Category: ABB

Process-level automation: The controller

The AC 800F hardware

The AC 800F has a modular structure. The CPU is

designed as a backplane to which various modules

– power supply units, Ethernet or fieldbus modules

– can be attached in line with the application.

On the fieldbus side, modules for PROFIBUS-DPV1.

FOUNDATION Fieldbus HSE, MODBUS (master/

slave, RTU or ASCII), IEC 608 0-5-101 and CAN for

Freelance Rack I/O are available. The fieldbus line

and the connected PROFIBUS slaves are entirely

configured and parameterized using the Control

Builder F engineering tool. No further external tools

are needed for configuration.

PROFIBUS slaves can be integrated into the system

using a GSD1) file or FDT/DTM ).

In the case of FOUNDATION Fieldbus, configuration

takes place using CFF ) or DD4) files. This allows

fieldbus parameterization even without connected

field devices.

The Freelance 800F process level

At the process level, a Freelance 800F system can

consist of several process stations that are connected

with I/O units. You have the option of running these

process stations either redundantly (CPU redundancy,

fieldbus module redundancy) or without redundancy.

Modular plug-in input/output modules are used in

accordance with the type and quantity of process

signals. With AC 800F, fieldbus-compliant compo

nents such as remote I/O or field devices can be

connected.

System communication

The operator and process levels communicate with

each other via the system bus (based on Ethernet)

with TCP/IP, where you can choose between various

transmission media such as AUI, twisted pair, fiber

optic or coaxial cable. A Freelance OPC server is

available for connecting to higher-level operator

stations (800xA) or other OPC clients. The real-time

process values and alarms from the Freelance sys

tem can be accessed via OPC. A „C“ programming

interface for Windows programs can be used for

external applications that do not use the standard

OPC interface. The DMS-API is used for this.

The Freelance 800F DigiVis operator level

The DigiVis operator stations use PC hardware, either

standard or industrialized in line with the application,

running under the Microsoft Windows operating

system. DigiVis supports dual-monitor operation,

meaning that two monitors can be used on a single

PC, operated using one mouse and one keyboard.

One engineering station and several operator stations

can be installed at the operator level. The Control

Builder F engineering station is used to configure and

commission the system. Usually, portable equipment

such as laptops, which allow configuration both in

the office and on site, is used. The operator level PCs

can also be used as engineering station. A permanent

connection to the engineering system is not neces sary.

System architecture

Freelance 800F is divided into an operator level and a

process level. The operator level contains the func

tions for operation and observation, archives and

logs, trends and alarms. Open-loop and closed-loop

control functions are processed in the controllers.

System communication

The operator and process levels communicate with

each other via the system bus (based on Ethernet)

with TCP/IP, where you can choose between various

transmission media such as AUI, twisted pair, fiber

optic or coaxial cable. A Freelance OPC server is

available for connecting to higher-level operator

stations (800xA) or other OPC clients. The real-time

process values and alarms from the Freelance sys

tem can be accessed via OPC. A „C“ programming

interface for Windows programs can be used for

external applications that do not use the standard

OPC interface. The DMS-API is used for this.

The same user-friendly configuration and support

features also apply to operation and observation. The

operator is supported by a mechanism providing not

only information from the plant but also operating

hints. For this purpose, for example, an intuitive

operator interface, logs, and sophisticated alarm and

message management function is available.

As hardware constitutes less of the price of an auto

mation system, the costs for creating user software

become more important, accounting for an average

of more than 50% of the total cost of an automation

project. This makes it clear that the mechanism, by

which cost structures can be changed to the user’s

advantage, must begin with engineering.

As hardware constitutes less of the price of an auto

mation system, the costs for creating user software

become more important, accounting for an average

of more than 50% of the total cost of an automation

project. This makes it clear that the mechanism, by

which cost structures can be changed to the user’s

advantage, must begin with engineering.

That‘s essentially why we‘ve developed Freelance

800F: to enhance cost efficiency by reducing engi

neering costs, while keeping hardware prices con

sistent with those of programmable logic controllers.

How can engineering costs be reduced?

• Use of only one engineering tool (Control Builder F)

to configure the entire system, consisting of  auto-

mation functions and the operator interface- with

displays and logs, as well as to configure fieldbus

lines (PROFIBUS, FOUNDATION Fieldbus, HART,

etc. ) and to parameterize field devices

• Automatic generation of the entire communication

between controllers and operator stations

• Lower cost and time investment for data input

due to a system-wide uniform database for field

devices, process stations and operator stations,

leading to data consistency within the entire system

• Uniform, system-wide plausibility check of user

programs via all process and operator stations up

to intelligent field devices, including formal check

for completeness and consistency of the user programs

• Graphical configuration with high-performance

editors in programming languages according to IEC 61131-3

– Function block diagram (FBD)

– Ladder diagram (LD)

– Instruction list (IL)

– Sequential function chart (SFC)

– Structured text (ST)

How can engineering costs be reduced?

• Use of only one engineering tool (Control Builder F)

to configure the entire system, consisting of  auto-

mation functions and the operator interface- with

displays and logs, as well as to configure fieldbus

lines (PROFIBUS, FOUNDATION Fieldbus, HART,

etc. ) and to parameterize field devices

• Automatic generation of the entire communication

between controllers and operator stations

• Lower cost and time investment for data input

due to a system-wide uniform database for field

devices, process stations and operator stations,

leading to data consistency within the entire system

• Uniform, system-wide plausibility check of user

programs via all process and operator stations up

to intelligent field devices, including formal check

for completeness and consistency of the user programs

• Graphical configuration with high-performance

editors in programming languages according to IEC 61131-3

– Function block diagram (FBD)

– Ladder diagram (LD)

– Instruction list (IL)

– Sequential function chart (SFC)

– Structured text (ST)

• Extensive function block library, to which user-

defined function blocks can be added; macro

library and graphics symbols to create graphics

and faceplates for user-defined function blocks

• Integration of any PROFIBUS-DP or PA slave

using the concept of the generic slave (using a

GSD-file) with the possibility of configuring these

components in user-defined dialogs

The quality of Freelance 800F is also reflected in the

robust hardware, which is immune to electromag

netic interference and bears the CE Mark as a quality

symbol for all its components.

In cases where demands on availability are particu

larly high, it is possible to configure the process

station including the modules redundantly. Fieldbus

lines, the system bus, and the operator stations can

also be configured redundantly.

The Freelance 800F control system provides power

ful automation that is cost-effective and easy to use.

Freelance 800F is ideally suited to applications re

quiring simple handling and attractively-priced hard

ware and software in power, process or environmental 

industry.

It is a sound investment in the future, with a simple

and clearly designed system based on the motto:

Minimum engineering – maximum automation

Communication

The RIO600 supports fast real-time horizontal GOOSE communication in accordance

with the IEC 61850 1st and 2nd edition standards for substation automation.

The RIO600 also supports Modbus TCP communication with a Modbus TCP client.

Both can be used in parallel in the same Ethernet bus.

The RIO600 sends and receives binary signals to and from ABB Relion®

protective relays and station automation units.

The RIO600 sends and receives binary signals between

 the protective relay and the station automation unit COM600.

The RIO600 subscribes to signals from five devices and publishes signals

to multiple devices depending on the user configuration.

Using the same Ethernet port, the RIO600 can be connected in parallel to

the PCM600 and the web browser via the same communication bus.

Hardware

Built on an industrial hardware platform, the RIO600 offers the same reliability,

performance and real-time functionality as ABB’s protection and control relays.

The modular design of the RIO600 makes it suitable for use in utility substations and

industrial environments with harsh electrical environments and climatic conditions.

A single RIO600 can have up to 40 I/O channels, and different types of I/O modules

can be stacked together in a completely flexible way to realise a wide range of applications.

The RIO600 subscribes to signals from five devices and publishes signals

to multiple devices depending on the user configuration.

Using the same Ethernet port, the RIO600 can be connected in parallel to

the PCM600 and the web browser via the same communication bus.

RIO600 communications include a current RJ-45 port or fibre optic LC Ethernet

for IEC 61850 GOOSE and Modbus TCP communications.

The RIO600 Web HMI is used for monitoring and diagnostics and 

all parameters can be configured by the user via the PCM600.