3bus208222 4.0 en industrial it quality control theory of operation guide

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Industrial IT Quality Control 4.0

powered by 800xA extended automation

Theory of Operation Guide

System Version 4.0

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NOTICE

The information in this document is subject to change without notice and should not beconstrued as a commitment by ABB. ABB assumes no responsibility for any errors that mayappear in this document.

In no event shall ABB be liable for direct, indirect, special, incidental or consequentialdamages of any nature or kind arising from the use of this document, nor shall ABB be liablefor incidental or consequential damages arising from use of any software or hardwaredescribed in this document.

This document and parts thereof must not be reproduced or copied without written permissionfrom ABB, and the contents thereof must not be imparted to a third party nor used for anyunauthorized purpose.

The software or hardware described in this document is furnished under a license and may be

used, copied, or disclosed only in accordance with the terms of such license.

This product meets the requirements specified in EMC Directive 89/336/EEC and in LowVoltage Directive 72/23/EEC.

Copyright 2005 ABB

All rights reserved.

Release: January 2005

Document Number: 3BUS208222 R4001

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TRADEMARKS

Registrations and trademarks used in this document include:

Windows is a registered trademark of Microsoft Corporation.

Acrobat Reader is a registered trademark of Adobe Systems Inc.

IndustrialITis a trademark of ABB.

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About This Book

GeneralThis book describes the theory of operation and troubleshooting tools and procedures for

Industrial IT Quality Control 4.0. The targeted audience includes ABB Project and Service

engineers. The user of this guide is expected to have experience with ABB IndustrialIT

products and the Industrial IT Quality Control 4.0 and to have attended the appropriate

training courses.

Intended User

Use of Warning, Caution, Information, and Tip Icons

This publication includes Warning, Caution, and Information where appropriate to point outsafety related or other important information. It also includes Tip to point out useful hints tothe reader. The corresponding symbols should be interpreted as follows:

Electrical warning icon indicates the presence of a hazard, which could result in electricalshock.

Warning icon indicates the presence of a hazard, which could result in personal injury.

Caution icon indicates important information or warning related to the concept discussed inthe text. It might indicate the presence of a hazard, which could result incorruption ofsoftware or damage to equipment/property.

Information icon alerts the reader to pertinent facts and conditions.

Tip icon indicates advice on, for example, how to design your project or how to use a certainfunction.

Although Warninghazards are related to personal injury, and Cautionhazards are associatedwith equipment or property damage, it should be understood that operation of damagedequipment could, under certain operational conditions, result in degraded process

performance leading to personal injury or death. Therefore, comply fully with all Warningand Cautionnotices.

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Document Conventions

The following conventions are used for the presentation of material:

1. The words in names of screen elements (for example, the title in the title bar of a window, thelabel for a field of a dialog box) are initially capitalized.

2. Capital letters are used for the name of a keyboard key if it is labeled on the keyboard. Forexample, press the ENTER key.

3. Lowercase letters are used for the name of a keyboard key that is not labeled on the keyboard. Forexample, the space bar, comma key, and so on.

4. Press CTRL+C indicates that you must hold down the CTRL key while pressing the C key.In this case, CTRL+C copies the selected object.

5. Press ESC E C indicates that you press and release each key in sequence. In this case, ESC EC copies the selected object.

6. The names of push and toggle buttons are boldfaced. For example, click OK.

7. The names of menus and menu items are boldfaced. For example, the File Menu.

8. The following convention is used for menu operations: MenuName > MenuItem >CascadedMenuItem. For example: select File > New > Type.

9. The Start menu name always refers to the Start menu on the Windows Task Bar.

10. System prompts or messages are shown in the Courier font. For example, if the user enters a valueout of range, the system might reply with the following message:

Entered value is not valid. The value must be 0 to 30.

11. User responses or inputs are shown in the boldfaced Courier font. For example, a user may berequired to enter the string TIC132 in a field. The string is shown as follows in the procedure:

TIC132

12. Variables are shown using lowercase letters.

sequence name

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Terminology

The following is a list of terms associated with the Theory of Operation Guide that youshould be familiar with. The list contains terms and abbreviations that are unique to ABB orhave a usage or definition that is different from standard industry usage.

Term Description

ActiveX Microsoft standard for integration of user interface components, based ondefinition of software interfaces.

Aspect An aspect is a description of some properties of a real world entity. Theproperties described could be mechanical layout, how the object iscontrolled, a live video image, name of the object etc. In the AspectIntegrator Platform is an aspect residing in an Aspect Object. Someexamples are circuit diagram, process display, and control logic.

Aspect Objects A computer representation of a real world entity like a pump, a valve, anorder or a virtual object like a service. This computer representation isimplemented by the Aspect Integrator Platform. An Aspect Object works likean information container for its aspects.

Aspect Server PC server that hosts the various QCS Object/Aspects and serves as theprimary gateway to external aspects systems.

ConnectivityServer

PC server that hosts MeasureIT

and ControlIT

applications and serves asthe primary connection between the QCS LAN and the outside world.

IndustrialIT IndustrialITis ABBs solution, that creates a business enterprise where yourplant automation, asset optimization, and collaborative business systemsare seamlessly linked in real time.

Industrial ITQuality Control 4.0

ABBs Quality Control Solution consisting of MeasureIT

Scanners/Sensors,Control

ITcontrollers (AC450, AC800M, and/or PC), Profile

ITactuators,

OperateIT

Process Portal consoles, and MeasureIT

/ControlIT

softwareapplications. Integrated with Pulp and Paper Making Suite 3.0.

Node A computer communicating an a network e.g. the Internet, Plant, Control orIO network. Each node typically has a unique node address with a formatdepending on the network it is connected to.

OPC An application programming interface defined by the OPC Foundation. Thestandard defines how to access large amounts of real-time data between

applications. The OPC standard interface is used betweenautomation/control applications, field system/devices and business/officeapplications.

OperateIT The name for the collection of products for daily operation and supervisionof an automated process.

Plant Explorer An application that is used to create, delete and organize Aspect Objectsand Aspects within the Aspect Integrator Platform. The plant explorerorganizes the Aspect Objects in structures of the plant.

Process Portal A Product containing functionality for efficient control and supervision of anautomated process. Key functions are presentation of process graphics,

process dialogs and presentation of alarms and trends.

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Term Description

Property A data field on an aspect on Aspect Object that can be accessed throughOPC using the standard Aspect Object reference syntax. A data field on anActiveX control accessible from the Visual Basic editor.

Structure A hierarchical tree organization ofAspect Objects. Each structure is used todefine a certain kind of relation between Aspect Objects. The functionalstructure for example, defines how a function can be divided into subfunctions, the location structure defines how different objects are executedby tasks, controllers etc. AnAspect Object can be located in severalstructures, for example both in a functional structure and in a locationstructure.

View AnAspect can have several ways to be presented depending on the taskperformed, like viewing or configuration. Each presentation form is called aview.

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Abbreviations

Term Description

CD Compact Disk

CPU Central Processing Unit

DHCP Dynamic Host Configuration Protocol

DNS Domain Name Server

DPI Dots per inch

GB GB Gigabyte

IP address Internet Protocol address

MB Megabyte

Mbps Megabits per second

MHz Megahertz

NetBIOS Network Basic Input Output System

NTFS NT File System

OEM Original Equipment Manufacturing

OPC OLE for Process Control

OLE Object Linking and Embedding

OS Operating System

PC Personal Computer

RAM Random Access Memory

SCSI Small Computer System Interface

SVGA Super Video Graphics Adapter

TCP/IP Transmission Control Protocol/Internet Protocol

WINS Windows Internet Name Services

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Table of Contents

CHAPTER 1 THEORY OF OPERATION ................................................................... 23

1.1 Overview .............................................................................................................................23

1.2 Physical Architecture .........................................................................................................231.2.1 Devices...................................................................................................................23

1.3 Software Package Deployment..........................................................................................24

1.4 Application Architecture ...................................................................................................251.4.1 Startup and Shutdown............................................................................................25

Client Connectivity ................................................................................................261.4.2 Quality Control PC Applications...........................................................................271.4.3 Scanners, Sensors and Advanced Scanning...........................................................27

Operation ...............................................................................................................28Configuration and Startup......................................................................................32

1.4.4 Production Accumulation ......................................................................................321.4.5 Reporting ...............................................................................................................33

1.5 Networking..........................................................................................................................33

1.6 Job Order Configuration...................................................................................................331.6.1 Overview................................................................................................................331.6.2 Database.................................................................................................................331.6.3 Configuration File Generation ...............................................................................34

Overview................................................................................................................34

XSLT Transforms ..................................................................................................34Main.xslt ................................................................................................................34DirectStruct.xslt .....................................................................................................35

1.6.4 Configuration File Deployment .............................................................................39Overview................................................................................................................39Graphical User Interface ........................................................................................40Directory structure at configuration Tool PC ........................................................40Destination Directory Structure .............................................................................42Actions ...................................................................................................................44

1.6.5 Troubleshooting .....................................................................................................44

General ...................................................................................................................44Configuration File Deployment .............................................................................44

1.7 OPC Server .........................................................................................................................451.7.1 Overview................................................................................................................451.7.2 Role of OPC...........................................................................................................451.7.3 Data Dictionary......................................................................................................451.7.4 Publishing ..............................................................................................................45

1.8 OPC Transporter ...............................................................................................................47

1.9 OPC Direct IT ......................................................................................................................471.9.1 Overview................................................................................................................47

1.10 Tag Lookup.........................................................................................................................47

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1.10.1 Overview................................................................................................................471.10.2 Usage......................................................................................................................501.10.3 Configuration .........................................................................................................50

Startup.xml.............................................................................................................50HSI server XML file ..............................................................................................52

HSI tags XML file .................................................................................................53Revision ID (RevID)..............................................................................................54

1.10.4 Troubleshooting .....................................................................................................54Task Manager ........................................................................................................55Debug Message Viewer (ABB Debug Client).......................................................55Windows Event Viewer .........................................................................................55OPC Direct IT View................................................................................................55OPC Inspector........................................................................................................55TagLookUp Viewer ...............................................................................................55

1.11 Startup Engine....................................................................................................................57

1.11.1 Overview................................................................................................................571.11.2 Usage......................................................................................................................571.11.3 Configuration .........................................................................................................57

1.12 System Status Reporting....................................................................................................571.12.1 Overview................................................................................................................571.12.2 Configuration .........................................................................................................57

1.13 DCOM .................................................................................................................................581.13.1 Overview................................................................................................................581.13.2 Usage......................................................................................................................581.13.3 Configuration .........................................................................................................58

CHAPTER 2 ASPECTS AND OBJECTS................................................................... 60

2.1 Overview .............................................................................................................................60

2.2 Object Type Structure .......................................................................................................60

2.3 Aspect categories and Filtering.........................................................................................60

2.4 Quality control aspect functionality .................................................................................61

2.5 Process Graphics ................................................................................................................622.5.1 Overview................................................................................................................622.5.2 Tag Lookup............................................................................................................62

2.6 Grade Code Handling ........................................................................................................622.6.1 Overview................................................................................................................622.6.2 Usage......................................................................................................................622.6.3 Configuration .........................................................................................................62

2.7 Coldstart File Handling .....................................................................................................622.7.1 Overview................................................................................................................622.7.2 Usage......................................................................................................................622.7.3 Configuration .........................................................................................................62

2.8 MD Control .........................................................................................................................62

2.8.1 Overview................................................................................................................622.8.2 Configuration .........................................................................................................63

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2.11.1 Overview................................................................................................................912.11.2 Application Framework Dependencies..................................................................91

ABB QCS Service..................................................................................................91OPC Publishing......................................................................................................92OPC Transporter Service .......................................................................................92

TagsLookup ...........................................................................................................92ABB HealthWatch .................................................................................................94

2.11.3 Configuration .........................................................................................................94Required Job Order Information ............................................................................94Deployment Directory Structure............................................................................95XML Documents ...................................................................................................95

2.11.4 Interface to Dependent Application.......................................................................962.11.5 Verify Configuration and Operation......................................................................96

QC Server Node.....................................................................................................96Process Portal Functional Structure .......................................................................98Error/Event Log File ..............................................................................................98

2.12 CD Actuator Agent.............................................................................................................992.12.1 Overview................................................................................................................992.12.2 Application Framework Dependencies..................................................................99

ABB QCS Service..................................................................................................99OPC Publishing....................................................................................................100OPC Transporter Service .....................................................................................100TagsLookup .........................................................................................................101

2.12.3 Configuration .......................................................................................................101Required Job Order Information ..........................................................................101Deployment Directory Structure..........................................................................103

XML Documents .................................................................................................1042.12.4 Interface to Dependent Application.....................................................................1052.12.5 Verify Configuration and Operation....................................................................105

QC Server Node...................................................................................................105Process Portal Functional Structure .....................................................................107Error/Event Log File ............................................................................................108

CHAPTER 3 TROUBLESHOOTING........................................................................ 110

3.1 Quality Control Diagnostics Aspect................................................................................1103.1.1 Configuration .......................................................................................................110

3.2 Debug Message Viewer ....................................................................................................111Key.......................................................................................................................111

3.2.2 Application Menu ................................................................................................112Mode ....................................................................................................................112Activity ................................................................................................................113

3.3 Windows Event Viewer....................................................................................................114

3.4 System Status Viewers .....................................................................................................1143.4.1 Quality Control Status Viewer.............................................................................1143.4.2 Nodes Status Viewer............................................................................................115

3.4.3 AC800M Controller Status Viewer .....................................................................1153.5 License Viewer..................................................................................................................115

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3.6 Task Manager...................................................................................................................116

3.7 OPC Inspector ..................................................................................................................117

3.8 OPC Direct ITViewer.......................................................................................................1173.8.1 Top Window - Active OPC Server Monitors ......................................................118

3.8.2 Bottom Window Active Data Points.................................................................1193.9 Control Builder.................................................................................................................121

3.10 Measurement Spreadsheets .............................................................................................121

3.11 Service Workstation .........................................................................................................121

3.12 Performance Monitor ......................................................................................................121

3.13 Collecting Information for Technical Support..............................................................1213.13.1 Information to Collect..........................................................................................1213.13.2 How To ................................................................................................................122

Screen Captures ...................................................................................................122Debug Message Viewer Contents ........................................................................122Event Log Contents .............................................................................................122

3.14 Trouble Shooting Flowcharts ..........................................................................................123

APPENDIX A. OPC TRANSPORTER ........................................................................ 128

A.1 Introduction ......................................................................................................................128A.1.1Purpose ......................................................................................................................128A.1.2Overview ...................................................................................................................128A.1.3Limitations, Restrictions, Caveats.............................................................................128

A.1.4XML Basics...............................................................................................................128A.2 Transporter File ...............................................................................................................129

A.2.1File Content ...............................................................................................................129A.2.2Element Definitions...................................................................................................130

........................................................................................................130 & ............................................................................131................................................................................................................131 ..............................................................................................................132 & .............................................................................................133 ...............................................................................................................133.............................................................................................................134 ........................................................................................................134..........................................................................................................135.......................................................................................................136 .......................................................................................................137 .........................................................................................................138 .........................................................................................................139 & ..................................................................................140 & .................................................................................141 ...................................................................................................................142 ...............................................................................................................144

A.2.3Data References.........................................................................................................145Variable Name .....................................................................................................145

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Data Type.............................................................................................................146Arrays...................................................................................................................146

A.2.4Transporter Programming Language.........................................................................146Comments ............................................................................................................146Declarations .........................................................................................................146

Arithmetic Expressions........................................................................................147Assignment Statement .........................................................................................148If Statement..........................................................................................................148Select Statement...................................................................................................148Example Element......................................................................................149

A.3 Operation ..........................................................................................................................149A.3.1Invocation..................................................................................................................149A.3.2Error recording ..........................................................................................................150

Event Log.............................................................................................................150Debug modes .......................................................................................................150

A.3.3Error recovery............................................................................................................151A.4 Document Type Definition...............................................................................................152

A.5 TPL Formal Definition ....................................................................................................154A.5.1 ::= ............................................................154

APPENDIX B. ACTIVEX CONTROLS LIST ............................................................... 156

B.1 Introduction ......................................................................................................................156

B.2 ActiveX Controls ..............................................................................................................156

APPENDIX C. TAGLOOKUP ACTIVEX CONTROLS ................................................ 163C.1 Introduction ......................................................................................................................163

C.2 ABB Auto Grid .................................................................................................................163C.2.1Introduction ...............................................................................................................163C.2.2Functionality..............................................................................................................163

Supported Data Types..........................................................................................163Visual Appearance ...............................................................................................163Scalar AttriIDs only .............................................................................................163Array AttriIDs only..............................................................................................164Mixed scalar and array AttriIDs ..........................................................................164

Mixed AttriIDs within a TagID ...........................................................................164User Interface.......................................................................................................165Show OPC Tag ....................................................................................................166Set Decimal Places...............................................................................................166Export to Excel ....................................................................................................166Copy Data to Clipboard .......................................................................................166OperateIT context extension................................................................................166

C.2.3XML Configuration...................................................................................................167XML Keywords ...................................................................................................167Example Configuration........................................................................................168

C.2.4Dependencies.............................................................................................................169

C.3 ABB Auto Plot ..................................................................................................................169

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C.3.1Introduction ...............................................................................................................169C.3.2Functionality..............................................................................................................170

Supported Plot Types and Data Requirements ....................................................170User Interface.......................................................................................................178Display Options Dialog .......................................................................................180

Rulers ...................................................................................................................182Zooming and Scrolling ........................................................................................182Stacking and Merging Plots .................................................................................183Rearranging Plots.................................................................................................184

C.3.3XML Configuration...................................................................................................184XML Keywords ...................................................................................................184Example XML Configuration..............................................................................188

C.3.4Dependencies.............................................................................................................189

C.4 ABB Command Button....................................................................................................190C.4.1Introduction ...............................................................................................................190

C.4.2Functionality..............................................................................................................190Basic XML Structure ...........................................................................................190Properties .............................................................................................................190

C.4.3DisplayType...............................................................................................................190C.4.4NumberOfButtons......................................................................................................191

XML Key Word...................................................................................................191C.4.5RevID.........................................................................................................................191C.4.6HelpID .......................................................................................................................191C.4.7Resource ....................................................................................................................192C.4.8Request ......................................................................................................................192C.4.9State ...........................................................................................................................192

C.4.10Confirm, ConfirmRes ..............................................................................................192C.4.11Writable, NotWritable .............................................................................................193

Right Click Menu.................................................................................................193C.4.12Show OPC Tag ........................................................................................................193C.4.13XML Keywords.......................................................................................................195C.4.14Example of XML File..............................................................................................196

C.5 ABB Indicator Control ....................................................................................................196C.5.1Introduction ...............................................................................................................196C.5.2Functionality..............................................................................................................197

Basic XML Structure ...........................................................................................197

C.5.3XML Key Word.........................................................................................................197C.5.4RevID.........................................................................................................................197C.5.5HelpID .......................................................................................................................197C.5.6Resource ....................................................................................................................198C.5.7Value..........................................................................................................................198C.5.8IndBackColor, IndForeColor.....................................................................................198C.5.9ReverseFlag ...............................................................................................................198

Right Click Menu.................................................................................................199C.5.10Show OPC Tag ........................................................................................................199C.5.11Example of XML File..............................................................................................199

C.6 ABB CD Mapping Control ..............................................................................................200C.6.1Introduction ...............................................................................................................200

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C.6.2Functionality..............................................................................................................200C.6.3RevID.........................................................................................................................200C.6.4HelpID .......................................................................................................................201C.6.5Resource ....................................................................................................................201C.6.6Confirm, ConfirmRes ................................................................................................201

C.6.7Writable, NotWritable ...............................................................................................201Right Click Menu.................................................................................................202

C.6.8Show OPC Tag ..........................................................................................................202C.6.9XML Keywords.........................................................................................................202C.6.10Example of XML File..............................................................................................203

C.7 ABB Enhanced Auto Grid Control.................................................................................204C.7.1Introduction ...............................................................................................................204C.7.2Tags XML..................................................................................................................205

Basic Structure .....................................................................................................205Attribute Key Words............................................................................................206

3.14.2 Event KeyWords..................................................................................................214C.8 ABB Tag Lookup Selector Control.................................................................................216

C.8.1Introduction ...............................................................................................................216C.8.2Tags XML..................................................................................................................216

Basic Structure .....................................................................................................216Attribute Key Words............................................................................................217

C.8.3Example.....................................................................................................................218XML.....................................................................................................................219

C.9 ABB AC800 Auto Grade Change Button.......................................................................221C.9.1Introduction ...............................................................................................................221

C.9.2Functionality..............................................................................................................221C.9.3XML Key Word.........................................................................................................221C.9.4Example Of XML File...............................................................................................222

C.10 ABB AC800 Auto Grade Change Current Info ............................................................222C.10.1Introduction .............................................................................................................222C.10.2Functionality............................................................................................................222C.10.3XML Key Word.......................................................................................................222C.10.4Example Of XML File.............................................................................................223

C.11 ABB AC800 Auto Grade Change Previous....................................................................224C.11.1Introduction .............................................................................................................224C.11.2Functionality............................................................................................................224C.11.3XML Key Word.......................................................................................................224C.11.4Example Of XML File.............................................................................................224

C.12 ABB OPC Tag AGC Level 1 Control .............................................................................225C.12.1Introduction .............................................................................................................225C.12.2Functionality............................................................................................................225C.12.3XML Key Word.......................................................................................................225C.12.4Example Of XML File.............................................................................................227

C.13 ABB OPC Tag AGC Level2 Control ..............................................................................228

C.13.1Introduction .............................................................................................................228C.13.2Functionality............................................................................................................229

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C.13.3XML Key Word.......................................................................................................229C.13.4Example Of XML File.............................................................................................231

C.14 ABB OPC Tag Level 1 singleline ....................................................................................232C.14.1Introduction .............................................................................................................232C.14.2Functionality............................................................................................................233C.14.3XML Key Word.......................................................................................................233C.14.4Example Of XML File.............................................................................................235

C.15 ABB OPC Tag Level 1 grid .............................................................................................235C.15.1Introduction .............................................................................................................235C.15.2Functionality............................................................................................................236C.15.3XML Key Word.......................................................................................................236C.15.4Example Of XML File.............................................................................................238

C.16 ABB OPC Tag Level 1 Vertical ......................................................................................239C.16.1Introduction .............................................................................................................239

C.16.2Functionality............................................................................................................240C.16.3XML Key Word.......................................................................................................240C.16.4Example Of XML File.............................................................................................242

C.17 ABB OPC Tag Level 2 singleline ....................................................................................242C.17.1Introduction .............................................................................................................242C.17.2Functionality............................................................................................................243C.17.3XML Key Word.......................................................................................................243C.17.4Example Of XML File.............................................................................................246

C.18 ABB OPC Tag Level 2 grid .............................................................................................246C.18.1Introduction .............................................................................................................246

C.18.2Functionality............................................................................................................246C.18.3XML Key Word.......................................................................................................246C.18.4Example Of XML File.............................................................................................249

C.19 ABB OPC Tag Speed Control .........................................................................................250C.19.1Introduction .............................................................................................................250C.19.2Functionality............................................................................................................250C.19.3XML Key Word.......................................................................................................250C.19.4Example Of XML File.............................................................................................253

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List of Figures

Figure 1-1 Example system architecture ............................................................................................24Figure 1-2 Software component architecture with example installation components ........................ 25Figure 1-3 Quality Control Application Architecture Overview............................................................ 26Figure 1-4 Main.xslt flow chart ............................................................................................................ 35Figure 1-5 Batch file location for Job Order configuration ..................................................................40Figure 1-6 After configuring system chose Deploy Job button ...........................................................40Figure 1-7 Directory structure on configuration tool PC .....................................................................40Figure 1-8 - Quality Control Object Server Overview .........................................................................46Figure 1-9 Tag Lookup flowchart on server........................................................................................49Figure 1-10 Tag Lookup on client ....................................................................................................... 50Figure 1-11 Tags XML Information Pop-up contains tag look-up information for the system............ 56Figure 1-12 Scanner Object Setup ..................................................................................................... 58Figure 2-1 Object Type Structure example.........................................................................................60Figure 2-2: Example of MD Project Create Tool Message for Variable Name Discrepancy.............. 65Figure 2-3: Example of Status Viewer ................................................................................................ 66

Figure 2-4: Example of MD Objects in Functional Structure ..............................................................66Figure 2-5: Example of MD Objects in Control Structure ...................................................................67

Figure 2-6: Simulation Configuration .................................................................................................. 68Figure 2-7: Example Faceplate...........................................................................................................68Figure 2-8: Example Right Click Menu ...............................................................................................69Figure 2-9: CD control job order configuration tab ............................................................................75Figure 2-10: ABB Debug Client for startup of CD control..................................................................80Figure 2-11: Status viewer example for CD control...........................................................................81Figure 2-12: Functional structure example for CD Control................................................................81Figure 2-13: CD control job order configuration tab with CD Coat Weight as an option for the CD

Type............................................................................................................................................85Figure 2-14: ABB Debug Client for startup of CDCTW......................................................................89Figure 2-15: Status viewer example for CDCTW............................................................................... 90

Figure 2-16: CD control job order configuration tab with LVC checkbox...........................................94Figure 2-17: ABB Debug Client for startup of LVC............................................................................98Figure 2-18: Status viewer example for LVC .....................................................................................98Figure 2-19: CD actuator agent job order configuration tab .............................................................103Figure 2-20: ABB Debug Client for startup of CD actuator agent.................................................... 107Figure 2-21: Status viewer example for CD actuator agent.............................................................108Figure 2-22: Functional structure example for CD actuator agents................................................. 108Figure 3-1 Quality Control Diagnostics Aspect in the Functional Structure...................................... 110Figure 3-2 Quality Control Diagnostics Example Display.................................................................110Figure 3-3 Debug Message Viewer Tool example ...........................................................................111Figure 3-4 Toolbar icons functionality............................................................................................... 112Figure 3-5 Available Application Debug Mode Selection for Scanner.............................................. 112Figure 3-6 Available Application Debug Mode Selection for OPC Transporter................................ 113

Figure 3-7 Application Activity status properties for Measurement Basis Weight ............................ 113Figure 3-8 Application Activity status properties for OPC Transporter............................................. 113Figure 3-9 Windows application log on Event Viewer ......................................................................114Figure 3-10 Quality Control Status Viewer example......................................................................... 115Figure 3-11 License Manager Utility ................................................................................................. 116Figure 3-12 Windows Task Manager aids in troubleshooting ..........................................................117Figure 3-13 OPC Direct IT Viewer .................................................................................................... 118Figure 3-14 OPC Direct IT Viewer Top Area ....................................................................................118Figure 3-15 OPC Direct IT Viewer Bottom Area...............................................................................119Figure 3-16 OPC Direct IT buttons ................................................................................................... 120Figure 3-17 OPC Direct ITConfiguration...........................................................................................121Figure 3-18 Windows message with OPC Server and tag information ............................................ 166Figure 3-19 Set decimal places using Windows pop-up................................................................... 166

Figure 3-20 Target dialog pop-up ..................................................................................................... 173Figure 3-21 Actuator profile modes and setpoints pop-up................................................................ 175Figure 3-22 Reflected Plot example.................................................................................................. 176

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Figure 3-23 Reflected Target Plot example......................................................................................177Figure 3-24 Reflected Target Plot pop-up for individual points ........................................................177Figure 3-25 X-Y plot example ........................................................................................................... 178Figure 3-26 User Interface OPC Tag information message box ...................................................... 179Figure 3-27 Right click in plot area to get pop-up menu options ...................................................... 179Figure 3-28 Measurement plot display options................................................................................. 180

Figure 3-29 Target Plot Display Options........................................................................................... 180Figure 3-30 Actuator Array Plot Display Options..............................................................................181Figure 3-31 Reflected Plot Display Options...................................................................................... 181Figure 3-32 Reflected Target Plot Display Options ..........................................................................181Figure 3-33 X-Y Plot Display Options ............................................................................................... 182Figure 3-34 Vertically stacked plots.................................................................................................. 183Figure 3-35 Merging Plots.................................................................................................................184Figure 3-36 Keywords for all plot types ............................................................................................184Figure 3-37 ABB Auto Plot example ................................................................................................. 189Figure 3-38 Display Type..................................................................................................................190Figure 3-39 DisplayType=1 ndtVerical ........................................................................................190Figure 3-40 DisplayType=2 ndtHorizontal ...................................................................................190Figure 3-41 Buttons resulting from XML file implementation............................................................ 191

Figure 3-42 Button state On..............................................................................................................192Figure 3-43 Button state Off..............................................................................................................192Figure 3-44 Using reserved resource string .....................................................................................193Figure 3-45 Button not writeable.......................................................................................................193Figure 3-46 Button writeable.............................................................................................................193Figure 3-47 Show OPC tag gives server names and tags associated with button .......................... 194Figure 3-48 CD Overview Indicator messages.................................................................................197Figure 3-49 CD Mapping ActiveX control .........................................................................................200Figure 3-50 Using reserved resource string .....................................................................................201Figure 3-51 Show OPC tag gives server and tag names .................................................................202Figure 3-52 Heirarchy Levels............................................................................................................218Figure 3-53 Automatic Grade Change button................................................................................... 221Figure 3-54 Automatic Grade Change Current Information Example .............................................. 222Figure 3-55 Automatic Grade Change Previous Pop-up Example................................................... 224Figure 3-56 Automatic Grade Change Level 1 Control Pop-up Example.........................................225Figure 3-57 Automatic Grade Change Level 2 Control Pop-up Example.........................................229Figure 3-58 OPC Tag Level 1 SingleLine example ..........................................................................233Figure 3-59 Level 1 Control Grid Example .......................................................................................236Figure 3-60 OPC Tag Level 1 Vertical Example...............................................................................240Figure 3-61 OPC Tag Level 2 SingleLine Example..........................................................................243Figure 3-62 OPC Tag Level 2 Grid Example....................................................................................246Figure 3-63 OPC Tag Speed Control Example ................................................................................250

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List of Tables

Table 1-1Industrial IT Quality Control 4.0 PC nodes and software .................................................... 23Table 1-2 System Status Reporter S_Status property meanings....................................................... 57Table 1-3 Aspects used to support Quality Control System Status Viewer Aspect............................57Table 2-1: OPC Transporter Groups for MD Control ..........................................................................64Table 2-2: CD control TagsLookup ControlID.................................................................................... 72Table 2-3: CD control job order information.......................................................................................74Table 2-4: CD control XML documents..............................................................................................76Table 2-5: CDCTW TagsLookup ControlID .......................................................................................84Table 2-6: CDCTW XML documents ................................................................................................. 86Table 2-7: LVC TagsLookup ControlID..............................................................................................93Table 2-8: LVC XML documents........................................................................................................95Table 2-9: CD actuator agent TagsLookup ControlID .....................................................................101Table 2-10: CD actuator agent job order information ......................................................................101Table 2-11: CD actuator agent XML documents ..............................................................................104Table 3-1 Active X Control names, file name, and interface definitions ........................................... 156

Table 3-2 Array value and ratio table................................................................................................164Table 3-3 Mixed scalar and array AttriIDs ........................................................................................164

Table 3-4 Mixed AttriIDs within a TagID ...........................................................................................165Table 3-5 XML keywords supported by ABB Auto Grid................................................................... 167Table 3-6 Display information ........................................................................................................... 169Table 3-7 Measurement Plot inputs .................................................................................................. 170Table 3-8 Actuator Array Plot inputs ................................................................................................. 173Table 3-9 Reflected Plot input...........................................................................................................176Table 3-10 Reflected Target Plot input.............................................................................................176Table 3-11 X-Y Plot inputs ................................................................................................................ 177

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Chapter 1 Theory of Operation

1.1 OverviewIndustrial IT Quality Control 4.0 is an application providing measurement and controlsolutions for the paper manufacturing process. The primary features are:

1. Scanning and measurement

2. Machine direction control of scanning measurement parameters (weight, moisture, ash,)

3. Advanced controls (speed change, automatic grade change, headbox, )

4. Cross direction (profile) control of scanning measurement parameters

5. Reporting

1.2 Physical Architecture

1.2.1 Devices

The normal Industrial IT Quality Control 4.0 consists of the following PC nodes andsoftware.

Table 1-1Industrial IT Quality Control 4.0 PC nodes and software

Node Type Function Software Required

Quality ControlConnectivityServer & AC800MConnectivityServer

Provides QualityControl measurementand controlfunctionality andaccess to AC800Mcontroller.

Process Portal

OPC Server for AC800M/C

Control Builder M Professional


Process PortalAspect Server

Standard ProcessPortal Aspect ServerFunctionality

Process Portal

AC800M Connect


Process PortalClient

Standard ProcessPortal ClientFunctionality

Process Portal

AC800M Connect


AC800M Controller MD and Level 1Control

Latest AC800M Firmware

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The normal Industrial IT Quality Control 4.0 will consist of one System 800xA Process PortalAspect Server, one System 800xA Process Portal Connectivity Server (Quality Control andAC800M) and some number of System 800xAProcess Portal Clients.

Figure 1-1 Example system architecture

1.3 Software Package Deployment

The diagram below illustrates, at a high level, the software components that for each type ofapplication PC node and the installation options for installing those components.

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3BUS208222R4001 25

t architecture with example installation componentsFigure 1-2 Software componen

1.4 Application Architecture

1.4.1

Architecture Overview. The QCS Service isnormally configured for automatic startup. It will run when the computer is started, even if

nectivity server machine. The QCS Services maintion component. This component is the top level

The Industrial IT Quality Control 4.0 PC based applications provide access to all of thesystem features except for machine direction and level 1 control, which are implemented inthe AC800M Controller. The Quality Control applications are COM EXE type applicationsand are referred to as components here.

Startup and Shutdown

Refer to Figure 1-3 Quality Control Application

no user logs on to the Quality Control Confunction is to launch the ABBQCSApplicaQuality Control application. It launches and coordinates all of the other Quality Controlapplications.


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Figure 1-3 Quality Control Application Architecture Overview

The ABBQCSApplication com tup Engine component to launch the otherQuality and utility applications. The Startup Enginecomponent starts the applications configured in the startup.xml file. This file is created and

y Control devices and application

ents.aspect

ags thatthey use. See the OPC Direct ITsection below.

ponent uses a StarControl application components

deployed to the ../System/config directory by the job order configuration tool. The contents

of startup.xml depend upon the number and type of Qualitfeatures configured. Typically there will be a separate component for each system feature orsubsystem. Refer to the Startup Engine section later in this document for more details.

Each Quality Control application component implements COM interfaces that allow theABBQCSApplication component to coordinate their activities. The ABBQCSApplicationuses these interfaces to tell the Quality Control Application components when to connect totheir OPC server, when to publish their OPC tags, when to shutdown, etc.

When the ABB QCS Service is stopped, it tells the ABBQCSApplication to shutdown. TheABBQCSApplication then uses the standard COM interfaces of each Quality Controlapplication component to tell the application components to shutdown.

Client Connectivity

Refer to Figure 1-3 Quality Control Application Architecture Overview,above. QualityControl process graphic displays do not normally use the normal OperateIT graphic elemMost Quality Control process graphic displays are based upon special process graphiccategories that contain logic for connecting to the Quality Control connectivity server. Seethe Aspects and Objects section later in this document for more details on these special

process graphic Aspect Categories.

Many of the Quality Control process graphic Aspects contain ActiveX controls that display /

modify OPC tags. These ActiveX controls use a tag lookup server to locate the OPC t

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3BUS208222R4001 27

PC Applications

Control applications are COM EXE type applications and are referred to in this

ere

ommonbroutine calls. A description of the data or command sequencing for several

tion

is

solating

ent

7. Speed Input

1.4.3

vities of a group of ABBSmartMeasurement objects, one started forent configured on that scanner. The scanner object acts as the owner of the

1.4.2 Quality Control

The Qualitydescription as application components or just components.

While application components each tend to implement only one subsystem or feature of theentire system, they frequently have a need to communicate with each other. To this end thare two methods used to interface from application component-to-component and to theoutside world. These are 1) via COM interfaces and 2) via OPC tags. The majority ofcommunication between components is through the COM interfaces which are cmethod or sufeatures will be found in the detailed descriptions below, and they make frequent reference tothese COM interface methods.

Due to the object-oriented nature of the application component implementation the interacbetween components can be quite complex with several back-and-forth transactions requiredto accomplish a relatively simple task. The advantage of this approach is that the software

modular and feature independent, allowing easy addition or removal of features and ifunctional responsibility for ease of diagnosis.

The primary Industrial IT Quality Control 4.0 application components are:

1. Scanner and Sensor

2. Color Measurem

3. Reporting Accumulation

4. Reporting

5. Reporting History

6. Roll Set

8. Grade and Shade File Handling

9. High Frequency Trending

Scanners, Sensors and Advanced Scanning

The application COM component ABBSmartPlatform.exe is responsible for all interactionwith the scanner and its complement of sensors. At startup, a separate ABBSmartPlatformobject is created for each scanner in the system. Once in operation, the ABBSmartPlatformobject coordinates the actieach measuremmeasurements and insures that all its measurements understand the current operatingconditions, such as the desired measurement mode, the position of the head package, etc. Thescanner object insures that all the sensor results are tabulated and reported in a coordinatedfashion and that the measurement results align with each other in time. In general, operatorcommunication with the scanner and measurement objects flows through the COM interfaces

associated with each object.


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Between the objects and the real-world physical devices reside the QC Object Server (QCOS)

s

Operation

Position

.

ct headntrol is performed by the scanner component. The CurrentHeadPosition OPC tagcurrent physical position of the head package to the scanner object.

Advanc

ers

ween the

ecise when both

measurements are from the same location on the process. The difficulty with this is that the

ognizing and coordinatingindividual scanner components, ABBSmartPlatform. It makes decisions about which scanner

rs

emscanner

ismfor the downstream scanners is designed in such a way that the origin (leader) of a command

.

The lead scanner may change at any time by virtue of its availability (local, out-of-operation,maintenance, etc.). The change of leadership is one of the commands that is synchronized

and its OPC tag-set. The Job Order Configuration Tool is used to define the physicalcomplement of scanners and sensors that will be available to talk to. Each scanner andmeasurement object subscribes to the full set of OPC tags available from that device.

The scanner keeps a list of its measurement objects that can be accessed through the scannerCOM interface. Some of the measurement specific operator commands (e.g., sample checkmode, compensation values, etc.) use this list to directly access specific measurement objecton a specific scanner. In this case, once they have identified the desired measurement object,they use the measurement COM interface to talk directly to that measurement object.

ing

Operationally, the scanners command OPC tag is the direct connection from the scannerobject to the physical scanner through the OPC interface. Once an operator command has

been received by the scanner object via the COM interface, it flows through this OPC tag

The commands are general in nature, asking the scanner to assume a particular state (e.g.offsheet, scanning, etc.) and waiting for the response in the mode OPC tag. No dire

package coreturns the

ed Scanning

Advanced Scanning is an optional, licensed, value-added feature that allows multiple scannto see the same part of the process. In a moving sheet process with several scannersdistributed along the length, it is useful to insure that each discrete measurement windowmeasures the same material, especially when there are mathematical relationships betmeasurements on different scanners. For example, a weight difference that subtracts oneweight from another on two different scanners is obviously more pr

measurements occur at different times by virtue of their separation on the process.

The mechanism for accomplishing this is to insure that different scanners start their scans atthe same command point on the process which is tracked between the scanners based upontheir relative separation and the line speed of the process. This feature is referred to asSynchronized Scanning.

A global component ABBGlobalScanner is responsible for rec

is most upstream and insures that scanner is aware that it is the leader. The leader isresponsible for starting new command points that will be followed by downstream scanne

followers. The software components of the Connectivity Server are entirely responsible foroperation of this feature. When activated, this feature causes each ABBSmartPlatformcomponent to override normal independent scanning operation of its connected SmartPlatform by changing the Smart Platforms mode from scan-at-will to scan-on-command.

Downstream follower scanners accept new command points from the leader and track thfrom the leader to themselves by monitoring the process line speed. Each individualis assigned a relative position on the process at startup which is used to decide when thecommand point has reached them and should be obeyed. The synchronization mechan

point is irrelevant and simply has to match the position of the specific downstream scanner

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3BUS208222R4001 29

lost

Change

termines when a command point will reach a downstream scanner, as

ow aosition to

based on the current line speed. Inords, if the scanner can successfully reach the other side of the process sheet andstart-scan command will arrive, then scanning is

may flow by thedownstream scanner before it is in a position to accept them i.e., the scanner is still moving

ss

Scanne

start scanning when a commandpoint becomes available. For example, a substantially slower scan time may insure that a

hel

ownstream scanner. The mechanism describedine speed) will insure that a scan will eventually occur, however,

ey are discarded and a catch-up is required.

y

duration oflay its scan until it is sure that

all scanners will have sufficient time to catch its first start-scan command point after a

ed as either

ween these two is that tracking is

considered only for the global type, not for the individual. An individual standardize request,whether via button or timer causes that scanner to become unavailable for synchronization.

between scanners so that intervening commands (and potentially measurements) are notto downstream scanners.

Missing Scans

By virtue of the fact that downstream scanners are dependent on synchronization for theirstart-scan command, it is possible for downstream scanners to miss scans. In these cases thenext best possibility for measurement is to wait for the next command point on this side ofthe process sheet to arrive; in other words to quit scanning until a complete bi-directional scanis tracked to this scanner. Some of the scenarios for missed scans and the mechanismsimplemented to reduce their occurance are:

of line speed

Since the line speed dechange in line speed will obviously have an impact. In general a decrease in line speed i

benign in the sense that the start-scan command will eventually reach the scanner, its justdelayed for a while. There is a delayed scan feature built into the tracking that will alldownstream scanner to proceed with a scan (and measurement) only if it can be in p

receive the next command point in