Installation and demonstration of

ABB IndustrialIT 800xA system

at Narvik University College
20.10.2006

Project report

By
Kristian Knudsen and Espen Seljemo

Master of Science students at

Narvik university college, department of Industrial Engineering
 Installation and demonstration of
ABB IndustrialIT 800xA system

Master of Science in Technology

NARVIK UNIVERSITY COLLEGE

Telephone: 76 96 60 00

Title Date
Installation and demonstration of 20.10.2006
ABB IndustrialIT 800xA SYSTEM Gradation:
at Narvik University College Open

Authors Amount of pages

Kristian Knudsen 33
Espen Seljemo Appendices
6
Department for Major subject
IBDK Industrial Engineering
Supervisor
Bjørn Solvang
Enterprise Contact person
PL/HIN Bjørn Solvang

Abstract
This project is an introduction to the IndustrialIT 800xA system made by the firm Asea
Brown Boveri (ABB). It is a very large, modern automation- and control system and it
is installed at many oil and gas facilities world wide. The 800xA system is not a plug
and play equipment. There are many options that must be taken before system
installation and during the installation to create exactly the environment you want.
The different communication forms and the width of possibilities with the I/O modules
make the 800xA hardware very scaleable against existing systems that already exist on
the market.

Keywords
Asea Brown Boveri, ABB, IndustrialIT, AC 800M controller, Automation, Network
topology, software, hardware, I/O modules, analogue input and output, digital input and
output, 800xA system, interface, cable connection, communication
Preface
The problem with most automation control systems is that they are seldom more than a
control system. This is where IndustrialIT system shows its true colors as a complete
system including control, analysis and maintenance in only one package.

This report is written by two master degree students at Narvik University College (NUC),
and is a part of the course Prosjektfag. We both have a Bachelor degree in Automation
from Høgskolen i Tromsø.

The object of this project is to set up a simple system using IndustrialIT 800xA system
from ABB. This is also an introduction project to our Master thesis. The duration of this
project is 15 days.

The main sources of this report are the research we have done and the documentation by
ABB. The documentation made by ABB is very thorough and extensive, this makes it
both good and hard to use. The total size of the documentation is approximately 16.000
pages which is renders it difficult to get trough it all.

The project main goal is to make us comfortable with IndustrialIT. This could have been
done by sending us on the courses held by ABB. But as NUC has a “no course” policy,
we are learning this by ourselves doing the trail and fail method. It actually makes us
understand the system better. Our journey trough the installation, configuration, and
finally, testing our system will give us the insight needed to show why IndustrialIT is such
a success.

We would like to thank our supervisor Bjørn Solvang for the help he has given us during
this project and our laboratory chief Tony Inge Ludvigsen. We would also like to thank
ABB by Ståle Stenberg and Arne- Ivar Iversen for their outstanding support on
IndustrialIT system.

Narvik 20.10.2006

_______________________ _______________________
Kristian Knudsen Espen Seljemo

1
Abstract
This project is an introduction to the IndustrialIT 800xA system made by the firm Asea
Brown Boveri (ABB). It is a very large, modern automation- and control system and it is
installed at many oil and gas facilities world wide, onshore and offshore and at other
industrial facilities. For example Statoil`s LNG facility Snehvit located at Hammerfest.

IndustrialIT 800xA is a huge and flexible system with many communication opportunities
to already exciting technology like Fieldbus, profibus and Hart. This makes it easy to
communicate with other systems and at the same time give the users the benefits that
IndustrialIT system gives.

It is equipped with powerful hardware and software which have many opportunities to
design and implement the system exactly after the given requirements.

We created a small system which consists of: One computer, one AC 800M controller
and I/O modules. Made a short program where we simulated the movement on sliding
doors in a shop when customers arrive. This program gave us an opportunity to test data
communication between computer and 800xA hardware equipment.

The 800xA system is not a plug and play equipment. There are many options that must be
taken before system installation and during the installation to create exactly the
environment you want. This makes the system very flexible and it can be installed or
implemented in almost any industrial environment.

In this project we had to read the following installation manuals for the 800xA system
and installed hardware and software systems separately before trying to communicate
with both parts. When installing this system we got a few but solid problems. We
discovered that the 800xA system is not just a Plug and Play package. There are many
opportunities and choices that must be made in planning the system and during the
installation. We used the trail and fail method to solve different problems that was not
explained in the manuals. Some problems that occurred in the installation process where
very strange and we could not find a solution to it so we needed to contact ABB for
support.

The different communication forms and the width of possibilities with the I/O modules
make the 800xA hardware very scaleable against existing systems that already exist on
the market.

Future work with 800xA system is to install a bigger solution which includes 3 nodes in a
network. One server node connected to a main controller with analogue or digital
equipment attached. On the other two nodes in this network we will create one operator
workplace and one engineering workplace.

2
Vocabulary
AC Alternating current, where current direction vary cyclically.
AC 800M Controller A controller which handles the signals from I/O modules.
AluRack A homemade rack for using in school experiments. These are
equipped with DIN rail for connecting electrical components.
Aspect Server “A server that runs the central functions of the Aspect Object
architecture, such as Aspect Directory, Structure and Name
Server, Cross Referencing, File Set Distribution, and so on.
The Aspect Server is normally used as the Windows domain
controller for the control and client/server networks.” [9]

Aspect System A software system, which implements one or several aspect

types by providing one or several Aspect System Objects.
[9]

Connectivity Server A server that provides access to controllers and other sources
for real-time data, historical data, and alarm and event data. A
node containing this is in our case connected to the AC 800M
controller. [9]
Control system A system used to automate a facility or process. Example;
controlling the air and heat in a building.
DC Direct current, constant flow of electrons in one direction.
DIN rail Standardized 35mm wide metal rail where electronic
equipment easily can be mounted on.
Foundation Fieldbus Fieldbuses are a type of industrial communication standard.
You can use several forms of transmitting data such as copper
cable, fiber optics or wireless. [8]
Hardware Physically equipment.
IndustrialIT ABB’s vision for enterprise automation. [10]
I/O Module Blocks that are connected to the AC 800M controller. These
can be either analog or digital, and handle input or output
signals.
IP Internet protocol standard for communication between nodes
in a network
LED Light Emitting Diode.
MAC Media access control is a unique ID address on the network
card. This address determines who is allowed to connect
physically to the media or node.
Node A computer communicating on a network e.g. the Internet,
Plant, Control or I/O network. Each node typically has a
unique node address with a format depending on the network
it is connected to.

3
Profibus A type of Fieldbus communication standard. This is one of
the most universal Fieldbuses.[8]
RJ 45 Connection plug on Ethernet communication cable
Software Computer programs for different use.
Topology The method or specific way computers and other network
devices are put together in network.

4
Figure list
Figure 1 Historical review .................................................................................................. 9
Figure 2 View over different aspects in IndustrialIT 800xA system ................................. 10
Figure 3 AC 800M controller ........................................................................................... 12
Figure 4 MTU Bracket...................................................................................................... 13
Figure 5 I/O Module ......................................................................................................... 13
Figure 6 AC 800M with two I/O modules ........................................................................ 14
Figure 7 Power Supply SD 821 ........................................................................................ 15
Figure 8 Own designed AluRack...................................................................................... 16
Figure 9 Connection example [5] ..................................................................................... 17
Figure 10 Internet protocol TCP/IP settings on PC .......................................................... 18
Figure 11 Topology tree of computer, controller and I/O [3]........................................... 19
Figure 12 Interference between interfaces in the 800xA system [7] page 43................... 22
Figure 13 Process portal and OPC server placing ............................................................ 23
Figure 14 Hardware tree in program Control Builder M Professional ............................. 23
Figure 15 Plant explorer workplace layout window ......................................................... 24
Figure 16 Program editor window .................................................................................... 25
Figure 17 Real object, Process window and Aspect objects [4] ....................................... 27
Figure 18 System connections on our 800xA system....................................................... 29
Figure 19 Future topology with tree nodes ....................................................................... 30
Figure 20 Command prompt window ............................................................................... 36
Figure 21 Setup wizard for OPC server account .............................................................. 37
Figure 22 Configuration Wizard start ............................................................................... 82
Figure 23 Configuration Wizard....................................................................................... 82

Table list
Table 1 Contents of 800xA system.................................................................................. 11
Table 2 Hardware requirement ......................................................................................... 11
Table 3 I/O modules information...................................................................................... 13
Table 4 Connection table 220V ........................................................................................ 15
Table 5 Connection table 24V .......................................................................................... 15
Table 6 Example of IP adresses ........................................................................................ 18
Table 7 Scheme over diagnostic LED’s on AC 800M [1]................................................ 36

5
Contents
1. Introduction..................................................................................................................... 7
2. Asea Brown Boveri (ABB)............................................................................................. 8
3. Historical review of automation systems........................................................................ 9
4. IndustrialIT 800xA system............................................................................................. 10
5. Hardware....................................................................................................................... 11
5.1 Computer requirements..................................................................................... 11
5.2 AC 800M Controller ............................................................................................... 12
5.3 I/O modules....................................................................................................... 13
5.4 Power supply..................................................................................................... 15
5.5 AluRack ............................................................................................................ 16
6 Communication......................................................................................................... 17
6.1 Cabling and Connections .................................................................................. 17
6.1.1 Switch or a hub ................................................................................................ 18
6.1.2 Directly to AC 800M controller....................................................................... 18
6.2 Network addresses ............................................................................................ 18
6.3 Firmware communication ....................................................................................... 19
6.4 Network topology ............................................................................................. 19
7 Software .................................................................................................................... 20
7.1 Software license ................................................................................................ 20
7.2 Software requirements ...................................................................................... 21
7.3 How to use the IndustrialITSoftware ................................................................. 21
7.4 Project explorer...................................................................................................... 23
7.5 Creating a new project ............................................................................................ 23
7.6 Plant Explorer ......................................................................................................... 24
7.6.1 Make a program ............................................................................................... 25
7.7 Offline programming .............................................................................................. 26
7.8 Draw network topology of a system ....................................................................... 26
7.9 Aspect object technology........................................................................................ 27
8. Result of the project ...................................................................................................... 28
8.1 Our 800 xA system ........................................................................................... 29
8.2 Future system configuration ............................................................................. 30
9 Capabilities of the 800xA system ............................................................................. 31
10 Discussion ............................................................................................................. 32
11 Conclusion ............................................................................................................ 33
12 References.................................................................................................................... 34
Appendix I. Documents attached on project CD .............................................................. 35
Appendix II. Troubleshooting........................................................................................... 36
Appendix III. Task description for IndustrialIT 800xA system project............................. 38
Appendix IV. Activity schedule for this project............................................................... 40
Appendix V. System installation ...................................................................................... 41
Appendix VI. Post installation.......................................................................................... 82

6
1. Introduction
This project ultimately started when NUC got sponsored the IndustrialIT 800xA system
from ABB. A package which contained of 4 sets with one AC 800M controller and
several analogue and digital modules. Since this is a completely new system there was no
one to set it up in the lab at NUC. We took upon us this task in May 2006, but we really
got the project going when the course Prosjektfag started.

As mentioned before there where no one but us who could set up the IndustrialIT system
at NUC. This was the beginning of our task.

Usually persons with background knowledge on the system would set it up. There are
different courses varying from beginner to expert and they are lasting up to three days. It
was not an alternative for us to go on these courses since we are under the impression that
we would learn more by figuring it out on our own, and some help from the instruction
manuals.

The report is built up in the following manner: First explaining what IndustrialIT is, then
we will present a short historical review on automation systems before we explain what
the system consist of. The Industrial IT 800xA can be divided in two parts, one hardware
part and one software part, this will be reflected in our report. The two main chapters will
describe these parts and a final part will explain the communication between software
and hardware. Our activity schedule and description on this project task can be seen in
Appendix III and IV.

This project is the evaluation form in the course Prosjektfag and it will also make the
introduction to our Master thesis and other future school projects.

We restrict our work to just install a small single node system with enough options to
make a presentation and introduction of this powerful software and hardware package.

7
2. Asea Brown Boveri (ABB)
The company which has produced the IndustrialIT is called Asea Brown Bovery (ABB).
Here is a little background on the firm.

In the late 1880`s the start of today’s firm ABB was created by Asea in Sweden and BBC
in Switzerland.

Asea was established back in year 1883. They where manufacturing electrical lightning
and generators in Sweden. Eight years later in Switzerland the firm Brown, Boveri and
Cie (BBC) was established in year 1891. They where working with high voltage AC
power equipment.

In year 1988 the two companies Asea and BBC merged into one company Asea Brown
Bovery. Today ABB is a world leading firm within electrical power, automation
technology and robotics. Within the firm there are different divisions who are focusing on
their core strengths: Power products and systems, automation products, process
automation and robotics.

ABB is located all over the world. This gives them a short distance to their markets
within power and automation.

Their vision is to provide leading power and automation technology to customers around
the whole world. A broad application know- how gives their customers fast and reliable
support which is some of their qualities.

For more information, please see www.abb.com

8
3. Historical review of automation systems
If we look back in time and see with a historical perspective on which control, and
automation systems we got. An illustration on when the different automation system was
created is shown in Figure 1.

Figure 1 Historical review

Early forms of automation were driven by clock type mechanisms or similar devices
using some form of artificial power source, a wound-up spring, channeled flowing water,
or steam.

In 1801, the patent was issued for the automated loom using punched cards. In 1835 the
relay was invented and was used up to late 1960 in automation, and it is still used today
in small and less complicated systems. Programmable Logic Controller (PLC) was
invented 1968 and replaced the relay automation. The PLC is still one of the most used
controllers in automation, but it has its lacks.

In 2004 the IndustrialIT 800xA system was released by ABB, and it soon became a
success in the world of industry.

9
4. IndustrialIT 800xA system
IndustrialIT 800xA system is a control system developed by ABB and was launched in
January year 2004. It is based on the principle of a PLC with the thought of a “brain”
controlling several I/O modules, but it is far more advanced. You might say that it is the
next generation of automation and control system.

The 800xA system includes many automation processes in one environment. It collects
many process controls and windows that can be presented on one system platform. With
this system there is no need for many different software packages and different hardware
solutions to make your process system speak together. IndustrialIT 800xA has everything
implemented and it can be connected to almost any old hardware communication systems
and new devices. For example (PLC, profibus, Fieldbus or HART)

Every control, maintenance and other important processes are collected and integrated
into one environment. Such as: Supervision of devices (motors, valves, etc), maintenance
data and documents, device and system drawings, control values, process values, and
other important information can be presented into one interface. System 800xA gathers
information from all these different sources in the process and presents this data in an
interface which is being used by: Technicians, production managers, operators or
engineers.

Different aspects of what IndustrialIT 800xA system contains of is illustrated in Figure 2

Figure 2 View over different aspects in IndustrialIT 800xA system

10
.

5. Hardware
The IndustrialIT 800xA hardware used in this project is delivered by ABB. Other
equipment and materials is delivered by NUC. This chapter will describe the different
parts used in this project.

In Table 1 there is a list over the hardware that NUC got sponsored from ABB. This
hardware can be assembled into a big system or it can be divided into max four small
systems. All hardware can be mounted onto standardized DIN rails. We decided to create
only one small system, which is described in part 8.1 in this report.

A hardware system consist of a main unit, the AC 800M controller and some analogue or
digital I/O modules attached. Numbers of modules that can be used depends on your
process and what it requires.

Table 1 Contents of 800xA system

800xA system modules
Module type Total units
AC 800M 4
AO810 4
AI810 4
DI810 4
DO810 4
MTU bracket 16
Power Supply 4

5.1 Computer requirements

Since the 800xA system has a powerful software package it demands a lot of resources
from the hardware on the computer. Many sub programs from 800xA are processed while
Windows is running. A fast computer is recommended. See Table 2 for more details
about hardware requirements on different computer installations.

Table 2 Hardware requirement

Server node Workstation node Single node
(Operator) (Operator/Engineer)
CPU At least 2,0 GHz At least 2,0 GHz At least 2,0 GHz
CPU CPU CPU
RAM 2GB RAM Minimum 1GB 2GB RAM
RAM
Hard drive 7200 rpm or higher 7200 rpm or higher 7200 rpm or higher
Operating system Windows XP Pro Windows XP Pro Windows XP Pro
English version English version English version

11
5.2 AC 800M Controller
AC 800M controller, shown in Figure 3, is the main unit in hardware system. This unit
contains of a 24 MHz CPU and 8MB of internal memory. Up to 12 I/O modules can
directly be connected to the controller via the electrical Modulebus and 84 I/O modules
can be connected to I/O clusters via the optical Modulebus. The controller is also
equipped with a backup battery and a compact flash memory slot which can be used to
store programs or be a safety device to prevent data loss when power failures interfere.

Figure 3 AC 800M controller

Main task of the controller is to send and receive I/O module signals from/to a computer.
Controller is equipped with two Ethernet ports for communication with other subsystems,
in a network such as operators or engineers. It also has two RS-232 ports for 3rd party
devices or for communication with program/debugging tools. There is also connection for
the usage of fiber optics communication which is recommended in areas with high
electromagnetic interference.

The mounting bracket on the AC 800M controller is made of metal. Because of this the
entire system will be grounded when you mount it to a DIN rail, if the DIN rail is
grounded. This means that the I/O modules that are attached to AC 800M controller are
also are grounded from this connection. Grounding is done to prevent interference from
surrounding systems that can interfere with the internal logic.

AC 800M controller is very flexible to communicate with other existing systems like:
RS-232, Profibus, Foundation Fieldbus, HART, TCP/IP Network or Fiber optics.

12
5.3 I/O modules
To open up for communication with equipments in the field it is necessary with a link
between the AC 800M controller and the equipments. This is where the I/O modules
enter. Equipment out in the field is connected directly to the modules.

There are 4 main groups of modules: Analogue in (AI), analog out (AO), digital in (DI)
and digital out (DO). What type of modules that are being used depends on if there is an
analogue or digital signal that is being sent out from the equipment. See Table 3 I/O
modules informationfor details about analogue and digital modules.

Table 3 I/O modules information

Module Type Channels Signal Type
Analog In 8 0..20mA, 0..10V
Analog Out 8 0..20mA
Digital In 2x8 24V
Digital Out 2x8 24V

I/O modules are attached to a MTU bracket. This must be done manually by pressing the
I/O module into the MTU bracket. There are some switches that must cohere before this
can be done. MTU bracket is shown in Figure 4 and the I/O module is shown in Figure 5.
Switches on the I/O module is not shown in the picture since it is on the backside of the
module.

Figure 4 MTU Bracket Figure 5 I/O Module

13
Different I/O modules that can be attached to the AC 800M controller by sliding them
into the controller. This is shown in Figure 6 where you have a control unit and two I/O
units. These are clipped on a DIN rail which is mounted on the AluRack.
For more information about installing the modules please see [2] page 76.

Figure 6 AC 800M with two I/O modules

I/O modules can be switched and replace when system is running and powered on. Only
the devices that are connected to this module will not work properly when failure
interfere

In oil and gas business a total shut down of entire system can cost a lot of money.
Application data can be stored at compact flash memory at every AC 800M controller so
it will be no data loss after a power failure or during module replacements. In case there
should be an error on the modules a LED on the front of the module will light up.

14
5.4 Power supply
A power supply is used to serve the 800xA hardware system with power. The power
supply converts 220V AC (input current) into 24V DC (output current), the power supply
is shown in Figure 7.

Figure 7 Power Supply SD 821

Power supply has a LED in upper left corner witch can tell if the power signal is OK or
not. The input current (220V AC) is placed underneath the power supply and the output
(24V DC) is placed on top. The connections are described in Table 4 and Table 5.

24V DC is coming out pins L+ and L-. When handling direct current it is very important
to connect positive (+) to positive and negative(-) to negative. These must not be crossed.

Table 4 Connection table 220V Table 5 Connection table 24V

N L1 L+ +24V
L L2 L- 0V
PE Earth

Power cables from L+ and L- on the controller must also be connected on L+ and L- on
the MTU bracket.

15
5.5 AluRack
We have designed a rack where all 800xA hardware equipment can be mounted.
The rack is made of aluminum and plastic profiles which are attached together. These
profiles are a patent from a Danish company named Porsa. See http://www.porsa.dk for
more details.

In Figure 8 our AluRack is shown.

Figure 8 Own designed AluRack

16
6 Communication
This chapter will describe different forms of communication between computer and
controller in the 800xA system.

6.1 Cabling and Connections

There are mainly two ways to do the communication between a computer and controller,
it is optical or using twisted pair Ethernet cable. Signal and communication cables must
not be routed nearby power cables with high voltage. This can interfere with the signals.
Choose shielded twisted pair cable to minimize the interference, or fiber optic cable to
remove all interference.

AC 800M controller has fiber optic as a connection option. With use of the fiber optic
port a 800xA system can be placed at any extreme electromagnetic conditions and still be
unaffected by it.

In Figure 9 we see an example on how the connection should be done and what type of
cable that should be used.

Figure 9 Connection example [5]

17
There are to ways of connections that can be used between the computer and AC 800M
controller, it is directly or using a switch or hub in a network.

6.1.1 Switch or a hub

Plug an shielded twisted pair Ethernet cable with RJ 45 connection plug into CN 1 port
on AC 800M controller and the other end into a switch or a hub.

6.1.2 Directly to AC 800M controller

If you are connecting directly from a computer to a controller it is important to use a
crossed shielded twisted pair Ethernet cable. The cable must be plugged into CN1 port on
the controller.

6.2 Network addresses

It is important to set up right addresses on the computer and AC 800M controller.
The IP address on the computer must in the same address area as the controller. See
Table 6 for an example. The IP address of the computer can be shown by selecting
properties on the networkcard in Windows XP. This is shown in Figure 10Figure 10.

Table 6 Example of IP adresses

PC IP: 172.16.0.100
AC 800M IP: 172.16.0.201

Figure 10 Internet protocol TCP/IP settings on PC

18
6.3 Firmware communication
Program Control builder M professional and AC 800M controller must have the same
version of firmware. If they do not have same version the system will not work properly.
See [6] for more details on how to check the firmware versions.

6.4 Network topology

There are different topologies that are possible with IndustrialIT. One node can be
connected to several controllers, and each controller can have many modules attached.
The topology possibilities with this system are almost endless since the number of nodes
is almost unlimited. The bottleneck in most cases is the licenses you have. In Figure
11Figure 11 there is an example with seven nodes and six controllers. In the example it is
used separated connectivity an aspect servers, and several nodes for other usage such as
engineers and operators.

Figure 11 Topology tree of computer, controller and I/O [3]

19
7 Software
The software we use in this project is a package named IndustrialIT developed by ABB. It
is a multi-usage package for automating and analyzing processes and activities in a
facility. To make the IndustrialIT software pack work there are some necessary steps that
needs to be taken.

1. Install system shell, described in Appendix V

2. Plan the system using System Planning tool, described in Appendix V
3. Do a post installation on the system, described in [6]
4. Configure users/user groups and connection, described in [7]
5. Set up your automation system, described in [7]

The software is integrated in Windows platform enabling the IndustrialIT to take full
control over the computer. An operator logs on to Windows and gain the user rights an
operator should have. When an engineer logs on the user rights will change to what an
engineer needs.

7.1 Software license

A license file is needed on every computer that is connected to an AC 800M controller.
This file is made ABB and contains information from the computer. NUC got license on:
One Core system, one operator workplace and one engineer workplace.

Every network card in a computer has a unique identification address called Media
Access Control, or better know as MAC. This address is found by using command
prompt window and typing in the command ipconfig /all
Recognize the name on the network card that you are connecting to the AC 800M
controller. Under this network card the correct MAC address is listed.
This MAC address is implemented into the license file.

20
7.2 Software requirements
The IndustrialIT 800xA system has some software requirements. These are important
when installing the IndustrialIT system.

Required assets for installation:

- Windows XP Professional English version
- CD/DVD Package from ABB
- Administrator rights on the computer
- Microsoft Word and Excel 2003 or newer
- Diskette with a system created in System Planner
- Turn off Windows Firewall and other firewalls that are included in some virus
programs.
- Download all hot fixes for your Windows XP from Windows update on the
Internet. This must be done to have a stable and safe system before you do
anymore installation. Note: This can only be done if you are using computers with
pre-installed Windows. If you are using a blank computer you will be prompted to
install hot-fixes during the installation.

7.3 How to use the IndustrialITSoftware

This part will explain different programs that are included in the IndustrialIT and how to
create a new automation system.

When all pre- and post installation is done to the system it is ready to make an
automation system on the computer. To make such a system there are two important
programs that are being used, it is Project explorer and Plant Explorer. See Figure
12Figure 12 for interference between these to software interfaces and the AC 800M
controller.
More details on how to do the post installation is described in appendix VI

From now on there are different windows and possibilities in the computer system
because of the different user rights between an engineer and operator.

21
Figure 12 Interference between interfaces in the 800xA system [7] page 43

22
7.4 Project explorer
The program Control Builder M Professional is also called Project Explorer after all
installation and configuration is done to the system. In project explorer it is possible to
make and set up a new project for your system.

7.5 Creating a new project

A new project can be started from program Control Builder M Professional. Choose
New project and AC 800M controller in this program. 800xA hardware system with
controller and I/O modules must be connected to the computer. The process portal and
OPC server must be running. This can be seen by a green icon (process portal) and a grey
icon (OPC server) which are placed in the right corner on the desktop. See Figure
13Figure 13 Process portal and OPC server for more details.

Figure 13 Process portal and OPC server placing

The same 800xa hardware system that is mounted together must be remade in a hardware
tree in the program Control Builder M Professional. All I/O modules in the system must
are placed under ModuleBus in the hardware tree. After creating this tree the next step is
to download this setup to the AC 800M controller. This is done in the same program
where the hardware tree is made. See Figure 14 Figure 14 Hardware tree in program
Control Builder M Professionalfor more details on the placing of the hardware tree.

Figure 14 Hardware tree in program Control Builder M Professional

23
7.6 Plant Explorer
The Plant Explorer is the heart of all IndustrialIT programs. This is where all
configurations and calibrations to the 800xA system are done. In Plant Explorer it is
possible to make automation programs.

See Figure 15 for Plant explorer workplace layout. Here the same hardware tree that was
made in Control Builder M Professional is reproduced. There is also created a new
Control project called HiN.

In Plant explorer alarms and events for the whole system is calibrated and configured.
Every changes made in Plant explorer are automatically updated in the program Control
Builder M Professional.

Figure 15 Plant explorer workplace layout window

24
7.6.1 Make a program
A control program is made by starting Program editor in Program1, 2 or 3 under
Programs in the hardware tree. In the program editor it is possible to use different kinds
of programming languages like: Structured text, structured function chart etc.

See Figure 16 for layout on Program editor. In this example there is made a program of
simulation sliding doors in a shop.

Figure 16 Program editor window

25
7.7 Offline programming
Test a program in offline mode is important to do before sending it to a controller. A
offline test is a safe way to check for errors and malfunctions in a program

Instructions on how to go in offline mode can seen in [7] at page 82.

7.8 Draw network topology of a system

In Plant explorer it is possible to draw the network topology in program Topology
designer. There are different templates to draw network connections or internal hardware
connections between controller and I/O modules. The finished network topology drawing
can be imported to the process window so that an operator or engineer can see how things
are connected together.

26
7.9 Aspect object technology
In a process window ABB uses aspect object technology to present and sort all
information about a process in an interface.

The Aspect Server collects all information about real time process and devices are
present in one graphical interface. In this interface there is collected many types of
information on a device like: Trend graphics, alarms, engine data, controls, maintenance
objects and other graphic elements. See Figure 17 for more details on aspect technology.

Figure 17 Real object, Process window and Aspect objects [4]

All field devices that are connected to AC 800M and I/O modules can be configured,
monitored and controlled by an operator.

Aspect object technology is both time and money savings if there are any failure at a
device or processes. The operator has all information collected on this device or
processes just a few mouse clicks away, instead of spread at different locations or other
peoples.

This reduces downtime, and highly efficiency maintenance of the different devices and
processes.

27
8. Result of the project
The goal of this project was to explore the possibilities with the IndustrialIT 800xA
system. To do this we created a small system with a simple automation program.

When we started this project we only knew that IndustrialIT 800xA system was the next
generation automation system. So we soon realized this was a comprehensive system
with lots of possibilities for creating control and analysis systems. This made it
impossible to get trough it all in the given time we had available in this project. We
decided to concentrate our effort on the creation of a small system which consists of:

− Computer with single node installation

− Network topology and communication
− AC 800M controller and I/O modules

We also created a system installation guide on how to plan and install a single node
system on a computer.

This project has given us the big picture on how the IndustrialIT 800xA system works and
how to install it on a computer. To emphasize that the installation is not just like
installing plug and play software like Microsoft Office on a home computer. The
IndustrialIT 800xA system requires a full day to just plan and install the core system on
one computer alone. After that all configurations on the installed system must be done
before the user can take advantage this automation system.

When we first started installing the core system on the computer we realized that it did
not has the necessary software and hardware for the IndustrialIT 800xA system.
This delayed the project substantially.

Throughout the project there have been lots of obstacles that we had to conquer. One of
the biggest problems has been the network topology and network communication. Since
we are on NUCs local area network we did not have all the possibilities we needed. This
meant that we had to come up with different kind of solutions. We still have the problem
of running Internet on the single node computer.

28
8.1 Our 800 xA system
The IndustrialIT system on NUC has 4 licenses with one core system, one operator and
one engineer. The core system can be divided on several nodes and the other nodes can
be used as workplaces for operators and engineers.

In our case we installed a single node system, having all servers on one node. This is best
on small systems and where the persons acquired for the system can use the same
computer. Our 800xA system consists of: One AC 800M controller, one digital input
module (DI 810) and one digital output module (DO 810). This was the only hardware
we needed to simulate our digital program. Network topology for our system is shown in
Figure 18.

Figure 18 System connections on our 800xA system

Since NUC did not have any analogue equipment to put in our system so we could
control it, the only option we got left was to use a digital solution.

We wanted to simulate customers who are going through sliding doors by activating a
photo cell in a shop. This program we are going to simulate digitally on the 800xA
system.

The programming will be done in structured text where we implement these variables:
- Doors opening
- Doors closing
- Photo cell
- Motor for sliding door 1
- Motor for sliding door 2
- Opening frequency
- Total openings

29
Our finished program will first be tested in offline mode. This is done to discover and
prevent any failures in our program that can damage the 800xA hardware.

When testing program in offline mode we see that every variable in the program changes
its value when they are being activated by simulation.

In online mode with the AC 800M controller we are going to test the same program but
now LED on each channel on the module will light up when a channel is activated.

8.2 Future system configuration

In the future we have planned a system with tree nodes as shown in Figure 19.
Here we have used one node as connectivity and aspect server, one engineering node and
one operator node. We use a hub as the link between the nodes and the controller.
This network topology makes the system more flexible with placing of the nodes. For
instance the engineer can sit on his or hers office and do changes in the program while
the hardware system is located another place.

Server node

Network link

Workstation node AC800M Workstation node

Operator With I/O Engineer
modules

Equipment
Figure 19 Future topology with tree nodes

30
9 Capabilities of the 800xA system
The main capabilities of the IndustrialIT 800xA system is flexibility, personalized
workplace and security.

Flexibility is strength
Flexibility in creating a small system with few I/O modules, or create a big system with
multiple of main controllers and I/O modules.

With different communication types like: Profibus, HART, and Fieldbus. The 800xA
system can easily be connected to almost any existing systems that are in today’s market.

Personalize workplace
An operator or engineer workplace in the 800xA system is behind various computerized
interfaces which can control an entire process or just a valve in the process.

There are many opportunities to personalize a workplace with graphics windows and
different colors and layouts.

Security
Different users have different needs in their access level. An operator does not need to
make changes in the program. The engineer on the other hand has to have rights to
change both the program and the external equipment settings. These user rifts definitions
is easily done in IndustrialIT.

31
10 Discussion
To really understand the capabilities of the IndustrialIT system you have to ask yourself
three questions.
Why should I use the system?
Where should I use it?
What can it do in my project?

You should use IndustrialIT because:

- Its flexible
- It gives you control over your facility
- It gives you security on who have access to the program code
- It is a all-in-one system

You should use it at:

- Any facility that requires automation
- Can use “old” forms for communication such as Fieldbus

It gives you:
- With all the packages it gives you one program to control and analyze the whole
process
- A future orientated control system
- Both local and centralized supervision

When this system is installed in the process it will start to improve the facilities results.
The new changes will be seen in controlling the processes, maintenance work and
calibrating equipments in the process. All data will be presented in a centralized interface
(process window) where logging trends, data sheets and documentation can be arranged
after the operator or engineer’s choices.

All documentation from ABB is very detailed and it explains every aspect on the 800xA
system. Every document and equipment got its own part number which makes it easy to
use. Since the documents contain so much information about different aspects we created
our own installation guide. This will help the user to easily installation and create a new
system. It is not necessary to read and understand all the following documentation from
ABB to create a small system.

32
11 Conclusion
Our result on this project is both the physical system that we have created and installed,
and also the knowledge we have learned us about the IndustrialIT 800xA system.
This knowledge about the system will be a background basis for future work on our
Master thesis that starts late of October 2006.

This project was a great opportunity for us to get more knowledge about this new
automation system from ABB. Since we both have a bachelor degree in Automation we
already have some background knowledge on automation systems and hardware. It is
recommended to have background knowledge about these objects for installing 800xA
system:
- Electronic
- Network and computer communications
- Windows platform and program installations
- Production and operation control interfaces
- Programming languages

The physical system we created was a single node installation of the 800xA system where
it is possible to communicate with one controller and its attached I/O modules. This
system can attach analogue or digital equipments that can be controlled with the
IndustrialIT environment. With this systems flexibilities there are almost no limits of what
this system can do.

Future work with 800xA system is to install a bigger solution which includes 3 nodes in a
network. One server node connected to a main controller with analogue or digital
equipment attached. On the other two nodes in this network we will create one operator
workplace and one engineering workplace. In the future this system can be used in other
school projects or in education.

Overall, the IndustrialIT 800xA system extends the scope of traditional control systems to
include all automation functions in a single operation and engineering environment so
that plants/mills can run smarter and better at substantial cost savings.

33
12 References
All internet addresses worked 20.10.06

[1] ABB documentation DVD Release Notes, Documentation,

3AFE68237432RevC_AC800M_CI858.pdf
[2] ABB documentation DVD Release Notes, Documentation,
3BSE020923R4101_CIO_General.pdf
[3] ABB documentation DVD Release Notes, Documentation,
3BDS011225R4001_Sys_Topology Designer.pdf
[4] ABB documentation DVD Release Notes, Documentation,
3BSE036903R4101_Sys_BasicOperation.pdf
[5] ABB documentation DVD Release Notes, Documentation,
3BSE036351R4101_AC800M_HWOp.pdf
[6] ABB documentation DVD Release Notes, Documentation,
3BUA000156R4101_Sys_PostInstall.pdf
[7] ABB documentation DVD Release Notes, Documentation,
3BSE035980R4101_CIO_BasicSW.pdf
[8] Homesite of Profibus,
http://www.profibus.com/pb/technology/description/#index_5
[9] ABB documentation DVD Release Notes, Documentation,
3BDS011222R4101_Sys_Configuration.pdf
[10] ABB documentation DVD Release Notes, Documentation,
3BSE034463R4101_Sys_AutomationSystemNetwork.pdf

34
Appendix I. Documents attached on project CD
ABB@HiN:
− Project report, word format
− Project report, pdf format
− ABB@HiN System installation guide

ABB documents:
(These documents are in property of ABB)

− 3AFE68237432RevC_AC800M_CI858.pdf

− 3BSE020923R4101_CIO_General.pdf

− 3BDS011225R4001_Sys_Topology Designer.pdf

− 3BSE036903R4101_Sys_BasicOperation.pdf

− 3BSE036351R4101_AC800M_HWOp.pdf

− 3BUA000156R4101_Sys_PostInstall.pdf

− 3BSE035980R4101_CIO_BasicSW.pdf

− 3BDS011222R4101_Sys_Configuration.pdf

− BSE034463R4101_Sys_AutomationSystemNetwork.pdf

35
Appendix II. Troubleshooting
IP communication trouble with AC 800M controller
Remove power supply cable from outlet.
Unscrew two front panel screws on AC 800M. Remove the whole module and let the
back plate still be attached on the DIN rail. This will reset AC 800M controller, it will
still have the same IP settings that has been made earlier in the IP Configuration program.

Wait 15 seconds and reattach module. Try to ping AC 800M IP address in command
prompt window (cmd). Write ping followed by the IP address of the controller. See
Figure 20 for more details on this ping command.

Figure 20 Command prompt window

AC 800M controller diagnostic LED’s

In the front panel of the AC 800M controller there are several LED’s for diagnostics.
These are described in Table 7.

Table 7 Scheme over diagnostic LED’s on AC 800M [1]

Status LED AC 800M controller
F Unit error or unit
initializing.
R Unit running
P Power on
Tx Indicates transmitting
data
Rx Indicates receiving
data

36
Account in OPC server
When entering service username and password in this window it is important to type in
exactly the same username and password as the windows user account.

Example: SINGLENODE1\800xAServiceAccount

See Figure 21 for details on setting up an OPC account

Figure 21 Setup wizard for OPC server account

37
Appendix III. Task description for IndustrialIT 800xA
system project

Installation and demonstration of

Industrial IT 800xA system
at Høgskolen i Narvik
By
Kristian Knudsen and Espen Seljemo
(Industrial Engineering)

Project name: ABB 800xA@HiN

What is IndustrialIT 800xA

The 800xA system is a big and flexible groundbreaking “all-in-one” control system
developed by ABB. It is a universal industrial IT system which contains of different
packages such as: Logistics, process control, surveillance, economics, etc.

The system contains two parts, one software part and a hardware part that are working
and communicating together. 800xA can be implemented in different environments or
laboratories, both for industrial and educational needs.

ABB 800xA@HiN
Department of industrial engineering at HiN got sponsored 4 complete Industrial IT
800xA systems from ABB in year 2005. We are going to install and demonstrate this
system in a laboratory at HiN.

Because of the systems magnitude it is not just inserting a CD in the computer and install.
There are several pre-requisites that have to be considered before installing such as
server/network settings and topology.

This system can be used in future teaching or courses at industrial engineering. Give
students an introduction in high technological control system which are being installed
and used at almost every on- and offshore installation here in Norway.
(Example: Statoil`s LNG fabric Snehvit at Hammerfest.) For future student work this
system can be a platform to do research and development for ABB or other companies
who use this system.

38
Main tasks of the project work are:
1. Study software installation guides on ABB Industrial IT 800xA SYSTEM.
Decide server topology and network settings.
2. Install software and control system on ABB 800xA@HiN computers
(Room A 4220).
3. Assemble 800xA modules on DIN rack and connect to industrial IT computer
system.
4. Describe possibilities and capabilities on ABB Industrial IT 800xA SYSTEM.
5. Demonstrate Industrial IT 800xA SYSTEM at HiN.
6. Write and deliver project report.

Evaluation: Group grading of candidates

Narvik 26.09.2006

_______________________ _______________________
Name Name

39
Appendix IV. Activity schedule for this project

7. Study software installation guides on ABB Industrial IT

800xA system. Decide server topology and network settings. 1 day

8. Install software and control system on ABB 800xA@HiN

computers (Room A 4220). 5 days

9. Assemble 800xA modules on DIN rack and connect to

industrial IT computer system. 2 days

10. Describe possibilities and capabilities on ABB Industrial IT

800xA system. (Part of project report) 1 day

11. Demonstrate Industrial IT 800xA system at HiN. 1 day

12. Write and deliver project report. 5 day

Project time
We have calculated to use 15 days to complete this project.

Costs
All material we need in this project is already in place. So there are no extra costs in this
project. Materials that we need for this project are:
DIN grid plate, DIN rail, own designed system rack, ABB 800xA system modules,
800xA system software, different software, and computers in network.

40
Appendix V. System installation
This document contains the steps needed to do when installing IndustrialIT 800xA system
on a computer. All of the pictures and figures used in this installation guide are
screenshots of the actual installation.

ABB Industrial IT
800xA system

Software installation guide

41
 1. Shell installation

Installation Shell
First window that pop up
when you insert the
installation CD.

Press Install 800xA

System Installation Shell

Then push Run on the

other windows who are
popping up.

Installation Shell

This will install the system

shell on your computer.

Press Install

If not Microsoft.NET Framework 1.1 is not installed. This system shell wizard will
automatically install this. When this is done system shell is finished with installation

42
2. Automated installation
Automated Installation

Press Run Automated

Installation

System Planner
This is the system planner.
It will make the system you
want for your
network/computers.

Press Next

43
 Choose Medium
Choose CD/DVD and push
DVD button in this window

44
 System planner wizard

Press Next

Windows
Here you can choose to use
computer with Windows
installed or if you want to
install windows.
If you choose to use
preinstalled Windows read
the System Installation
guide for prerequisites
before installing the
software.
We have used blank pc’s
This option makes a silent
installation of Windows on
c:\
Press Next

45
 Nodes
The wizard prompts you to
choose a node setup.
We have used single nodes,
this creates the entire
system on one computer.

Click for Single

Engineering Node

Press Next

Connectivity
Choose the device
connectivity. In this system
there is only the AC 800M.

Press Next

46
 Field bus
There is no usage of field
bus.

Press Next

Workgroup/Domain
In this system we use
workgroups.

Press Next

47
 Summary

Press Next

Installation

Press Next

48
 System Configuration
Choose workgroup, service
account,
password(Narvik8515) and
system description.

Press Next

Summary
Use the default settings on
all but password. Choose
an easier password. We
have used abb here.

Press Next

49
 Node Name
Write in the name you
want to use for your
node/nodes

Press advanced
If you want to change the
IP-adress of the
node/nodes. This is not
necessary.

Press Next

System configuration IP
Mark the box as shown in
figure.

Press Next

50
 System configuration IP
This will show the IP-
address for the node.

Press Next

Summary

Press Next

51
 Setup Package
Choose where to store the
package. Use a diskette.

Press Next

Setup Package

Press Next

52
 Setup Package
For information about the
setup package click on the
link in the window.

Press Next

Finished
You have now completed the
System Planner and are
ready to start with the
installation of Industrial IT.

Press Finish

53
Computers without Windows
If you are using computer without Windows, or want to reinstall Windows you have to
choose this in the System Planner.

To do a silent installation insert the Windows CD and the diskette created in System
Planner. This will install Windows automatically with the needed configurations on your
local hard drive (c:\). NB: Silent installation will format all data on local hard drive (c:\)

Installing Windows with the help of the disk you have created in System Planner is the
safest way of installing the system. This is because most of the settings needed by
Industrial IT are set automatically.

When using a pre-installed Windows there are a lot of requisites that have to be done to
your system. These are described in the System Installation book.

54
 3. Industrial IT Single node installation guide
The installation of Industrial IT on a computer is self-explaining. We have done a single
node installation and created an installation guide. It is very important that you read the
information given in each step, and that you have patience with each step. If you rush
trough the installation and don’t let each step finish it might compromise the rest of the
installation.

Required assets for installing Industrial IT on a computer

- Windows XP Professional CD
- CD/DVD Package from ABB
- Administrator rights on the computer
- Microsoft Word and Excel 2003 or newer
- Diskette with a system created in System Planner
- Turn off Windows Firewall and other firewalls that are included in some virus
programs.
- Download all hot fixes for your OS from Windows update on the Internet.
This must be done to have a stable and safe OS before you do anymore
installation. Note: This can only be done if you are using computers with pre-
installed Windows. If you are using a blank computer you will be prompted to
install hot-fixes during the installation. This should be done.

If the installation should crash there is two ways of starting it again.

- Restart PC, and the installation process should continue.
- The other way is to manually restart it as shown in figure below.

- Start
- Programs
- ABB industrial IT 800xA
System
- System Installation Shell
-Continue System installation

55
Manual start of installation, this requires a System Planner diskette

- Start
- Programs
- ABB industrial IT 800xA
System
- System Installation Shell
- Setup a new system

Manually Installation
Start

Manually Installation
Start

Click on Browse

56
Manually Installation Start
Browse after the stored
installed package. File
ending *.cct

Press Next

Manually Installation Start

Example:
*.cct file stored on floppy A:\

Press Next

57
Automated installation, this requires a System Planner diskette.

Installation Start
This is the start of the
installation of Industrial It
on your computer.
This will automatically
start when you have done a
silent Windows
installation.

Press Next

Installation Wizard
The wizard shows what is
about to be done.

Press Next

58
 Network Settings
On the installation the
network settings from the
diskette will be used.

Press Next

Network Settings
Shows computer name and
network settings.

Press Next

59
Network Checklist

Press Next

Network Checklist

Press Next

60
 Restart

Finish

Installation

Press Next

61
 Installation Wizard

Press Next

Windows Components

Press Next

62
Checklist Windows

Press Next

Checklist Windows

Press Next

63
 Restart

Press Next

Installation Wizard

Press Next

64
 Choosing Workgroup
Here you choose the
workgroup you want to
use.

Press Next

Checklist Windows

Press Next

65
Checklist Windows

Press Next

Restart

Press Next

66
 Installation Wizard

Press Next

Add Groups
Creating the groups used in
the 800xA program.
Use the default settings.

Press Next

67
 Add Users
Setting up the users.

Press Next

Create Service Account

Setting up the service
account in Windows.

Press Advanced

Input password. We have

used ”Narvik8515”.

Press Next

68
 Checklist Windows

Press Next

Checklist Windows

Press Next

Insert the IIT800xA-41-1 DVD#1 in the

DVD-rom.

Press OK

69
 Installation Wizard

Press Next

System Checker
Gives you general
information about the
system. Also checks if you
have the needed
administrator rights.

Press Next

70
 System Checker
Checks if your PC satisfy
the requirements.

Press Next

System Checker
Checks if needed programs
are installed.

Press Install

This has to be done until all

required programs are
installed.

Press Next

Restart the PC

71
Installation Wizard

Press Next

Installation Wizard

Press Next

72
Check user rights

Press Next

Check hardware

Press Next

73
 System Checker
Checks if the Windows
components where
installed.

Press Install
If there is a program
missing, press install on it.

Press Next

System Checker
Checks if 3rd programs are
installed.

Press Install
Install the programs
needed.

Press Info
This will give additional
information on the 3rd party
programs needed.

74
 WMI SNMP Provider
This message appears
when pressing info.
Follow this to install WMI
SNMP.

WMI SNMP Provider

Mark the “Management
and..” as shown in the
figure.

Press Details

75
 WMI SNMP Provider
Mark the checkbox as
shown in the figure.

Press OK

Press Next
When Windows
Component Wizard
window opens. This will
install the component.

System Checker

Press Next
When all 3rd party
programs have been
installed1.

1
Visual Basic 6.0 does not need to be installed at this point.

76
 System Checker
Displays the installation
report.

Press Finish

Backup
We have chosen not do
make a backup in the
installation.

Press Skip

77
 Install Industrial IT
This is when you start to
install the Industrial IT
software.

Press Install

Choose installation medium

Choose the medium you want to install the
software package from.

Press Cancel

78
 Information Box

Press OK

Installation
Write the password you
have chosen in the
password block.

Press Next

79
 Installation
Settings that will be
executed.

Press Next

Installation

Press Next

80
 Installation
The rest of the steps are
automated.
When installation is
complete, do a restart of
the computer.
The installation takes time
and you should not restart
the computer or start any
other programs while
install.

81
Appendix VI. Post installation
After system installation has been done, your new system must be configured on your
computer. This is a walkthrough of what is necessary to do in the post installation.

Open Post installation document file [6]. Follow this instruction and start Configuration
wizard from the Start menu as shown in Figure 22.

Figure 22 Configuration Wizard start

Configuration wizard window will pop up, as shown in Figure 23

1. Chose Create system, see Figure 23. After choosing your configuration options
the system will configure itself with your options. This configuration will take
approximately 35 minutes. Do nothing on your computer while this is being
installed.
2. Check that connectivity server is running.
3. Check that firmware version in AC 800M controller is similar to the version in the
program Control builder M professional.

Figure 23 Configuration Wizard

82