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Leading paths to greater awareness, faster response and better decisions

Handling the unplanned outages has become the number-one priority for many companies today. On an average, operators deal with thousands of alarms per day. Hence, they should face no more than two alarms per 10-minute period but alarm overload distracts the operators and often causes unplanned downtime.

For maximum plant performance, high performance HMI and advanced alarm management helps to improve the operator’s tools and work environment. An ABB case study reveals savings of more than $800.000 from upgrading to a high performance HMI.

Importance of HMI

In control rooms of old, the number of alarms was limited by the amount of space on the control room panel board and the cost of wiring equipment from the production area to the board.

Annunciators, indicators and switches (to acknowledge and clear a resolved alarm) had to be essential to justify a place on the panel. If a new alarm was needed, an existing alarm would usually have to  make way.

This began to change with digital signals and the distributed control system (DCS) in the 1980s. Panel boards were replaced by monitors and servers, and signals were transmitted from plant equipment to computer processors, where the signals were turned into actionable information. But the alarms were overloading the control room and terms such as flooding, nuisance, chattering, fleeting and stale were coined to describe them and their effect on the operators.

Overview

Features and Benefits

■ Advant Master extended with

System 800xA for growth and

non-stop performance

Reducing time to decision and action

System 800xA Process Portal delivers

the exact information, filters out noise

to facilitate consistent, sound business

decisions, and provides the right tools

for the relevant user to take action as

quickly as possible

Optimizing plant asset availability

and performance

System 800xA real-time Plant Asset

Management features increase in process

uptime while reducing costs through

predictive and proactive maintenance.

Control, I/O and fieldbus for all plant needs

System 800xA offers a comprehensive

controller suite of standards-based hardware and software as well as a complete

line of industrial I/O for all plant needs.

System 800xA integration of all major

international standard fieldbuses offers

lower lifecycle costs through cost savings

in design, implementation and operation

of field equipment.

Automation System ABB Procontic T200.

Modular, powerful, decentrally expandable

The ABB Procontic T200 automation system isa modular control system that largely satisfiesthe requirements of today and tomorrow.

Thanks to its rack based architecture and widerange of modules, the ABB Procontic T200 canbe assembled to suit most any application.

The simple handling and planning of thesystem saves time and money.

ABB Procontic T200 programming software islBM-compatible and provides efficient processdisplay, PLC operation, and connection to fieldbuses.

ABB Procontic systems are designed for heavy-duty industrial operation and are distinguishedby their resistance to interference (EMC).

Extensive diagnostic functions of the ABBProconticT200 simplify commissioning andtroubleshooting of the system.

Efficient and easy-to-program serial bussystems connect separately located stations

The ABB Procontic field bus, ZB10, ex-changes process data with the other ABBProcontic systems.

The ABB Procontic T200 bus ZB20 is de.signed specially for data exchange betweenABB Procontic T200 stations, transportingparameters, and downloading programs.

Serial interfaces on the communication processor are also available for transfer ofprograms and signal states to an operatingstation.

An ABB Procontic T200 control consists, in itssimplest form, of a module rack, a central unit,program memory, an input module, an outputmodule, and a power supply unit.

Expansion module racks provide ample roomfor further input and output devices. 

Fourcentral units classified according to their ex-pandability and a series of pre-processors andinterface equipment 

enable optimum adaptationof the ABB Procontic T200 to the respectivecontrol task. 

The T200 can be configured cen-trally (in the immediate vicinity) or decentrally.

Powerful, responsive and accurate control of

industrial cranes in all types of environment.

For both new and retrofit installations.

ASTAT® for industry!

ASTAT, with slip-ring motors, has become the

leading technology for new heavy industrial

cranes in the growth regions of the world.

In Europe, ASTAT is mostly used for retrofit

installations or when normal industrial drives

are unable to fulfil the requirements.

We supply ASTAT solutions for applications up

to 4000 A or 4700 kVA.

The ASTAT Digital Crane Motion Controller has

better control and information properties

compared to earlier controllers. Equally

important is the focus on quality of hardware

components. The digital controller can be

mounted on a steel plant crane in hot countries

such as India without extra cooling or air

conditioning. This capability provides additional

benefits to worldwide industrial crane users.

i.e. The crane control system must withstand

dirty, hot and cold environments in addition to

difficult power supply systems. This has forced

us to integrate functions like brake control, time

relays, logic control and thermistor relays into

the ASTAT controller. 

Regulations

Concerning the Setting up of Installations

Apart from the basic “Regulations of the Setting up of

Power Installations” DIN VDE*0100 and for “The Rating

of Creepage Distances and Clearances” DIN VDE 0110

Part 1 and Part 2 the regulations “The Equipment of Power Installations with Electrical Components” DIN VDE 0160

in conjunction with DIN VDE 0660 Part 500 have to be

taken into due consideration.

Further attention has to be paid to DIN VDE 0113 Part 1

and Part 200 in case of the control of working and processing machines. If operating elements are to be mounted near parts with dangerous contact voltage DIN VDE

0106 Part 100 is additionally relevant.

If the protection against direct contact according to DIN

VDE 0160 is required, this has to be ensured by the user

(e.g. by incorporating the elements in a switch-gear cabinet). The devices are designed for pollution severity 2 in

accordance with DIN VDE 0110 Part 1. If higher pollution

is expected, the devices must be installed in appropriate housings.

General setup rules

An ABB AC 31 system always includes an AC 31 central unit. There are three types of central units:

– The 40 series central unit, with a local inputs / outputs extensions interface

– The 50 series central unit, with a local inputs / outputs extensions interface

and a CS 31 bus interface

– The 90 series central unit, with a CS 31 bus interface

Each central unit incorporates a specific number of binary inputs / outputs and occasionally

analog. It is possible, depending on the central unit, to increase the number of inputs / outputs,

to add input / output extensions connected directly to the central units or remote input / output

units via the CS 31 twisted pair.

Central units with extensions

The 40 and 50 series. It’s possible to increase the number of inputs / outputs of the basic

central unit by adding up to 6 local extension units of either type, binary or analog (Figure 1-1).

2.2. Central units with CS 31 bus

The 50 and 90 series. It’s possible to increase the number of inputs / outputs of the basic

central unit by adding remote units. The central unit controlling the system is called the

MASTER central unit. The maximum bus length is 500 m without an amplifier and 2000 m with

3 amplifiers (1 NCB or NCBR unit enables bus amplification for 500 m).

AC31 maintenance seminars

Getting knowledge of the programming language and

the hardware components, possible combinations,

start-up of a model plant including trouble shooting in

the automation system, in the area of the process interface level and in the model plant itself.

AC31 project planning seminars

Project planning, programming and commissioning of

model plants. Principles of networking and the data

exchange via serial interfaces (process control). Practical training at the automation systems.

AC31 maintenance seminars

Getting knowledge of the programming language and

the hardware components, possible combinations,

start-up of a model plant including trouble shooting in

the automation system, in the area of the process interface level and in the model plant itself.

Accuray Systems

AccuRay designed, manufactured and marketed computer-based automation and management

information systems for manufacturing processes to save raw materials and energy,

increase productivity, lower costs and improve product quality. AccuRay automation systems

controlled manufacturing processes in the pulp and paper, rubber, plastics, textile and metals industries.

AccuRay systems measured the basic properties of materials, such as weight, moisture, thickness, width, opacity and component content.

The technologies for performing such measurements employed a variety of physical and electronic principles that included nuclear,

X-ray, infrared, radio frequency, optical, pneumatic and electromagnetic techniques.

AccuRay technology and expertise has helped ABB maintain its status as the leading provider

of measurement and control technologies for the Pulp and Paper industries.

Technology Trends

Technology is changing our behavior at a fast pace. A large part

of today’s modern process automation system now consists of

server-client technology, inherited from the office automation

(IT) world. With the introduction of open standards for operating

systems and standard PC hardware and software, a new

challenge was introduced to process automation system owners.

In the past there was a level of protection from frequent software

updates and constantly increasing connectivity requirements,

now these parameters are in a constant state of flux. The

industry has embraced this technology as process automation

supplier’s shift from proprietary hardware and software to

custom-off-the-shelf (COTS).

MNS incoming solutions are verified by testing in

accordance with IEC 61439 series, in addition to

IEC 60947-1 required for the individual apparatus,

and engineered to meet the requirements of

IEC 61641. This ensures ABB’s offering of ‘Proven

Safety Plus’ for operators and plant.

Incoming options

All ACBs have as a minimum the following

features:

• Manual charging lever and ‘charged’ indication

• Manual open/close push buttons

• Mechanical ‘open’/’closed’ indication

• Mechanical signalling of ‘overcurrent’ release

• 4 auxiliary contacts

Project specific options

• Gas sealed connections to the main busbars

(separation wall)

• 3 or 4 pole solutions

• Withdrawable/fixed configuration

• Top or bottom cable entry/bus duct

• 50% or 100% neutral

• Shunt opening/closing release

• Undervoltage release

• Electrical signalisation of ACB status

• Key locking facilities

• Shutter locking facilities

• Mechanical indication ‘racked in’/’racked

out’/’test isolated’ position

• Locking in racked in/racked out/test

isolated position

• Switch disconnector option

• ACB handling truck

• Configuration and test unit

Power contact

Connection to the distribution bars is realized

using the precision-engineered MNS power

contacts. The power contact is characterized by a

turn-able bearing, thus decoupling cable stress

and electrical contact. Consequently any cable

bending forces cannot affect the stability of the

power contact.

The mechanical stabilisation is taken over by

the supporting plate and the contact spring

where the contact fingers ensure positive

electrical contact. Contact fingers are silver

plated as standard.

The contact has been subjected to several tests in

order to prove the sophisticated design and the

high quality:

• Verification by testing acc. IEC 61439 series

• Corrosion test acc. DIN 50017 and

IEC 60068-2-60

• Crimping quality check acc. IEC 61238-1

• Vibration and shock test acc. IEC 60068-2-6

and IEC 60068-2-27

A condaptor unit facilitates the horizontal

distribution of power from the vertical

distribution bars for 6E/4 and 6E/2 modules, see

illustration on page 35. The condaptor enables

the modules to be located adjacently within the

same horizontal position of the cubicle.

Modules of size 6E and above are connected

directly to the vertical distribution bars.