§ Modbus TCP§ IEC 870-5-104§ Support of SD Card for Application &

Firmware§ Display for maintenance, process value …§ New Profibus master with built-in line

redundancy§ System Bus (100 MB)§ 100% more capacity§ 100% faster§ 100% compatible§ Up to 10 direct IOs, more IO types§ 4x Ethernet on board, 2x Serial

§ New Control Builder F§ Improved auto router in FBD§ Tag/Var list Excel like with easy import/exp.§ Keep several editors open at once§ Optimized for engineering workflow

improvements – auto-accept reduces clicks!§ Fully compatible to former versions§ Project Tree with auto-hide§ Installation in 5 minutes§ WIN 7 look & feel, new icons

92013

Version


1. Easy to Install –Less than 5 minutes

2. Easy to Learn –Less than a week

3. Easy to Understand –Available in your language

4. Easy to Engineer –Everything using one tool

5. Easy to Backup –Entire application is just one file,fits on a small memory stick

6. Easy to Scale –Grows on a linear scale

7. Easy to Demo –Runs on any notebook

8. Easy to Sell –Customers love it and finally

9. Easy to Make Money

What Characterizes Freelance?The 9 E’s!!

May 23, 2013 | Slide 49

1 2 3

4 5 6

7 8 9


§ Central access to all fieldinformation

§ Field devices completely integratedinto control system engineering§ Only one tool for engineering,

commissioning and diagnostics§ Save money in

§ Engineering§ Commissioning§ Testing§ Service and maintenance

§ Assembly close to the field§ Reduction of field wiring and

space requirements§ All components match and are

optimized to work together

Why use Freelance?

May 23, 2013 | Slide 50


Liquefied petroleum gas (LPG) recovery+ process§ 1 x Control Builder F Engineering Station

§ 2 x DigiVis operator stations

§ 1 x redundant AC 800F controller

§ 1 x S800 remote I/O station, ca. 200 I/Osignals

§ Linking Device 800HSE, ca. 70 I/Osignals Foundation Fieldbus

Oil & Gas applications

June 4, 2012 | Slide 51

Styrene production§ 1 x Control Builder F Engineering Station


§ 2 x redundant AC 800F controllers

§ 22 x S800 remote I/O stations, ca. 3,000I/O signals


Plastics Production (Monomer)§ 2 x DigiVis operator stations

§ 1 x redundant AC 800F controller

§ S800 remote I/O stations, ca. 400 I/Osignals

§ S900 remote I/O stations, ca. 100 I/Ointrinsic safe signals

§ 800xA Batch management

Chemical applications

June 4, 2012 | Slide 52

Coal (High Sulphur) to Methanolproduction§ 4 x Control Builder F Engineering stations

§ 16 x DigiVis dual screen operator stations

§ 18 x AC 800F controllers

§ S800 remote I/O stations, ca. 6,000 I/Osignals

§ Integrated production schedule system

§ Integrated digital video monitor system


Pelletizing plant to process andexport iron§ 2 x Control Builder F Engineering

workstations§ 4 x Process Portal operator

workplaces§ 14 x redundant AC 800F controllers§ S800 I/O remote I/O stations, ca.

10,000 I/O signals

Mineral applications

| Slide 53

Cement Factory§ 3 x DigiVis operator stations§ 2 x AC 800F controllers§ S800 remote I/O station, ca. 1,000

I/O signals

June 4, 2012


Sugar Refinery

§ 1 x Control Builder F engineeringstation

§ 12 x DigiVis Operator Station

§ 5 x AC 800F controllers

§ 4,400 Rack I/O signals

Consumer applications

| Slide 54

Animal food production fromSugar Canes

§ 2 x 2 DigiVis operator station

§ 1 x AC 800F controller

§ S800 remote I/O stations, 700 I/Osignals

§ 800xA Batch management

June 4, 2012


Steel production




§ 3 x single AC 800F controllers

§ 2,000 I/O Rack I/O’s

Other applications

| Slide 55

Bio Diesel Plant




§ S800 remote I/O station, 1,500 I/O’s

June 4, 2012


Slab furnace§ 1 x Control Builder F engineering

station§ 15 x DigiVis operator stations§ 6 x AC 800F controllers§ S900 remote I/O stations,

ca. 2,000 I/O’s

Other applications

| Slide 56

Container Glass Production§ 1 x Control Builder F engineering

station§ 6 x DigiVis operator stations§ 11 x redundant AC 800F controllers§ S900 remote I/O stations,

ca. 4,200 I/O’s

June 4, 2012

© ABB / PA / Control Systems| Slide 57

Renewable Energy Power Plant




§ S800 remote I/O stations, ca. 3,000I/O signals

Other applications

Waste Water Treatment




§ S800 remote I/O stations, ca. 900I/O signals

June 4, 2012


Questions

June 4, 2012 | Slide 58

abb process automation, thwe lin han freelance … · the easy-to-use process control system abb...

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