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Product Guide

Control and Operation – AC800M – Minerals Library

Operation – AC400 Connect – Minerals Library
Operation – Siemens PCS7 CEMAT Connect – Minerals Library

Version 5.1/4a

Based on Project BU Minerals Library

Prep. ATBPA/W.Vidal 12.07.2007
Appr. ATBPA/M.Knabenhans 12.07.2007
Doc. kind Product Guide Doc. Item

Title Industrial IT System 800xA des. des.

Minerals Library version 5.1/4a Resp. dept. CHIND / ATBPA

Document number Lang. Rev. ind. Page 1
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 1. SYSTEM 800XA CONTROL AND OPERATION AC800M MINERALS
LIBRARY ................................................................................................................... 4
1.1 Control AC800M Minerals Library................................................................. 4
1.1.1 Basic Objects.................................................................................. 4
1.1.2 Communication Objects .................................................................. 6
1.1.3 Consumer Objects .......................................................................... 6
1.1.4 Group Objects ................................................................................ 7
1.1.5 Loop Objects .................................................................................. 8
1.1.6 Report Objects................................................................................ 8
1.1.7 Power Monitoring Objects ............................................................... 9
1.1.8 Composite Object Templates.......................................................... 9
1.1.9 Energy Management .................................................................... 10
1.1.10 Support for Process Panel 800 ..................................................... 12
1.1.11 Basic Objects................................................................................ 14
1.1.12 Group Objects .............................................................................. 19
1.1.13 Consumer Objects ........................................................................ 25
1.1.14 Loop Objects ................................................................................ 39
1.1.15 Reporting Objects ......................................................................... 41
1.1.16 Composite Object Templates........................................................ 42
42
1.1.17 Electrical Control – Energy Management ...................................... 43
1.1.18 Power Distribution Monitoring ....................................................... 43
1.1.19 Energy Management .................................................................... 46
1.2 Some Implementation Concepts................................................................. 54
1.2.1 Look and feel ................................................................................ 54
1.2.2 PCC (Priority Command Connection) ........................................... 55
1.2.3 Point of Control (POC) .................................................................. 57
1.3 Technical and Performance Data ............................................................... 67
1.3.1 System Performance and Capacity............................................... 67
1.3.2 System Example ........................................................................... 69
Memory Space Requirements and Execution Times ..................................... 69
1.3.3 Performance Data ........................................................................ 71
1.4 Related Documents .................................................................................... 75
1.5 Licenses and Ordering Minerals AC800M Control and Operation............... 76
1.5.1 Minerals Library License ............................................................... 76
1.5.2 Minerals License Point.................................................................. 76
1.5.3 Ordering Examples ....................................................................... 76
2. SYSTEM 800XA OPERATIONS AC400 CONNECT MINERALS LIBRARY ........... 78
2.1 Functional Description ................................................................................ 78
2.1.1 Analog Input (AI, AiandUnit, AIBar)............................................... 78
2.1.2 Analog Output (AO, AoandUnit) .................................................... 79
2.1.3 Digital Input (DI)............................................................................ 80
2.1.4 Digital Output (DO, DOTxt) ........................................................... 81
2.1.5 Group Sequence Start / Stop Controller (GROUP) ....................... 82
2.1.6 Pre-Selection (PREBIN) ............................................................... 83
2.1.7 Start Warning (STW) .................................................................... 83
2.1.8 Motor Controller (Motor) .............................................................. 84
2.1.9 Damper/ Actuator Controller (MOTP) ............................................ 85
2.1.10 Valve Control (Valve) .................................................................... 86
2.1.11 PI Controller (PIControl) ............................................................... 87
2.1.12 PID Controller (PIDControl) .......................................................... 88
2.2 Licenses and ordering PPA AC400 Minerals Connect ................................ 89
2.2.1 Tag ............................................................................................... 89
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 2.2.2 Ordering Example ......................................................................... 89
3. MINERALS OPERATIONS FOR SIEMENS PCS7 CEMAT ..................................... 90
4. SUPPORT AND TRAINING ..................................................................................... 91
4.1 Minerals Support ........................................................................................ 91
4.1.1 Design Review.............................................................................. 91
4.1.2 Life Cycle Services ....................................................................... 91
4.2 Minerals Training ........................................................................................ 91
4.2.1 H658 IndustrialIT 800xA Applications for Minerals –
Engineering with EBase and Control Builder M............................. 92
4.2.2 H651 IndustrialIT 800xA Applications for Minerals –
Configuration and Operation ......................................................... 93
4.2.3 H652 Industrial IT 800xA Applications for Minerals –
Operation...................................................................................... 94
REVISION HISTORY ...................................................................................................... 95

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1. SYSTEM 800XA CONTROL AND OPERATION AC800M MINERALS LIBRARY
The IndustrialIT System 800xA Minerals Library comprises of
· Control AC800M Minerals Library, which contains the software modules that are used
to configure applications using the AC800M controllers.
· Operations AC800M Connect Minerals Library, which provides display elements and
faceplates for monitoring and control of objects, defined by means of the AC800M
Minerals Library.
· Operations Process Portal AC400 Connect Minerals Library, which provides display
elements and faceplates for monitoring and control of objects defined by means of the
AC400 BMI Type Circuit Library.
The documentation for all these elements is included on the installation CD-ROM.
This version runs on System 800xA Version 5.1 with Feature Pack 4.

1.1 Control AC800M Minerals Library

Control AC800M Minerals Library contains controller software modules that are used to
configure applications (main focus being in Minerals Industry) using the AC800M
controllers.
A set of purpose-build, typical, software modules has been developed, supporting the
process requirements for these applications. These software modules are developed with
the ABB Control Builder M Professional programming tool, as Control Module Types
(CM). The coding of the Control Modules is compliant with the IEC 61131-3 standard.
These software modules comprise the Minerals Library, and are grouped in eight different
object categories:
· Basic Objects
· Communication Objects
· Consumer Objects
· Dosing Objects
· Group Objects (sequencing)
· Loop Objects
· Power Monitoring Object
· Report Objects
· Energy Management

A separate Reference Manual is available for each object category providing more
details.

1.1.1 BASIC OBJECTS

The Basic Objects (AI, AO, DI, DO) provide access and control for process IO-signals and
calculated IO-signals.
Basic functions such as blocking and forcing of signals, control of output and limit level
changes are integrated in these objects.
PCC Bus Light concept created for all devices in BMIStandard. Through this new PCC
Bus Light version we have now the possibility to see the DIS, DIC, AIS and AIC limit that
is causing some fault to the consumer object. In addition it is possible to see in the AIS,
AIC, DIS and DIC faceplate what is the motor that it is connected to.
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 A detailed description of the basic objects and their interfaces is given in the reference
manual Basic Objects.
Reference Table: Basic Objects for process IO-signals
Name Type Function Data Type
AIS CM Analog input module for 1 process signal. The AISData
functions are blocking & forcing of input value, 4
limit levels, 3 alarm priorities, alarm delay, alarm
blocking, alarm disabling/enabling.
Write: use AIC control module
Read: IO.<TagName>.FilteredSignal.Value
Interlock: IO.<TagName>.<Limit>.Normal
AOS CM Analog output module for 1 process signal. The AOSData
functions are manual / auto mode, tracking of mode
and output changes, 2 output limits.
Write: IO.<TagName>.AutoValue
Together with IO.<TagName>.SetAuto
Read: IO.<TagName>.Signal.Value
DIS CM Digital input module for 1 process signal. The DISData
functions are blocking and forcing of input value, 3
alarm priorities, alarm delay, alarm blocking, alarm
disabling/enabling from application software.
Write: use DIC control module
Read: IO.<TagName>.Signal.Value
Interlock: IO.<TagName>.Signal.Normal
DOS CM Digital output module for 1 process signal. The DOSData
functions are manual / auto mode, tracking of mode
and output changes.
Write: IO.<TagName>.AutoValue
Together with IO.<TagName>.SetAuto
Read: IO.<TagName>.Signal.Value

Reference Table: Basic Objects for calculated IO-signals

Name Type Function Data Type
AIC CM Analog input module for 1 calculated signal. The AISData
functions are the same as for the AIS. AIC uses the
same data type as AIS.
Write: IO.<TagName>.Signal.IOValue
Read: IO.<TagName>. FilteredSignal.Value
Interlock: IO.<TagName>.<Limit>.Normal
AOC CM Analog output module for 1 calculated signal. The AOSData
functions are the same as for the AOS. AOC uses
the same data type as AOS.
Write: IO.<TagName>.AutoValue
Together with IO.<TagName>.SetAuto
Read: IO.<TagName>.Signal.Value
DIC CM Digital input module for 1 calculated signal. The DISData
functions are the same as for the DIS. DIC uses the
same data type as DIS.
Write: IO.<TagName>.SigHW.IOValue

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 Name Type Function Data Type
Read: IO.<TagName>.Signal.Value
Interlock: IO.<TagName>.Signal.Normal
DOC CM Digital output module for 1 calculated signal. The DOSData
functions are the same as for the DOS. DOC uses
the same data type as DOS.
Write: IO.<TagName>.AutoValue
Together with IO.<TagName>.SetAuto
Read: IO.<TagName>.Signal.Value

1.1.2 COMMUNICATION OBJECTS

Communications objects establish and supervise the communication between two
AC800M controllers or between different applications or diagrams.
A detail description of the objects and their interfaces is given in the module
description Communication Objects.
Reference Table: Communication Objects
Name Type Function Data Type
GCC_Com_ CM The GCC_Com_M extends the group drive bus to GCC_ComD
M another diagram and/or application ata
· Point-to-point communication to
GCC_Com_S via Communication Variable
GCC_Com_ CM The GCC_Com_S extends the group drive bus to GCC_ComD
S another diagram and/or application ata
· Point-to-point communication to
GCC_Com_M via Communication Variable
PCC_Com_ CM The PCC_Com_Drive is used to connect the PCC PCC_ComD
Drive bus if the Signal and Drive are located in different ata
diagrams and/or applications:
· Point-to-Point Communication via one
Communication Variable transferred to the
PCC_Com_Signal Block
PCC_Com_ CM The PCC_Com_Signal is used to connect the PCC PCC_ComD
Signal bus if the Signal and Drive are located in different ata
diagrams and /or applications:
· Point-to-Point Communication via one
Communication Variable transferred to the
PCC_Com_Drive Block

1.1.3 CONSUMER OBJECTS

Consumer objects provide access and control for the physical devices (consumers) in
the plant.
Basic functions such as operator orders, detailed interlock and alarm indication,
tracking of mode and status changes, are integrated in these objects.
A detailed description of the consumer objects and their interfaces is given in the
reference manual Consumer Objects.
Reference Table: Consumer Objects
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 Name Type Function DataTypes
MOT1 CM The Control Module Type MOT1 is used to control a MOT1Data
motor with one direction (one speed) in a drive
group or standalone.
MOT1_VVVF CM The Control Module Type MOT1_VVVF is used to MOT1VVVFD
control a motor with one direction and variable ata
speed in a drive group or standalone.
MOT2 CM The Control Module Type MOT2 is used to control a MOT2Data
motor with two directions (two speeds) in a drive
group or standalone.
MOT2_VVVF CM The Control Module Type MOT2_VVVF is MOT2VVVFD
used to control a motor with two direction ata
and variable speed in a drive group or
standalone.
MOTP CM The Control Module Type MOTP is used to control MOTPData
a motorized valve or damper with or without
analog position feedback in a drive group or
standalone.

VLV1 CM The Control Module Type VLV1 is used to control a VLV1Data

normally-closed one-way valve with one or two
coils in a drive group or standalone. Up to two
position limit switches (open and closed) can be
supervised.
VLVNO1 CM The Control Module Type VLV1 is used to control a VLVNO1Data
normally open one-way valve with one or two
coils in a drive group or standalone. Up to two
position limit switches (open and closed) can be
supervised.

1.1.4 GROUP OBJECTS

The Group Objects provide access and control for a process group or process group
related features.
Basic functions such as operator orders, detailed interlock and alarm indication,
tracking of mode and status changes, pre-selection of group members and startup
warnings are integrated in these objects.
A detail description of the group objects and their interfaces is given in the reference
manual Group Objects.
Reference Table: Group Objects
Name Type Function Data Type
GROUP CM Group sequence. The functions are starting, GrpInput
stopping of group members in a sequential order, GrpOutput
summary status indication of all pre-selected group GrpDrvCon
members (ready, run, off), 4 start and 4 stop
interlocks, emergency quick stop.
DriveGroup CM Technological group can handle auxiliary DriveGroupD
equipment and main drives like one system ata
GrpCycleCtrl CM Cycle controller for the group. This control module GrpCycle
can be used for cyclic activation and deactivation of CntrlData
group members by means of a script (e.g. silo
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 aeration, cool down lubrication etc.). Several
GrpCycleCtrl objects can be added to one GROUP.
PREBIN CM Pre-selection module. The function is to activate or PreBinData
deactivate one or a set of group members such as
consumer objects or loops during the group start
up.
STW CM Start Warning module. The function is to provide a STWData
start up warning for an individual consumer object
or a group.
GroupStep CM The GroupStep module can be used to: Not defined
· Start / Stop equipment not controlled by a
consumer object or loop. (e.g. valve
represented by a DOS)
· Start / Stop consumer objects located in
another controller.
· Start / Stop consumer objects controlled by
more than 2 groups.

1.1.5 LOOP OBJECTS

Loop objects provide access and control for analog open and closed control loops.
Basic functions such as operator orders, detailed alarm indication, tracking of mode
and status changes, are integrated in these objects.
A detailed description of the loop objects and their interfaces is given in the reference
manual Loop Objects.
Reference Table: Loop Objects
Name Type Function Data Type
PIDCtrl CM State-of-the-art PID Closed loop controller with feed PIDCtrlData
forward, anti wind up and gain scheduling functions.

1.1.6 REPORT OBJECTS

Report objects provide access to counter values or summarize Analog Values over
time (integrator). They provide a focused historical archiving for detailed
information.
The different counter types provide total following functions:
· Total and shift value summation
· Reset counter value from controller or from the Operator Station (via the faceplate)
· Adjustment (positive & negative) of counter value and constant from the
Operator Station (via the faceplate)
· Operator Station Interface (graphic element and faceplate)
A detailed description of the report objects and their interfaces is given in the module
description Report Objects.
Reference Table: Report Objects
Name Type Function Data Type

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 PulseCount CM Pulse Counter is used to count pulses and sum PulseCount
them up for production data reports. Data

Reporting CM The ReportingCount is giving all featuring Reporting

Count from PulseCount and additionally a focused CountData
historical archiving for detailed information

1.1.7 POWER MONITORING OBJECTS

Power monitoring objects are intended for supervision and control of power distribution
equipment such as switchgear, and protection relays using serial connectivity (e.g.
Profibus or Modbus). The objects are designed as composite control modules
containing one module for the communication. This module can be modified to adapt
to the requirements of the equipment.
A detail description of the objects and their interfaces is given in the module
description Power Monitoring Objects.
The Control Module Types for Power Distribution Monitoring objects and their
corresponding Structured Data Types are located in the library BMIEnergy 1.0-0 for
Control Builder Professional.
Reference Table: Power Monitoring Objects
Name Type Function Data Type
Circuit Breaker CM Control an IED Control Device with CircuitBreaker
up to 2 Breakers with Isolator and Data
Earth Switch in a drive group or
standalone
CircuitBreakerA Composite CM: Interface to an ABB REF542+ CircuitBreaker
BBREF542Plus connected via ModBus ABBREF542P
Circuit Breaker +
3 AIC (Current, lusData
Voltage, Power) + 1
Counter (Energy)
PFCCtrl CM Power Factor Correction Controller PFCCtrlData
with up to 8 Circuit Breaker (Steps)

1.1.8 COMPOSITE OBJECT TEMPLATES

The library contains a so called wrapper framework to compose project specific
consumer objects having serial communication interface (Profibus, Modbus, etc.)
between control system and device. The intention is to provide samples of how to
implement project specific serial devices. The samples included in the library shall be
used as templates, i.e. copied and adapted to the project specific requirements if
required.
The Control Module Types and their corresponding Structured Data Types are located
in a dedicated Library per Interface like BMI_MNSIS, BMI_MNSiS_MBTCP,
BMI_UMC22, BMI_UMC100 and BMI_ACS8x0.
Reference Table: Serial Communication Objects
Name Type Function Data Type
MOT1VVVF_ACS8x0 Composite CM: ABB Drive system with MOT1_VVVFData
MOT1_VVVF ProfibusDP interface
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 ACS500, ACS600,
ACS800 or ACS1000
MOT2VVVF_ACS8x0 Composite CM : ABB Drive system with MOT2VVVFData
MOT2_VVVF ProfibusDP interface
ACS500, ACS600,
ACS800 or ACS1000
UMC22 Composite CM ABB UMC22 MCC device MOT1UMCData
MOT1_MNSIS Composite CM ABB MNS iS MCC with MOT1_MNSISData
MOT2_MNSIS MOT1 + AIC (Current or Power) ProfibusDP Interface
MOTP_MNSIS MOT2 + AIC (Current or Power)
MOTP + AIC (Current or Power)
MOT1_MNSiS_MBTCP Composite CM: ABB MNS iS MCC with MOT1_MNSiS_MBT
MOT2_MNSIS_MBTCP MOT1, MOT2, MOTP Modbus over TCP/IP CPData
Interface
MOTP_MNSIS_MBTCP
MOT1_UMC100 Composite CM: ABB UMC100 with MOTx_UMC100Data
MOT2_UMC100 MOT1, MOT2, MOTP PROFIBUS Interface
MOTP_UMC100

1.1.9 ENERGY MANAGEMENT

Energy Management functions are licensed as an option to Minerals Control Library.
Energy Management Objects are intended for supervision of the electrical feeders,
monitoring and controlling of loads with the target to ensure that the Energy
consumption of the Plant respects given conditions.
The Control Module Types for Energy Management objects and their corresponding
Structured Data Types are located in the library BMI EnergyMgmt 1.0-0. for Control
Builder Professional.
Reference Table: Examples of Energy Management Objects
Name Type Function Data Type
Load Composite CM Load : Load_DataType
Enable grouping of MV-Switchgear according Plant
Load
Sections in order to monitor and control their
Energy consumption

Composed from : Load +

3 DIC (Warning, Interlock,Tripping) +
1 Reporting_Counter (EnergyCost)

Load Load Shedding Load Shedding: LoadSheddingData

Shedding Enable to ensure that the Energy consumption of
the Plant respects certain conditions according
priorities

Power Composite CM PowerDemand Supervision: PowerDemandData

Demand Enables input of tariff structure and their given
PowerDemand
Supervision conditions to respect coming from the Energy
Supervision
supplier

Composed from : PowerDemandSupervision +

8 Tariffs / each Tariff composed from 8 TariffSet +
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 1 DIC (syncPulseAlarm) +
6 AIC Total Power, Total Current,
ActualEnergyInInterval,
ForecastEnergyAtIntervalEnd,
EnergyMovingInterval,PeakPowerExceededTime,

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 1.1.10 SUPPORT FOR PROCESS PANEL 800
BMI standard symbol library for Process Panel P800 is included in the Minerals
Control and Operation Library.

The Process Panel 800 Object types provide access and control for the following
standard control modules:
·MOT1
·MOT2
·MOTP
·MOT1VVVF
·MOT2VVVF
·VLV1
·VLVNO1
·GROUP
·PREBIN
·AIS
·AIC
·AOS
·AOC
·DIS
·DIC
·DOS
·DOC
All Process Panel objects have the following common basic functions:
· Manual control from the Process Panel (via commands and input fields)
· Status and operation indication
· Mode selection from the Process Panel (via commands)

· Data exchange through a single access variable

For more info consult the documentation: Process Panel Reference Manual 3BHS
240189
Control – AC800M – Minerals Library
Operation – Process Panel - AC800M Connect – Minerals Library

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 · Operations AC800M Minerals Library
Operations AC800M Minerals Library integrates the Control AC800M Minerals Library
with the Process Portal. The AC800M Connect Minerals Library provides display
elements and faceplates on the Process Portal, for monitoring and control of objects
defined by means of the AC800M Minerals Library.
The figure below shows examples of the display elements with status indication of
equipment as presented on the process displays.
See as well chapter 1.2.1 Look and feel.

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 Example of a motor Faceplate (Extended View)

Tag name
Description

Point of Control Call up Call up

indication Object Object
Alarm Event
Motor status List List
Indication
Change Point of
Control

Seq => Sequence

Cen => Central
Start motor Loc => Local

Stop motor

Acknowledge Alarm Extended view

1.1.11 BASIC OBJECTS

1.1.11.1 Analog Input (AIS, AISandunit, AISbar)

Main purpose of Module: Analog Input Interface

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 The analog input module for 1 IO-signal provides the following features:
· Blocking and forcing of input value generating event (even on new forced values)
· Threshold detection and alarming on 4 alarm limit levels (L2,L1,H1,H2)
· Threshold detection and eventing on 2 Process Limit levels (Plo, Phi)
· Adjustable Low Pass Filter.
· FilteredSignal Rate of change calculation and alarm. The ROC is presented in %
of Total Range per second.
· All Substatus for DP, PA and FF Field Devices will generate error control when
quality is Bad or Uncertain for AIS Control Module.
· Common or Individual alarm delay for all 6 limits.
· Alarm blocking (from faceplate). All alarm limit levels will be blocked.
· Alarm disabling/enabling of each alarm limit individually (from application program /
Faceplate); generating events when blocked.
· Trend for Signal Value, Filtered Value and Rate of Change
· Signal Error Pre-Warning with adjustable alarm delay
· Process Panel status indication and operation

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 1.1.11.2 Analog Output (AOS, AOSandUnit)
Main purpose of Module: Analog Output Interface

The analog output module for 1 IO signal provides the following features:
· Automatic control from a superior application
· Manual control from the Operator Station (via the faceplate)
· Tracking of mode and output changes
· Output limitation high/low
· On-Line trend with actual output value shown in the faceplate.
· All Substatus for IO and FF Filed Device will generate error control when quality is
Bad or Uncertain for AOS Control Module
· Process Panel status indication and operation

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 1.1.11.3 DIGITAL INPUT (DIS)
Main purpose of Module: Digital Input Interface

The digital input module for 1 IO signal provides the following features:
· Blocking and forcing of input value generating event (even on new forced values)
· Alarming if input value differs from pre-defined (healthy; normal position) state
· Warning time to be used to generate a pre warning alarm or event before the
main alarm (failure) occurs.
· Ready Delay time to hold the alarm position in order to prevent noisy signals to
clear and re-activate the alarm very often.
· Alarm delay
· Alarm blocking (from faceplate). All alarm limit levels will be blocked.
· Alarm disabling/enabling (from application program)
· On-Line trend with actual input value
· Process Panel status indication

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 1.1.11.4 DIGITAL OUTPUT (DOS, DOSTXT)
Main purpose of Module: Digital Output Interface

The digital output module for 1 IO signal provides the following features:
· Automatic control from a superior application
· Manual control from the Operator Station (via the faceplate)
· Manual control from the Process Panel
· Tracking of mode and output changes
· On-Line trend with actual output value shown in the faceplate.
· Process Panel status indication and operation

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 1.1.12 GROUP OBJECTS

1.1.12.1 Group Sequence Start / Stop Controller (Group01)

Main purpose of Module: Sequence controller for starting / stopping a drive group

Group Off
Group Starting
Group on Hold
Group Running
Group Stopping

The group sequence start / stop module provides the following features:

· Starting / stopping of group members (up to 999 motors, valves, etc) in a

sequential order with Supervision of First Step in Hold, First Step Not Off on
Faceplate.
· Consumer objects have 4 different Point of Control (POC): SEQ, CEN, LOC, and
Out Of Service.
· Modularity on Group control : Settings of the Consumer POC when Group starts
(immediate, only on Step, never)
· Summary status indication of all pre-selected members (Ready, run, off)
· Alarming when exceeding maximum start-up / shut-down time
· 1 Safety interlock, 1 Chain Auto interlock, 4 start and 4 stop interlocks
· Emergency quick stop
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 · Hold function. Interrupts start-up respectively shut-down sequence
· Show Tag function. Displays the tag numbers of the group members on the
process display (adjacent to the graphic symbol of the members)
· Show Mem function. Emphasizes the group members on the process display
and indicates the start step number of each member.
· Simulation mode (Analog value, motor feedback….), to simulate feedback signals
of all group members.
· Auto Mode, starting and stopping the group with a delays from IA Interlock
· Unconditional Start, the operator or maintenance user is enabled to start the group
disregarding any preselected Drives that are not Ready for Start (Start Interlock, IC
interlock, Presel Missing still active).
· Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
· Process Panel status indication and operation
· Indication of TagName on the Group Faceplate for Consumers / StepOneGroup
/ StepTwoGroup and PID in case of:
§ Consumer not ready for start
§ Group in Hold
§ Actual Starting / Stopping Step
· A Link button to access the faceplate of the indicated object

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 · indication of 4 start and 4 stop interlocks
· In the case that sub-ordinate object is causing an interlock then the actual Tag
name of the faulty object is dynamically propagated into the Group for the
operator quickly to see the reason for a problem

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 1.1.12.2 Group Sequence Cyclic Controller (GrpCycleCtrl)
Main purpose of Module: Sequence controller for a cyclic activation of equipment

The module handles sequential and cyclic activation and de-activation of devices. Typically
used to control silo aeration valves when silos containing fine bulk materials are discharged.
The module provides:
· Program selector with 3 programs selectable from faceplate or application
· 1 Safety interlock, 1 Chain Auto interlock, 2 start interlocks, 1 Previous drive
· Consumer objects have 4 different Point of Control (POC): SEQ, CEN, LOC, and
Out Of Service.
· 2 External Alarm inputs and 2 External Warning inputs
· Sequence cycle time supervision, Alarming when exceeding maximum start-up /
shut-down time
· Continuous execution or execution during a defined number of cycles
· Next step control from faceplate or application
· Modularity on Group control : Settings of the Consumer POC when Group starts
(immediate, only on Step, never)
· 2 stepping modes (ByTime, ByTime and condition)
· 2 restart modes (step 1, last step)
· Automatic step over if all drives of a step are out of service or not selected
· Ready for start summary of all drives included in the selected program.

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 · Show Mem function. Emphasizes the group members on the process display
and indicates the start step number of each member.
· Simulation mode (Analog value, motor feedback….), to simulate feedback signals
of all group members.
· Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
· In the case that sub-ordinate object is causing an interlock then the actual Tag
name of the faulty object is dynamically propagated into the Group for the
operator quickly to see the reason for a problem

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 1.1.12.3 Pre-Selection (PREBIN)
Main purpose of Module: Routing control

PREBIN has no faceplate. Clicking on the push button symbol toggles the state. In case
stand-by preselection is configured, an additional button is provided for each pre-selection to
define the current stand-by selection.

The pre-selection module allows the operator to select or de-select a single device or a set
of devices within a group. By e.g. pressing “Silo1” all objects belonging to the route to silo 1
are pre-selected. This does however, not cause a start-up of equipment, it is just a selection.
When initiating a group sequence start, selected devices will start up in a sequential order;
de-selected devices will shut down in a sequential order (provided they were in a running
state).
In case stand-by pre-selection is active, a pre-selected and running drive will initiate a
switchover (group start) when tripping, automatically starting up the stand-by pre-selected
drives.

1.1.12.4 Start Warning (STW)

Main purpose of Module:
Control for buzzers and flashlights, prior to a remote start of equipment

STW has no stand-alone graphic element and no faceplate. It is tightly integrated with motor
and group control. See Group control graphic element.

The start warning module is integrated with the consumer objects (e.g. MOT1, MOT2,
MOTP, etc.). When a start command for a motor is initiated, the start warning module first
triggers the buzzers and/or flashlights before it returns the actual start release for the motor.
Different buzzers and flashlights can be assigned to appropriate start warning modules,
which in turn are assigned to appropriate consumers.

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 1.1.13 CONSUMER OBJECTS

1.1.13.1 Motor Controller – non reversing (MOT1)

Main purpose of Module: Controller for a motor with one direction (one speed)

Alarm

Interlock

Off

Bad Quality (OPC)

Running

Running, Central

Running, Central,
Interlock Blocked

The control module for a one-direction motor provides the following features:

· Tight group sequence control integration (start/stop or open/close) from the

corresponding drive group. Sequence order within a group can be configured by
simply entering the step number parameter (1..999). Could be simulated from
the group, with or without any alarms.
· Tight integration of object control and start warning in order to automatically
actuate audible and/or visible warning devices prior to starting up.
· Out of service function. Enables the operator to take single motors out of control
(No Action from the group, Faceplate neither LCB)
· Motor current indication and high limit warning supervision
· User definable Warning indication
· 3 additional interface inputs with MCC; for e.g. Overtemp, Overload & Availability
· 2 functional back process inputs with feedback time supervision for e.g. speed,
pressure or flow supervision. Pulsed feedback supported as well with actual Period
time shown on the Faceplate.
· 1 Safety interlock, 1 Chain Auto Interlock, 4 Process interlocks, 1 Previous drive
· 2 of the in total 4 Process (run) interlocks, can be configured as pure start
interlocks
· Totalisation and indication of run time (in hours) and number of starts
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 · Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
· Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
· Process Panel status indication and operation
· Alarming during Simulation can be enabled for testing the Interlock, Feedback
· Alarming Condition defined by a Project Constant :
For Standard BMI Library, the consumer object alarming is enabled on:
§ Start order given, or
§ Consumer object in Auto mode
For Non Standard BMI Library, the consumer object alarming is enabled on:
§ GroupStart and Motor Preselect (or StandBy), or
§ POC is in Cen and Motor is started, or
§ Otherwise Not Ready Treatment is shown

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 1.1.13.2 Variable Speed Drive Controller (MOT1_VVVF)
Main purpose of Module: Controller for a variable speed drive motor

The control module for a variable speed drive has basically the same functionality as MOT1,
with the following additions:

· Tight group sequence control integration (start/stop or open/close) from the

corresponding drive group. Sequence order within a group can be configured by
simply entering the step number parameter (1...999). Could be simulated from
the group, with or without any alarms.
· Tight integration of object control and start warning in order to automatically
actuate audible and/or visible warning devices prior to starting up.
· Out of service function. Enables the operator to take single motors out of control
(No Action from the group, Faceplate neither LCB)
· Motor current indication and high limit warning supervision
· User definable Warning indication
· Motor speed indication
· Speed set point coming from the corresponding drive group (Automatic) or from the
Operator Station / Process Panel (Manual)
· Speed set point low and high limitation
· 3 additional interface inputs with MCC; for e.g. Overtemp, Overload & Availability
· 2 functional back process inputs with feedback time supervision for e.g. speed,
pressure or flow supervision. Pulsed feedback supported as well with actual Period
time shown on the Faceplate.
· 1 Safety interlock, 1 Chain Auto Interlock, 4 Process interlocks, 1 Previous drive
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 · 2 of the in total 4 Process (run) interlocks, can be configured as pure start
interlocks
· Totalisation and indication of run time (in hours) and number of starts
· Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
· Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
· Process Panel status indication and operation
· Alarming during Simulation can be enabled for testing the Interlock, Feedback, etc.
· Alarming Condition defined by a Project Constant:
For Standard BMI Library, the consumer object alarming is enabled on:
§ Start order given, or
§ Consumer object in Auto mode
For Non Standard BMI Library, the consumer object alarming is enabled on:
§ GroupStart and Motor Preselect (or StandBy), or
§ POC is in Cen and Motor is started, or
§ Otherwise Not Ready Treatment is shown

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Title Industrial IT System 800xA
Minerals Library version 5.1/4a
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 1.1.13.3 Motor Controller – reversing (MOT2)
Main purpose of Module: Controller for a motor with two directions (or two speeds)

The control module for a reversing motor has basically the same functionality as MOT1,
however with the following adaptations:

· Tight group sequence control integration (start/stop or open/close) from the

corresponding drive group. Sequence order within a group can be configured by
simply entering the step number parameter (1..999). Could be simulated from
the group, with or without any alarms.
· Tight integration of object control and start warning in order to automatically
actuate audible and/or visible warning devices prior to starting up.
· Out of service function. Enables the operator to take single motors out of control
(No Action from the group, Faceplate neither LCB)
· Motor current indication and high limit warning supervision
· User definable Warning indication
· 3 additional interface inputs with MCC; for e.g. Overtemp, Overload & Availability
· 2 functional back process inputs with feedback time supervision for e.g. speed,
pressure or flow supervision. Pulsed feedback supported as well with actual Period
time shown on the Faceplate.
· 2 feedback run signals (one feedback for each direction)
· 1 Safety interlock, 1 Chain Auto Interlock, 4 Process interlocks, 1 Previous drive
· 2 of the in total 4 Process (run) interlocks, can be configured as pure start
interlocks
Doc. kind Product Guide Project BU Minerals Library
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Minerals Library version 5.1/4a
Document number Lang. Rev. ind. Pages 29
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 · All interlocks, except equipment interlocks, are direction related
· Totalisation and indication of run time (in hours) and number of starts.
· New Remaining Time Indication for the step shown in the Group faceplate and in
the Consumer Objects as well
· Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
· Process Panel status indication and operation
· Alarming during Simulation can be enabled for testing the Interlock, FeedBack,..
· Alarming Condition clearly defined by the mean of Project Constant :
For Standard BMI Library, the consumer object alarming is enabled on:
§ Start order given, or
§ Consumer object in Auto mode
For Non Standard BMI Library, the consumer object alarming is enabled on:
§ GroupStart and Motor Pre-selection (or StandBy), or
§ POC is in Cen and Motor is started, or
§ Otherwise Not Ready Treatment is shown

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Minerals Library version 5.1/4a
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 1.1.13.4 Variable Speed Drive Controller – reversing (MOT2_VVVF)
Main Purpose of Module: Controller for a variable speed motor with two directions

The control module for a reversing variable speed motor is a combination of the MOT2 and
MOT1_VVVF modules, with the following features:

· Tight group sequence control integration (start/stop or open/close) from the

corresponding drive group. Sequence order within a group can be configured
by simply entering the step number parameter (1..999). Could be simulated
from the group, with or without any alarms.
· Tight integration of object control and start warning in order to automatically
actuate audible and/or visible warning devices prior to starting up.
· Out of service function. Enables the operator to take single motors out of control
(No Action from the group, Faceplate neither LCB)
· Motor current indication and high limit warning supervision
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 · User definable Warning indication
· Speed set point and limitation from the corresponding drive group (Automatic) or from
the Operator Station / Process Panel (Manual) separately for X and Y direction
· 3 additional interface inputs with MCC; for e.g. Overtemp, Overload & Availability
· 2 functional back process inputs with feedback time supervision for e.g. speed,
pressure or flow supervision. Pulsed feedback supported as well with actual Period
time shown on the Faceplate.
· 2 feedback run signals (one feedback for each direction)
· 1 Safety interlock, 1 Chain Auto Interlock, 4 Process interlocks, 1 Previous drive
· 2 of the in total 4 Process (run) interlocks, can be configured as pure start
interlocks
· All interlocks, except equipment interlocks, are direction related
· Totalisation and indication of run time (in hours) and number of starts.
· Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
· Supervision of the Actual Speed feedback during Start and Stop as configurable
condition for alarming and feedback to the drive group
· Alarming Condition defined by a Project Constant :
For Standard BMI Library, the consumer object alarming is enabled on:
§ Start order given, or
§ Consumer object in Auto mode
For Non Standard BMI Library, the consumer object alarming is enabled on:
§ GroupStart and Motor Pre-selection (or StandBy), or
§ POC is in Cen and Motor is started, or
§ Otherwise Not Ready Treatment is shown

Doc. kind Product Guide Project BU Minerals Library

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Minerals Library version 5.1/4a
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1.1.13.5 Damper/ Actuator Controller (MOTP)
Main purpose of Module:
Controller for a motorized damper with or without analog position feedback

The control module for a motorized damper/actuator provides the following features:

· Tight group sequence control integration (start/stop or open/close) from the corresponding
drive group. Sequence order within a group can be configured by simply entering
the step number parameter (1..999). Could be simulated from the group, with or
without any alarms.
· Tight integration of object control and start warning in order to automatically actuate
audible and/or visible warning devices prior to starting up.
· Out of service function. Enables the operator to take single motors out of control (No
Action from the group, Faceplate neither LCB)
· 2 additional interface inputs with MCC; for e.g. Overload & Availability
· 2 position feedback signals with error indication if both are present at the same time
· 2 running feedback signals
· 1 Safety interlock, 1 Chain Auto Interlock, 1 Process interlock
· 1 Force interlock
· All interlocks are direction related
· Automatic position control either with internal or external set point, Analog or Digital
· Position set point low and high limitation.
Doc. kind Product Guide Project BU Minerals Library
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Minerals Library version 5.1/4a
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 · New Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
· Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
· Process Panel status indication and operation
· Alarming during Simulation can be enabled for testing the Interlock, FeedBack,..
· Alarming Condition clearly defined by the mean of Project Constant :
For Standard BMI Library, the consumer object alarming is enabled on:
§ Start order given, or
§ Consumer object in Auto mode
For Non Standard BMI Library, the consumer object alarming is enabled on:
§ GroupStart and Motor Preselect (or StandBy), or
§ POC is in Cen and Motor is started, or
§ Otherwise Not Ready Treatment is shown

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1.1.13.6 Normally-closed Control (VLV1)
Main purpose of Module: Controller for a normally-closed one-way valve or actuator

The module controls valves with one or two coils and up to two position limit switches. It
provides:

· Tight group sequence control integration (start/stop or open/close) from the corresponding
drive group. Sequence order within a group can be configured by simply entering
the step number parameter (1..999). Could be simulated from the group, with or
without any alarms.
· Tight integration of object control and start warning in order to automatically actuate
audible and/or visible warning devices prior to starting up.
· Out of service function. Enables the operator to take single motors out of control (No
Action from the group, Faceplate neither LCB)
· 1 additional interface inputs with MCC; for e.g. Availability
· 2 position feedback signals with error indication if both are present at the same time.
Timer delay.
· 1 Safety interlock, 1 Chain Auto Interlock, 2 Process interlocks, 1 Previous drive.
· One or two-coil, energized till Feedback or steadily features enabled.
· New Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
· Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName

Doc. kind Product Guide Project BU Minerals Library

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Minerals Library version 5.1/4a
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 · Process Panel status indication and operation
· Alarming during Simulation can be enabled for testing the Interlock, FeedBack,..
· Alarming Condition defined by a Project Constant :
For Standard BMI Library, the consumer object alarming is enabled on :
§ Start order given, or
§ Consumer object in Auto mode
For Non Standard BMI Library, the consumer object alarming is enabled on :
§ GroupStart and Motor Preselect (or StandBy), or
§ POC is in Cen and Motor is started, or
§ Otherwise Not Ready Treatment is shown

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1.1.13.7 Normally-open valve Control (VLVNO1)
Main purpose of Module: Controller for a normally-open one-way valve or actuator

The module controls valves with one or two coils and up to two position limit switches. It
provides:

· Tight group sequence control integration (start/stop or open/close) from the corresponding
drive group. Sequence order within a group can be configured by simply entering
the step number parameter (1..999). Could be simulated from the group, with or
without any alarms.
· Tight integration of object control and start warning in order to automatically actuate
audible and/or visible warning devices prior to starting up.
· Out of service function. Enables the operator to take single motors out of control (No
Action from the group, Faceplate neither LCB)
· 1 additional interface inputs with MCC; for e.g. Availability
· 2 position feedback signals with error indication if both are present at the same time.
Timer delay.
· 1 Safety interlock, 1 Chain Auto Interlock, 2 Process interlocks, 1 Previous drive.
· One or two-coil, energized till Feedback or steadily features enabled.
· New Remaining Time Indication for the step shown in the Group faceplate and in the
Consumer Objects as well
· Operator Station Interface (graphic element and faceplate) including detailed alarm
and interlock indications, separated between the object and its TagName
· Process Panel status indication and operation
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 · Alarming during Simulation can be enabled for testing the Interlock, FeedBack,..
· Alarming Condition defined by a Project Constant :
For Standard BMI Library, the consumer object alarming is enabled on :
§ Start order given, or
§ Consumer object in Auto mode
For Non Standard BMI Library, the consumer object alarming is enabled on :
§ GroupStart and Motor Preselect (or StandBy), or
§ POC is in Cen and Motor is started, or
§ Otherwise Not Ready Treatment is shown

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1.1.14 LOOP OBJECTS

1.1.14.1 PID Controller (PIDCtrl)

Main purpose of Module: Loop Controller with parametrical proportional, integral and
derivative characteristics

The PID Controller has 2 different operation modes.

Manual Mode

Automatic Mode
Setpoints for every mode may come from Faceplate
(Operator) or External (E1A, E2A, E1M, E2M)
MV à Measured Value
SP à Setpoint

Faceplate of a PID-Controller

PID module for closed loop control has the following options:
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 · Auto tuning of control parameters P, I and D
· Gain scheduling
· Feed forward control
· Anti wind up
· 2 external set point references, that can be written from the application
· 2 external controller output references, that can be written from the application
· Limit supervision of measured value and deviation, with integrated alarm annunciation
· Alarm and event handling with 3 alarm priorities
· Set point high and low limitation
· Controller output high and low limitation
· Event logging for control mode changes and set point changes
· Tracking and balancing modes
· FF State Machine possibility to set Cascade Mode position automatically when
requested from the faceplate or from the FF Function Block.
· Status of MV, ActuatorPos and OUTP signals. All Sub-status for DP, PA and FF Field
Devices will generate error control when quality is Bad or Uncertain for MV and OUTP
· Threshold detection and event treatment on 2 Process Limit levels (Plo, Phi)
· Alarm disabling/enabling of each alarm limit individually (from application program /
Faceplate); generating events when blocked (same for MV).

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1.1.15 REPORTING OBJECTS
Main purpose of Module: Report objects provide access to counter values.

Counters Control Module Type supports the following functions:

· Total and shift value Summation
· Reset counter value from controller or from the Operator Station (via the faceplate)
· Adjustment (positive & negative) of counter value and constant from the Operator
Station (via the faceplate)
· Operator Station Interface (graphic element and faceplate)

4 different modes can be used as:

· Pulse Counter (used to count pulses and multiply them with a factor)
· Integrator (used to integrate an Analog Input signal in case no pulse is available)
· Accumulator with external pulse (used when getting counter values from serial
interfaces)
· Delta Accumulator (used when getting counter values from serial interfaces)

And additionally a focused historical archiving for detailed information is also available:
· Actual Shift / Last Shift
· Actual Day / Last Day
· Actual Month / Last Month
Such as on kWh consumption for Cement Mills, Tons of material used for production, running time
of production critical equipment:

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1.1.16 COMPOSITE OBJECT TEMPLATES
Main purpose of composite objects is to provide serial communication interface and
methods to retrieve and present the extensive amount of information provided by the
“intelligent” devices.
The library contains a so called Serial Object Framework in form of a composite Control Module
for implementing serial (fieldbus, etc.) connected equipment. The modularity of the Control
Module allows equipment specific adaptation of the communication part to be used with the
standard object (MOTx, VLVx, CircuitBreaker, etc.) functions.

Serially connected, usually intelligent devices have the ability of providing much more
information of their functional status. The faceplate with its limited space is not seen as a
suitable media to present all the additional information, most of which is not process operation
related.

Therefore configurable link buttons have been provided in the Faceplate “Extebded Info” Area to
allow direct access to additional aspects of the serial object from the Operator Station.

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1.1.17 ELECTRICAL CONTROL – ENERGY MANAGEMENT
The Electrical Control functionality is implemented in the 800xA Minerals Library using the
same basic software and system functions as process control. The equipment interfaces
and the electrical control applications can be located in dedicated controllers or they can
co-exist with the process control applications hence allowing a cost optimized
implementation for small electrical rooms and sub stations.
The Electrical Control functionality contains following main categories of functions
· Supervision and visualization of Power Distribution network(s) – “single line
diagram”. The information can be provided on the Operator Workplace terminal or
on dedicated Electrical Workplace terminals or both.
· Energy Management functions (Optionally available) This functionality is based on
a specific Library which is an extension to the Minerals Control library.

1.1.18 POWER DISTRIBUTION MONITORING

The Power Distribution Monitoring objects provide access and control for supervision and
control of power distribution equipment such as switchgear, and protection relays using
serial connectivity (e.g. ProfibusDP, Modbus or IEC61850).
The functional scope of the Power Distribution Network Monitoring contains
- the connectivity to the power distribution feeders and protection relays
- implementation of the feeder objects into system 800xA
- operating faceplates and the associated functionality of the objects
- graphical display (single line display) of the power network
- indication of the main measured values of each feeder
- access to detailed status data of each equipment (scope of data dependent
on each device and used communication)
The functions are available on all (or selected) Operator Workplaces or on dedicated
Electrical Workplaces.

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1.1.18.1 Circuit Breaker
The Control Module Type CircuitBreaker is used to control a motorized Circuit Breaker
with up to 1 CB and 2 Isolators, in a drive group or standalone.

Next to the common basic functions for consumer objects, the following functions are
supported for CircuitBreaker:
· Operation modes
· Selection of individual Breaker for operation
· Open / Close order to operate the breaker
· Indication of Breaker status
· Indication of Switches
· Current, Voltage and Power indication
· User definable Warning indication
· 3 additional interface inputs for each CB; for e.g. Trip, General Alarm & Ready
· 2 functional back process inputs with feedback time supervision; for e.g. CB, Isolator
or Earth Switch ( ESW) Pos.Closed, Pos.Open
· 3 Process interlocks for the CB and 2 per Isolator.
· Totalisation and indication of CB Close time (in hours) and number of CB Trip and
Close
· Alarming during Simulation can be enabled for testing the Interlock, FeedBack,..

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1.1.18.2 CircuitBreakerABBREF542Plus
Power Distribution Monitoring objects provide a composite Control Module with serial
interface to implement the supervision and operation of power network switchgear
equipment. The example below presents ABB REF542+ with Modbus communication.
The Control Module can easily be adapted to other equipment and communication types.
Central Mode (operator) – C indication,
Indication of Switches
Indication of Voltage, Current, Power

Central Mode (operator) – C indication,

Indication of Breaker status
Indication of Voltage, Current, Power

The Control Module can easily be adapted to other equipment and communication types.
Next to the common basic functions for group objects, the following functions are
supported:
· Operation modes
· Selection of individual Breaker for operation
· Open / Close order to operate the breaker
· Communication link error
· Indication of Breaker status
· Indication of Switches
· Indication of Voltage, Current, Power
· Button to access complete Serial information
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Minerals Library version 5.1/4a
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1.1.19 ENERGY MANAGEMENT
The Energy Management System consists of three major modules communicating
together:
· Power Demand Supervision
· Load Shedding Control (optional automatic switching-off)
· Load (Definition of a set of Circuit Breakers)

The Energy Management objects provide access and

control for supervision of the electrical feeders, monitoring
and controlling of loads with the target to ensure that the
Energy consumption of the Plant respects given conditions.

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This is an Example where at 19:42 a load was switched on

o Forecast Energy At Interval End

o Actual Energy In Interval
o Energy Moving Interval
o Warning Level (90% pf alarm Level)
o Alarm Level

For this example, the ForeCast Energy At Interval End shows nicely that is based on the
ActualEnergyInInterval and the TotalPower. It calculates how much Energy will be used at the end of the
Metering Interval if the actual Power is steady till then.
This is the fastest method as shown on the trends : the light blue curves is the first to cross the Warning
Level !

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1.1.19.1 Load
The Load Control Module Type enables grouping of MV-Switchgear according Plant
Sections in order to monitor and control their Energy consumption.

It contains following features :

· Communication between LoadShedding Module and the connected MV-Switchgear
(up to 8 MV-Switchgear, otherwise please use the corresponding Function Block
included in the EnergyMgmt Library “Loads_CB_Compacting” (§3.4 Function Block)
· Possibility to connect MV-Switchgear into Load for monitoring only and not for
shedding (MV/LV Trafo.Feeder).
· Calculation of total momentary load (active and reactive power)
· Calculation of momentary total load factor (utilization factor)
· Issuing of warnings and alarms. For example in the case of:
o Locking off of loads
o Disconnection of loads

All of these Informations are available to the operator through standard interfaces from the BMI Library:
· Faceplate (see extended Faceplate §3.3.3.2)
· Multi-Trends (see extended Faceplate §3.3.3.2)
· Graphical Elements (see §3.3.1)

The Load Object is moreover extended by graphical Elements of

· DIS for direct access to Eventing / Alarming
· Counter for direct access to Cost Supervision
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1.1.19.2

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1.1.19.3 Loadshedding
The LoadShedding Control Module Type permit to ensure that the Energy consumption
of the Plant respects certain conditions according priorities.

It contains following features :

· Communication between PowerDemand Module and the Loads
· Locking / releasing of loads according to the load situation within the metering period.
· Disconnection (load shedding) of loads according to the load situation within the
metering period.
· Operating modes Eventing & Selection: Manual / Auto / Ext
· Consideration of certain priorities for disconnection of loads
.

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Link from LoadShedding to CB’s via Load

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1.1.19.4 PowerDemandSupervision

The Powerdemandsupervision Control Module Type enables input of tariff structure and
their given conditions as defined by the Energy supplier

Actual Tarif
conditions

Permanent
conditions

Actual Tarif always shown on the base View

It contains following features :

· Consideration of a certain tariff structure given by the energy supplier up to 8 different
tariffs each of them including up to 8 different TariffSets
· Supervision of time synchronisation for metering period.
· Calculation of total energy consumption over metering period
· Calculation of total energy consumption forecast at end of metering period
· Calculation of momentary total power factor and limit supervision
· Issuing of warnings (90%) and alarms. For example in the case of:
o Forecast Energy At Interval End
o Actual Energy In Interval
o Energy Moving Interval
o Peak Power Exceeded Time
o TotalCurrent

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 · As well as Issuing of warnings (90%) and alarms in case of :
o Missing time-synchronization signal if the Signal is missing for longer then two
times Metering Interval time.
o Impending change of tariff interval

This is an Example where at 19:42 a load was switched on

o Forecast Energy At Interval End

o Actual Energy In Interval
o Energy Moving Interval
o Warning Level (90% pf alarm Level)
o Alarm Level

On this exemple, the ForeCast Energy At Interval End shows nicely that is based on the
ActualEnergyInInterval and the TotalPower. It calculates how much Energy will be used at the end of the
Metering Interval if the actual Power is steady till then.
This is the fastest method as shown on the trends : the light blue curves is the first to cross the Warning
Level !

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1.2 Some Implementation Concepts

1.2.1 LOOK AND FEEL

The library contains several possibilities to adapt its behavior both visually and
functionally. The customization possibilities are described more closely in the reference
documentation (Minerals Library Overview).
Below is an example of color coding in form of 6 predefined look and feel setup that can
be switched online. They can be as well extended and further customized.
1. Minerals Standard: Keeps the BU Minerals 4.1 look and feel
2. Holcim Standard: Holcim standard requirements regarding color and shapes
3. Hybrid Standard: The new BU Minerals style as an option for customers
4. Standard Type 4: Minerals Classic with red cross in case of not ready
5. VALE Standard: VALE Standard requirements regarding color and shapes
6. ASM: Alarm Status Monitor

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1.2.2 PCC (PRIORITY COMMAND CONNECTION)
PCC is a normally used structure of the application program to implement logical
connections between various application objects. It uses structured variables and hence
increases both the engineering easiness (one logical connection) and information
exchange (multivariable connection) between application objects.

This overview shows the structure of PCC. PCC

Bus

Group

Motor
Digital Input

Group Drive
Bus Analog Input
Motor
Digital Input

Through the PCC Bus it is possible to see the DIS, DIC, AIS and AIC limit that is causing
some fault to the consumer object on the Group and Motor Faceplates. The tag name of
the alarming input signal is shown on the faceplate of the consumer. In the same way you
will find the link from DIS, DIC, AIS and AIC faceplate to the consumer tag name.
Alarms can be acknowledged at any Faceplate, i.e. the acknowledgement given on the
Group level will be propagated through the Motor down to the Signal level.

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Examples of the use of PCC:

Forwarding of Warning thru PCC:

Group faceplate Consumer faceplate Signal faceplate

Forwarding of Failure thru PCC:

Group faceplate Consumer faceplate Signal faceplate

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1.2.3 POINT OF CONTROL (POC)
Group and consumer objects have four different Point of Control (modes):

- SEQuence

- CENtral
- LOCal

- Out of Service.
All POC are selectable from the operator workplace. The point of control defines from where the
object will be controlled. In order to control an object the corresponding POC must be selected
before giving any command to the object. For safety reason, stopping an object or closing a gate
is always possible, no matter which control mode has been chosen.

Sequence: The object is controlled by a superior application program e.g. from a drive group
sequence. Sequence mode can be set from the operator station or by the application program.
Central: The object is controlled by the operator station by means of the start/stop or open/close
push buttons on the faceplate. Start/stop or open/close from a superior application program is
also possible in this mode. The Central mode can be set from the operator workplace only.

Consumer Objects in POC Sequence and Central have two sub-modes:

Man (default):
An object is controlled by a rising edge start / stop command, either released from the
operator station or from the superior application program.

Auto:
An object is controlled by an input IA (IA =1 starts the motor, IA=0 stops the motor). Typical use
of the auto mode is on/off control by thermostats, level switches, etc.
In Central Auto and Sequence Auto mode the operator cannot control the object
any more from the operator station. Stopping a motor and closing a gate is always
possible.
Local:

The object is controlled from the field via the pushbuttons on the local control box (LCB). To
operate a drive locally, the drives need the local release from the CCR operator. The point of
control has to be changed in the CCR and can be set for a complete drive group or for every
object individually.
The interlocks are de-activated in this mode except the safety interlock IC (Rope Switches,
Bearing/Winding Temp., Vibrations etc.). Further more the two feed back signals (FB1 and FB2 –
for example speedswitch) are also de-activated while pressing and holding the start/open push
button. Typically, the Local mode is for maintenance purposes.

Note: Alarms are disabled when an object is in Local mode (no alarm acknowledgment on the
operator station necessary when object is operated from the field).

Out of Service: The object is not in service and cannot be started from any location. It also means
that the object will be skipped when running a superior group sequence. Out of Service mode can
be set and re-set from the operator station only with special user rights.

The Figure below shows the Control Modes and their graphical presentation for the Group and
Consumer Objects. Please note that for better operator guidance the default POC (Central for
Group and Sequence for Drives) is not indicated by a character on the process display.

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Doc. kind Product Guide Project BU Minerals Library
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Group Sequence Start / Stop
For Group Control the ABB BU Minerals Library applications provide state of the art functionality
for sequence start, stop, route and monitoring of all process objects in the plant.

Group Status Indications and monitoring

The figure below shows all possible status indications of the group as presented in the process
display.

Group off Gray

Green arrow up and Start warning
Group starting / Startwarning
flashing
Group running Green filled
Group running / restart required Light blue filled, white
as pre-selection has changed arrow up / Green filled
Group stopping Green arrow down flashing

Group running with warning in Green filled with thick orange frame
some of connected equipment

Group failure and in hold (not off

but as well not fully running) – Light blue half filled with thick red frame
not ready for start

Group in hold, ready to restart Light blue half filled

Group off, start interlock active Gray / red arrow up

Group run, stop interlock active Green filled / red arrow down

Group not ready for start because

of Failure in at least one of the Gray with thick red frame
connected consumers

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The group constantly monitors all process objects assigned to it and updates the status in real time. The
faceplate provides additional detailed indication on:

· Tag Name of the Object not ready for start or in hold

· Interlock text for group start and stop interlocks
· Actual step and tag during Start-up and stopping
· Indication of pre-selection missing or error

Example of Group Faceplate indicating

Group not Ready for Start Group Starting Group in Hold

Tagname of Object not Tagname of Object in Tagname of first object
Ready for Start actual Step in Hold

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 Starting a group

A group may be started, if all pre-selected equipment assigned to the group is ready for start, the
pre-selection is set correctly and no group start interlock is active. Initial starting is possible from
status “Off / Ready for Start”. A group restart can be preformed from the status: “Stopping”,
“Hold” or “Running”.
Before starting the group, the pre-selections such as selecting alternative routing, standby units,
set points, etc., may be adjusted. The new settings are indicated in the process display and the
faceplate.
Pressing the “start” button in the faceplate the following steps are executed:
1. An audible start-up warning is activated for all related equipment, optional the start warning
can be configured to be executed prior the start of individual equipment. The group indicates
“Starting / PreWarning”
2. After a certain adjustable time, the start-up warning stops and the equipment starts to run,
respectively moves into the position according to the programmed sequence and used pre-
selections. The group indicates “Starting” and the step number and tag name of the actually
started equipment can be monitored on the faceplate.
3. A successful start-up is indicated by the group status indication changing to “Running”. In
case any important equipment fails during the start-up, the group indicates “Hold” resp.
“Drive(s) not Ready for Start”.

Unconditional Start (available in extended Faceplate)

Additionally a group can be started by an unconditional start, even with equipment not ready for
start. That means that the group will start until the start step of the equipment which is not ready
for start. This function is not active in case of a group start interlock.

Stopping a group

A group may be stopped in case there is no stop interlock active (e.g. group can’t be stopped
because another group is still not off). Stopping is possible from any status, even the group
“Starting” status.
Pressing the “stop” button changes the indication to stop and all equipment will be sequentially
stopped or moved to the defined “off” position, leaving the equipment in a suitable condition for
the next start-up – transport systems emptied of material, dampers turned to safety position.
After a successful stop the group indicates “Off / Ready for Start”.

Instant Stop / Quick Stop

A stop may be performed instantly disregarding the programmed appropriate stop order by
pressing the “quick stop” button in the faceplate. The “instant stop” stops all equipment in the
group simultaneously. For actuators and Loop controllers the specific action to be executed at a
quick stop can be adjusted individually. The instant stop can be activated at any time (even if a
stop interlock is active). In such a case the other drives and/or groups are stopped according to
the process interlocks.

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 The figure below shows a simplified flow diagram for a Sequential Group Start with route
change over (stopping of all not selected equipment)

NO

All Selected Indication Drives not

Equipment Ready Ready for Start
NO

Preselection Indication Preselction (on faceplate

Correct Missing or Error only)
YES

Group Start Indication Group Start

YES YES
Interlock Active Interlock

AND NO

CEN Control Mode SEQ

Start from
AND AND Application
Start from FPL Program

OR

Indication Group
Start Warning
Starting

NO

Sequential Start of Equipment Fault,

All Selected
NO Next Preselected Time Out or Hold
Equipment Running
Equipment Command

Indication Drives not

YES YES Ready for Start or Group
YES Time Out

NO

Sequential Stop of
All not Selected Next not Time Out or Hold
NO
Equipment Off Preselected Command
Equipment

Indication Alarm Group

YES
YES Time Out

All Selected
Status Group
Equipment Run YES
Running
(Group Run)

NO
NO Status Group Hold

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 The figure below shows a simplified flow diagram for a Sequential Group Stop.

YES

Indication Group Stop

Group Stop
Interlock (on
Interlock Active
Faceplate only)

NO

OR AND
Stop from FPL

Indication Group
Stop from Stopping
Application
Program

NO

Sequential Stop of Time Out or Hold

All Equipment Off NO
Next Equipment Command

Indication Alarm Group

YES YES
Time Out
YES

All Equipment Off

YES Status Group Off
(Group Off)
NO

NO Status Group Hold

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 The figure below shows a simplified flow diagram for an Instant Stop.

Quick Stop
from
Quick Stop from Application
FPL Program

OR

Indication Group
Stopping

NO

Stop Command to Time Out or Hold

All Equipment Off NO
all Equipment Command

Indication Alarm Group

YES YES
Time Out
YES

All Equipment Off

YES Status Group Off
(Group Off)
NO

NO Status Group Hold

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 Error during start-up

If an alarm condition arises during the group start sequence (e.g. fault or process interlock of
equipment starting or already running) the start-up will be interrupted automatically and the group
indicates, “Hold / Drive(s) not Ready”. The object name of the equipment causing the fault is
presented in the group faceplate and the operator can directly link to the equipment faceplate to
get more detailed information.

“Hold” means that only a part of the group is in operation (not completely started or stopped). At
this state by pressing the “stop” button, the rest of the group is stopped in accordance with the
stop sequence or if the fault can be removed, the start sequence may be reactivated by selecting
the group and pressing the “start” button again.
A group may be started, if all pre-selected equipment assigned to the group is ready for start, the
pre-selection is set correctly and no group start interlock is active. Initial starting is possible from
status “Off / Ready for Start”. A group restart can be preformed from the status: “Stopping”,
“Hold” or “Running”. Additionally a group can be started by an unconditional start, even with
equipment not ready for start, meaning the group will start until the start step of the equipment
which is not ready for start.

Before starting the group, the pre-selections such as selecting alternative routing, standby units,
set points, etc., may be adjusted. The new settings are indicated in the process display and the
faceplate.

Manual Hold

The operator may manually interrupt the starting or stopping or quick stop procedure of a group at
any time by pressing the “hold” button on the faceplate. In this case the group will indicate hold
until the starting or stopping process is continued.

Pre-selections

The pre-selection function allows motors to be included in the start-up process of a group. By
setting and resetting the pre-selections, the operator may define which objects should be
activated or deactivated by the next start command. Even a flying change of the pre-selection
(e.g. automatic change of silo filling) may be programmed. This is a fully automatic change of the
pre-selection during the group running status.

By clicking with the left mouse button on the pre-selection button, the pre-selection will be
set/reset. The status of the pre-selection is shown on the button. At the group start any changes
of the pre-selections will be taken into account and the new configuration of the pre-selections is
activated.

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 The figure below shows the possible status of 66reselection.

Light gray steady

Blue flashing

Light blue steady

Dark gray flashing

Red frame

The operator is allowed to change the pre-selections when a group has following status:
¨ Group is stopped completely
¨ Group is running (flying change over)
¨ Group is in HOLD mode
¨ Pre-selection change is not interlocked by the process (dimmed indication)

During a start-up or a stop of the group, a pre-selection change is prohibited.

If only one pre-selection setting is allowed to be active at the time, the other pre-selections are
deactivated automatically (radio button function). If more pre-selection settings are possible at the
same time, the operator can manually chose the configuration.

Missing – and wrong pre-selection combinations prevent a group start. There is then an indication
on the group faceplate.

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1.3 Technical and Performance Data

1.3.1 SYSTEM PERFORMANCE AND CAPACITY

Here are some key numbers by which the system configuration is verified. Several
parameters will limit the system size and it is highly dependent on the application which
parameter will hit the limit first. Direct result of this is that it is difficult to give any strict
system size number. It is even possible to exceed some limits if other parameters are
reasonably below their respective limit. For example, more controllers may be viable if the
total data flow between them and to the server and workplace layer is well within the limit.
Regarding the capacity of the connectivity server, performance is heavily dependent on
the configuration and the machine hardware. A dedicated connectivity server will have
very high performance, for example, a dedicated connectivity server, ≥3GHz, with 8Gbyte
RAM will provide 32 000 OPC-items/second.

Recommended Minerals Library values:

Performance parameters
Execution time = 500ms for all objects, 50 to
150ms for dedicated part of the code (e.g. stop on
limit switch, local start/stop) Results in about 45% CPU load
I/O to HMI time Approximately 1.5 s
Download time per node Less than 60 s
HMI black out during download Less than 5 s

S800 I/O on Profibus, DI and DO minimal scan

time Approximately 120 ms with 1200 I/O per bus

To achieve the above performance

parameters abide by the following rules:
DEFINITION: Minerals Object = Motor, Group, PID, AI, DI on HMI
On Average, 1 Minerals Object = 10 OPC items
# of Minerals Objects per display = 200
# of OPC Items per display = 2000
# of Screens (Clients) per Connectivity Server = 16

DEFINITION: Minerals Controlled Object = Loop/Motor/Drive/Actuator/Valve/Group

· PM860 60 controlled objects per controller
· PM861 120 controlled objects per controller
· PM864 220 controlled objects per controller
· PM866 330 controlled objects per controller

Minerals Library Summary:

· Up to 12000 I/O or 16 simultaneous operator screens (32 000 OPC items) per 1 of 1oo2
Connectivity server with 8GB RAM.
· Workplace PC with 4GB RAM
· The maximums of the platform values always apply.

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 Platform values: (see 3BSE041434) Per system
# of controllers 80 (12 per connectivity server)
# of clients (depends on server configuration) 40
# of remote clients (depends on server configuration) 15 (8 per remote server)
# of connectivity servers 12 out of which 8 for AC800M controllers
# of aspect servers 1 (1oo2 or 2oo3 redundant)
# of Tags (Aspect Object with Faceplate) 60’000
# of Aspect Objects 200’000
# of concurrently updating data points (OPC items) 30’000/second per connectivity server
The latest platform values should always be checked with the ABB Products group before any
commitment is made.

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1.3.2 SYSTEM EXAMPLE
Following picture illustrates the maximum capacity values in terms of I/O signals (HW I/O
and SW signals) in an application that has a mixture of 20% analogue signals and 80%
digital signals. Note that this conversion to I/O signals is purely mathematical and fully
based on the mixture of analogue/digital given above. It is made to help in practical
configurations where normally only the number of I/Os is known. Changes in the mixture
will impact the maximum limits, that is, an increase of analogue signals will reduce the
maximum limits.
/
200 - 250 Objects / display (= 2000 OPC Items) max 32’000 OPC Items = Max 16 screens/Server

PP Client PP Client PP Client PP Client PP Client PP Client PP Client PP Client PP Client PP Client

Client/Server Network (TCP/IP)

Aspect Server Engineer IT

200’000 Objects Connectivity Max 12’000I/O per.

Server
Con Server pair
Control Network (Ethernet)

Minerals std Lib:

PM866: Up to 3000 I/O
PM864: Up to 2000 I/O
Profibus Profibus PM861: Up to 500 I/O Profibus

(avg. 10 I/O (hw&serial)

per object)
S800/S800L Universal S800/S800L Universal S800/S800L Universal
I/O Motor I/O Motor I/O Motor
Controller Controller Controller

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MEMORY SPACE REQUIREMENTS AND EXECUTION TIMES
The following table shows the memory space requirements and typical execution times for
the ControlIT AC800M Minerals Library control modules. The execution times and the
memory requirements were measured using the Control Builder M 5.0 SP1, with the 5.1-
2 release of the Minerals Library.
For more information about execution times for I/O, see AC800M User’s Guide.
Note that the Control Modules make heavy use of conditional execution and the Peak
Load (esp. Alarm Generation) is multiple times higher that the typical Load.

Control Module Memory Requirements Execution Time Notes

First Instance Add. Inst AC800 PM861
kB kB ms
0.24(Indic. only)
AIS 45.1 6.2 0.60(3.0) new for 5.1/2 30.3.09
AOS 12.2 2.2
0.02 (Indic. only)
DIS 18.4 2.9 0.06 (0.55)
DOS 10.3 0.7
Normal Cycle Time
usually 500 ms
Fast:0.02 Fast Cycle Time usually
MOT1 69.8 11.8 Normal:0.53(1.8) 50 ms
MOT2 71.0 13.1
Fast:0.02
ConPu:0.25 ConPu Cycle Time
MOTP 105.9 18.5 Normal:0.75(2) usually 150 ms
VLV1 65.6 9.1 0.26(1.5)
MOT1_VVVF 82.3 15.4 0.75(2)
MOT2_VVVF
VVVF_Serial 154 36.8
PulseCount 9.2 3.2
ReportingCount 17.2 3.2 0.5 Cycle Time < 250 ms
PIDCtrl 156 23.0
GrpCycleCtrl 91.2 15.7
Group 42.1 7.7
Circuit Breaker 77 14 2(5)
REF542+ ModBus 177 39

Load 74.1 19.3

Only one
instance
LoadShedding 29.7 needed..
Only one
instance
PowerDemand 133.7 needed..

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1.3.3 PERFORMANCE DATA

1.3.3.1 Task Performance Data

The following table shows the memory space requirements and typical Task Load while
executing ControlIT AC800M Minerals Library control modules.
Each Task from a controller has a Properties Window for checking the execution time.
There may be some differences between the Requested and the Actual Execution Time
but it has to be ensured that this stays in a suitable range.

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1.3.3.2 Application Performance Data
The following table shows the memory space requirements and typical Controller Load
while executing ControlIT AC800M Minerals Library control modules.
To ensure the application reliability, you should pay attention of following Points:
Cyclic Load should never exceed 50%. Changing the application task connection and / or
the task properties (Period time)

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 This interaction Window can be found in the System Control Module

1.3.3.3 Display Performance Data

The following table shows the timing summary and a Subscription Overview for one
display using ControlIT AC800M Minerals Library graphic element.
To ensure the application reliability, you should pay attention of following Points:
Number of failed items to not overflow over a long-period the system and the Time
needed for All Data received, which should stay in an acceptable Range (2000ms) for the
operator.

General Diagnostic Display (Right mouse click on one display)

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OPCData Diagnostic Display (Right mouse click on one display)

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1.4 Related Documents
The figure below shows the structure of all related documentation.

Function Description
MINERALS (BMI)
IIT FUNC DES 00

Project Documentation Documentation Guideline

<Project> <Project>
<Customer> <Customer>

Configuration Standard Product Guide

MINERALS (BMI) Standard Product Manuals
C IT Design 00
Minerals Library

Reference Manual OperateIT PP

Minerals Library -
Overview

Reference Manual
ControlIT AC800M

Minerals Library -
Basic Objects

Reference Manual

Minerals Library -
Communication Objects

Reference Manual

Minerals Library –
Consumer Objects

Reference Manual

Minerals Library -
Dosing Objects

Reference Manual

Minerals Library -
Group Objects

Reference Manual

Minerals Library -
Loop Objects

Reference Manual

Minerals Library -
Power Distribution Objects

Reference Manual

Minerals Library -
Report Objects

Figure 1 Document Organization Reference Manual

Minerals Library
Process Panel

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1.5 Licenses and Ordering Minerals AC800M Control and Operation
This section aims to help project personnel when ordering the Minerals Library for
integration with System 800xA SV5.x Control and Operations products.
Preferably, use Wizard 800xA with the Minerals 3BHS128715/x.wcat and
3BHS128715/x.wprc installed. Ordering is made using the EDI file generated by Wizard
Order module and sending it to [email protected].

1.5.1 MINERALS LIBRARY LICENSE

Minerals Library License is sized using the minerals license points (MLP). Minerals Library
does not use a Tag license (Tag). This is to simplify the ordering and handling of the
licenses.
Since version 5.1 and introducing the Minerals license enforcement in the system, the
Minerals License size is counted based on the effective application size using Minerals
Library. Only the MLPs related to Minerals applications are considered in the license size.
Prerequisites for use of the Minerals Library:
§ The System 800xA SV5.x Core System and its standard system libraries are
installed and licensed.
§ Minerals Library licenses for the number of used MLPs has to be ordered.
§ Minerals Library has to be installed (since version 5.1 as a system extension)
§ The license Key (a .SLA file) for the Minerals Library has to be generated in ABB
SoFa and installed in the 800xA system licensing server.

1.5.2 MINERALS LICENSE POINT

The Minerals License Points are calculated by the number of used Minerals Library
Control Modules:
Type of Block MLP count
Digital I/O (DIS, DOS) 1
Analog I/O (AIS, AOS) 2
Consumer Objects (MOTx etc.) 5
Loop Objects (PIDCtrl) 4
Circuit Breaker 5
Add 20% to the total CLP count to leave a margin for further growth.

1.5.3 ORDERING EXAMPLES

The CD-ROM with the software and documentation should be ordered.
From the Price List for 1.4 Control and Operation; AC800M; Minerals Library 5.1/x:
1 of Control&Operation;AC800M;MineralsLib5.1/x;SW&DocCD 3BHS205193R03

1.5.3.1 Ordering Example 1

For this example, take the following configuration: Three controllers with different capacity
and different MLPs.
· Controller 1 has 350 MLPs

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 · Controller 2 has 550 MLPs
· Controller 3 has 1100 MLPs
The above configuration requires the price list items listed below.

From the Price List for 1.4 Control and Operation; AC800M; Minerals Library 5.1/x:
System-wide license for 2000 MLPs (350+550+1100) is calculated as follows:
1 of Control;AC800M;MineralsLib5.1/x; BaseLic 3BHS200491R03
20 of Control;AC800M;MineralsLib5.1/x;100CLP;<=5000CLP 3BHS200492R03

1.5.3.2 Ordering Example 2

For this example, assume 8000 MLPs are required, this needs the price list items listed
below.

From the Price List for 1.4 Control and Operation; AC800M; Minerals Library 5.1/x:
1 of Control;AC800M;MineralsLib5.1/x; BaseLic 3BHS200491R03
50 of Control;AC800M;MineralsLib5.1/x;100CLP;<=5000CLP 3BHS200492R03
30 of Control;AC800M;MineralsLib5.1/x;100CLP; 5001-20000CLP 3BHS200493R03

Doc. kind Product Guide Project BU Minerals Library

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2. SYSTEM 800XA OPERATIONS AC400 CONNECT MINERALS LIBRARY

2.1 Functional Description

Operations AC400 Connect Minerals Library integrates the BMI AC400 Type Circuit
Library with the Process Portal. The AC400 Connect Minerals Library provides display
elements and faceplates on the Process Portal, for monitoring and control of objects
defined by means of the BMI AC400 Type Circuit Library. These are intended for sites
with an installed based of AC400 controllers and AS500 that need to connect to the
Process Portal.
The process display elements and faceplates have the same look and feel, as well as
similar functionality, as the AC800M Connect elements listed above. There is a display
element and a faceplate for each BMI Type Circuit Library element in the AC400.

2.1.1 ANALOG INPUT (AI, AIANDUNIT, AIBAR)

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2.1.2 ANALOG OUTPUT (AO, AOANDUNIT)

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2.1.3 DIGITAL INPUT (DI)

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2.1.4 DIGITAL OUTPUT (DO, DOTXT)

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2.1.5 GROUP SEQUENCE START / STOP CONTROLLER (GROUP)

Group Off
Group Starting
Group Holding
Group Running
Group Stopping

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2.1.6 PRE-SELECTION (PREBIN)
Main purpose of Module: Routing control

PREBIN has no faceplate. Clicking on the push button symbol toggles the state.

The pre-selection module allows the operator to select or de-select a single device or a set of
devices within a group. By e.g. pressing “Silo1” all objects belonging to the route to silo 1 are
pre-selected. This does however, not cause a start up of equipment, it is just a selection. When
initiating a group sequence start, selected devices will start up in a sequential order; de-selected
devices will shut down in a sequential order (provided they were in a running state)

2.1.7 START WARNING (STW)

Main purpose of Module:
Control for buzzers and flashlights, prior to a remote start of equipment

STW has no faceplate. The symbol is mainly used for presentation purposes on the faceplates
for MOT1, MOT2, MOTP, etc.

The start warning module is tight integrated with the control modules for MOT1, MOT2, MOTP,
etc. When a start command for a motor is initiated, the start warning module first triggers the
buzzers and/or flashlights before it returns the actual start release for the motor. The start
warning function can be configured depending on the point of control, e.g. point of control
Sequence and Central with start warning, Local without start warning. If configured, the graphic
symbol is displayed on the corresponding faceplate.

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2.1.8 MOTOR CONTROLLER (MOTOR)

Alarm

Ready for Start

Off

Bad Quality (OPC)

Running

Running, Central

Running, Central,
Interlock Blocked

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2.1.9 DAMPER/ ACTUATOR CONTROLLER (MOTP)

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2.1.10 VALVE CONTROL (VALVE)

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2.1.11 PI CONTROLLER (PICONTROL)

Auto Mode – A indication, Measured Value and Setpoint

Manual Mode – M indication, Measured Value and Output

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2.1.12 PID CONTROLLER (PIDCONTROL)

Auto Mode – A indication, Measured Value and Setpoint

Manual Mode – M indication, Measured Value and Output

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2.2 Licenses and ordering PPA AC400 Minerals Connect
Preferably, use Wizard 800xA with the 3BHS128715/x.wcat and 3BHS128715/x.wprc
installed. Ordering is made using the EDI file generated by Wizard Order module.

2.2.1 TAG
The licensing system for AC400 Connect is based on calculating Tags. A Tag represents
an object regardless of the number of data points it holds, examples are:
• signal objects, i.e. AI, AO, etc.
• motor, valve objects
• generic OPC items with one or several OPC properties
• user defined object types
Licenses
Minerals AC400 Connect is an add-on to standard System 800xA AC400M Connect and
both licenses are required.
Minerals AC400 Connect contains display elements and faceplates for the BMI AC400
objects/type circuits.
Prerequisites for use of this software:
· The System 800xA SV5.x Core System is installed, with the AC400 Connect
Option.
· The AC400 controllers have the BMI Type Circuit Library installed.

2.2.2 ORDERING EXAMPLE

Assume the following configuration:
· Controllers, with different capacity and different Controller License Points (CLPs).
· Three Process Portal workplaces
The tag count is calculated at 17’000 tags.
This configuration requires the following licenses:

From the Price List 1.6 Operation; AC400M Connect; Minerals Library 5.1/x:

System-wide license for 17’000 tags is calculated as follows:

1 of Operation;AC400Connect;MineralsLib5.1/x;BaseLic 3BHS200501R02
7 of Operation;AC400Connect;MineralsLib5.1/x;1000Tags 3BHS200503R02
1 of Operation;AC400Connect;MineralsLib5.1/x;10000Tags 3BHS200504R02

The CD-ROM with the software for above functions should also be ordered.
1 of Operation;AC400Connect;MineralsLib5.1/x;SW&Doc CD 3BHS200505R02

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3. MINERALS OPERATIONS FOR SIEMENS PCS7 CEMAT
This library provides the 800xA Object Types including faceplates and graphic elements
for Siemens PCS7 using CEMAT application library.
For additional information, please contact
[email protected] or [email protected]

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4. SUPPORT AND TRAINING

4.1 Minerals Support

4.1.1 DESIGN REVIEW

BU Minerals offers the service to execute a Design Review for the 800xA system
configuration and application design in a Minerals delivery project. This review is based on
defined documents and will be executed by BU Development Center or by a certified
engineering unit.
Within ABB this review service is mandatory in projects where BU4170 (Minerals) certified
personnel is not available.
The Design Review Service can be ordered from Minerals Library price list. The Service
fee contains the coverage of the working hours at the home location of the executing unit.
Possible expenses for executing the review in another location must be covered by the
ordering unit.

4.1.2 LIFE CYCLE SERVICES

Please see the price list for BU Minerals: Life Cycle Services for ordering 24 hour or other
support from the BU Minerals centre.

4.2 Minerals Training

Minerals Training is an important part for successful project engineering and hence a
prerequisite for certification.
Please see the schedule and information from BU Minerals: Learning Center – ABB
University Switzerland for training that is available on the Minerals Control Libraries.
For ordering, see the price list for:
· IndustrialIT Applications for Minerals – Engineering with PDA Tool (CH110)
· IndustrialIT 800xA Applications for Minerals – Configuration and Operation (CH112)
· IndustrialIT 800xA Applications for Minerals – Operation (CH113)

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4.2.1 H658 INDUSTRIALIT 800XA APPLICATIONS FOR MINERALS – ENGINEERING WITH EBASE
AND CONTROL BUILDER M
Duration 7 days.
Objectives
Participants will follow the engineering workflow and utilize Engineering Base (EBase) to handle
bulk data and create efficiently and professionally Minerals control applications for System 800xA
with AC800M Controllers.
Upon completion of this course students know the basic functionality of EBase and know how to
set up a project and import customer data in EBase. Using EBase, they are able to configure
Minerals control applications and generate bulk data via typicals. They know how to export the
prepared application from EBase to Control Builder M, where they will finalize it by programming
the interlock (glue) logic for the different consumer and group objects. They can use the import /
export, download / upload and copy functions. They know the detailed functionality of the different
objects in the Minerals library with the required data types and understand the program structure.
Contents
Engineering workflow
Minerals Library
Introduction to EBase Electrical
Application configuration with EBase
- Import customer data
- Generate object related signals
- I/O allocation
- Configure objects and start/stop sequences
- Parameterized Interlocks and Preselections
Export to Control Builder M
Programming of interlock (glue) logic
Download to Controller AC800M and online test
Methods
The course flow is based on a practical exercise, where students will configure and program a
complete Cement Transport Group. Group. Lectures and demonstrations are done before each
main exercise. The teacher is then guiding the students through the exercises, step by step.
Participants
Engineering and planning personnel responsible for the bulk data handling and control
programming for Minerals applications at the start phase of the project.
Prerequisites
Attendance of course H561.

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4.2.2 H651 INDUSTRIALIT 800XA APPLICATIONS FOR MINERALS – CONFIGURATION AND
OPERATION
Duration 10 days.
Objectives
Participants learn the operation and configuration of the IndustrialIT Extended Automation
System 800xA by using the Minerals application libraries.
Upon completion of this course, the students know the architecture of the automation
system and the hardware components of the controller. They know how to configure,
modify and test controller application programs with the Control Builder M programming
tool. They are able to operate the user interface Process Portal and can configure process
graphics, trends and alarms. They know the basic functionality of the different objects in
the Minerals Library with the required data types and understand the program structure.
Contents
System 800xA architecture
Controller AC800M Hardware Configuration
Plant Explorer, Engineering Workplace and Control Builder M
Variables and Data types
Monitoring and testing applications
Programming according IEC 61131-3,
Function Block Diagram (FBD) and Structured Text (ST)
Advanced configuration with Control Modules and Structured Data Types
Minerals Libraries and Minerals Applications
OPC Communication
Operator Workplace
Configure Process Graphics
Configure Alarm and Events
Configure Historical Data Collection and Trend Displays
Backup / Restore of the System
Workshop Engineering
Methods
Lectures, demonstrations and practical exercises. At the end of the course a workshop is
done. This workshop covers a larger exercise and is used to consolidate the most
important items from the training which the students will need for their future work.
Participants
Engineering, planning, operating, commissioning, maintenance and service personnel,
working in the field of Minerals Applications
Prerequisites
Students shall know the fundamentals of working with Control Systems, have basic
knowledge of Windows Operating System and of technical English.

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Minerals Library version 5.1/4a
Document number Lang. Rev. ind. Pages 93
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4.2.3 H652 INDUSTRIAL IT 800XA APPLICATIONS FOR MINERALS – OPERATION
Duration 2 days.
Objectives
Participants learn to operate a plant that is controlled by an IndustrialIT Extended
Automation System 800xA, based on Minerals application libraries.
Upon completion of this course, the students know the basic system architecture and are
able to log on into the system. They understand the user interface Process Portal and
know how to navigate through the system. They know the basic functionality of graphic
displays and faceplates. They are able to monitor and control relevant objects of the plant.
They know how to acknowledge alarms and are able to use event and alarm lists as well
as trend displays.
Contents
Overview IndustrialIT 800xA System
Basic System architecture
Log on into the system
Operator interface
Navigation through the system
Graphic displays
Faceplates
Operation
- Basic objects
- Consumer objects
- Group objects
- Loop objects
Events and alarms
Historical data and trend displays
BMI Search tool
Methods
Lectures, demonstrations and practical exercises
Participants
Operators who need to control and supervise the plant
Prerequisites
No special knowledge required

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Minerals Library version 5.1/4a
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REVISION HISTORY
Rev. Page (P) Description Date
ind. Chapt.(C) Dept./Init.
draft Original document 26.07.03 ATBAM/GPC
A Reviewed and corrected, added AC400 Connect 04.09.03 ATBAM/GPC
B Reviewed and updated to 2.1/1 08.03.04 ATBAM/GPC
C Reviewed and updated to 3.1/1 01.06.04 ATBAM/GPC
D Reviewed and updated to 3.1/3 10.11.04 ATBAM/GPC
E Updated to 4.0/0 27.05.05 ATBAM/HT
F Update for Minerals Library Release 5.0/0 16.01.2006/N.B
G Updated license structure for SV5.0 08.12.06 / HT
H Updated for Minerals Library Release 5.0/1 28.06.2007 / MB
I Document structure changed. 11.10.07 / HT
Changed license structure and ordering for 2008 SV5.x
Added Design Review
Added Siemens CEMAT connectivity
J Updated for Energy Management Release 5.0/2 27.08.2008 / NB
K clean up and new Performance Measurements for 5.0/2 24.04.2009 / LK
L Added license structure changes and enforcement 5.1/1 22.12.2009 / HT
M Updated for Minerals Library Release 5.1/3 30.09.2010 / CT
N Updated for Minerals Library Release 5.1/4 16.04.2012 / YM
O Update for 5.1/4a Release 16.09.2013 / LK

Doc. kind Product Guide Project BU Minerals Library

Title Industrial IT System 800xA
Minerals Library version 5.1/4a
Document number Lang. Rev. ind. Pages 95
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ABB Switzerland Ltd No. of p.