Operator’s optimal Human Machine Interface based on 800xa

Yousef Iskandarani, Andreas Biseth Nymoen and Hamid Reza KarimiDepartment of Engineering

University of AgderJon Lilletuns vei 9, 4879 Grimstad

Norwayyousef.iskandarani@uia.no

Abstract: This work is about ABB 800xa, whit focus on HMI. ABB is today a world leading company when itcomes to technology, and the ABB 800xa system is one for a kind. ABB 800xa is a way to build a control systemfor plants(factory’s). The HMI (Human Machine Interface) is the connection between the machine and human.HMI gives you en graphic overview over the control system, and gives the possibility to create events and alarms.When a HMI is completed you will be able to control the whole plant(factory).

800xA provides integrated engineering environment for development and reuse of system standard,[1] suchas operators display, field devices and control logic. The Industrial IT system 800xA is built upon ABBs AspectTechnology. Aspect objects concept allows organization of objects and aspects into different structures, dependingon which context is to be viewed. Aspect Objects are organized into structures that represent different viewsof the plant, such as Functional-, Control and Location Structure. One object may be placed multiple times indifferent structures. The idea of placing the same object in multiple structures is based on the IEC standard1346 [2]The difference between Plant Explorer and Windows Explorer, is Plant Explorer have a number ofstructures representing the same plant the same plant, while Windows Explorer have not. The grate ting aboutthees structures is that they can b built and changed at any time.

Key–Words: Object Oriented Programming, Dynamic object, Static Object, Embedded Object, plant mapping,800xa system, Industrial IT

1 ABB history

ABB has been around for over 30 years, it was startedby the firm ASEA (Allmanna Svenska Elektriska AB)and BBC (Brown Bovery & Cie). Both companieshad a large turnover and with about 100000 employ-ees each. ABB is working to develop products andtechnology solution in power and automation. Today;ABB is the world’s leading on the market when itcomes to technology and automation. And today isthe have offices in more than 100 countries.

In the early 80’s they began to create controlsystems. But the breakthrough in this came just a fewyears ago, and it became on if the most popular today.The system is called Extended Automation System800xA, this have won numerous awards, and thismade it possible for the workers and be able to controleverything from a control room, instead of having towalk around to check the machines. This made safetyat work higher, providing more opportunities in theworkplace.

2 Industrial IT ABB 800xa system800xA provides integrated engineering enviromentfor development and reuse of system standard,[1]such as operators display, field devices and coltrollogic. The Industrial IT system 800xA is built uponABBs Aspect Tehcnology. Aspect objects connectsplant data and function and the aspect object repre-sent real objects, such as pumps valves, devices andcontrollers. Aspect Objects are organized into struc-tures that represent different views of the plant, suchas Functional-, Control and Location Structure. Oneobject may be placed multiple times in different struc-tures. The idea of placing the same object in multiplestructures is based on the IEC standard 1346 [2]

2.1 Plan ExplorerPlant explorer is based on Windows XP plattform isthe window you need to know. The Plant explorer isthe main tool for building control modules and graph-ical display. It is also used to create libraries and con-figure and add elements and list. In the Plant explorerthe first window that will appear is the type of struc-

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ture and Root.in the root you can create aspect, ac-cess aspects that you have created in other structures.Like displays and control structure. The most com-mon structures:

1. Control Structure: Shows the control network interms of networks, nodes, fieldbuses, and sta-tions.

2. Function Structure: Shows the plant from theprocess point of view.

3. Location Structure: Shows the physical layout ofwhat equipment is located where in the plant.

Figure 1: ABB 800xa Library structure

2.2 Control StructureBefore you start to build your control program, youneed to create a control network and a control struc-ture in the control structure. From this structure youcan open the newly created Project, so you are able toopen the correct project in the Control builder. Youneed to connect standard libraries and it is also possi-ble to create you own control modul-, function block-and data type into your own library. Control Mod-ules can include program code, visual representation,interaction, data acquisition, communication etc, andis a powerful concept for turning new solutions intoblack boxes that can be reused over and over again

From control structrure you can set-up the systemwith a hardware or a software controller. We used asoft controller in this project and this make you able totest the system before you implement it to a physicalplant via hardware. Soft controller make up a virtualplant and future operator can test the system andpractise on the system before the control the live plant.

Control Builder M supports all the five IEC611313 standard languages[3], i.e. Instruction List,

Figure 2: ABB 800xa EPlant control structure

Structured Text, Function Block Diagram, SequentialFunction Chart, and Ladder Diagram. In addition,ABB have extended the IEC 611313 POU (ProgramOrganization Units) types with Control Modules. .[4]

2.3 Workplace StructureOprerators work place, her we can change color ontrend display. we can change the event color and pro-cess color. you can also create a startup display whichis the main window to your plant. From this struc-ture there are settings to change how many screensyou want to use and you can also customize the ap-perance of these. The startup display contains a ap-plication bar, process alarm and event tool bar, startupdisplay and startup bar.

2.4 Function StructureFrom function structure, it is possible to createdifferent objects and aspects, like graphic displayand trend display. We used both trend display andgraphic display to show the operatore historical dataand trending from different process parameters, liketemeprature, pressure, tankvolum etc. The trenddisplay needs historical data from a data collectoror a log. From the library structure, you can createdifferent log template and specify storage parametersand what kind of log type you need. And from whichsource, like OPC.

3 Introduction to Human MachineInterface

A human machine interface (HMI) is an interfacewhich connects the human with the machine. Twocomponents are needed in a human interface, firste

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Figure 3: ABB 800xa EPlant function structure

there is an input. A operator needs a way to tell themachine what to do, to make request, or adjust someparameters or values. In 800xa the operator use a key-bord and a graphic display to send commands to thesystem.The interface also require a output, which allows theoperator to see updated information on the progressof the commands, status lights and alarms. All this in-formation could be view on a computer screen.Typicalsoftware includes operator functionality to handle nor-mal and abnormal situations, customized operator en-vironment, flexible access to relevant displays and in-formation, and direct access to field devices and em-bedded systems. Context menus link graphical ob-jects with displays, faceplates, manuals, etc. Tem-plate displays include trends y=f(t), operating fieldsy=f(x), alarm lists, faceplate groups. Multitrend win-dow can be configured online by dragging tags fromtag browser or process graphics. Faceplates with dif-ferent size and content support different users andtasks

Figure 4: The HMI to the candle plant

The graphic editor in 800xa is fast and a effec-tive tool to create operator displays. It is a state-of

the art editor with a comprehensive graphic symbollibrary and easy to use expression editor. You cancreate an accurate pictorial presentation of your plantbecause of the extensive graphic symbols, the sym-bols can also be used to control different parametersin the plant, such as starting the plant and set point ofa PID. The symbols library include (pie chart symbollibrary, factor symbol library, general elements etc).You can personlized your own symbol, and save it ina personal library. The expression editor is based onthe Microsoft Visual basic code and is easy to use andyou can control a lots of the symbols properties bychanging the expression. Like an alarm that you wantto pop-up. Set the correct Singel control modul ex-pression in the visible flag.

4 Expression builder and elementbrowser

The graphic editor is based on Microsoft Visual ba-sic and all the syntax is written in Visual Basic code.iif(expression, true, false). The first thing that have tobe done is connecting the builder with the applicationin the control modul and trend display in the root inPlant Explorer. The element browser will give you theavaiable variables that you have written in your Con-trol Network and application. Number of connectedelements will appear in the element browser. If oyuneed to connect an aspekt link or trenddispaly this canbe done form the root.

Figure 5: Element Browser and expression builder inHMI

In the expression builder you can write your Vi-sual basic code and program different kind of ele-ments or changing apperence and behavior in the op-erator display. You can change text color with built-inevent colors or process graphic colors.

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5 Static and dynamic ObjectsFrom the Symbol library it is possible to choose be-tween static or dynamic elemenets from the graphiclibrary. Static symbol is just a symbol with no otherproperties the changing color or size like pipes, con-veyor belt, text label, numeric indiactors, toggle andpush buttons. But when you need a symbol to changescolors or appearence during the process, you need tocreate a dynamic object. Choose a Std factory elementand click on properties. You can have 5 different an-imation setting none, analoge and discrete. Choosediscrete value, and when you have decided how manyyou need. You just use the expression builder to setwhat kind of single control module you need to con-nect it with.

5.1 Static Object: Pipes and toggle buttonStatic object will not change during operation and arement to be object that visulize the plant object liketanks, pipes, conveyor belt and buttons. Button liketoggle or push button can be used to start the processor the plant, but nothing else.

Figure 6: Static objects, the visulizing of the HMI

5.2 Dynamic Object: Mix pumpInsert SFC Standar object, go to Properties and selectpumps, here you can choose between many differentpumps. You should pick the one that best representyour plant, and then drag and drop it into the opera-tors graphics.You can set the pump to be in automaticmode or manual mode.In the Expression Builder Animation and style youcan choose different dynamic properties and the di-mension for your dynamic symbol.

For our Mix pump we have choosen two Discretevalues and need to add expression to the colors.When the auto mode is set for the mix pump, it will

Figure 7: Dynamic object: Mix Pump

turn green. We add the expressionDiscreteValue1 (Single control modul:mix pump.auto),while in manual mode it will turnyellow. We give it the expression(Single control modul:mix pump.manual) for Dis-creteValue2.

6 Historical data and trendABB 800xa have like the other DCS system the abilityto log values. The log values are transfered to differ-ent system and different people. If the equipment needmaintenence, the managers need to see the plants ef-ficency and its assets, and all values can be presentedin a trend display. The trend display will show theoperaters different process values and therefore ableto act according to different parameters and espectedresults.

Figure 8: Historical data set-up

You need to configure the log from the controlstructure, so you can set the different values you wantto have in your trend display. And you can change

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the log type (Direct, Hierarchial, lab Data). In cool-ing reservoir we used direct log type and in the avgtemp we used hierarchial. From the log config win-dows you are also abel to change the how often youwant to collect data and how it should be prestented toyou. The first thing you have to do, is getting the rightvalue from the already created log template. And thenassign a variable for each avialable color in the trenddisplay.

Figure 9: Historical data set-up

From the function structure, you need to create anew aspect as an trend display. In the trend displayyou can customize the view of the trend signals bychanging colors and adjusting the scale to your per-sonal taste. The system can collect complex and loadsof information, and visualize it to the operators in asimple and effective manner.

7 ExperimentsWe needed to test if the expressions in the Graphic dis-play corresponded with our Control Modul. The firstjob was to build and set-up the control modul and con-nectivity. When this job was done, we started to workwith the graphic display and the start up display in theWorkspace. The first thing we check was alarm func-tion and the dynamic elements in pumps and valves.We also need to check if all values are at initial valueand the start up the system is working correctly.

Test sequence

1. Start from main and test the 30sec timer

2. Test the press code and the no additive or waxalarm

3. Testing the whole process and process restart

4. Trigger alarm

5. Test of plant graphic dispaly

8 Presentation of findingsThe first problem that occured was all of the initialvalues and levels in the tanks were set to 0, this re-sulted in that the alrms went off, when we pushed theproses stert button. So we programmed a new con-troller code, that set tank levels and temepratur to startvalues.

9 Start from main and test the 30sectimer

There was no problem with this code, the alarm forempty press was activated and the mixture pump ac-tive light changed form green to gray, when the timerreach 30 sec. The failure pump was activated becauseof the alarm, and the singel control modul like it issupposed to do when the proses aborted.

Figure 10: Test 1 mix tank alarm

Color explanation

1. Gray system switched off

2. Green system switched on

3. Yellow system in stand-by

10 Test if the press and function isworking properly

before we start with this test we have to do a coldrestart and set the candle press.high.active. The testresult was OK, and the No additive or wax alarm wasactivated after 60 sec. You can see before the alarmwas activated that the status light is green for coolingprocess, mix pump ON and that the whole process isstarted. And when the alarms is activated the failurepump was activated and no additive or wax alarm.wecould se a greeen ligth for cooling process was acti-vated and Mix pump ON. And this started the process.the alarm whent off and activated the Failure pump,and no addetive and wax alarm started.

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Figure 11: Test 2 process abored, additive and statusligth off

11 testing the whole process and pro-cess restart

This test was successfull and the candle plant didwhat we had programmed it to do. The process wasrestarted after 20 sec and the status light was switchoff and on again after the process was restarted. Someof the process variables didt behave like we had pro-grammed them to do, lik the PID function and thelevel indicators.

12 Triggering alarmsWe tested the alarms, by triggering the temperaturesto see if the process stoped. If two of three temper-ature sensor is activated in cooling reservoir the hightemperatur in cooling resrvoir will be activated. Thetest was successfull. All alarm behaved like we antic-ipated, when we changed tank levels and temperature.

13 ConclusionWhat we have learned in this project is to implementa code from the control builder into a graphic display,so it is more visual for the operator to see if any val-uas are abnormal or when an alarm is activated. Therewasnt much of a problem during the testing, but wehad som problem with the PID values and the trenddisplay. The trend display were not showing the val-ues we intended it to use it for, we had to change the

values manually to see some changes in the graph.the ABB 800xa is powerfull tool to design and imple-ment a control system for the candlelight plant, andwe learned much during this course.

AcknowledgmentThe authors would like to thank the technical staff inthe engineering department at the University of Agderfor providing the means which advanced this work.Morever, special thanks to the Industrial IT 800xa de-velopers for making it possible to implement the ob-ject oriented algorithm using the Industrial IT soft-ware.

References:

[1] R. Franke and J. Doppelhamer, “J., online appli-cation of modelica models in the industrial it ex-tended automation system 800xa,” in Proceedingsof 5th International Modelica Conference, 2006.

[2] R. Franke, B. Babji, M. Antoine, and A. Isaks-son, “Model-based online applications inthe abb dynamic optimization framework,”in Proc. of the 6th Int. Modelica Confer-ence, Bielefeld. www. modelica. org/events/-modelica2008/Proceedings/sessions/session3b1.pdf, 2008.

[3] K. John and M. Tiegelkamp, IEC 61131-3:Programming Industrial Automation Systems:Concepts and Programming Languages, Re-quirements for Programming Systems, Decision-Making Aids. Springer Verlag, 2010.

[4] D. Kristiansen and K. Lindegaard, “A frame-work for automatic testing of industrial controllercode,” in The 2006Int. Conf: Software Engineer-ing Research and Practice (SERP’06), Las Vegas,NV. Citeseer, 2006.

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