T308-02 System Architecture - RevC

System 800xA Training

Chapter 2 - 1

Chapter 2 System 800xA Architecture

TABLE OF CONTENTS Chapter 2 System 800xA Architecture.................................................................................................................................... 1

2.1 General Information ..................................................................................................................................................... 2 2.1.1 Objectives.............................................................................................................................................................. 2 2.1.2 Legend .................................................................................................................................................................. 2 2.1.3 Reference Documentation ...................................................................................................................................... 2

2.2 System Overview ......................................................................................................................................................... 3 2.2.1 Options Grouped in Functional Areas..................................................................................................................... 4 2.2.2 Controller Integration............................................................................................................................................. 5 2.2.3 Use of Standards.................................................................................................................................................... 5

2.3 Aspect Objects Concept................................................................................................................................................ 6 2.3.1 Aspects and Objects ............................................................................................................................................... 6 2.3.2 Example of a Control Valve ................................................................................................................................... 7 2.3.3 Intuitive Navigation ............................................................................................................................................... 8 2.3.4 Aspect Framework................................................................................................................................................. 9

2.4 System Topology........................................................................................................................................................ 10 2.4.1 Domain Server..................................................................................................................................................... 11 2.4.2 Aspect Server ...................................................................................................................................................... 11 2.4.3 Connectivity Server ............................................................................................................................................. 11 2.4.4 Application Server ............................................................................................................................................... 11 2.4.5 Plant Network...................................................................................................................................................... 12 2.4.6 Client/Server Network ......................................................................................................................................... 12 2.4.7 Control Network .................................................................................................................................................. 12 2.4.8 Single Node System............................................................................................................................................. 13 2.4.9 AC 800M Redundancy......................................................................................................................................... 14 2.4.10 Remote (Thin) Client ......................................................................................................................................... 15

T308-02 System Architecture - RevC

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2.1 General Information

2.1.1 Objectives

On completion of this chapter you will be able to:

• Tell how 800xA fits into the IIT strategy

• Describe the network structure in an 800xA architecture

• Describe the functionality of the major components

• Explain the concept of Aspects and Objects

2.1.2 Legend

> Indicates when you go from one menu to a sub-menu

Italic Indicates object and file names

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

Bold Indicates important topics

Indicates start/explanation of student activity

2.1.3 Reference Documentation

3BSE038018 Industrial IT 800xA – System System Guide – Functional Description

3BSE041434 Industrial IT 800xA – System System Guide – Technical Data and Configuration Information

3BSE034463 Industrial IT 800xA – System Automation System Network – Design and Configuration

3BSE036903 Industrial IT 800xA – System Basic Operation


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2.2 System Overview

The IndustrialIT Extended Automation System 800xA is a comprehensive process automation system. It covers operation and configuration of continuous and batch control applications.

System 800xA has been developed incorporating Information Technology with the experience and know-how collected over decades of successful deliveries and customer installations.

800xA System offers more than a traditional Distributed Control System. It gives you a single application to organize and access all plant information.

As expected, you have functionality like graphics, faceplates, alarm management and trending available. However, with the unique integration principles based on the Aspect Object technology, you can easily integrate information like Live Video, Documentation (using Word for example), Quality Analysis, and Maintenance Information (from SAP or Maximo for example).

System 800xA provides a secure, reliable, control environment with built in security features such as access control, user authentication, and audit trail capability.


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2.2.1 Options Grouped in Functional Areas

The 800xA system functionality is divided into a Base System and a set of options, grouped in Functional Areas. The options represent functions that can be added to the system based on the needs of the process that should be controlled.

Operations Provides a consistent method for accessing enterprise-wide data and for interacting with multiple applications from any connected workstation in the plant or office.

Engineering Integrated engineering environment supports the complete lifecycle of the automation project, from planning, through configuration and library management, to commissioning and operation to minimize system ownership costs.

Safety Scalable IEC 61508 and IEC 61511 compliant SIS (Safety Instrumentation System) that spans the entire safety loop, including SIL rated field devices, I/O modules, controllers, and field actuators.

Information Management Collects, stores, retrieves and presents historical, process and business data to enhance the usefulness of data from all operations.

Batch Management Recipe management, batch and procedural control according ISA S88.01

Asset Optimization Assess and reports equipment conditions in real-time to optimize maintenance and calibration work flows.

Control and I/O Suite of standards-based hardware and software, complimented with a full line of industrial I/O interfaces.

Field Buses / Device Management Integration of intelligent field devices via all major fieldbus standards.


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2.2.2 Controller Integration

Controllers are integrated with the system through “Connectivity packages”, which are offered as options to the 800xA System. These packages provide access to real time data, historical data, and alarm & event data for instance using predefined faceplates.

The 800xA System provides connectivity to 800xA controllers as well as controllers from earlier system offerings:

• AC 800M (default set)

• Advant Master AC400 & AC100

• Symphony Harmony Infi-90

• Symphony Melody / AC 870P

• Freelance / AC 800F

• DCI System Six

• MOD 300

• Safeguard

• PLC Connect (connection to any PLC via OPC Server)

2.2.3 Use of Standards

System 800xA uses standard hardware, operating system software and protocols. This allows data to be obtained not only from ABB systems but from a variety of sources such as other brands of control systems or from lab entries.

It also allows making this data available to ABB and other manufacturers’ systems such as historians and maintenance management programs.

n Windows 2003 / XPn Internet Explorern Visual Basicn ActiveX Controlsn OPC - OLE for Process Controln Microsoft Component Object

Model (COM)n PROFIBUSn Fieldbus Foundation


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2.3 Aspect Objects Concept

A central problem in plant operations, as well as asset life cycle management, is the need to organize, manage, and have access to information for all different aspects of a great number of plant and process entities.

The Aspect ObjectsTM architecture is a cornerstone of the IndustrialIT concept and enables enterprise wide information availability in a unified way. It provides information-centric navigation – a consistent way to instantly access all information without having to know how and by which application the information is handled.

2.3.1 Aspects and Objects

The system model objects of the real process equipment or entities are called Aspect Objects. They can be physical process equipment, like a valve, or more complex, like a reactor. Other examples are: products, material, batch procedures, manufacturing orders, and customer accounts.

Each of these Aspect Objects is a container of references to all information pertaining to a real object. The various types of information related to the object are called Aspects. Examples are: process graphic, faceplate, alarm, trend, report, order definition, mechanical layout etc.

ModelObject

RealObjectReal

Object

ControlBuilder M

ProcessPortal

MS Excel

Auto CAD

Control

Faceplate

Graphics

Report

Drawings

It is necessary to be able to implement these aspects using many different applications, both existing and new, from ABB, third parties and customers. These applications are called Aspect Systems and must cooperate to provide an integrated view and functionality of the object.

Examples are: Graphics Builder for graphics, Auto CAD for mechanical layout, SAP for order handling etc.


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2.3.2 Example of a Control Valve

For example a valve is a real object and has many types of data associated with it. It has manufacturer’s specifications, mechanical drawings, a maintenance schedule and history, ordering information for parts, physical location in the plant, faceplate for operator interface, graphic symbol for display on graphics, and many other possible types of information.

Maintenance RecordMaintenance Record

Operator NotesOperator Notes

P & I DiagramP & I Diagram

Product DescriptionProduct Description

Simulation ModelSimulation Model

Control LogicControl Logic

Control DialogControl DialogControl Dialog

Process GraphicsProcess GraphicsProcess Graphics

Traditionally, these types of information are found in many separate systems or in many different document formats. An Aspect Object presents this data as a menu of choices accessible by right clicking on the object anywhere it appears in the system. The various types of information related to the object, in this case the valve, are called Aspects.


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2.3.3 Intuitive Navigation

Quick access to displays and information is provided with web browser tools. Favorites, history lists, shortcuts, and hot keys provide navigation through a process production facility quickly and accurately.

Right click on the object in the Graphic

Available Aspects

Right click on the object in the Alarm List

Use of the right mouse button provides access to additional details via a context menu. The same context menu is available, showing all aspects, independent whether you select it e.g. in the graphic display or in the alarm list.


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2.3.4 Aspect Framework

From a software architecture perspective, the foundation of the 800xA System is the Aspect Framework (afw). It is a software package that integrates all IndustrialIT enabled products via their Aspect Objects, irrespective of where they may reside in the network.

Other Aspect SystemsBatch Management

Information ManagementInformation Management

AssetOptimizationAssetOptimization

Aspect Framework / System 800xA Platform

Field DeviceIntegrationField DeviceIntegration

AC800M AdvantAdvant HarmonyHarmony MelodyMelody Other OPC Although the various aspects and their associated software may reside on multiple networks or computers, each Aspect Object carries with it the built-in collection of characteristics or Aspects. All aspect objects are stored in a central location called the Aspect Server.

NOTE! The Aspect Framework can handle up to 200’000 Aspect Objects.

Although all objects reside in this central location, data needs to be configured only once for use throughout the system. There are many Aspect Systems and thus many options for where data can be entered. There are also many places where the same data can be viewed so that generally, data can be entered and viewed where it is relevant.


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2.4 System Topology

The System 800xA architecture assumes a system of computers and devices that communicate with each other over different types of communication networks, as illustrated conceptually here.

The Workplaces uses either dedicated client computers or combined client/server machines allowing both client and server applications to run in one PC for larger configuration.

Client/Server Network

Control Network

Fieldbus

Controllers

Aspect Server(s)

Field devices

Workplaces

Connectivity Server(s)

ApplicationServer(s)

DomainServer(s)

- Single- 1oo2- 2oo3

- Single- 1oo2

System communication in the 800xA System is based on Ethernet and TCP/IP networks. Servers run software that provides system functionality, Workplaces run software that provides various forms of user interaction.

NOTE! Server configuration and selection are important factors for system performance.

The 800xA system uses a central licensing mechanism. One designated computer, typically the domain controller, should contain the central licensing server (CLS).


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2.4.1 Domain Server

Small systems can run without a Domain Controller. In this case the nodes and users are handled by a Windows Workgroup. The configuration of users and security must then be done on all nodes separately within the Workgroup.

The user handling in a Windows Domain is done from a central location – the Domain Server. Every domain must have at least one domain server, but for resilience a domain should have multiple domain servers.

2.4.2 Aspect Server

The Aspect Server provides the Aspect Directory and the services related to object management, names, security, etc. It is the heart of the 800xA system. As such it must be accessible to all nodes all of the time.

In small system systems the Aspect Server can be combined with other functions such as Application or Connectivity Servers in a single node (computer).

The Aspect Server supports “1 out of 2” or “2 out of 3” redundancy. In “1 out of 2” redundancy, the Aspect Directory is readable and writable as long as one Aspect Server is on-line. With “2 out of 3” redundancy, two Aspect Servers must be running to write to the Aspect Directory, but with any one Aspect Server on-line, the system is useable for operation but not for configuration.

2.4.3 Connectivity Server

The Connectivity Server provides access to the controllers and other data sources throughout the network. Several groups of Connectivity Servers may exist in a system, each serving one set of data sources. The AC 800M Connectivity Server is one of many different types of Connectivity Servers in the 800xA System.

Examples of services are:

• OPC Data Access

• OPC Alarm and Event

• OPC Historical Data Access

• System messages

NOTE! Maximum 12 AC 800M controllers can be connected to one Connectivity Server (single or redundant).

2.4.4 Application Server

Run various types of system applications, such as:

• Batch Management

• Asset Optimization


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2.4.5 Plant Network

The Plant network can be dedicated for process automation purposes or be a part of the plant intranet already available on a site.

Further connection of the Plant network to the Internet or any other type of external network should be performed in accordance with adequate network security practices.

2.4.6 Client/Server Network

The Client/Server network is used for communication between servers, and between client workplaces and servers.

Via a router, the Client/Server network can be connected to a plant intranet, and via a firewall to the Internet. For performance and integrity reasons, connection of foreign systems directly to the Control and Client/Server networks should be avoided. The Client/Server network can optionally be made redundant.

For any installation larger than a Single Node system and small systems that use Windows Workgroup, the 800xA system nodes must reside within a dedicated Windows 2000 Domain. This requires you to set up a domain controller and DNS server. All other 800xA System server and client nodes must be configured to be members of the domain.

2.4.7 Control Network

The Control network is a local area network (LAN) optimized for high performance and reliable communication, with predictable response times in real time. It is used to connect controllers to the servers. Controllers are nodes that run control software.

Controllers and Connectivity Servers are connected to the Control network. The Control network can optionally be made redundant.

Field buses are used to interconnect field devices, such as I/O modules, smart sensors and actuators, variable speed drives, PLCs, or small single loop devices, and to connect these devices to the system, either via a controller or directly to a server.

NOTE! For smaller systems and for systems where network separation is not desired, the Client/Server Network and Control Network can be combined in one Automation System Network.


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2.4.8 Single Node System

A Single Node System is intended for very small applications, where all 800xA server and workplace functionalities reside in a single PC.

Automation Network

Fieldbus

Controllers

Field devices

Aspect ServerConnectivity ServerWorkplace (Client)

The system has only one node, within which all servers as well as the client applications are installed. Only a few controllers can be connected.


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2.4.9 AC 800M Redundancy

System 800xA provides the highest degree of fault tolerance to meet the most demanding application needs for maximum system uptime. Optionally redundant I/O, controllers, control networks, FieldBus networks, Connectivity Servers, Aspect Servers, and Operator Workplaces are available with automatic switchover.

Redundant ModuleBusSolution

Upper CPU Lower CPU

Control Network

ProfiBus DP

ProfiBusDP-V1 ModuleBus

Optic Cable

CEX-Bus

CEX-Bus

RCU Link

Redundant I/O Module

Connectivity Server(s)Connectivity Server(s)


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2.4.10 Remote (Thin) Client

Remote Clients enables remote access to an 800xA system from a standard PC without ABB-specific software installed. Only the Internet Explorer is required to access the data.

The Remote Client provides operation capabilities and access to historical information. Configuration capabilities are limited on the remote client.

Client/Server Network

Control Network

Fieldbus

Controllers

Aspect Server(s)

RouterFirewall

Field devices

Firewall

Internet

Workplaces

Connectivity Server(s)

Thin Clients

ApplicationServer(s)

Thin Clients

CitrixServer(s)

The remote client functionality is achieved using Windows Terminal Services in an application server node. This node is sometimes called the Remote Client server node.

Optionally these services can be provided using a Citrix server as shown in the example above.


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Documents

T308-02 System Architecture - RevC