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TABLE OF CONTENTS
Chapter 2 - 1
T568-02 Freelance System Architecture - RevC
2.1.1 Objectives
On completion of this chapter you will be able to:
• Give an overview about ABB Industrial IT concept
• Describe the network structure in the Freelance architecture
• Describe the functionality of major components
• Recall Freelance Add On Tools
• Outline the Freelance licensing model
2.1.2 Legend
> Indicates when you go from one menu to a sub-menu
Italic Indicates object and file names
“ “ Indicates dialog box buttons, tabs, menus etc.
Bold Indicates important topics
Indicates start/explanation of student activity
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Freelance Training
Ethernet TCP/IP
Controller
AC 800F AC 800F AC 700F
redundant
PROFIBUS
Remote I/O
Rack-IO
S800 S900 S700
Rack-based
Foundation Controller
Fieldbus
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Program List
Instruction list
Structured Text
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Freelance Training
The operator level DigiVis originating from the control system Freelance is based on
the Microsoft operating system Windows XP SP3. DigiVis is to be created very fast
by its simple structures. The objects necessary for the operation are configured and
commissioned with the engineering Tool Control Builder F. Freelance allows to
configure up to 100 operator stations for operation and observation. A maximum of 10
operator stations can be assigned to a process station, because there is a limit of
connects for a process station. Per connection a maximum number of 1400 Byte data
is possible.
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Message Line
Tool Bar
System Display
(Module Diagnostics)
Group Display
SFC Display
Message list
DigiVis allows to operate the automated process either with mouse or keyboard.
DigiVis offers the following process operation features:
• Faceplate library for Freelance controllers
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• Customized Faceplates
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T568-02 Freelance System Architecture - RevC
2.3.3.1 AC 800F
At the process level, a Freelance system can consist of several process stations that are
connected with I/O units. You have the option of running these process stations either
redundantly (CPU redundancy, field bus module redundancy) or without redundancy.
Modular plug-in input/output modules are used in accordance with the type and
quantity of process signals. With AC 800F, field bus-compliant components such as
remote I/O or field devices can be connected.
The AC 800F has a modular structure. The CPU is designed as a backplane to which
various modules power supply units, Ethernet or field bus modules can be attached in
line with the application. On the field bus side, modules for PROFIBUS-DPV1,
FOUNDATION Field bus HSE, MODBUS (master/slave, RTU or ASCII), IEC
60870-5-101 and CAN for Freelance Rack I/O are available. The field bus line and the
connected PROFIBUS slaves are entirely configured and parameterized using the
Control Builder F engineering tool. No further external tools are needed for
configuration.
PROFIBUS slaves can be integrated into the system using a GSD1 file or FDT/DTM2.
In the case of FOUNDATION Field bus, configuration takes place using CFF3 or DD4
files. This allows field bus parameterization even without connected field devices.
Also Freelance Rack I/O can be connected to the AC 800F, in which case a CAN
module is used. This allows you to operate five I/O racks, with a total ofaround 1000
I/Os, for each AC 800F. The I/O racks are equipped with a link module and up to nine
I/O modules and can be mounted separately at a distance of up to 400 m from the AC
800F.
The field bus module for PROFIBUS DP enables connection of remote I/O units such
as the S700, S800 or S900.
Whereas the S700 and S800 are generally used in process automation, the S900 is
preferred, due to its extended channel diagnostics and intrinsic safety, in the chemicals
segment and in areas where explosion protection is required.
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2.3.3.2 AC 700F
The AC 700F process station consists of a CPU module, which can be extended with
up to eight I/O modules and one Profibus module. The following modules are
available:
• PM 783F CPU module
• CM 722F Profibus module
• AI 723F Analog input module
• AI 731F Analog input module (Thermocouple)
• AO 723F Analog output module
• AX 722F Analog I/O module
• DC 732F Digital I/O module
• DX 731F Digital I/O module
• DX 722F Digital I/O module
The CPU module PM 783F is the data-processing module of the AC 700F process
station. To the left of the CPU module one Profibus module CM 722F can be
connected. If the Profibus module is not used the dummy coupler module TA 724F
has to be connected to protect the coupler slot. Next to Profibus the AC 700F process
station supports Modbus Master/Slave. The Modbus interface is placed at the CPU
module, so no special module is needed. I/O modules can be connected right of the
CPU module. The PM 783F module works with a Motorola Power PC (MPC8247).
The application data are battery-backed in a 2 MB SRAM.
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For outputs O0 to O3 both Current and Voltage output configuration is possible. For
O4 to O7 only voltage output configuration is possible. The range can be selected for
the corresponding output. The following ranges are available:
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T568-02 Freelance System Architecture - RevC
2.3.3.3 S700
The S700 Remote I/O consists of a digital input/output module DC 705F which works
together with the Field Bus Plug (a Profibus connector) as Profibus slave. It can be
extended with up to seven further I/O modules. Next to the I/O modules of the AC
700F controller the following modules are available:
• DC 705F Digital I/O module (FBP Interface module)
• AC 722F Analog I/O module
• AX 721F Analog I/O module
• DC 722F Digital I/O module
• DC 723F Digital I/O module
• DI 724F Digital input module
• DA 701F Digital/Analog I/O module
• CD 722F Frequency Input Module
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For outputs O0 to O3 both Current and Voltage output configuration is possible. For
O4 to O7 only voltage output configuration is possible. The range can be selected for
the corresponding output. The following ranges are available:
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For outputs Current and Voltage output configuration is possible. The range can be
selected for the corresponding output.
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2.3.4 Emulator
The Soft Controller (Emulator) is downloaded from the Freelance setup CD as shown
below.
To start an instance of the Emulator, select Internet Explorer and type “http://localhost:8888”
The Emulator administrator page will be displayed as shown above. Enter the resource
ID in the Station ID (shown as 100 in the example above), and then click on “Start
Resource ID
Controller”
When the Emulator has been started the window will appear as below.
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In the taskbar select “Hardware structure > Network “ and check that the Resource ID
is set as the Station ID on the emulator, and the IP address corresponds to that on
which the emulator is running.
It can be seen in the project tree that the process station has now been allocated to the
Emulator.
Further instances of the Emulator can be started and resources allocated as required.
NOTE! An emulator cannot be assigned to a process station that
has been configured as a redundant station.
2.3.5 Gateway
The gateway stations D-GS are used to make data from the Freelance system available
to other systems. In principle, all the data from the Freelance system can be read and
written via a gateway station. In addition to each gateway station in a Freelance
system, the appropriate server software from the add-on packages a OPC Server F,
trend server, DDE and Maestro UX must also be installed in the network.
(If, for example, a gateway station of OPC gateway type is configured in a Freelance
system, then the OPC Server F software must be installed on a PC that is linked on the
network with the Freelance process stations.)
For each gateway station it is configured which tags and variables are available to the
other system for reading and/or writing via the gateway.
Correlation to a physical station is carried out in the hardware structure. An assigned
gateway station is represented by the label GWY. In the course of commissioning, the
data specified is made available to the other stations by loading the gateway station.
The following gateway types are available:
• DCP gateway
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A DCP gateway is used for coupling the Maestro UX control system. It runs on a
CPU module DCP 02GWY or DCP 10GWY which is installed in any process
station rack.
• OPC gateway
The OPC gateway runs a PC, on which an OPC-Server F is installed.
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• UNI gateway
The gateway type UNI gateway is intended for DMS API use.
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WXP Aspect
Server
CBF CBF
Connectivity
WXP WXP Server
W2003 Server
Project 1 Project 2
800xA Operations is running on the operating system Windows 2003 server and
Windows XP. Thereby a Client/Server structure for the human system interface is
given.
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The connection to AC 800F process stations is made by OPC gateways, which are
configured in CBF. From the view of 800xA Operations the process data is
transmitted by OPC servers.
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S800 I/O
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The Freelance system use standard Ethernet and TCP/IP protocol to communicate
between its’ nodes, therefore the first step is to setup the IP addresses of the AC 800F
controllers and the PCs.
The setting of IP address of PCs is well known, we concentrate on setting IP address
for the AC 800F controller.
For Freelance system, there are two different methods of setting the IP address:
1. Standard setting which require to setup all the IP addresses with the same format
as:
172.16.1.X (here X stands for the last number of IP address)
and to setup the subnet mask as:
255.255.240.0
2. Non- Standard setting which allows you to setup any IP address and subnet mask
for Freelance system nodes.
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CFG OK é
R/S
Batt
IPAddr ETH
FBP R/S
Batt
42 ETH
FBP
ê
Ser Ser
IO-Bus Diag IO-Bus Diag
ê é ESC OK
Press OK to save
SAvE
ETH
R/S
Batt
FBP
Ser
changes or ESC to
IO-Bus Diag cancel
OK
Configure
Hold RUN during RUN ESC Res.- ID, CPU Load or
Startup à starts the Free Text
Controller in Stop
Mode R/S: Stop
Id
R/S
Batt
StArt ETH
FBP
Ser
R/S
Batt
7
ETH
FBP
Ser
IO-Bus Diag IO-Bus Diag
2.7 Redundancy
Two AC 800F can be linked to enable operation in redundancy mode. In addition to
the Ethernet module in slot E1 for normal network communication a second Ethernet
module is present in slot E2. A point-to-point connection called the Redundancy link
is set up between the Ethernet modules in the E2 slots of the two AC 800F.
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Operator station
Process interface constructed in racks: Functions:
§ Flexible rack positioning § Plant-specific graphics:
§ Front-panel connection technique (code able blocks § Single displays with mini trend display
§ and screw terminals) § Standardized displays:
§ Replaceable during operation § Overview display
§ Group display
§ SFC display
§ Trend display
§ Time scheduler display
§ System display
§ Faceplates
§ Message list and operator hint list
§ System diagnosis
§ Control aspect (shows configuration)
§ Archiving
§ Logging
Process interface for AC 800F: Display:
§ Flexible rack positioning for field bus modules § Display update: approx. 1 s
§ Replaceable during operation § Display build-up time: 1...2 s
Signal update for the rack modules: Capacity per operator station:
§ Binary signals: selectable from 2 ms § Max. 1 overview display
§ Analog signals: selectable from 10 ms § Max. 96 group displays
§ Max. 42 trend displays
§ Max. 12 logs
§ Max. 2000 messages in the message list at any
one time, further messages only stored
temporarily in the process stations.
§ Number of graphic displays depends on hard
disk capacity
Power supply
Alternating voltage:
§ 230 V, (-15%...+10%)
§ 115 V, (-15%...+10%)
§ Direct voltage: 24 V, (-20%...+35%)
§ Interruption: < 20 ms without function disturbance
Electromagnetic compatibility (EMC):
§ Radio interference suppression according to EN 55022 and EN 55014
§ Interference immunity according to IEC 801, EN 60801 and VDE 0843
§ Security level 3 and NAMUR industrial standard
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Hardware Requirements
Control Builder F
Hard disk for installation 500 MB free disk space
Hard disk for operation 10 GB free disk space
Operating system Microsoft ® Windows XP Prof. SP3
Speed ≥ 2 GHz
RAM 1 GB
Ethernet card with support Interface BNC/AUI/TP
DigiVis
Hard disk for installation 500 MB free disk space
Hard disk for operation ≥ 2 GB free disk space
Recommended for archiving ≥ 80 GB (depending on configuration)
Operating system Microsoft ® Windows XP Prof. SP3
Speed ≥ 2 GHz
RAM 1 GB
Graphics card for dual monitor Matrox Millenium P650
Matrox Extio F1400
ATI Fire GL V3100
Nvidia Quadro FX540
Ethernet card with supp. Interface BNC/AUI/TP
OPC Server F
Hard disk for installation 500 MB free disk space
Hard disk for operation ≥ 2 GB free disk space
Operating system Microsoft ® Windows XP Prof. SP3
Microsoft ® Windows 2003 or 2008
Server (for 800xA Connectivity)
Speed ≥ 2 GHz
RAM 1 GB
Ethernet card with supp. Interface BNC/AUI/TP
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Padlock icon:
Open padlock = operation enabled
Closed padlock = operation disabled
2.13.4 DigiBrowse
DigiBrowse is an additional program for the Freelance System.
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DigiBrowse permits viewing archived trend and log files without DigiVis. The data
can be presented in graphic form or as tables. The graphic presentation can be scaled
as desired, to facilitate examination of particular past process events. In addition, it is
possible to convert the data to ASCII format, making it readable by other programs,
such as, for example, data base or spread sheet programs.
If DigiBrowse is installed on a PC connected to the DigiNet S system bus, files
archived at the operator stations are transferred with FTP (File Transfer Protocol) to
this PC and connected via DigiNet S. The transfer of archive files from the different
operator stations is automatic, manual or event-driven, as configured in Control
Builder F.
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2.14 Licensing
In order to offer market-appropriate functions and features, structure and pricing, the
system is divided into base parts and options. In addition scaling of tags, logs, etc. is
made to further optimize a system for a specific application.
When needed, expansions can be purchased and the system grows with the customer’s
needs.
It is important to recognize that installation is separate from licensing. Installation is
never prevented due to lack of licensing. However, a license is required in order to use
the corresponding applications.
EngineerIT
Control Builder F
(Standard, Professional)
ControlIT
Control SW
(Basic, Advanced)
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2.14.2 EngineerIT
The options of all Freelance controllers have been grouped in kits that are scalable
through the number of I/Os. As a result, the licenses of each controller can be adapted
to the customer’s needs.
The following Control Builder F versions are available:
• Control Builder F Standard
• Control Builder F Professional
All Control Builder F versions support the following functions:
• Configuration and commissioning of user programs
• Tree view of the programs for convenient program overview and selection
• IEC 61131-3 programming (FBD, IL, LD, ST, SFC)
• Graphical hardware configuration
• Integral Field bus configuration for PROFIBUS DP/PA and FOUNDATION Field
bus
• IEC 61131-3 data types and user-defined (structured) data types
• Project-wide variables and function block lists
• Online cross-reference
• Efficient plausibility check
• Extensive online help
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2.14.3 ControlIT
ControlIT offers two license types.
• Basic control software license
• Advanced software license
The license functionality can be adapted to the customer’s needs for every controller,
and the number of I/Os can be extended in steps of 50.
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