Freelance Process Automation Made Easy

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

2 ABB Control Systems Extended Automation & Essential Automation

3 Freelance is a DCS 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 + I/O S700 S800 S900 May 10, 2013 Slide 3

4 System Structure - Highlights Easy system structure Improved Freelance Engineering AC 900F redundant with Profibus IO SD Card support for AC 700F SD Card support for AC 900F Performance improvements for AC 700F AC 900F (non-red.) with 10 direct IO S800 high density digital modules Telecontrol on Ethernet Additional S700 direct module types Modbus TCP for all Freelance Controllers

Freelance Scalable Architecture Start with Freelance As small as 50 I/Os + 1 OS/ES (all in one PC) Grow easily later by adding...... I/Os to existing Controller.

5 Freelance Scalable Architecture Start with Freelance As small as 50 I/Os + 1 OS/ES (all in one PC) Grow easily later by adding I/Os to existing Controller... Additional DigiVis Operator Stations... Additional Controllers... Fieldbus... Historian / Information Management... DigiClient xA Operator Station May 10, 2013 Slide 5

6 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 May 10, 2013 Slide 6

languages User defined function blocks and

for OS (DigiVis) Graphic macro library and

symbols and function blocks Global database

7 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 May 10, 2013 Slide 7

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

8 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 May 10, 2013 Slide 8

9 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 May 10, 2013 Slide 9

10 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 May 10, 2013 Slide 10

11 Engineering - ABB OPC Tunnel Eliminates complicated DCOM configuration Control Builder F OPC Tunnel Client Download Operations OPC Tunnel Client OPC Tunnel Server OPC Tunnel Server Freelance Trend Server 3 rd party OPC Server May 10, 2013 Slide 11

12 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 May 10, 2013 Slide 12

13 DigiVis Freelance Operations Control Builder F DigiVis AC 700F AC 800F AC 900F Engineering Tool Operator Station Controller Controller + I/O S700 S800 S900 May 10, 2013 Slide 13

14 Thi s im 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) of Diagnostics) with Contents) aspects views Minimum Engineering Maximum Automation DigiVis AC 700F AC 800F AC 900F pre-engineered May 10, 2013 Slide 14

data via Excel Macros Getvalue(<variable>,<next_position>)

15 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 May 10, 2013 Slide 15

16 DigiVis - Selected features Aspect Technology for fast navigation Right click External Aspect May 10, 2013 Slide 16

diagrams of CBF in the DigiVis environment No additional

17 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 November 28, 2011 Slide 17

18 DigiVis - Selected features Control Aspect continued SFC display view Active Step FBD SFC Active Transition FBD May 10, 2013 Slide 18

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

19 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 May 10, 2013 Slide 19

20 DigiVis PLC Integration Common DigiVis for several Freelance projects Project 3 Project 1 Project 2 Freelance OPC Server Freelance OPC Server A means to put DigiVis as Operator Station for more than one Freelance project May 10, 2013 Slide 20

21 Controller Scalable choice of AC 700F - AC800 F - AC 900F Control Builder F DigiVis AC 700F AC 800F AC 900F Engineering Tool Operator Station Controller Controller + I/O S700 S800 S900 May 10, 2013 Slide 21

year AC 700F 250 100% 1 1 2008 AC 800F PM 802F AC 800F PM 803F 400 200% 2 4 2000 1,000

22 Freelance Controller Family **AC 900F= 100% compatible and 100% more power Name IOs typical Performance Ethernet ports Fieldbus slots Intro. year AC 700F % AC 800F PM 802F AC 800F PM 803F % , % AC 900F Standard AC 900F Light AC 900F Premium 1, % serial May 10, 2013 Slide 22

23 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 May 10, 2013 Slide 23

24 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 May 10, 2013 Slide 24

Freelance I/O S800 I/O Full range of signal types including AI, AO, DI, DO, Temp, Pulse, Frequency, Relay HART functionality 0.

25 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 S800 - Process I/O for General Purpose Hot swap of modules Redundancy also on I/O module level Flexible configuration and installation May 10, 2013 Slide 25

Freelance IO continued S800 High Density I/O modules DI818

(2-25 pin D-sub) DI828-16 channel 120V / DO828-16 channel

MTUs w/25 pin D-subs Approximately 20% space savings in

26 Freelance IO continued S800 High Density I/O modules DI818 / DO channel 24V TU818 (Screw Terminations) TU819 (2-25 pin D-sub) DI channel 120V / DO channel Relay TU851 (Screw Terminations) TU852 and TU854 redundant MTUs w/25 pin D-subs Approximately 20% space savings in typical project (approx. 70% digital signals) May 10, 2013 Slide 26

Freelance I/O S900 I/O Remote I/O for mounting in ATEX Zones 1 and 2 applications

.. +70 C ambience temperature Full range of signal types including AI, AO, DI,

HART functionality Hot swap of modules, communication interfaces and power supply

27 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 May 10, 2013 Slide 27

IE Ethernet Control Builder F + DigiClient

28 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 Redundant AC 800F Controller Industrial Ethernet May 10, 2013 Slide 28

29 Freelance DigiClient Instance in IE DigiVis Graphic screens, Trends, faceplates, etc can be viewed in Internet explorer using DigiClient. May 10, 2013 Slide 29

No additional software needs to be installed on the client computer.

30 Freelance DigiClient Benefits Low cost Up to 80% more cost effective than other Thin Client/Web server solutions. Minimal engineering effort. DigiVis objects are seamlessly integrated. No additional software needs to be installed on the client computer. Use Internet explorer or Remote desktop to access DigiVis Graphics, Faceplates, Trends, etc. No further configuration required. Quick to install & no additional training required. May 10, 2013 Slide 30

31 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 May 10, 2013 Slide 31

32 DCS Upgrades can address some of your Pains Customer 1. Meet customer to identify customer pains 2. Apply and/or Develop pain relief medication products and services May 10, 2013 Slide 32

Automation Software Investment Protection Peace of Mind Maintenance Plan for Freelance

33 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?

34 Software Version : Freelance V9.2 SP3 Windows Operating System? Freelance supported on Windows 7 (32 & 64 bit OS) Windows XP SP3 still supported Mixture of Windows XP & 7 supported OPC Server and Trend Server supported on : 2003 Server and 2008 Server May 10, 2013 Slide 34

Buttons: Reset Toggle On/off 2 slots for communication modules 4 x Ethernet 10/100MB 1x

35 New AC 900F release June 2013 Layout and Interfaces Battery (behind display device) Display (optional) SD card LEDs: Power Error Run/Stop Prim/Sec Battery Switches/ Buttons: Reset Toggle On/off 2 slots for communication modules 4 x Ethernet 10/100MB 1x Diag/ Radio-Clock 2x serial lines Modbus Power 24V Up to 10 direct IO modules May 10, 2013 Slide 35

36 AC 900F in Freelance Engineering 2013 AC 900F configuration AC 900F Fully equipped May 10, 2013 Slide 36

500 IO for typical Process Industry application Drives Up to

37 AC900F IO Connectivity Non Redundant Configuration S700 Direct IO Up to IO for typical Process Industry application Drives Up to 320 via direct IO (10 modules) Profibus for more S800/S900 Hart Device Remote IO PA Device May 10, 2013 Slide 37

38 New Freelance Engineering Tool Control Builder F in Version 2013 release June % compatible with former versions Intuitive auto router in Function Block Diagram (FBD) editor Multiple programs simultaneously open Optimized for efficient Engineering, fewer clicks with auto-accept! Even 18 years old Controllers still supported Installation in just 5 minutes & 10 clicks! May 10, 2013 Slide 38

Freelance V2013 Engineering Tool CBF start page in version 2013 Intuitive access to main actions Recent files are displayed - Could be used for Project versioning

39 Freelance V2013 Engineering Tool CBF start page in version 2013 Intuitive access to main actions Recent files are displayed - Could be used for Project versioning Graphical project preview for easier distinction of projects Direct access to CBF login Recent projects Project preview System documentation May 10, 2013 Slide 39

40 Freelance V2013 Engineering Tool Project tree view in version 2013 Both project tree and editors simultaneously 3 menu levels Pull down menu General icons Editor specific icons Multiple editors open parallel, switch by tab navigation Project tree with optional auto-hide New icons Intuitive jump to hardware manager May 10, 2013 Slide 40

41 Freelance V2013 Engineering Tool Variable list view in version 2013 Excel-like filter and sort functions in Variable/Tag list Direct MS Excel import/export May 10, 2013 Slide 41

42 Freelance V2013 Engineering Tool New protocols: Modbus TCP Transfer rates in 10baseT networks: up to 360,000 registers per second Transfer rates in 100baseT networks: up to 3,600,000 registers per second Simple protocol based on standard Ethernet Reduced installation effort by standard Ethernet networks Can be connected directly via internet (for remote stations, distributed devices, web applications) High transfer rates May 10, 2013 Slide 42

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

43 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 May 10, 2013 Slide 43

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

44 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) May 10, 2013 Slide 44

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

45 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 May 10, 2013 Slide 45

What Characterizes Freelance? The 9 E s!! 1 2 3 4 5 6 7 8 9 1. Easy to Install Less than 5 minutes to get going 2. Easy to Learn Keep your intellectual property 3.

46 What Characterizes Freelance? The 9 E s!! Easy to Install Less than 5 minutes to get going 2. Easy to Learn Keep your intellectual property 3. Easy to Understand Available in 9 languages 4. Easy to Engineer All you need is one tool 5. Easy to Backup Entire application is just one file, fits on a small memory stick 6. Easy to Scale From few to a few thousand IOs 7. Easy to Try out Runs on most common PC hardware 8. Easy to Justify This DCS is good value for little money 9. Easy to Make Money Produce rather than fix May 10, 2013 Slide 46

47 Q&A May 10, 2013 Slide 47

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

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