Chapter 1 Course Information

Trouble shooting and Maintenance Course
Chapter 1 Course Information and Introduction

TABLE OF CONTENTS
Chapter 1 Course Information and Introduction .................................................................................................................... 1-i

Chapter 1 Course Information and Introduction ................................................................................................................... 1-1
1.1 Name ........................................................................................................................................................................ 1-1
1.2 Duration.................................................................................................................................................................... 1-1
1.3 Description................................................................................................................................................................ 1-1
1.4 Student Profile........................................................................................................................................................... 1-2
1.5 Prerequisites.............................................................................................................................................................. 1-2
1.6 Reference Material .................................................................................................................................................... 1-2
1.6.1 Introduction ........................................................................................................................................................ 1-2
1.7 Course schedule ........................................................................................................................................................ 1-2
1.8 Lesson 1 - The Application Process Model and CB Project......................................................................................... 1-3
1.8.1 Description ......................................................................................................................................................... 1-3
1.8.2 Objectives........................................................................................................................................................... 1-3
1.8.3 The Boiler process model.................................................................................................................................... 1-3
1.8.4 The Control Builder project BOILER.................................................................................................................. 1-4
1.8.5 Process Portal A interaction ................................................................................................................................ 1-4
1.8.6 Exercise 1.1 Investigate and interact with the Boiler process ............................................................................. 1-7
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1-ii
1.1 Name
Course: Trouble shooting and maintenance course
1.2 Duration
4 days.
1.3 Description
Understand IndustrialIT architecture.
Trouble shoot and make diagnostic of locally connected I/O, Communication

Interfaces and CPU. Download correct firmware.
Add application functionality in Control Builder and Process Portal, the student is
able to test and commissioning the new functionality.
Trace signals in a Control Builder project and follow signal from I/O to a Process
Graphic display.
Backup and restore Control Builder Projects including handling of Cold Retain
values.
Trouble shoot communication between controllers.
Add a Profibus slave and be able to use Profibus diagnostic tools.
Redundant controllers and Network.
Understand the OPC communication between AC 800M controller, 3:rd party

OPC servers and Process Portal A.
Use Status Viewer as tool for checking controller status, node status and processes
in Process Portal A.
Understand and trouble shoot security problems.
Use the navigation possibilities to find object in Process Portal A.
Monitor and trouble shoot problem with Process Graphics.
Use the Import/Export tool and Backup.
Use diagnostic possibilities in window.
Collect log files for further analyses.

1-1

1.4 Student Profile

Maintenance personnel of the customer. Service engineers who maintains and trouble
shoot customer systems..
1.5 Prerequisites
The student has the know how how to use Windows 2000 and XP
Operating Systems.
Basic AC 800x programming know how. The student should be able to
handle the programming tool.
Process Portal know how. The user should be able to understand what is
object, aspects, systems and structures in Process Portal.
1.6 Reference Material

1.6.1 Introduction
The student gets this course binder. Control Builder M Professional and Process Portal
A have built in manuals in the help menu.
To order the product documentation NOT found in your course binder, contact your
local sales office or ABB headquarters.
1.7 Course schedule

Day 1
Day 2
Hardware description of Signal tracing from I/O to

AC800M and I/O
graphics
Extend an application Hardware diagnostics
Communication between
controllers
Day 3
Day 4
Profibus diagnostics
Security and Users
Redundant controller
Process Graphic
diagnostics
OPC communication
System Status
Import/Export and
Backup/Restore
Window diagnostic
Log files
1-2
1.8 Lesson 1 - The Application Process Model and CB Project

1.8.1 Description
In this chapter you will find an explanation of the Application process model, which
will be called Boiler in the rest of this course. You will also learn how the Control
Builder project BOILER is designed.
1.8.2 Objectives
On completion of this lesson you will be able to:
Describe the Boiler process model.

Understand the BOILER Control Builder project.
Interact with the project using CB and PPA.
1.8.3 The Boiler process model.

The Boiler process model consists of 2 parts. One part implements the logic of the
process to control and an other part simulates all process signals. These 2 parts are
completely separated from each other. All the supposed I/O interaction are published
as Access Variables. A the process simulation part application interacts with these
access variables and simulates responses from valves motors and temperatures.
An activation of a valve will now look like this:
1. The valve is activated by the sequence in the control application. The order
appears on a variable, which can be seen for the process simulation application.
2. The Process simulation application reads the order and with some delay it writes
the feedback to the control application.
1-3

Control Application
Feedback
Order
Simulation Application
Figure 1. 1 Interaction between Control Application and Simulation
1.8.4 The Control Builder project BOILER

The BOILER Control Builder project controls the BOILER process model.
It contains project-specific libraries, two application and one controller. The control
application presents two boilers, one boiler is implemented as function blocks and the
other boiler is implemented as control modules. The simulation application contains
code for simulation the I/O of the process. The simulation application uses MMS
communication to exchange data with the control application.
1.8.5 Process Portal A interaction

Start the Operator Workplace for your Boiler Process. Click on one of the Boilers in
order to enter one of the Boilers.
1-4
Figure 1. 2 The Boiler process in PPA.
Use the Start button to start the process sequence. Remember, all objects must be in
automatic mode in order to start the sequence. Normally only the PID must be
changed. Click on an object icon to bring up its faceplate.
1-5

Figure 1. 3 Faceplate for a ValveUni process object
Use the faceplate buttons to control the object.
Figure 1. 4 Auto / Manual button
Figure 1. 5 On / Off button
The object icon change its appearance according to its status.
Figure 1. 6 Valve icon closed / opened indication
Motor icon stop/ start indication
Figure 1. 7 Motor icon stop/ start indication
1-6
1.8.6 Exercise 1.1 Investigate and interact with the Boiler process
Please do exercise 1.1.
1-7

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Trouble shooting and Maintenance Course