# Candle Plant process automation based on ABB 800xA Distributed Control Systems

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2 Figure 1: Process description of a candle making process. Figure 3: Example for a Function Block Diagram, Source: Design of control system - Industrial design of Control systems by Yousef Iskandarani functions are available. The execution order of the function blocks is defined at first by the order of their creation. It is graphically represented by the order of the boxes in FBD (from the left to the right and from the top to the bottom). It is also possible to change the order by drag and drop. Some examples of possible functions inside a single function block are given in figure 2. In figure 3 an example for a simple Function Block Diagram process is shown. Figure 4: Example for a Ladder Logic. is constructed by placing several (minimum two) variables in series (like in an electrical circle). On the other hand the OR function is exposed by placing two or more variables in parallel. This RLL code represents the following Boolean expression: q 1 = (u 1!u 3 + q 1 )!q 2 u 2 (1) 3.3 Instruction List (IL) Figure 2: Arithmetic operator, Source: ABB T Function Block Diagram - RevA 3.2 Relay Ladder Logic (RLL) A RLL program consists of a several number of rungs and connections (lines). The inputs are only binary. The logical functions AND, OR and NOT are represented by the symbols:.+!. Thus a RLL code is considered as a graphical description of a Boolean statement, as illustrated in figure 4. [2] The output variable of the equation is represented by a circle. The inputs are represented by pairs of two parallel bars. A diagonal line between the bars indicates the variable as NOT. The AND function Instruction List (IL) or also Statement List (STL - Siemens) is a low level programming language. The variables and function call are defined by the common elements so different languages can be used in the same program. This simple example represents the following Boolean expression: ST2 = (ST1 OR T4 OR T5) AND T1. A( O ST1 O T4 O T5 ) AN T1 = ST2 3.4 Structured Text (ST) One of the opportunities of writing a Code in ABB is the Structured Text (ST) - Code. It is very easy to read and understand due to its logical and structured layout. It contains a broad range of possible features for assignments, expressions, conditional statements, iterations and more. ISBN:

4 Figure 7: Single Control Module in the application structure. connected to the variables of the single control module. You can see how to do this in figure 8. Figure 9: ABB800xa. Overview of the workflow with the Figure 8: Connection between Control Modules. 5 ABB800XA Now we finished all the basic preparation and we are able to start with the real engineer work. Therefor we begin with the Plant Explorer like My eplant from ABB where we are able to administrate all our control systems. It is the origin from where each action happens. To maintain a good overview over your control systems and their objects, My eplant uses different structures for controls, functions and libraries. After creating a new control network and in it a new control project it is possible to go on with the Project Explorer like ABBs Control Builder M. Control Builder is used to create new hardware, to build up libraries and applications, to set task connections, to simulate applications and much more. The first step is to include all the libraries which are needed for implementing the process. ABB already provides lots of useful libraries. If specific elements are necessary, you have the option to create your own libraries as mentioned in section VII. Subsequently we continue with the applications. An application includes programs and control modules which contain the executable code (section VIII on page 4). It is important to connect to all the libraries which are used in the application. Furthermore we have to create a controller in the menu item Controllers. We can connect the application to the controller on which it should run. 6 Runtime Setup Once we included all the required libraries it is necessary to create applications. One controller can run different applications which include programs as well as control modules. While a program is the traditional way of executing a code, it has many advantages to use control modules. They are much faster and get along with less memory. The opportunity to choose between five coding languages of the ICE standard is given in both cases. The possibility to create own libraries, function blocks and control modules is one of ABB s most significant benefits. These components are the fundament for ABB s object orientation. [4] [1] [4] [?] Basically are control modules similar to data types, but control modules do not just include a structure of basic data types, they also contain ISBN:

6 Now it is possible to go through the program step by step and verify if everything works the right way and does not cause any problems. We are able to change the values of variables and parameters and to test and verify each Control Module separately. The next two figures show a testing situation in our program. If the temperature sensor T1 measures a temperature with 85 C or less the process should hold on until the temperature rises over 85 C. Then the mixture pump should go on and pump the liquid from the candlemix tank to the candle press. The Control Builder supports all the five IEC standard languages. In the control builder all relevant data types like Booleans, integers, floating point numbers, etc. are supported. Programs can be developed off line and execution simulated without having a controller connected. Projects in Control Builder contain one or several applications. Each of these applications contains a set of programs and control modules. Program code, functions, Function Blocks and Control Modules can be placed freely in any of these. The users are able to create their own data, function-block and control module types. The possibility to create Control Modules provides a powerful concept for establishing often used functions and processes into the control loop. Control Modules can include program codes, visual representations, interaction, etc. The objects are stored in libraries and therefore ready for re-use in current and future applications. Figure 12: Testing of the mixture pump 1 The opportunity to create a Human Machine Interface (HMI) provides an easy visualization for every implementation. Another advantage is the simulation of the whole control system without any hardware. Thus, it is possible to guarantee a safe and reliable program for the final application. References: [1] Industrial it - compact control builder ac 800m - basic control software - introduction and configuration. volume 5. ABB. Figure 13: Testing of the mixture pump 1 10 Conclusion Process automation has been implemented successfully uisng Object Oriented method. The following has been implemented using the 800xA Industrial IT software from ABB. The Control software is objective oriented in a structured way, which means that changes made to an object type or instance, only affects that type or that instance only. Therefore ABB 800xa Control Software is very adequate for applications of huge industrial processes and complex control loops. [2] A. Falcione and B.H. Krogh. Design recovery for relay ladder logic. Control Systems Magazine, IEEE, 13(2):90 98, [3] Yousef Iskandarani. Design of control system - setting up projects in 800xa - the art of graphical design. human machine interface using abb 800xa. University of Agder, [4] David M. Robinson. Digital system design with control modules. University of Delaware, Newark, Delaware. ISBN:

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