ABB AC 800F Engineering Manual
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ABB AC 800F Engineering Manual

ABB AC 800F Engineering Manual

Process station engineer it control builder f
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Engineer
Control Builder F
Engineering Manual
Process Station - AC 800F
Gross Automation, 1725 South Johnson Road, New Berlin, WI 53146, www.ssacsales.com, 800-349-5827

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  • Page 1 Engineer Control Builder F Engineering Manual Process Station - AC 800F Gross Automation, 1725 South Johnson Road, New Berlin, WI 53146, www.ssacsales.com, 800-349-5827...
  • Page 2 The designations used and the products shown/mentioned in this manual have not been specifically marked regarding existing industrial property rights. No part of this manual may be reproduced without prior written permission from ABB Automation Products. Should you find any mistakes in this manual, please make a copy of the appropriate page(s) and send it/them to us with your comments.
  • Page 3 Engineering Manual Process Station – ABB FieldController 800 Gross Automation, 1725 South Johnson Road, New Berlin, WI 53146, www.ssacsales.com, 800-349-5827...
  • Page 4 Gross Automation, 1725 South Johnson Road, New Berlin, WI 53146, www.ssacsales.com, 800-349-5827...

  • Page 5: Table Of Contents

    Power fail signal (PF) and power fail ................16 Safety values for field devices ..................16 Configuration of process station AC 800F in the hardware structure ....17 Inserting Process Station AC 800F ................. 17 Process station AC 800FR redundant (new)..............18 Inserting modules in the AC 800F ...................
  • Page 6 Prozeßstation ABB FieldController 800 Commissioning of AC 800F ..................30 Operating via resource AC 800F ..................30 Task ..........................32 6.2.1 Process image display .....................33 Program list (PL).......................34 State displays in the project tree ..................34 6.4.1 Resource state displays ....................35 6.4.2 Resource state diagram ....................37 6.4.3...

  • Page 7: Notes On This Manual

    Process Station ABB FieldController 800 Notes on this manual To grant direct access to information, we have used different types of scripts and symbols. Script Meaning Italics Representation for (selectable) menu items or parameters. Inputs to be made via the keyboard, also via virtual keys.
  • Page 8 Gross Automation, 1725 South Johnson Road, New Berlin, WI 53146, www.ssacsales.com, 800-349-5827...

  • Page 9: General

    The Process station bus (CAN) connects a maximum of five I/O units to the AC 800F. It is used to transmit the input/output values from the AC 800F to the I/O modules. For this purpose, the AC 800F is equipped with fieldbus module FI 810F.
  • Page 10 • AM 801F : Battery module for redundant battery back-up The FieldController fieldbus modules are driven by the CPU board in the AC 800F housing. The data transmitted by the fieldbus modules is processed according to the configured link modules and then transferred to the operator station via the Ethernet modules and the DigiNet S system bus.

  • Page 11: Loading The Operating System And Eprom's

    Loading the operating system and EPROM’S Bootstrapping the Boot-EPROM’s The Boot-EPROM version on the AC 800F must match the software version of the engineering software. The Boot-EPROM can be updated during installation using DigiTool, although an up- date can also be carried out later using DigiTool Configure.

  • Page 12: Loading The Operating System

    Process Station ABB FieldController 800 Loading the operating system The operating system can be loaded by bootstrap via the system bus into the station. Requirement It is necessary that no operating system be present in the FieldController (RUN/STOP Led off). If necessary a general reset must be performed be- forehand.

  • Page 13: Configuration Of Resource Ac 800F In Project Tree

    AC 800F is displayed or AC 800FR for the redundant FieldController. A redundant process station type AC 800FR consists of two AC 800F. In each case both Field- Controllers are connected via a redundancy link and appear to the user in the project tree as a process station resource.

  • Page 14: Inserting A D-Ps Or D-Ps/Red Resource

    Process Station ABB FieldController 800 Inserting a D-PS or D-PS/RED resource Select target position of new process station → insert over a new process station can be inserted over the selected object → Insert under a new process station can be inserted under the selected object →...

  • Page 15: Processing And Failure Action

    Process Station ABB FieldController 800 Processing and failure action Automatic error handling at task level Error handling at task level is described in the flow chart (page 39). When an error is identified in a user program, an error task is executed once. The error- task is the highest priority task (priority 100) of a resource and is used to handle errors in user programs by user programs.

  • Page 16: Task Error Messages

    Process Station ABB FieldController 800 Task error messages ErrorNo Error text in status field Description INT/DINT overflow Signed integer or time operation caused overflow INT/DINT underflow Signed integer or time operation caused underflow INT/DINT div. by 0 Signed integer division by zero UINT/DINT div.

  • Page 17: Task Error Characteristics

    Process Station ABB FieldController 800 Task error characteristics Execute command Error occurred? Enters error information Enter error inform. in global variables: - ErrorNo in global variables - ErrorProgram - ErrorTask Current task = error task? Execute error task Recoverable error &&...

  • Page 18: Startup And Shutdown Performance Of The Modules

    Process Station ABB FieldController 800 Startup and Shutdown Performance of the Modules A signal for connection monitoring is continuously exchanged between I/O modules and the FieldController CPU of the process station or FieldController. If this signal does not appear for more than 250 ms (for 500 kbit/s) and/or 1,25 s (for 100 kbit/s ) both sides detect the interruption of the connection.

  • Page 19: Configuration Of Process Station Ac 800F In The Hardware Structure

    Inserting Process Station AC 800F The process station AC 800F can be inserted in the system in either the tree view or the system view. After INSERT, the object appears in both the tree view and the system view.

  • Page 20: Process Station Ac 800Fr Redundant (New)

    Otherwise the display is identical to the non-redundant FieldController. The selection list of the redundant AC 800F only offers modules marked with an R at the end, e.g. FI 830FR. The R stands for redundancy-capable and simply means that the parameter dialog differs slightly from the non-redundancy-capable object.

  • Page 21: Inserting Modules In The Ac 800F

    800FR) by a simple double click. Insertion of the modules is only possible in the upper basic unit. The selection list of the redundant AC 800F only offers modules marked with an R at the end, e.g. FI 830FR. The modules for the redundant AC 800F are identically constructed to those of the non-redundant AC 800F.

  • Page 22: Parameterization Of Ac 800F

    Module type, Profibus module here (FI830F 1_4_F1) Default name with station position 4, slot F1 Parameterization of AC 800F The FieldController takes the fieldbus modules, thus enabling several fieldbusses to be con- nected to this station, including different ones. The station must be allocated to a resource (D-PS). This defines which software part of the user program runs on which process station.

  • Page 23: Module Data Of Ac 800F

    Process Station ABB FieldController 800 5.4.1 Module data of AC 800F ac001us.bmp The module service data is only displayed during commissioning if a communication con- nection to the process station or FieldController exists at the same time. See also Engineering Manual, System Configuration, Commissioning.

  • Page 24: Location Of Ac 800F

    Process Station ABB FieldController 800 5.4.2 Location of AC 800F ac002us.bmp Rack location IP1 or IP2 Cabinet name Optional text details of cabinet identifier for FieldController with IP address 1 IP1 or IP2 Rack bay name Optional text details of rack bay identifier for FieldController with IP address 1 Gross Automation, 1725 South Johnson Road, New Berlin, WI 53146, www.ssacsales.com, 800-349-5827...

  • Page 25: Ac 800F Boot Parameters

    RAM_Free is set to 0, then both PRAM_Size and the maximum number of objects must be reduced. The AC 800F has 4 Mbytes memory. The memory is subdivided into differ- ent parts as listed below. The following are filed in the Flash memory : •...
  • Page 26 Process Station ABB FieldController 800 The RAM memory is divided into sections :: • object directory • PRAM • redundancy memory • object data • communication management The memory for the objects, memory for PRAM and, if available, memory for redundancy can be adjusted in the boot parameters of the resource.
  • Page 27 Select the I/O protocol Redundancy Default, - I/O EPROM’s capable of redundant operation must be plugged on all I/O modules. Not redundant As of version 6.1 (AC 800F only) not supported. Gross Automation, 1725 South Johnson Road, New Berlin, WI 53146, www.ssacsales.com, 800-349-5827...

  • Page 28: Ac 800F Modules

    802F power supply module for 24 V DC and redundant power supply, which meets stricter re- quirements for the availability of the power supply. For further parameter information and object data, see Parameterization of AC 800F, page 20 and Diagnostic data for objects, page 28.

  • Page 29: Ethernet Modules Ei 801F, Ei 802F, And Ei 803F

    There are three different variants : Ethernet module EI 801F with 10Base2 (Cheapernet or BNC), Ethernet module EI 802F with AUI connection and Ethernet module EI 803F with Twisted Pair connection. For further parameter information and object data, see Parameterization of AC 800F, page 20 and Diagnostic data for objects, page 28. 5.5.3 Battery module AM 801F Battery module of the FieldController.

  • Page 30: Can Module Fi 810F

    Freelance 2000 D-PS process station. Below the CAN module, a CAN master must be configured. For further parameter information and object data, see Parameterization of AC 800F, page 20 and Diagnostic data for objects, page 28. For each FieldController, it is possible to connect only one station bus (CAN) line with maximum 5 racks.

  • Page 31: Sta Error Codes

    Process Station ABB FieldController 800 5.6.1 STA Error codes If "Module fault" is reported for the module, correct operation of the I/O module is not guaranteed and no data are transmitted. The errors are saved bit-coded in the error code. The following are...

  • Page 32: Commissioning Of Ac 800F

    Process Station ABB FieldController 800 Commissioning of AC 800F Operating via resource AC 800F ac013us.bmp For redundant FieldControllers a redundancy toggle is initiated (toggle be- tween Primary and Secondary CPU). A toggle is possible only in SYNC status. The FieldController is loaded with the operating system and is initialized. In OOTSTRAP the case of redundancy only the Primary is loaded with the operating system.
  • Page 33 Process Station ABB FieldController 800 In the initialization, the FieldController performs a cold start. Any user pro- NITIALIZE gram already present is also deleted. The redundancy is now no longer ac- tive. The Secondary enters the “No BS” state. A cold start task -is per- formed once.

  • Page 34: Task

    Process Station ABB FieldController 800 Task Select project object task → Project → Header ac014us.bmp If configured for autostart, the task starts automatically when the resource is started. All lower-level program lists and programs start along with the task as long as the program list parameter has been set ON.

  • Page 35: Process Image Display

    Process Station ABB FieldController 800 6.2.1 Process image display Select project object task → Project → Header → S ac015us.bmp Variable name Variable name, max. 16 characters Type Data type, e.g. REAL, BOOL, UINT etc. State CLEAN Object is correct and loaded.

  • Page 36: Program List (Pl)

    Process Station ABB FieldController 800 Program list (PL) Select project object program list → Project → Header ac016us.bmp Processing Selected program list is switched on, and with it all lower-level programs. All function blocks with configured processing state set to ON are evaluated with each task cycle.

  • Page 37: Resource State Displays

    Process Station ABB FieldController 800 The color of the node in the display provides information about the effects of its configuration change on other objects. Higher-level information may also need to be updated in the station. In commissioning, nodes are displayed in the same formats as in configuration.
  • Page 38 Process Station ABB FieldController 800 Cold start stopped The command to cold start the resource had been initiated by the person responsible for commissioning, or from the system function „Force cold start”. Indicates self-test of the FieldController was OK, however, the...

  • Page 39: Resource State Diagram

    Process Station ABB FieldController 800 6.4.2 Resource state diagram State diagrams of redundant FieldControllers, see Page 47, States of the active Field- Controller (Primary). HW reset Force HW reset Hold Self test falled Self test ok and Self test ok and...

  • Page 40: Task State Displays

    Process Station ABB FieldController 800 6.4.3 Task state displays Ready Task already loaded and manual start possible. If no autostart has been configured for a task, it reverts to the ready state after each cold start and has to be restarted.

  • Page 41: Task State Diagram

    Process Station ABB FieldController 800 6.4.4 Task state diagram Unrecoverable errors are errors in configuration, for example division by zero. In this case the task, and in particular the program, should be checked. Non-existent Load Delete Delete Unrecoverable error Unrunnable...

  • Page 42: State Displayed In The Hardware Structure

    Process Station ABB FieldController 800 State displayed in the hardware structure After loading the resource in the FieldController, the system or FieldController knows which mod- ules and field devices are configured. The components (modules, devices) themselves may not have been installed yet, or the position of the installed component may not match the positions (slots) or bus addresses configured.

  • Page 43: Module State In The System And Station Views

    Process Station ABB FieldController 800 6.5.2 Module state in the system and station views The modules in the FieldController modules are displayed in various different colors according to their current state. ac018us.bmp Color and state transparent (rear view) There is no module configured in this slot, nor is any module installed in the station.

  • Page 44: State Of The Basic Unit

    Process Station ABB FieldController 800 6.5.3 State of the basic unit On insertion into the hardware structure the FieldController is displayed with its basic unit. The FieldController basic unit indicates whether the unit is active, inactive or faulty. Where a fault is indicated, this is generally due to the unit not being detected at all, i.e.

  • Page 45: Redundancy

    Process Station ABB FieldController 800 Redundancy In the case of redundancy a bumpless toggle is achieved between the active FieldController (Pri- mary)and a passive FieldController (Secondary), so that : • in the case of CPU failure the outputs of the I/O components are maintained, •...

  • Page 46: Synchronization

    Process Station ABB FieldController 800 Synchronization The active FieldController (Primary) automatically ensures that the passive FieldController (Sec- ondary) can take over in the event of redundancy. The adjustment of operating system, user pro- grams and redundancy data necessary for this is performed via a redundancy connection, the re- dundancy link.

  • Page 47: Redundancy Toggle

    Process Station ABB FieldController 800 Redundancy toggle If any of the following occur at the Primary, a redundancy toggle is initiated deliberately between Primary and Secondary: • the Prim/Sec toggle switch of the FieldController is actuated, • the Prim/Sec button of the resource is actuated in commissioning mode, •...

  • Page 48: Status Diagram Of The Active Fieldcontroller (Primary)

    Process Station ABB FieldController 800 Status diagram of the active FieldController (Primary) Primary no OS Download operating system no redundant Load user programms no Secondary Load user programs in Secondary Start Redundancy Resource toggle not sync Synchronize process data Overload Resource...

  • Page 49: States Of The Active Fieldcontroller (Primary)

    Process Station ABB FieldController 800 States of the active FieldController (Primary) The following redundancy states are displayed for the redundant resource reported on the re- source (project tree). not redundant The operating system is loaded but the user program is not yet completely loaded.

  • Page 50: Status Diagram Of The Passive Fieldcontroller (Secondary)

    Process Station ABB FieldController 800 Status diagram of the passive FieldController (Secondary) Secondary no OS Download of Secondary not Sync Redundancy toggle Synchronize process data sync Primary Redundancy toggle di1783us.sg States of the passive FieldController (Secondary) no operating system Operating system not active. The Secondary CPU is waiting for the trans- mission of the user programs.

  • Page 51: Technical Data On Redundancy

    Process Station ABB FieldController 800 Technical data on Redundancy Link monitoring Link monitoring between the Primary and a Secondary is carried out for FieldControllers linked via the CAN modules at 250 ms / 500 KBits/s (1250 ms / 100 KBit/s). If the FieldControllers are only connected via the Red-Link (Ethernet), link monitoring is ??? (approx.
  • Page 52 Process Station ABB FieldController 800 • Renew the resources assignment for the variables. This can be done manually or automati- cally. • The global system variables for the previously non-redundant resources, which have been used in programs or pictures, still have the previous resource allocation in the Variables List.
  • Page 53 Hardware structure ........................40 Configuration fault ........................... 42 Default names Modules ............................20 Diagnosis information for modules....................28 Diagnostic data..........................42 AC 800F............................21 DigiTool ............................. 7 DigiVis..............................7 Engineering station..........................7 EPROM-Download..........................9 Error code..........................28, 29 STA .............................. 29 Error handling of task ........................
  • Page 54 Process Station ABB FieldController 800 I/O unit..............................8 Insert Modules............................19 Load Operating system and EPROM's....................9 Profibus module EPROM......................10 Modbus ............................7, 8 Module Detail view ............................42 Network configuration ........................43 Operating system D-PS/FC Resource ........................10 Load .............................10 Parameter fault ..........................42 Power fail ............................16 signal ............................16...
  • Page 55 Toggle ............................45 Redundant ressource Status display ..........................47 Secondary ............................44 Serial interface module FI 820F...................... 27 Service data AC 800F............................21 Shutdown............................16 State display ..........................40, 42 Diagnostic data detected......................42 Program list..........................39 Resource ............................. 35 Task .............................
  • Page 56 Gross Automation, 1725 South Johnson Road, New Berlin, WI 53146, www.ssacsales.com, 800-349-5827...

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