T315-02 System Architecture - RevC

System 800xA Training
Chapter 2 System 800xA Architecture
TABLE OF CONTENTS
Chapter 2 System 800xA Architecture .......................................................................................................................................... 1 2.1 General Information............................................................................................................................................................. 2 2.1.1 Objectives ..................................................................................................................................................................... 2 2.1.2 Legend .......................................................................................................................................................................... 2 2.1.3 Reference Documentation............................................................................................................................................. 2 2.2 System Overview................................................................................................................................................................. 3 2.2.1 Options Grouped in Functional Areas .......................................................................................................................... 4 2.2.2 Controller Integration ................................................................................................................................................... 5 2.2.3 Use of Standards ........................................................................................................................................................... 5 2.3 Aspect Objects Concept....................................................................................................................................................... 6 2.3.1 Aspects and Objects...................................................................................................................................................... 6 2.3.2 Example of a Control Valve ......................................................................................................................................... 7 2.3.3 Intuitive Navigation ...................................................................................................................................................... 8 2.3.4 Aspect Framework........................................................................................................................................................ 9 2.4 System Topology ............................................................................................................................................................... 10 2.4.1 Domain Server ............................................................................................................................................................ 11 2.4.2 Aspect Server.............................................................................................................................................................. 11 2.4.3 Connectivity Server .................................................................................................................................................... 11 2.4.4 Application Server ...................................................................................................................................................... 11 2.4.5 Plant Network ............................................................................................................................................................. 12 2.4.6 Client/Server Network ................................................................................................................................................ 12 2.4.7 Control Network ......................................................................................................................................................... 12 2.4.8 Single Node System.................................................................................................................................................... 13 2.4.9 AC 800M Redundancy ............................................................................................................................................... 14 2.4.10 Remote (Thin) Client ................................................................................................................................................ 15 2.5 Client / Server Principle..................................................................................................................................................... 16 2.5.1 Aspect Directory......................................................................................................................................................... 16 2.5.2 Example: Graphic Display.......................................................................................................................................... 16 2.5.3 Distributed Engineering.............................................................................................................................................. 17 2.5.4 Multi-System Integration ............................................................................................................................................ 18 2.6 Configuration Wizard ........................................................................................................................................................ 19 2.6.1 How to Connect/Disconnect Clients ........................................................................................................................... 19
Chapter 2 - 1
T315-02 System Architecture - RevC
2.1 General Information 2.1.1 Objectives

On completion of this chapter you will be able to: Tell how 800xA fits into the IIT strategy Describe the network structure in an 800xA architecture Describe the functionality of the major components Explain the concept of Aspects and Objects Explain the Client/Server principles
2.1.2 Legend
> Italic Bold Indicates when you go from one menu to a sub-menu Indicates object and file names Indicates dialog box buttons, tabs, menus etc. Indicates important topics Indicates start/explanation of student activity
2.1.3 Reference Documentation

3BSE038018 3BSE041434 3BSE034463 3BSE036903 Industrial IT 800xA System System Guide Functional Description Industrial IT 800xA System System Guide Technical Data and Configuration Information Industrial IT 800xA System Automation System Network Design and Configuration Industrial IT 800xA System Basic Operation
Chapter 2 - 2
2.2 System Overview

The IndustrialIT Extended Automation System 800xA is a comprehensive process automation system. It covers operation and configuration of continuous and batch control applications. System 800xA has been developed incorporating Information Technology with the experience and know-how collected over decades of successful deliveries and customer installations.
800xA System offers more than a traditional Distributed Control System. It gives you a single application to organize and access all plant information. As expected, you have functionality like graphics, faceplates, alarm management and trending available. However, with the unique integration principles based on the Aspect Object technology, you can easily integrate information like Live Video, Documentation (using Word for example), Quality Analysis, and Maintenance Information (from SAP or Maximo for example). System 800xA provides a secure, reliable, control environment with built in security features such as access control, user authentication, and audit trail capability.
Chapter 2 - 3
2.2.1 Options Grouped in Functional Areas

The 800xA system functionality is divided into a Base System and a set of options, grouped in Functional Areas. The options represent functions that can be added to the system based on the needs of the process that should be controlled.
Operations Provides a consistent method for accessing enterprise-wide data and for interacting with multiple applications from any connected workstation in the plant or office. Engineering Integrated engineering environment supports the complete lifecycle of the automation project, from planning, through configuration and library management, to commissioning and operation to minimize system ownership costs. Safety Scalable IEC 61508 and IEC 61511 compliant SIS (Safety Instrumentation System) that spans the entire safety loop, including SIL rated field devices, I/O modules, controllers, and field actuators. Information Management Collects, stores, retrieves and presents historical, process and business data to enhance the usefulness of data from all operations. Batch Management Recipe management, batch and procedural control according ISA S88.01 Asset Optimization Assess and reports equipment conditions in real-time to optimize maintenance and calibration work flows. Control and I/O Suite of standards-based hardware and software, complimented with a full line of industrial I/O interfaces. Field Buses / Device Management Integration of intelligent field devices via all major fieldbus standards.
Chapter 2 - 4
2.2.2 Controller Integration

Controllers are integrated with the system through Connectivity packages, which are offered as options to the 800xA System. These packages provide access to real time data, historical data, and alarm & event data for instance using predefined faceplates. The 800xA System provides connectivity to 800xA controllers as well as controllers from earlier system offerings: AC 800M (default set) Advant Master AC400 & AC100 Symphony Harmony Infi-90 Symphony Melody / AC 870P Freelance / AC 800F DCI System Six MOD 300 Safeguard PLC Connect (connection to any PLC via OPC Server)
2.2.3 Use of Standards

System 800xA uses standard hardware, operating system software and protocols. This allows data to be obtained not only from ABB systems but from a variety of sources such as other brands of control systems or from lab entries. It also allows making this data available to ABB and other manufacturers systems such as historians and maintenance management programs.

Windows 2003 / XP Internet Explorer Visual Basic ActiveX Controls OPC - OLE for Process Control Microsoft Component Object Model (COM) PROFIBUS Fieldbus Foundation
Chapter 2 - 5
2.3 Aspect Objects Concept

A central problem in plant operations, as well as asset life cycle management, is the need to organize, manage, and have access to information for all different aspects of a great number of plant and process entities. The Aspect ObjectsTM architecture is a cornerstone of the IndustrialIT concept and enables enterprise wide information availability in a unified way. It provides information-centric navigation a consistent way to instantly access all information without having to know how and by which application the information is handled.
2.3.1 Aspects and Objects

The system model objects of the real process equipment or entities are called Aspect Objects. They can be physical process equipment, like a valve, or more complex, like a reactor. Other examples are: products, material, batch procedures, manufacturing orders, and customer accounts. Each of these Aspect Objects is a container of references to all information pertaining to a real object. The various types of information related to the object are called Aspects. Examples are: process graphic, faceplate, alarm, trend, report, order definition, mechanical layout etc.
Control Builder M
Control
Real Object
Model Object
Faceplate Process Portal Graphics
MS Excel Report Auto CAD Drawings
It is necessary to be able to implement these aspects using many different applications, both existing and new, from ABB, third parties and customers. These applications are called Aspect Systems and must cooperate to provide an integrated view and functionality of the object. Examples are: Graphics Builder for graphics, Auto CAD for mechanical layout, SAP for order handling etc.
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2.3.2 Example of a Control Valve

For example a valve is a real object and has many types of data associated with it. It has manufacturers specifications, mechanical drawings, a maintenance schedule and history, ordering information for parts, physical location in the plant, faceplate for operator interface, graphic symbol for display on graphics, and many other possible types of information.
Maintenance Record P & I Diagram
Control Logic Process Graphics
Product Description Control Dialog
Simulation Model
Operator Notes
Traditionally, these types of information are found in many separate systems or in many different document formats. An Aspect Object presents this data as a menu of choices accessible by right clicking on the object anywhere it appears in the system. The various types of information related to the object, in this case the valve, are called Aspects.
Chapter 2 - 7
2.3.3 Intuitive Navigation

Quick access to displays and information is provided with web browser tools. Favorites, history lists, shortcuts, and hot keys provide navigation through a process production facility quickly and accurately.
Right click on the object in the Graphic
Right click on the object in the Alarm List
Available Aspects
Use of the right mouse button provides access to additional details via a context menu. The same context menu is available, showing all aspects, independent whether you select it e.g. in the graphic display or in the alarm list.
Chapter 2 - 8
2.3.4 Aspect Framework

From a software architecture perspective, the foundation of the 800xA System is the Aspect Framework (afw). It is a software package that integrates all IndustrialIT enabled products via their Aspect Objects, irrespective of where they may reside in the network.
Batch Information Asset Field Device Management Management Optimization Integration
Other Aspect Systems
Aspect Framework / System 800xA Platform
AC800M
Advant
Harmony
Melody
Other OPC
Although the various aspects and their associated software may reside on multiple networks or computers, each Aspect Object carries with it the built-in collection of characteristics or Aspects. All aspect objects are stored in a central location called the Aspect Server. NOTE! The Aspect Framework can handle up to 200000 Aspect Objects.
Although all objects reside in this central location, data needs to be configured only once for use throughout the system. There are many Aspect Systems and thus many options for where data can be entered. There are also many places where the same data can be viewed so that generally, data can be entered and viewed where it is relevant.
Chapter 2 - 9
2.4 System Topology

The System 800xA architecture assumes a system of computers and devices that communicate with each other over different types of communication networks, as illustrated conceptually here. The Workplaces uses either dedicated client computers or combined client/server machines allowing both client and server applications to run in one PC for larger configuration.
Domain Server(s)
Application Server(s)
Workplaces Client/Server Network
Aspect Server(s)
Connectivity Server(s)
- Single - 1oo2 - 2oo3
- Single - 1oo2
Control Network Controllers
Fieldbus Field devices
System communication in the 800xA System is based on Ethernet and TCP/IP networks. Servers run software that provides system functionality, Workplaces run software that provides various forms of user interaction. NOTE! Server configuration and selection are important factors for system performance.
The 800xA system uses a central licensing mechanism. One designated computer, typically the domain controller, should contain the central licensing server (CLS).
Chapter 2 - 10
2.4.1 Domain Server

Small systems can run without a Domain Controller. In this case the nodes and users are handled by a Windows Workgroup. The configuration of users and security must then be done on all nodes separately within the Workgroup. The user handling in a Windows Domain is done from a central location the Domain Server. Every domain must have at least one domain server, but for resilience a domain should have multiple domain servers.
2.4.2 Aspect Server

The Aspect Server provides the Aspect Directory and the services related to object management, names, security, etc. It is the heart of the 800xA system. As such it must be accessible to all nodes all of the time. In small system systems the Aspect Server can be combined with other functions such as Application or Connectivity Servers in a single node (computer). The Aspect Server supports 1 out of 2 or 2 out of 3 redundancy. In 1 out of 2 redundancy, the Aspect Directory is readable and writable as long as one Aspect Server is on-line. With 2 out of 3 redundancy, two Aspect Servers must be running to write to the Aspect Directory, but with any one Aspect Server on-line, the system is useable for operation but not for configuration.
2.4.3 Connectivity Server

The Connectivity Server provides access to the controllers and other data sources throughout the network. Several groups of Connectivity Servers may exist in a system, each serving one set of data sources. The AC 800M Connectivity Server is one of many different types of Connectivity Servers in the 800xA System. Examples of services are: OPC Data Access OPC Alarm and Event OPC Historical Data Access System messages NOTE! Maximum 12 AC 800M controllers can be connected to one Connectivity Server (single or redundant).
2.4.4 Application Server

Run various types of system applications, such as: Batch Management Asset Optimization
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2.4.5 Plant Network

The Plant network can be dedicated for process automation purposes or be a part of the plant intranet already available on a site. Further connection of the Plant network to the Internet or any other type of external network should be performed in accordance with adequate network security practices.
2.4.6 Client/Server Network

The Client/Server network is used for communication between servers, and between client workplaces and servers. Via a router, the Client/Server network can be connected to a plant intranet, and via a firewall to the Internet. For performance and integrity reasons, connection of foreign systems directly to the Control and Client/Server networks should be avoided. The Client/Server network can optionally be made redundant. For any installation larger than a Single Node system and small systems that use Windows Workgroup, the 800xA system nodes must reside within a dedicated Windows 2000 Domain. This requires you to set up a domain controller and DNS server. All other 800xA System server and client nodes must be configured to be members of the domain.
2.4.7 Control Network

The Control network is a local area network (LAN) optimized for high performance and reliable communication, with predictable response times in real time. It is used to connect controllers to the servers. Controllers are nodes that run control software. Controllers and Connectivity Servers are connected to the Control network. The Control network can optionally be made redundant. Field buses are used to interconnect field devices, such as I/O modules, smart sensors and actuators, variable speed drives, PLCs, or small single loop devices, and to connect these devices to the system, either via a controller or directly to a server.
NOTE!
For smaller systems and for systems where network separation is not desired, the Client/Server Network and Control Network can be combined in one Automation System Network.
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2.4.8 Single Node System

A Single Node System is intended for very small applications, where all 800xA server and workplace functionalities reside in a single PC.
Aspect Server Connectivity Server Workplace (Client)
Automation Network Controllers
The system has only one node, within which all servers as well as the client applications are installed. Only a few controllers can be connected.
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2.4.9 AC 800M Redundancy

System 800xA provides the highest degree of fault tolerance to meet the most demanding application needs for maximum system uptime. Optionally redundant I/O, controllers, control networks, FieldBus networks, Connectivity Servers, Aspect Servers, and Operator Workplaces are available with automatic switchover.
Control Network Upper CPU CEX-Bus ProfiBus DP RCU Link ProfiBus DP-V1 CEX-Bus
Lower CPU
ModuleBus Optic Cable
Redundant ModuleBus Solution Redundant I/O Module
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2.4.10 Remote (Thin) Client

Remote Clients enables remote access to an 800xA system from a standard PC without ABB-specific software installed. Only the Internet Explorer is required to access the data. The Remote Client provides operation capabilities and access to historical information. Configuration capabilities are limited on the remote client.
Internet
Thin Clients
Firewall Thin Clients
Router Firewall
Citrix Server(s)
Application Server(s)
Workplaces Client/Server Network
Aspect Server(s)
Connectivity Server(s) Control Network
Controllers
The remote client functionality is achieved using Windows Terminal Services in an application server node. This node is sometimes called the Remote Client server node. Optionally these services can be provided using a Citrix server as shown in the example above.
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2.5 Client / Server Principle 2.5.1 Aspect Directory

The Aspect Framework includes an Aspect Directory, where all aspect objects and their aspects are registered, and also all aspect systems and the operations they support.
Client Application
1 2 Aspect Framework
Aspect Directory
3 Process Graphics
4 Reports
5 etc.
Control
Aspect Systems
To perform an operation on an aspect object, an application (i.e. an Aspect System) retrieves an interface for that operation from the framework.
2.5.2 Example: Graphic Display

Lets take a process graphic as an example. The aspect Graphic display is installed on the Aspect Server and will be called by the Operator Workplace.
Aspect System Graphic Display
Client Operator Workplace(s)

ig nf Co
da ta
on ati ur
Re al -ti m
Client/Server Network
ta da
Aspect Server(s)
Aspect Directory
Control Network
If we look then on a valve within the process display, the icon is provided by the Aspect Server and the dynamic status indication (open/closed) is provided by the Connectivity Server.
Chapter 2 - 16
2.5.3 Distributed Engineering

The 800xA System supports distributed engineering: Off-Site Engineering In an off-site environment, engineering tasks may be performed off-line in an isolated manner from other users. When the off-site tasks are completed, the user modifications can be applied to the on-line system through the export/import features. On- Site Engineering The on-site Engineering Environment is used for final testing of applications before introducing them into the Production Environment, and for changes and additions occurring once the Production System is in operation.
Engineering Environment
Data Exchange
Production Environment
The import/export feature allows for selective transfer of configuration data between systems. In addition, it is possible to compare configuration data between the different systems and create reports on the differences.
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2.5.4 Multi-System Integration

System 800xA SV5 SP1 will support multiple 800xA Systems. Multi-System integration makes it possible to view and operate objects configured in one 800xA System from another 800xA System. Geographically separate 800xA systems with local control rooms to be controlled from a common control room Sectioning of multiple line processes to increase integrity and simplify maintenance Making staged commissioning without interfering with running processes possible
Central Control Room
Subscriber
System D
Local Control Rooms
System A
Provider
System B
Provider
System C
Provider
NOTE!
Only AC 800M controllers are supported in Provider System(s) with SV5.0 SP1
Chapter 2 - 18
2.6 Configuration Wizard

The Configuration Wizard is the central place to: Create/Delete an 800xA System Start/Stop an 800xA System Add extensions to the 800xA System Connect/Disconnect clients and servers
2.6.1 How to Connect/Disconnect Clients

Clients as well as servers can be connected /disconnected from the Aspect Server only. To connect a client, follow these steps: 1. Double click on the icon Configuration Wizard on the desktop. 2. Select System Administration and click Next.
3. Select your system and click Next.
Chapter 2 - 19
4. Select Nodes and click Next.
5. From the next menu you can add/remove clients and servers.
NOTE!
Refer to the separate course T305 Administration and Installation for more information.
Chapter 2 - 20

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