Category: ABB

Controller integrated or stand-alone condition

monitoring

The AC500 condition monitoring module FM502

is a natural part of the AC500 platform and

Automation Builder engineering suite, and can be

used in different condition monitoring concepts,

stand-alone or control integrated.

Due to the easy programming in PLC languages,

it is usable for a variety of use cases and is espe

cially suitable for plant, line and machine builders

as easy extension of their offering.

If controller integrated

• it enables at very reasonable cost

• the best prediction horizon as it can measure

online, when best measurement quality is given

without scheduling production interruptions

• while continuously protecting the application in

real time e.g. with the same or other sensor(s).

• Further inputs can be used as fast data logger

e.g. precisely documenting process quality.

Therefore it is not only able to continually check

the mechanical components but also gives fast

protection for spontaneous and large failures

even while measuring. The condition monitoring

mode creates a database internally or externally

for predictive maintenance. Automatic and user

assisted responses can be enabled to prevent

costly consequences including total failures.

As many as 16 vibration sensors + 2 encoder

counters can be connected.

Simplified engineering

The Process Control Objects (PCO) library for

AC500 V2 contains a function block for each

object. The control task is engineered with the

AC500 engineering tool Automation Builder.

The communication between the objects in Sys

tem 800xA and the function blocks in AC500 is

configured with Bulk Data Manager, which is part

of the System 800xA Engineering toolset. A li

brary with ready-made symbols and faceplates

for the objects is available for System 800xA engineering.

Integrated documentation

For engineering, the function blocks for AC500

include the user documentation. The faceplates

provide multi-language support for the text ele

ments and allow adaptation of the color codes of

the elements to the preferences of the application.

Availability

The Process Control Objects Library (PCO) for

AC500 V2 is available in Automation Builder as of

version 2.2.3. The Automation Builder installation

also contains the required OPC server. The corre

sponding 800xA PLC Object Library for 800xA or

Compact HMI can be ordered via the 800xA 6.0.3

add-on features list.

Integration of AC500 PLC into System 800xA

The AC500 PLC hardware can be used for certain

process control functions while the operator

benefits from user experience in System 800xA.

Proven libraries are provided for System 800xA

and AC500. This allows programming control

tasks in the AC500 PLC while System 800xA is the

operator interface. For large distributed projects,

many AC500 PLCs can be connected to a System

800xA node.

Process Control objects

Twelve objects are available which cover the

following functionalities:

• Digital and analog setpoints

• Analog measurement with threshold alarm

functions

• Valve control

• Motor control with or without variable speed

drives

• Proportional integral controller

Communication between System 800xA and AC500 PLC

Communication between the AC500 function

blocks and the objects in System 800xA uses the

PLC Connect option of System 800xA and the

AC500 OPC Server.

AC500-eCo CPU as S500 remote I/O

When the AC500-eCo compact CPU is used as

remote I/O, it can be programmed with  Automa

tion Builder for local intelligence while communi

cating via the open protocols Modbus TCP or

Modbus RTU with a CPU that will then be the

master of this intelligent remote I/O station. The

AC500-eCo CPU can be expanded by I/O modules

from the S500 and S500-eCo range.

S500 remote I/O with Modbus TCP

ABB provides a configurator in the Automation

Builder tool, which allows the configuration of

Modbus TCP I/O stations with the communica

tion interfaces CI521-MODTCP or CI522-MODTCP

in the same style as the AC500 configuration. For

larger applications a Bulk Data Manager tool can

be used. The configuration can be stored in the

communication interface, which allows using

the configured station with any PLC or PC that

supports Modbus TCP. This e.g. allows the use

directly on other controllers or monitoring

systems as e.g. ABB Ability™ Data Center Auto

mation or external systems.

Thanks to the Modbus feature that allows

several masters to exchange data with the same

slave, it is possible to use the I/O station as

shared devices with up to 10 PLC CPUs.

The Modbus masters can access the process data

of the I/O stations in two different ways:

• Fixed mode: each I/O module in the station

uses a separate register address range, which

requires separate Modbus read/write opera

tions for the modules in the station.

• The dynamic mode allows to pack the data of all

I/O modules in the station in one data structure

that can be exchanged in one single read/write operation.

S500 remote I/O

The availability of different fieldbus communi

cation interfaces makes it easy to use S500 I/O

modules as remote I/O for nearly any PLC and

PC. The S500 remote I/O station consists of a

communication interface and I/O modules. The

smallest configuration can be just the communi

cation interface with the onboard I/O channels.

Communication interfaces are available for the

following fieldbuses:

• PROFIBUS

• PROFINET/PROFIsafe

• EtherCAT

• Modbus TCP

• CANopen

• ABB CS31 System Bus

Easy engineering

The electronic configuration files that are

provided by ABB for different fieldbus systems

make it easy to configure the S500 remote I/O

station in your engineering tool. The files such as

GSD and GSDML are available for download at

www.abb.com/plc. For Modbus TCP remote I/O

stations a dedicated configurator is included in

Automation Builder and for larger applications a

Bulk Data Manager tool can be used.

Engineering suite

• ABB Automation Builder is the integrated soft

ware suite for machine builders and system

integrators requiring state-of-the-art produc

tive machine and system automation.

• Combining the tools required for configuring,

programming, debugging and maintaining

automation projects from one common intuitive

interface, Automation Builder addresses the

largest single cost element of most of today’s

industrial automation projects – software.

Programmable Logic Controllers PLCs

• The AC500-eCo, AC500. AC500-XC and AC500-S

scalable PLC ranges provide solutions for small,

medium and high-end applications.

• Our AC500 PLC platform offers different perfor

mance levels and is the ideal choice for high

availability, extreme environments, condition

monitoring, motion control or safety solutions.

• Our AC500 PLC platform offers interoperability

and compatibility in hardware and software

from compact PLCs up to high end and safety PLCs.

Control panels

• CP600-eCo, CP600 and CP600-Pro control

panels offer a wide range of features and func

tionalities for maximum operability.

• ABB control panels are distinguished by their

robustness and easy usability, providing all the

relevant information from production plants

and machines at one single touch.

PLC Automation product family

Overview

ABB offers a comprehensive range of scalable PLCs and robust HMI control

panels. Since its launch, the AC500 PLC platform has achieved significant

industry recognition for delivering high performance, quality and reliability.

AC500 HA offers hot standby redundancy

Hot swap of S500 I/O modules for increased availability

S500 I/O modules run with various controllers

AC500 PLC integration in ABB AbilityTM System 800xA

IEC 61850 protocol for substation and switchboard automation with AC500

AC500-S functional safety

Condition monitoring with AC500 PLC

AC500 PLC platform product ranges

PLC training and support offering

Application examples and notes

Automation Builder

Comprehensive range

• ABB delivers scalable, flexible and efficient

ranges of automation components to fulfill all

conceivable requirements of the most diverse

automation applications.

• ABB’s automation devices deliver solutions with

high performance and flexibility to be effec

tively deployed within various industries and

applications including water, building infra

structure, data centers, renewable energy,

machinery automation, material handling,

marine and many more.

Available accessories

– 120/240 Vac to 12Vdc GP and exp power supplies

– Pole or pipeline mounting kits

– Cold weather enclosure (also available in pipe mount

configuration)

– Regulators (carrier and calibration blend)

– SD memory card

– Export crating

– Tool kit

– Various maintenance kits

Installation dimensions

Specifications

– Designed for gas streams with the following characteristics:

– Clean is defined as having no particles larger than 1

micron and no more than 1 milligram of solids per cubic

meter of gas

– Dry is defined as no more than 7 psi of water per million

cubic feet of gas

– Dry is also defined as having less than 0.1 ppm of liquid

at the coldest ambient condition expected at the coldest

point in the system (the liquid can be water, oil, synthetic

lubricant, glycol, condensed sample, or any other nonvapor contaminate)

– Stable gas is defined as a vapor containing less than 0.1 ppm

of liquid when the vapor is cooled to 10°C below the coldest

ambient temperature possible at any point in the system

– Single stream capability. Manual calibration required

Historical data

The NGC8106 is designed to retain historical data. This data

can be used for audit trails, maintenance, and troubleshooting

to verify transmitter operation over time and provide a limited

data backup for communication link reliability.

The user is allowed to configure the period of the data

retained by the NGC8106 via the Operator Interface. The

default1 memory configuration provides the most recent 480

analysis cycles containing:

Stream averages for the (default1) 840 last hours, 35 last

days and the most recent last month analyses. Operational

parameters for the (default1) last 480 cycles (Diagnostics

Report): Audit logs (default1); Data retained by the NGC8106

can be collected via a remote communication link or by the laptop

PC local operator interface PCCU.

Gain a practical understanding of

the PGC2000 Process Gas

Chromatograph.

Course type and methods

This is an instructor led course with approximately

one third consisting of hands-on activities.

Student Profile

This training is intended for end user analyzer

technicians, operators or engineers responsible for

the operation of the PGC2000 Process Gas

Chromatograph.

Prerequisites

This is an entry level course designed for personnel

new to this analyzer system or those needing

refresher training.

Course objectives

Upon completion of this course, student will have a

basic understanding of the operation of the PGC2000

Process Gas Chromatograph.

Main Topics

• Basic Sample Systems

• Basic Gas Chromatography

• Analyzer Operation

• Controller Section

• Oven Section

Duration

The duration is 4 days.