CH112-04 Project Framework - RevB

800xA Minerals Training

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Chapter 4 Project Framework

TABLE OF CONTENTS Chapter 4 Project Framework ........................................................................................................................................................ 1

4.1 General Information............................................................................................................................................................. 2 4.1.1 Objectives ..................................................................................................................................................................... 2 4.1.2 Legend .......................................................................................................................................................................... 2

4.2 Automation Solution............................................................................................................................................................ 3 4.2.1 Control Project.............................................................................................................................................................. 4 4.2.2 Working in the Plant Explorer / Engineering Workplace ............................................................................................. 4 4.2.3 Working in the Project Explorer of Control Builder M ................................................................................................ 4 4.2.4 How to Create a Control Network ................................................................................................................................ 5 4.2.5 How to Create a Control Project ................................................................................................................................... 7 4.2.6 How to Start the Control Builder M.............................................................................................................................. 8

4.3 Project Explorer – Overview ............................................................................................................................................. 10 4.3.1 Online Help................................................................................................................................................................. 11 4.3.2 Toolbar Buttons .......................................................................................................................................................... 12 4.3.3 Project Tree................................................................................................................................................................. 12 4.3.4 Limits.......................................................................................................................................................................... 16

4.4 The POU Editor ................................................................................................................................................................. 17 4.4.1 Program Organization Units ....................................................................................................................................... 17 4.4.2 Editor Overview.......................................................................................................................................................... 18 4.4.3 Declaration Pane......................................................................................................................................................... 20 4.4.4 Message Pane.............................................................................................................................................................. 21 4.4.5 Code Pane ................................................................................................................................................................... 23

4.5 Test (Simulation) Mode..................................................................................................................................................... 25 4.6 Project Explorer – Plant Explorer ...................................................................................................................................... 26

4.6.1 Synchronization .......................................................................................................................................................... 28

CH112-04 Project Framework - RevB

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4.1 General Information

4.1.1 Objectives

On completion of this chapter you will be able to:

• Create a new Project in the 800xA system.

• Navigate in the Project Explorer.

• Structure the Application

• Describe the POU editor

• Interpret a Functional Specification.

4.1.2 Legend

< > Indicates a key name.

| Indicates when you go from one menu to a sub-menu.

Bold Indicates a menu name or an option in a menu, or file structures

“ “ Indicates dialog box buttons, tabs, instructions etc.

Indicates start/explanation of student activity


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4.2 Automation Solution

An Automation Solution is the integrated automation system for administration, maintenance and control. In System 800xA, you can create and handle many Control Projects which can comprise libraries, applications, controllers, security, graphic, history logs, etc.

The Project Explorer in Control Builder M and the Plant Explorer / Engineering Workplace should be considered as two separate interfaces for building and maintaining Control projects.

Plant Explorer /Engineering Workplace

Handles manyControl projects

AdministerControl projects

Faceplates andAlarm Lists

Operator Workplace

Control Builder MProject Explorer

Handles oneControl project

BuildsControl projects

Download toAC 800M controller

Control system

AC800MAspect System

800xA System

As an engineer you will continuously shift between the Project Explorer (Control Builder M) and the Plant Explorer (800xA workplace) while building Control Projects.

Control Builder M Professional is the certified tool to configure SIL certified applications. SIL stands for Safety Integrity Level, as specified in the standard IEC-61508. To run SIL certified AC 800M applications, you need the SIL certified AC 800M High Integrity controller.


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4.2.1 Control Project

Engineers, who are new with the Control Builder M programming tool, typically equate a program to a Control project. It is not the same thing.

Control projects are the 'traditional' programs for control within each geographical plant area (Control Network). They hold all the applications and controllers for controls like library objects, IEC 61131-3 code, hardware configuration, faceplates, etc.

4.2.2 Working in the Plant Explorer / Engineering Workplace

The following actions can / should only take place from the Plant Explorer / Engineering Workplace:

• View Aspects in Structures

• Editing graphics with Visual Basic

• Working with the Import/Export Tool for subsets of an Automation System

• Maintaining Backup and Restore for a complete Automation Solution

• Configuring security

• Maintaining Libraries via 'Library version definition' aspect

• Creating new library versions

4.2.3 Working in the Project Explorer of Control Builder M

The following actions can/should only take place from the Project Explorer:

• Creating hardware The Project Explorer only provides (lists) the relevant modules that can be connected to a certain object.

• Setting an application in Test and Simulate mode

• Upgrading applications

• Downloading applications to controllers

• Setting task connections


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4.2.4 How to Create a Control Network

Note that building operations for libraries and applications can be done to a great extent in the Project Explorer as well as in the Engineering Workplace.

The Plant Explorer / Engineering Workplace should be used to create the Control Network and establish a Control Project. A Control Network is used to group connected OPC Servers.

NOTE! The “Control Network” in the Control Structure corresponds to the physical Control Network.

1. Select the Control Structure in the Plant Explorer Workplace. This is the structure used to create Control Networks, set the OPC data source definition aspect, and create Control Projects.

2. Right mouse click on the Root and select “New Object” from the Context menu.


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3. Select the object type “Control Network” and give a suitable name.

4. The result will look like this:


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4.2.5 How to Create a Control Project

After you have created a Control Network, create a Control Project.

A Control Project groups applications and controllers together from the Project Explorer. Several Control Projects can be created in one Control Network.

1. Right mouse click on the Control Network object and select “New Object” from the Context menu.

2. Select a controller from the 800xA family (in our case select AC 800M)

3. Type in the name for the Control Project, such as “Project_XX”.


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4.2.6 How to Start the Control Builder M

When you created the Control Project object in the Plant Explorer / Engineering Workplace the Control Builder M application will automatically open.

If the Control Builder M application does not open automatically, right mouse click on the Project_XX, Control Project of the Control Structure and select “Open Project” from the context menu.


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You can also start Control Builder M Professional from the start menu of Windows.

Start | Programs | ABB Industrial IT | 800xA Engineer IT Control Builder M

It is also possible to use the shortcut on the desktop if this was installed.


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4.3 Project Explorer – Overview

The Project Explorer is a separate window with a menu bar and a Toolbar. The window is split into two separate viewing areas (panes). In the upper pane, the project is displayed in a tree view control with folders and in the lower pane there are three tab controls for Description, Check and Message.

The Project Explorer is a tool you can use to create, modify and navigate in a project. You can select all objects such as data types; functions and function block types and display them in an editor.

Lower Pane / Description Tab

A description, written in the editor (e.g. the program editor), of the selected object in the tree view control is displayed in the Description tab.

Lower Pane / Check Pane

A check of a selected object, e.g., an Application and its contents is performed when you select Check in the pop-up menu (click with the right mouse button). If any errors are found, they are displayed in the Check pane. Double-click on an error to locate the exact position of the error in an editor.

Lower Pane / Message Tab

The Message tab displays system activity messages, e.g., going from offline to online mode and opening files.


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4.3.1 Online Help

There is a powerful online help feature in the Control Builder.

Start the help with the help icon or select Help | Help Topics from the menu bar. You can also press <F1>, which provides context sensitive help on the item currently selected.

The Help Topics dialog box enables you to locate topics in the help files by using the table of contents (Contents tab), by selecting keywords that are assigned to topics (Index tab), or by searching for words within the file (Find tab).


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4.3.2 Toolbar Buttons

The Toolbar provides quick access to frequently used commands or options

Test Mode

Use this button for offline testing of the user programs, with no controller required. It compiles and simulates the project. All tasks are executed locally in the PC.

Online F5 Use this button to connect to the controller, e.g., if you want to debug the program code in running mode.

Download Project and Go Online

CTRL-D The program code in the application is compiled and downloaded for execution in the controller. The application automatically enters Online mode (see above).

NOTE! Downloads should be done always from the same Engineering Station.

4.3.3 Project Tree

The project is displayed in a tree view with the contents indented in an outline based on their logical hierarchical relationship. The objects in the Project Explorer are each represented by a name and an icon. By clicking on the button with a plus or minus sign beside the folder, you can expand or collapse an icon and the corresponding container.

The Project Tree contains 3 directories:


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4.3.3.1 Libraries

The Libraries folder contains all libraries used in a project. By inserting a library in to a project, its type will become available to connect to an application.

The libraries System, BasicLib, and IconLib are available in the Project Explorer by default when the Project is created. There are a number of additional libraries that can be inserted.

The libraries contain type definitions such as Data Types, Functions and Function Block Types and Control Module Types that can be used in the project.

4.3.3.2 Applications

A Control Project may contain one or more applications. The application is the largest organizational unit in any controller. However a controller may execute several applications. Each application may be considered as an independent object in the controller.

In the application create the Program(s) or Control Modules containing the program code to be compiled and downloaded for execution in the Controller(s). Each application to be used must be connected to a Controller by adding the Application to the Applications folder of the Controllers folder.

An application may contain up to 64 Programs. This means that you can split the control strategy into different parts, depending on required interval times and priorities.

NOTE! In this document the word “Code” refers to any instructions that the controller can execute.


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You may choose to write code in any one of 5 language editors in Control Builder:

Instruction ListLD A

ANDN B

ST C

Instruction ListLD A

ANDN B

ST C

Function Block Diagram

A C

B

C:= A AND NOT B;

Structured Text

C:= A AND NOT B;

Structured Text

A B C

-| |--|/|----------------( )

Ladder Diagram

A B C

-| |--|/|----------------( )

Ladder Diagram

Step 1 N FILL

Step 3

Step 2 S Empty

Transition 1

Transition 2

Sequential Function Chart

Step 1 N FILL

Step 3

Step 2 S Empty

Transition 1

Transition 2

Step 1 N FILL

Step 3

Step 2 S Empty

Transition 1

Transition 2

Transition 1

Transition 2

Sequential Function Chart

AND

All languages are available for both Programs and Control Modules. Choose the language that most suites your needs or preference.

There are two types of container that can be used to hold code in a control builder application:

• Control Modules

• Programs

Programs have a traditional look and feel and represent a traditional approach to application design and build. Within each program a selection of language editors may be used. Each program may be divided into ‘Code Blocks’ or ‘Tabs’, which may be thought of as sub-programs. In some editors you may divide the tab into several pages.

Control Modules are another way of compiling code which has many advantages over the traditional programs – applications written with control modules will use less memory and execute faster than those written with programs.

Application

Control Module 1

Control Module 2

Control Module N

Program 1 Program 2 Program N


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4.3.3.3 Controllers

The hardware definition and the I/O connection are done in the Controllers folder. In the root of the Controllers folder of each project, several controllers can be created. When you create a new project or insert a new controller, is it suitable to select the controller you intend to use in the project (AC800M or AC800M_Highintegrity).

The access variables are used for communication between applications, which may exist in the same controller or in different controllers. Hardware units are added to the tree structure representing physical hardware units.

The Applications containing the code are not executed unless a “work scheduler” - a Task - is connected and serves as an “engine” running the code in the controller. In the root of the Tasks folder of each Controller, several tasks can be created. Each Controller has three default Tasks labeled Fast, Normal and Slow with their interval times set to 50ms, 250ms and 1000ms respectively.

Each application to be used must be connected to a controller, by adding the application to the Connected Applications folder of the Controllers folder


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4.3.4 Limits

4.3.4.1 General Limits

• Max 64 programs per application

• Max 256 applications per project

• Max 8 applications per controller

• Max 32 tasks per controller

Application programming can be done from any Engineering Station in the system at the same time.

There is no access management. That means any changes will be overwritten by the last person who saves!

4.3.4.2 Minerals Applications Rule

1 Process Section 1 Application 1 Controller

That means, one process section is implemented in one application which is loaded in one controller.

Examples of process sections in Minerals applications: • Cement Mill • Kiln • Cooler • Raw Mill • Bunker Transport


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4.4 The POU Editor

4.4.1 Program Organization Units

The IEC 61131 standard describes Programs, Functions and Function Blocks as Program Organization Units or POUs. These units help you organize your automation project into code blocks to minimize code writing and optimize the code structure and code maintenance. The Functions and Function Blocks POUs are not limited to "one-time-use". You can use them repeatedly and in a recursive structure.

The ABB Extensions adds to the IEC 61131 standard two more POUs – Single Control Module (SCM) and Control Modules (CM) which are used for more sophisticated and efficient programming.

The figures below describe the hierarchical structure of the POUs. You could use both the Function Block and the Control Module recursively to an unlimited depth whereas the Program or Single Control Module is a "top-level" POU.

The Minerals Applications prefer to utilize SCM – CM programming method.

The Application contains the code that is to be compiled and downloaded for execution in the controller. An application should be seen as a container more than as a programming object, since it does not contain any code of its own. The application is the top hierarchical level.


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4.4.2 Editor Overview

Open the POU editor by double clicking on a Program, or right mouse click and choose Editor.

The POU editors of Program, Function Blocks and Control Modules have basically the same look and functionality. This section describes the functions and functionality of a Program.

The configuration of Control Modules and Function Blocks are covered later in this course.


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Toolbar Icons

The tables below describe menu commands, toolbar icons and keyboard short cuts common to all editors. Editor-specific functions are described in the chapter of respective editors.

Toolbar

icon Keyboard

hot key Description

Ctrl + U Saves the changes and closes the editor.

Ctrl + W Save the changes but does not close the editor.

Ctrl + B Checks the editor contents for errors. The result is displayed in the "Check" tab in the output pane. Double-click on the lines with error messages to jump directly to the place where an error occurred.

Ctrl + P Prints the current pane on a printer.

Ctrl + J Displays a screen preview of printer output.

Ctrl + Z Undoes the most recent action. You can undo several steps,

except in the ST code editor, which only supports undoing the most recent action. Not available in the SFC editor.

Ctrl + Y Recalls the last undo action. Not available in the ST code

and the SFC editor.

Ctrl + X Cut.

Ctrl + C Copy.

Ctrl + V Paste.

Ctrl + F Standard find function. Note: the function only searches the

current pane and present code block.

F3 Finds the next occurrence of a specified text string. Note:

the function only searches the current pane and present code block.

Standard find function, but searches all panes and all code

blocks (find in the Editor).

Toggles the display of the lower pane - the message pane.

Ctrl + I Inserts statements like if-then-else, for-loop, etc.

Ctrl + Space Fills in the rest of the name, for example, a variable name in

the code pane (complete word).

Ctrl + J Inserts a variable, data type or attribute in the declaration

pane or in the code pane.

INS Inserts a function or function block.

Ctrl + L Inserts a function.

Ctrl + E Edits a type. The type can be write protected, for example if

it is a system-protected type or an user-protected type.

Ctrl + M Edit Parameter List. Opens the connection editor for

parameter input assistance.


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4.4.3 Declaration Pane

Use the declaration pane to declare variables and Function Blocks. Depending on which editor you use, different declaration grids can be displayed by selecting the tabs at the bottom of the declaration pane.

NOTE! Copy/paste from MS programs like Excel is possible.

Variables

The variables in the program are the holders of values. They are declared by giving each a name and by assigning a data type. A single program may contain many variables and they must be declared when they are used. Variables can be written in Microsoft Excel and then copied and pasted to the declaration pane of the POU editor.

Function Blocks

Function Blocks must be declared in the Function Blocks tab before they are used in the ST or IL languages (Not necessary in the FBD or LD editors)


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4.4.4 Message Pane

The message pane consists of three tabs: Description, Check and Find in Editor.

Description

In the description tab, you can write notes in plain ASCII text. The notes are common to all code blocks and grids. It does not change depending on which tab is activated. The description is displayed in the lower pane of the tree view control by marking the edited object (for which a description has been written), e.g. a program in the tree view control and after that selecting the Description tab.

Check

When you are validating code, error messages are displayed in this pane. Double-click an error message to quickly go to the place where the error occurred.


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Find in Editor

You can use the Find in Editor command to search for a word in the entire current editor. The result is presented as a list in the message pane under the Find In Editor tab. You can double-click the row in the message pane to go quickly to the occurrence of the word.

NOTE! These commands can be used after text selection in the table or the code pane. The search is then performed through the selected text.


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4.4.5 Code Pane

The code pane is divided into code blocks. In the example below each tab contains a code block in one of the different programming languages. It is advisable to arrange the code in blocks to improve the overall code structure and readability.

The order of execution is determined by the order of the tabs for Function Blocks and Programs. The execution order for Control Modules is set up by the system for the most effective order possible.

NOTE! Code blocks may be rearranged by clicking right on the tab and selecting “Arrange” from the Context menu.


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Change the language

To change language on a code block, right click on the Code tab and select “Change Language”.

Select the new Language for the code block and click “OK”.

NOTE! The Language of a code block can only be changed if there is no programming code in the block

Code blocks can be rearranged, deleted and renamed by right click on the code tab.


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4.5 Test (Simulation) Mode

It is possible to simulate a project without using any physical hardware.

Save the project and then either select the “Test” button or select Tools > Test Mode from the menu in the Project Explorer to simulate the project.

Error Messages

If there is an error in the project when you request a Check or when you try to go to Test Mode, an error message is written in the Message tab of the Project Explorer.


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4.6 Project Explorer – Plant Explorer

This section gives you an overview about the link between the Project Explorer in Control Builder M and the Control Structure in the Plant Explorer.

On the first view there are some objects which do not have corresponding objects on the other working side. But some objects are located on different places.


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Some more interrelations between the Project Explorer and the Plant Explorer are explained here.


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4.6.1 Synchronization

Control Builder M is continuously synchronized with the Aspect Directory on System 800xA.

This synchronization mechanism works in both ways i.e. if you do something in Control Builder it is “mirrored” to the Aspect Directory and vice versa.

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CH112-04 Project Framework - RevB