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Engineering Manual
Process Station - AC 700F
TM
Freelance 2013
Engineering Manual
Process Station - AC 700F
NOTICE
The information in this document is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this document.
In no event shall ABB be liable for direct, indirect, special, incidental or consequential
damages of any nature or kind arising from the use of this document, nor shall ABB be
liable for incidental or consequential damages arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used
for any unauthorized purpose.
The software or hardware described in this document is furnished under a license and
may be used, copied, or disclosed only in accordance with the terms of such license.
This product meets the requirements specified in EMC Directive 2004/108/EC and in Low
Voltage Directive 2006/95/EC.
Copyright 2013 ABB
All rights reserved.
Release:
Document number:
July 2013
2PAA103857R0501
TRADEMARKS
All rights to copyrights and trademarks reside with their respective owners.
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Table of Contents
About this book
Use of warning, caution, information, and tip icons .............................................................. 7
Terminology............................................................................................................................ 8
Document conventions ........................................................................................................... 8
Table of Contents
Task ...........................................................................................................................32
Task state displays.....................................................................................32
Task error messages ..................................................................................34
Task error object .......................................................................................35
Task state diagram.....................................................................................36
Task processing .........................................................................................36
Process image display ..............................................................................37
Program list (PL) .......................................................................................................38
Program list state display ..........................................................................38
Processing of the program list ..................................................................39
State displays in the project tree ................................................................................39
Status displays in the hardware structure...................................................................40
State in the tree view.................................................................................40
Module state in the system and station views ...........................................40
State of the basic unit................................................................................41
State of the modules..................................................................................41
Index
Warning icon indicates the presence of a hazard which could result in personal
injury.
Tip icon indicates advice on, for example, how to design your project or how to
use a certain function
Although Warning hazards are related to personal injury, and Caution hazards are
associated with equipment or property damage, it should be understood that
operation of damaged equipment could, under certain operational conditions, result
in degraded process performance leading to personal injury or death. Therefore,
comply fully with all Warning and Caution notices.
Terminology
Terminology
The Glossary contains terms and abbreviations that are unique to ABB or have a
usage or definition that is different from standard industry usage. Please make
yourself familiar to that.
You will find the glossary at the end of the Engineering Manual System
Configuration.
Document conventions
The following conventions are used for the presentation of material:
The words in names of screen elements (for example, the title in the title bar of
a window, the label for a field of a dialog box) are initially capitalized.
Capital letters are used for the name of a keyboard key if it is labeled on the
keyboard. For example, press the ENTER key.
Lowercase letters are used for the name of a keyboard key that is not labeled on
the keyboard. For example, the space bar, comma key, and so on.
Press CTRL+C indicates that you must hold down the CTRL key while
pressing the C key (to copy a selected object in this case).
Press ESC, E, C indicates that you press and release each key in sequence (to
copy a selected object in this case).
The names of push and toggle buttons are boldfaced. For example, click OK.
The names of menus and menu items are boldfaced. For example, the File
menu.
The Start menu name always refers to the Start menu on the Windows
Task Bar.
Document conventions
You may be told to enter the string TIC132 in a field. The string is shown as
follows in the procedure:
TIC132
Variables are shown using lowercase letters.
sequence name
Document conventions
10
System overview
The system view shows the graphic view of the hardware structure.
The system bus (Ethernet) links the individual stations with each other. It transmits
data between the process stations, the operator stations and the engineering station
through twisted pair cables. Communication within the AC 700F process station,
that is, data transmission between the CPU and the I/O modules, is realized through
the station bus (I/O bus).
The Engineering station (workplace) is based on a PC with the Microsoft
Windows operating system and the Control Builder F engineering software. It is
11
System overview
used for system configuration, documentation and commissioning. After these tasks
have been completed, it can be used remotely and for other purposes.
The operator station (workplace) is based on a PC with the Microsoft
Windows operating system and the DigiVis operator station software. Control
Builder F and DigiVis can be used simultaneously on the same PC.
A scalable Freelance system consists of operator stations and process stations. AC
700F and other Freelance process stations (controllers) can be used in a mixed or
pure arrangement.
Specific positions are assigned to the possible stations, either directly by doubleclicking a position in the graphic view, or in a dialog when they are inserted in the
tree structure.
> System > Hardware structure > System object (HWSYS) > Edit > Insert
AC700F_Hwstr.png
12
ra002us.bmp
> Start > Programs > Accessories > Command prompt c:\> ping ip address
of the AC 700F
You can set the IP adress either directly on the process station using the front
panel keys and display or you can edit the IP parameters through the diagnostic
interface. See Mounting and Installation Manual AC 700F, First
Commissioning.
13
> Start > All Programs > ABB Industrial IT > Freelance <version> >
Configure
Follow the steps below to configure IP address of one or more process stations.
CONFIGURE.png
14
Download
Cancel
> In the Configure dialog box, select Controller firmware update in the tree
structure
> Enter the controller IP address in the right pane
> Select Update boot software check box > Click Download button
Download Information_us.png
The Configure tool downloads the boot code first and then downloads the operating
system.
If PM 783F prompts you to enter the IP address, follow the steps below:
> Enter the PM 783F IP address once again through controller push buttons
before the TCP/IP communication time-out appears
> The Configure tool proceeds downloading the operating system software and
completes this sequence. PM 783F indicates Flash and restarts. It is now ready
for use e.g. loading the user application
15
The following error message displays when the communication time-out occurs:
EPROM failed_configure.png
16
ra003us.png
17
Inserting a task
In the process station, the actual programs are run in the tasks. The programs are
processed either with program lists or with the sequential function charts.
18
PS insert_AC700F.png
> Select a system object (HWSYS) in the tree view > Edit > Insert
> Select station type > Select a position for inserting
Or
> Select a station position in the system view > Double-click
19
Allocating a resource
Allocating a resource
When a station is allocated, it is automatically activated or a search operation is
carried out in the Control Builder F Commissioning mode to find the station on
the system bus.
In this way, the parts of the user program configured in the project tree are allocated
to the stations.
> Click the gray text field of the station > Edit > Resource allocation
> Select the corresponding resource from the list
Or
> Double-click the gray text field of the station
> Select the corresponding resource from the list
Inserting modules
Modules can be inserted in the process station either in the tree view or the station
view. After Insert, the object appears in both the tree view and the station view. The
object is shown in the corresponding slot. In the station view, the modules can be
equipped by double-clicking.
> Select process station in the tree view > Edit > Insert
> Select module type > Select a free slot
Or
> Select slot (C1, P, L1-L8) in the station view > Double-click
The following modules are available:
PM 783F
CM 772F
CI 930F
DA 701F
DC 732F
DI 724F
DX 722F
DX 731F
20
CPU module
PROFIBUS module
PROFIBUS module
Analog/Digital Input/Output module
Digital Input/Output module
Digital Input 32x
Digital Input/Output module
Digital Input/Output module
AI 723F
AI 731F
AO 723F
AX721F
AX 722F
AC700F_new.png
21
You can access the PS parameters by selecting the PS in the tree view or graphics
view.
Select PS in the tree view > Right-click > Parameters
Or
Select PS in the tree view > Edit > Parameters
Parameter settings include the Module data, the Boot Parameter and the IO
communication.
General module data
AC700F05us.bmp
Rack location Details the location of the rack where the process station is
accommodated.
Cabinet name Freely configurable text field for entering the cabinet name.
Rack bay name Freely configurable text field for entering the rack bay name.
Location
22
Boot Parameter
AC700F06us.bmp
All configurable boot parameters of a resource will cause a project error when
they are changed. You have to initialize the resource to execute the boot
parameter changes.
For the actual memory calculation of a process station, all configured boot
parameter must be taken into account. The algorithm which is used for the
plausibility check, is not complete if more than one parameter is set near to the
maximum value. Although, there is no error reported from the check routine, the
load process into the process station cannot be performed properly. The controller
may produce a fatal error, the user has to remove the battery to perform a cold
start.
The maximum total used memory is 1600KB, which is a sum of
1) The configured PRAM size (in KB) and
2) (Maximum number of Objects configured) * 16bytes / 1024
Tasks
Information about the tasks that are run in the background. Every
communication link occupies internal system resources like
additional memory or system objects.
23
Network buffer Area of memory in kilobytes that is reserved for the communication
links.
Interface objects
Maximum number of objects that can be reserved for interfaces.
Memory
AC700F08us.bmp
24
IO communication
AC700F07us.bmp
25
IO cycle time
Displays the relevant information related to the cycle time of the I/O
modules.
Fastest possible
The I/O communication determines the fastest possible cycle for
I/O communication, depending on the configured modules.
Depending on the configuration, the fastest possible cycle is
between 0.8 milliseconds and up to 2 milliseconds.
Not faster than
The cycle time can be limited to the value specified here in order to
reduce the CPU load through I/O communication. The I/O
communication will then calculate a cycle time that does not fall
below the specified minimum value. The possible value range is
between 1 millisecond and 20 milliseconds.
Actual cycle time
The actual cycle time in microseconds.
IO monitoring
The detection cycles of the I/O modules. 10 up to 50 detection
cycles are possible. Thus, the monitoring time results from the
current I/O cycle time multiplied by the number of detection cycles.
When the monitoring time has elapsed, the input values immediately assume
their configured safety value (hold last value or configured substitute value). The
I/O modules recognize the interruption of communication when the monitoring
time has elapsed and then assume their safety values.
26
AC700F10us.bmp
Resource states
A resource can assume various states that are displayed in the project tree behind the
objects and in the dialog box of the resource.
The display of resource states is divided into three parts:
27
No connection
The system bus connection has been interrupted, or initialize all is
currently being executed, or no connection is possible, for example,
because of an invalid network address.
No operating system
Seen when system is first switched ON, or after initialize all of
resource
Stopping
This state is only displayed if task processing takes a relatively long time.
Stopped [HW]
Resource has been Stopped by pressing the RUN key on the CPU
module.
Stopped [SW]
Resource has been Stopped by selecting Stop in commissioning.
If the resource is stopped while a task is at a break point, then this task switches
to not executable state. The error task is not initiated.
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 CPU module was OK, but
the RUN key on the CPU module was kept pressed or the resource
was stopped by the person responsible for commissioning before
achieving running state.
The cold start task, Name.ColdSt (where Name = resource name) is executed
only when the resource is started (STOP to RUN). When cold starting, all the
resource data is initialized. The operating system is not affected and the output
module channels assume their safety values.
28
This state is only displayed if task processing takes a relatively long time.
Running
29
di1501us.eps
30
Resource processing
Bootstrap
Initialize all
Initialize
Cold start
Warm start
The number of power fail signals that have caused a warm start is counted in a
system variable (xxxx.NoPowerFail) which is reset to zero in the event of a cold
start. The time of the last power fail signal can be read in another system variable
(xxxx.PowerOffTim).
Run/Stop
31
Task
Task
Select project object task > Project > Header
di1526uk.bmp
For a description of the configured data, see also Engineering Manual System
Configuration, Project tree.
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.
Task state displays
Ready
If no autostart has been configured for a task, it reverts to the ready state after
each cold start and has to be restarted.
Non-existent
Not loaded
Not executable
32
Task
After manual start of the task or when the task has been set up with
Autostart.
If a stopped task is reset to the ready state (not visible) with Reset, no change to
its state of stopped is displayed to the user. When Stop is changed to Start, the
RUN task is executed.
A task starts automatically if the RUN key on the CPU module is pressed to
switch to running mode and the previous state of the task was running.
braked
When the debugger is running, the task is at a break point. This state
can be quit using Single-step or Go in the program with the break
point.
If the resource is stopped while a task is at a break point, then this task switches
to not executable state. The error task is not initiated.
33
Task
34
Description
INT/DINT overflow
INT/DINT underflow
INT/DINT div by 0
UINT/DINT div by 0
REAL overflow
REAL underflow
REAL div by 0
10
DT overflow
11
DT underflow
12
UINT/UDINT overflow
13
UINT/UDINT underflow
128
129
FB error integer
A function block from the function block library has triggered an integer overflow or
underflow, the error can only be detected
following execution of the block and, thus,
no recovery is possible.
Task
Description
130
FB error real
A function block from the function block library has triggered a REAL overflow or underflow, the error can only be detected following execution of the block and, thus, no
recovery is possible.
131
132
133
Execution abort
134
135
If an error occurs in processing the task, the number of the object that caused the
error is displayed. The path to the object giving rise to the error can be displayed
through Info.
35
Task
di1502us.eps
Task processing
Start
Execute once The selected task is executed precisely once. Task subsequently
reverts to the stopped state.
36
Stop
Task
The task can also be stopped by keeping the RUN key on the CPU module
pressed.
Reset
Close
Show...
Select project object task > Project > Header > Show...
di1529uk.bmp
Variable name
Type
State
CLEAN
DIRTY
37
CREATE
DELETE
Access
READ
WRITE
Offset
ra017us.bmp
Version error
Program list was loaded but the version do not match
38
not loaded
On
Off
di1533us.bmp
Close
On
Off
39
AC700F_Error indication.png
In the tree view, state information is shown thus: active (black), faulty (red) and
inactive (gray). The color coding is applied to the object information (text) rather
than the icon.
Module state in the system and station views
The modules of the process station are displayed in various different colors
according to their current state.
Color and state
transparent (Rear view)
There is no module configured in this slot, neither is any module
installed in the station.
gray
40
red
yellow
orange
Force state
green
A green bar is displayed at the top of the module (only for I/O
modules). At least one channel on the module has been forced.
On insertion into the hardware structure the AC 700F process station is displayed
with its basic unit. The 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, that is, not being installed or being impossible to address through the system
bus.
dark gray
light gray
red
The detail view provides some detailed information about the I/O modules of the
process station, thus enabling the user to easily identify the modules.
The state of modules is indicated by a colored triangle.
41
AC700F19us.bmp
AC700F13us.bmp
AC700F11us.bmp
AC700F12us.bmp
42
43
44
45
AC700F14us.bmp
General data
Name
Full name of the CPU module. The name is taken over from the tree
structure.
Short text
Long text
46
Location
Display mode
Defines what is to be indicated by the CPU modules LCD. The
following options are available: Station ID, Run/Stop state, CPU
load and Free text.
Text
If the Free text option is chosen above, then here you can enter free
text (up to 6 characters) to be indicated on the module LCD (6-digit,
7-segment display).
AC 700F_IO Editor_Output_us.png
47
Component
Data type
Variable
Comment
AC700F15_us.png
48
Component
Name of the CPU module error type. Three error types are possible
(STA, BTL and ERR, see the table below).
Data type
Variable
Comment
Comment
INT
no
RO
Module location
SnrNo
STRING8
no
RO
HrvNo
STRING8
no
RO
SrvNO
STRING8
no
RO
Dur
DINT
no
RO
DispText
STRING8
yes
RW
Diagnostic data
STA
UDINT
no
RO
Bit-coded state
BTL
BOOL
no
RO
Battery low
PNE
BOOL
ERR
BOOL
RO
Module defective
Cause
0x0001
Self-test error
0x0002
Configuration
does not match
49
Bit # Error
Error code
in
code
hexa
Fault
STA decimal decimal
50
Cause
0x0004
0x0008
16
0x0010
Communication
error
The module has not correctly signaled in the given period (no keep
alive signal).
CM 772F
CI 930F
Parameters of CI 930F
The PROFIBUS module parameters can be called up for display through the
parameter setting dialogs. The current values can also be read in the commissioning
mode.
Select module in the tree view > Right-click > Select Parameters
Or
> Double-click the module in the graphic structure
51
Parameters of CI 930F
CI_930 Parameter.png
General data
Name
Full name of the PROFIBUS module. The name is taken over from
the tree structure and can be edited.
Short text
Long text
Module data
Serial number Indicates the sequential serial number from manufacturing.
Hardware version
Indicates the hardware version of the module.
Software version
Indicates the version of the software.
These values are only available in commissioning mode.
52
Location
Parameters of CI 930F
CI 930 IO Editor.png
Component
Name of the PROFIBUS module error type. Two error types are
possible (STA and ERR, see the table below).
Data type
53
Parameters of CI 930F
Byte
Bit
Number of the first bit in the start byte of the parameter block.
Length
Variable
Comment
Comment
INT
no
RO
Module location
SnrNo
STRING8
no
RO
HrvNo
STRING8
no
RO
SrvNO
STRING8
no
RO
Dur
DINT
no
RO
DispText
STRING8
yes
RW
Diagnostic data
STA
UDINT
no
RO
Bit-coded state
ERR
BOOL
no
RO
Module defective
CI 930F
The different error cases are bit coded into diagnosis data STA.
54
Parameters of CI 930F
Fault
Cause
0x0001
0x0002
Empty slot
0x0004
Identification
error
0x0008
Self-test error
16
0x0010
Old self-test
error
Example:
STA = 24 (decimal) => 0x0018 => old hardware errors in module and self-test error
in module.
55
Parameters of CM 772F
The PROFIBUS module parameters can be opened for display through the
parameter setting dialogs. The current values can also be read in the commissioning
mode.
Select module in the tree view > Right-click > Select Parameters
Or
> Double-click the module in the graphic structure
AC700F14_1_us.bmp
General data
56
Name
Full name of the PROFIBUS module. The name is taken over from
the tree structure and can be edited.
Short text
Long text
Parameters of CM 772F
Module data
Serial number Indicates the sequential serial number from manufacturing.
Hardware version
Indicates the hardware version of the module.
Software version
Indicates the version of the software.
These values are only available in commissioning mode.
Location
57
Parameters of CM 772F
AC700F15_1_us.bmp
Component
Name of the PROFIBUS module error type. Two error types are
possible (STA and ERR, see the table below).
Data type
58
Byte
Bit
Number of the first bit in the start byte of the parameter block.
Length
Variable
Comment
Parameters of CM 772F
Comment
INT
no
RO
Module location
SnrNo
STRING8
no
RO
HrvNo
STRING8
no
RO
SrvNO
STRING8
no
RO
Dur
DINT
no
RO
DispText
STRING8
yes
RW
Diagnostic data
STA
UDINT
no
RO
Bit-coded state
ERR
BOOL
no
RO
Module defective
CM 772F
The different error cases are bit coded into diagnosis data STA.
STA Error codes
Error
Bit # Error
code
in
code
hexa
STA decimal
decimal
Fault
Cause
0x0001
0x0002
Empty slot
0x0004
Identification
error
59
Parameters of CM 772F
Error
Bit # Error
code
in
code
hexa
STA decimal
decimal
Fault
Cause
0x0008
Self-test error
16
0x0010
old self-test
error
Example:
STA = 24 (decimal) => 0x0018 => old hardware errors in module and self-test error
in module.
60
Direct I/O
The following figure shows the I/O modules directly connected to the CPU module
of AC 700F.
AC700F_IO.png
61
Direct I/O
Detailed diagnosis
Description
Analog/ Digital Input/Output module
Digital I/O module
Digital Input 32x
Digital Input/Output module
Digital Input/Output module
Analog Input module
Analog Input module (Thermocouple)
Analog Output module
Analog/ Digital Input 4x, Analog Output 4x
Analog I/O module
For more information on I/O modules and its parameters, refer to Engineering
Manual IO Modules AC 700F/AC 900F.
62
Index
A
N
C
CI930 ........................................................ 51,
CM 772F
PROFIBUS module CM 772F .................
CM772 ..................................................... 56,
Commissioning
Hardware structure ...................................
Configuration fault ..........................................
Control Builder F ............................................
CPU module PM 783F ....................................
Node ............................................................... 39
54
O
56
59
40
43
11
45
Object data
CI 930F ................................................... 54
PM 783F .................................................. 49
Operating system ............................................ 16
Download ................................................ 16
Operating system and Controller firmware update
13
Operator station .............................................. 12
D
Debugger .........................................................
Detail view
Module .....................................................
Diagnosis
CI 930F ....................................................
CM 772F ..................................................
PM 783F ..................................................
DigiVis ............................................................
Direct I/O modules ..........................................
33
41
53
57
48
12
61
P
Parameter fault ...............................................
Parameters
CI 930F ...................................................
PM 783F .........................................................
PM783 ..................................................... 45,
Process image display ....................................
Process station ................................................
43
51
45
49
37
19
R
E
Engineering station ......................................... 11
F
Firmware update ............................................. 13
Resource
status display ........................................... 27
S
State display ............................................ 40, 42
63
Index
43
38
27
11
T
Task ................................................................
Error messages ........................................
Error object ..............................................
Error text ..................................................
Processing ................................................
State diagram ...........................................
64
32
34
35
34
36
36
2PAA103857R0501
Contact us
ABB Inc.
Control Technologies
Wickliffe, Ohio, USA
Phone: +1 440 585 8500
E-Mail: industrialitsolutions@us.abb.com
www.abb.com/controlsystems
ABB AB
Control Technologies
Vsters, Sweden
Phone: +46 (0) 21 32 50 00
E-Mail: processautomation@se.abb.com
www.abb.com/controlsystems
Note:
ABB S.P.A.
Control Technologies
Sesto San Giovanni (MI), Italy
Phone: +39 02 24147 555
E-Mail: controlsystems@it.abb.com
www.abb.it/controlsystems
TM