Oomesh Maharaj, Freelance - MEA Region Product Manager, Control Technologies, Tech days Cape Town 2014

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1 Oomesh Maharaj, Freelance - MEA Region Product Manager, Control Technologies, Tech days Cape Town 2014 Essential Automation Freelance Process Automation Made Easy

2 ABB Control Systems Extended Automation & Essential Automation

3 What is Freelance? Freelance is a Distributed Control System made up of these components Control Builder F DigiVis AC 700F AC 800F AC 900F Engineering Tool Operator Station Controller Controller Controller + I/O s S700 S800 S900

Freelance Small footprint for Hardware and Software Software

in one PC) Simple peer to peer communication between Process &

in 5 min & max. 10 clicks Grow easily later by adding.

.. Additional DigiVis Operator Stations... Additional Controllers.

4 Freelance Small footprint for Hardware and Software Software Hardware Start with Freelance As small as 50 I/Os + 1 OS/ES (all in one PC) Simple peer to peer communication between Process & Operator stations 100 day Demo installation period Installation in 5 min & max. 10 clicks Grow easily later by adding I/Os to existing Controller... Additional DigiVis Operator Stations... Additional Controllers... Fieldbus... Historian / Information Management... DigiClient xA Operator Station for Server Client architecture

(optionally redundant) AC 700F Controller with direct I/O Panel 800 Add more

5 Freelance Scalable Architecture Start Small 1 PC - optional Dual Screen Engineering: Control Builder F Operator Station: DigiVis Industrial Ethernet (optionally redundant) AC 700F Controller with direct I/O Panel 800 Add more controllers Add Panel 800 Profibus Modbus AC 700F Controller Start with few I/O!!

6 Freelance Scalable Architecture can be expanded easily Add more Operator Stations Engineering Station: Control Builder F Operator Stations: DigiVis Operator Stations: Extended Operator Workplace Industrial Ethernet (optionally redundant) Add Redundancy AC 700F Controller with direct I/O Profibus Panel 800 AC 900F Controller AC 800F Controller Foundation Fieldbus AC 800F or AC 900F Controller, redundant S800 I/O S800L I/O Modbus Profibus Universal Motor controller S700 I/O Profibus Field Devices S900 I/O

7 Freelance Engineering

8 Control Builder F Freelance Engineering Control Builder F DigiVis AC 700F AC 800F AC 900F Engineering Tool Operator Station Controller Controller + I/O S700 S800 S900

9 Engineering Control Builder F Single engineering tool for all Software Hardware and software configuration Integrated fieldbus management IEC programming languages User defined function blocks and faceplates Hardware Graphics configuration for OS (DigiVis) Graphic macro library and standard function blocks More than 200 symbols and function blocks Global database System wide Cross-referencing of signals

Freelance Engineering Fieldbus Management in Freelance Built-in Fieldbus support for PROFIBUS Fieldbus FOUNDATION HART MODBUS and others Covers bus and device configuration

10 Freelance Engineering Fieldbus Management in Freelance Built-in Fieldbus support for PROFIBUS Fieldbus FOUNDATION HART MODBUS and others Covers bus and device configuration Setting Fieldbus topology and parameters E.g. transmission rates and addresses Scan bus for new devices Easy configuration and diagnostics of field devices with FDT-technology

FDT/DTM (Field Device tool / Device type manager)

station AC 800F Controller AC 800F Controller,

11 FDT/DTM (Field Device tool / Device type manager) How does it work? Engineering Station: Control Builder F Operator Stations: DigiVis DigiVis Extended Diagnostic station AC 800F Controller AC 800F Controller, redundant Various DTM suppliers S800 I/O S800L I/O Profibus S900 I/O ABB Group May 27, 2014 Slide 11

12 Engineering ABB Drives integration Ready to use libraries Integration with ACS 350, 550, 800 on Profibus and Modbus No additional cost for Freelance Drives library UMC22 & UMC100 Profibus intergration libraries also available...download library from AKS

13 Engineering - Bulk Data Manager Human-error free fast engineering using Excel Excel workbook PRO file Variables Tags P-Tree Objects e.g. Graphics Automation Interface Bulk Data Manager Import Export Automation Interface CBF C-Tree DB Parameters FB Parameter Templates

14 Freelance Operations

15 DigiVis Freelance Operations Control Builder F DigiVis AC 700F AC 800F AC 900F Engineering Tool Operator Station Controller Controller + I/O S700 S800 S900

Freelance Operations DigiVis Easy Operation & Diagnostics of entire system Redundancy with 2 DigiVis Stations Offers many visualization options: Dual monitor operation Free

16 Freelance Operations DigiVis Easy Operation & Diagnostics of entire system Redundancy with 2 DigiVis Stations Offers many visualization options: Dual monitor operation Free graphic displays Standard graphic elements Bitmaps, 3D macro library Clearly structured faceplates for operator interventions including group displays Trend displays including historian

17 Freelance Operations More visualization options Automatically generated system displays for Hardware diagnostics Alarm pages for specific plant areas Sequence control displays Shift logs Event logs Excel reports Data archiving

18 This image cannot currently be displayed. DigiVis Pre - engineered easy to use Graphic design software SFC Event System Group Alarm Automatic Faceplate Overview Trend list Display Line Display (Access Context & Tool (Data (Module (Table on Bar Menu Historian) Tags) Diagnostics) of with Contents) aspects views Minimum Engineering Maximum Automation DigiVis AC 700F AC 800F AC 900F pre-engineered

19 DigiVis - Excel Based Reporting Enjoy your control/production data with Excel features Excel Reports for Freelance Defining runtime data via Excel Macros Getvalue(<variable>,<next_position>) Operating reports (start, stop, ) like Freelance logs

20 DigiVis - Selected features Aspect Technology for fast navigation Right click External Aspect

interlock diagrams of CBF in the DigiVis environment

21 DigiVis - Selected features Control Aspect CBF Viewer CBFViewer shows the function block diagrams and interlock diagrams of CBF in the DigiVis environment No additional engineering required Right click Control Aspect

22 DigiVis - Selected features Control Aspect continued SFC display view Active Step FBD SFC Active Transition FBD

Freelance controllers into operation with DigiVis via OPC Safety PLCs PLCs from

23 DigiVis PLC Integration Main Use Case AC500 OPC Server Hima OPC Server Siemens OPC Server 800xA OPC Server A means to integrate PLCs found in the vicinity of Freelance controllers into operation with DigiVis via OPC Safety PLCs PLCs from package units Legacy PLCs to be replaced step wise by Freelance ABB Group May 27, 2014 Slide 23

24 Freelance Controllers

25 Controller Scalable choice of AC 900F - AC800 F - AC 700F Control Builder F DigiVis AC 700F AC 800F AC 900F Engineering Tool Operator Station Controller Controller + I/O S700 S800 S900

direct I/O Support SD card for firmware update and application download/upload

26 Freelance Controller AC 900F AC 900F Controller Typically up to 1500 I/Os Redundancy for high availability Optional display for easy diagnostics Up to 10 direct I/O Support SD card for firmware update and application download/upload Connectivity Profibus HART Modbus TCP & RTU Telecontrol (IEC /104) G3 compliant as standard

27 Freelance Controller AC 800F AC 800F Controller PM 803F: Typical up to 1000 I/Os Redundancy for high availability Fieldbus support Profibus Foundation Fieldbus HART Modbus TCP* & RTU CAN for Freelance Rack I/O Hot swap of Fieldbus modules Telecontrol (IEC /104) AC 800F coated (G3 compliant) hardware components available

28 Freelance Controller AC 700F AC 700F Controller I/O scan time of 2ms possible CPU capacity for 300 I/O s Support SD card for firmware update and application download/upload Temperature range: C Monitoring of channels: Short circuit & line break CPU PM 783F: Front panel display for easy diagnostics 1 Ethernet port (10 / 100Mbit) Modbus TCP and Telecontrol 1 Profibus Master 1 RS-232 / 485 port Modbus 1 RS-232 port - extended diagnostic AC 700F attracts PLC users to use DCS

29 Freelance I/O

30 Freelance I/O Choose from S700 S800 S900 Control Builder F DigiVis AC 700F AC 800F AC 900F Engineering Tool Operator Station Controller Controller + I/O S700 S800 S900

Freelance I/O S700 I/O Full range of signal types including AI, AO, DI, DO, Temp, Pulse, Frequency, Relay Inputs & Outputs mixed in one module 14 different I/O modules : 7 Digital

31 Freelance I/O S700 I/O Full range of signal types including AI, AO, DI, DO, Temp, Pulse, Frequency, Relay Inputs & Outputs mixed in one module 14 different I/O modules : 7 Digital types 6 Analog types 1 Analog + Digital type S700 - Compact Profibus Remote I/O DC 705F FBP Interface module is a DC module 8 DI + 8 DC I/O Channels Easy Configuration using Templates

32 Freelance I/O S800 I/O Full range of signal types including AI, AO, DI, DO, Temp, Pulse, Frequency, Relay HART functionality C ambience temperature G3 Compliant Hardware components Hot swap of modules S800 - Process I/O for General Purpose Redundancy also on I/O module level Flexible configuration and installation Approximately 20% space savings in typical project (approx. 70% digital signals)

Freelance I/O S900 I/O Remote I/O for mounting in ATEX Zones 1 and 2 applications + signals from Zone 0 / 1 / 2-20.

Safety for hazardous environments HART functionality Hot swap of modules, communication interfaces and power supply G3

33 Freelance I/O S900 I/O Remote I/O for mounting in ATEX Zones 1 and 2 applications + signals from Zone 0 / 1 / C ambience temperature Full range of signal types including AI, AO, DI, DO, Temp, Pulse, Frequency S900 - Intrinsic Safety for hazardous environments HART functionality Hot swap of modules, communication interfaces and power supply G3 Compliant Hardware components Hot configuration in run, full online configuration capabilities CB220 Compact Box ABB Group May 27, 2014 Slide 33

34 Freelance Additonal

+ DigiClient on IE Router or Firewall DigiClient Server : High Performance Server (Windows 2003 / 2008) AC

35 Freelance DigiClient Simple Integrated Architecture Office network - Internet Explorer or Remote desktop to launch of DigiClient DigiClient on IE DigiClient on IE Ethernet Control Builder F + DigiClient on IE DigiVis + DigiClient on IE Router or Firewall DigiClient Server : High Performance Server (Windows 2003 / 2008) AC 700F Controller AC 800F Controller Industrial Ethernet Redundant AC 800F Controller ABB Group May 27, 2014 Slide 35

36 Freelance DigiClient Instance in IE DigiVis Graphic screens, Trends, faceplates, etc can be viewed in Internet explorer using DigiClient. ABB Group May 27, 2014 Slide 36

37 Freelance also used with System 800xA Server Client Architecture and additional features Workplaces Domain Server(s) Asset Server) Aspect Server(s) Connectivity Server(s) Control Network Controllers Fieldbus Field Devices ABB Group May 27, 2014 Slide 37

Automation Software Investment Protection Peace of Mind Maintenance Plan for Freelance

38 Automation Sentinel The way to make your DCS fit for the future! System Life Cycle Management Take advantage of continuous improvements and enhancements Automation Software Investment Protection Peace of Mind Maintenance Plan for Freelance EVOLUTION V1 V2 V3 V4 V5 V6 V7 V8 V9 V2013 Former Versions Newest Version On which version is your Freelance System?

39 Freelance Success Stories

Freelance Success story End customer: Northam Platinum Project/Application: Plant wide automation of Decline Shaft / UG2 plant / Fire Detection / Surface area /

2SP1 Projects, Windows 7 Project 1 (Plant area) : 1 x Combi Engineering Station 3 x DigiVis (Dual monitor) 7 500 I/O license Project 2 (Mining area) : 1 x Combi

40 Freelance Success story End customer: Northam Platinum Project/Application: Plant wide automation of Decline Shaft / UG2 plant / Fire Detection / Surface area / Underground area Typical Automation from ABB: 2 x Freelance V9.2SP1 Projects, Windows 7 Project 1 (Plant area) : 1 x Combi Engineering Station 3 x DigiVis (Dual monitor) I/O license Project 2 (Mining area) : 1 x Combi Station 9 x DigiVis (3 x Dual monitor, 6 x Panel PC) I/O license 11 x AC 800F (PM 803F) with S800 I/O 10 x AC 700F CPU with S800 I/O Profibus interface to DOL, VSD and DP instruments PGIM V Full clients, 1000 History logs ABB Group May 27, 2014 Slide 40

Automation from ABB: 1 x Combi Engineering Station 8 x DigiVis (Dual monitor) Windows 7, Freelance V9.

41 Freelance Success story End customer: Nampak Glass Project/Application: Glass Bottle & Container production Furnace and Batch house. Replace Siemens S7 300 / Citect SCADA system. Automation from ABB: 1 x Combi Engineering Station 8 x DigiVis (Dual monitor) Windows 7, Freelance V9.2SP1, 5000 I/O license 11 x redundant AC 800F (PM 803F) with S800 & S900 I/O Profibus interface to VSD and Softstarter DigiClient (10 concurrent users)

Automation from ABB: 1 x Combi Engineering Station 3 x DigiVis (Dual monitor) Windows 7, Freelance V9.

42 Freelance Success story End customer: Exxaro Alloystream Project/Application: Lethaba project Classified Process information Replace Siemens S7 400 / Adroit SCADA system. Automation from ABB: 1 x Combi Engineering Station 3 x DigiVis (Dual monitor) Windows 7, Freelance V9.2SP1, 3000 I/O license 1 x AC700F / 5 x AC 800F (PM 803F) with S700, S800 and Siemens ET200 I/O Profibus interface to VSD, DOL, S7-300 PLC & Weigh Scales MES interface to Wonderware

Freelance Success story End customer: Omnicane Milling Operations, Mauritius Project/Application: Plantation White Sugar Refined Sugar Automation from ABB: 1 x Combi Engineering

43 Freelance Success story End customer: Omnicane Milling Operations, Mauritius Project/Application: Plantation White Sugar Refined Sugar Automation from ABB: 1 x Combi Engineering Station 16 x DigiVis Windows XP SP3, Freelance V9.1, 3000 I/O license 10 x AC800F, S800 I/O and Siemens ET200 I/O Profibus interface to VSD, DOL & Weigh Scales Modbus to 60 x Power meters

Summary Highlights of Freelance Easy to install, to learn and to

operator interface and documentation Just one tool for engineering,

(PROFIBUS, Foundation Fieldbus, HART) Start a DCS with 16 signals

44 Summary Highlights of Freelance Easy to install, to learn and to engineer Available in your Language: localized engineering tool, operator interface and documentation Just one tool for engineering, commissioning, and diagnostics High-end fieldbus solutions (PROFIBUS, Foundation Fieldbus, HART) Start a DCS with 16 signals System with cost efficient and really integrated HSI (DigiVis) Customers love it!!

45 Q&A

Freelance Process Automation Made Easy

Lance Johnson, Business Development Manager, Control Technologies, Johannesburg, 8-9 May 2013 ABB Technology Days - Essential Automation Freelance Process Automation Made Easy ABB Control Systems Extended