3BSE041880-610 A en Control AC 800M Getting Started

SYSTEM VERSION 6.
ABB Ability™ System 800xA

AC 800M
Getting Started
SYSTEM VERSION 6.1
ABB Ability™ System 800xA

AC 800M
Getting Started
Document Number: 3BSE041880-610

Document Revision: A
Release: February 2019
Trace back information Main Publication:

Tool version: 5.2.025
Build date: 2019-02-06 at 16:08:47
Domain: ABBPA
Workspace, version, checked in: 800xA Main, a212, 2019-02-06
Master: ix-360492-AC 800M Getting Started.xml
Recipe: ix-363494-6.1_AC 800M Getting Started.rcp
PDF stylesheet: ix-315381-PDF-Stylesheet.xml
Customer stylesheet: ix-315380-CustomerStylesheet.xml
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Table of Contents
Table of Contents
About this User Manual

User Manual Conventions ................................................................................. 12
Warning, Caution, Information, and Tip Icons ...................................... 12
Terminology ....................................................................................................... 13
Released User Manuals and Release Notes .................................................... 13
1 Introduction
1.1 General ............................................................................................................. 15
1.2 Product Overview .............................................................................................. 15
1.2.1 ABB Start Menu ................................................................................... 16
1.2.2 Project Explorer ................................................................................... 17
1.2.3 Libraries ............................................................................................... 18
1.2.4 Control Builder Functions .................................................................... 20
1.2.5 Manuals ............................................................................................... 20
1.2.6 Online Help .......................................................................................... 21
1.3 Before You Begin .............................................................................................. 22
1.3.1 Configuration ........................................................................................ 22
1.3.2 Configure OPC Server ......................................................................... 23
2 Control Builder User Interface

2.1 Introduction ....................................................................................................... 25
2.1.1 About Project and its Objects .............................................................. 25
2.1.2 About Entities and Reservation ........................................................... 26
2.1.3 About Environments ............................................................................ 27
2.2 Project Templates .............................................................................................. 28
2.3 Project Explorer ................................................................................................. 29
2.3.1 Title Bar, Menu Bar and Toolbar .......................................................... 29
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Table of Contents
2.3.2 Project Explorer Pane .......................................................................... 30

2.3.3 Libraries Folder .................................................................................... 30
2.3.4 Applications Folder .............................................................................. 32
2.3.5 Controllers Folder ................................................................................ 34
2.3.6 Drag-and-Drop in Project Explorer ...................................................... 35
2.3.7 Context Menus ..................................................................................... 37
2.3.8 Reservation Status ............................................................................... 37
2.3.9 Message Pane ..................................................................................... 38
2.3.10 Editors .................................................................................................. 38
2.3.11 Refresh Project .................................................................................... 40
3 MyDoors Project
3.1 Introduction ....................................................................................................... 41
3.2 Building a Shop Door Project ............................................................................ 41
3.2.1 Specifications ....................................................................................... 42
3.2.2 Defined Variables ................................................................................. 42
3.2.3 Creating MyDoors Project .................................................................... 44
3.2.4 Diagrams .............................................................................................. 45
3.2.5 Variables and Signals .......................................................................... 46
3.2.6 Create Logic for Door Timer and Counters .......................................... 53
3.2.7 Testing MyDoors Project ...................................................................... 68
4 Hardware Configuration
4.1 Configure Hardware .......................................................................................... 73
4.1.1 Changing a CPU Unit .......................................................................... 74
4.1.2 Adding the IO Modules DO814 and DI810 .......................................... 75
4.2 Connect Signals to I/O Channels ...................................................................... 78
4.2.1 Configure Photo Cell Signal for Input I/O Channel .............................. 78
4.2.2 Configure Motor Signals for Output I/O Channels ............................... 79
4.2.3 Reading I/O addresses from the Application ....................................... 80
4.2.4 Releasing Reservations ....................................................................... 81
4.3 Ethernet I/O Wizard ........................................................................................... 81
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Table of Contents
5 Connecting the Controller and Go Online

5.1 Firmware Upgrade ............................................................................................ 83
5.1.1 Firmware Upgrade via the Serial Cable (TK212A) .............................. 84
5.2 Setting IP Addresses ......................................................................................... 86
5.2.1 Setting IP Address for Controller ......................................................... 86
5.2.2 Setting IP Address for PC .................................................................... 90
5.3 Download Project via Ethernet .......................................................................... 91
5.3.1 Setting the System Identity in Control Builder ..................................... 91
5.3.2 Downloading the Project to the Controller ........................................... 94
5.4 Test the Diagram Online .................................................................................... 98
5.4.1 Forcing I/O Values ............................................................................... 98
5.5 What's Next? ..................................................................................................... 99
6 View Live Data in Plant Explorer

6.1 OPC Server ....................................................................................................... 101
6.1.1 Setting up Variable Communication ..................................................... 101
6.2 Plant Explorer ....................................................................................................103
6.2.1 Starting the Plant Explorer ................................................................... 103
6.2.2 Subscribing Controller Data ................................................................ 105
6.2.3 Navigating between Project Explorer and Plant Explorer .................... 105
Appendix A Functions and Settings

A.1 Ready-made Projects for CB Professional ........................................................109
A.1.1 Import an Example to 800xA ............................................................... 109
A.2 Testing ............................................................................................................... 110
A.3 Simulation ......................................................................................................... 111
A.3.1 Simulation Controllers ..........................................................................112
A.3.2 Applications in Simulation Controllers ................................................. 112
A.3.3 Mark Controller for Simulation ............................................................. 112
A.3.4 Mark Application for Simulation ........................................................... 113
A.3.5 Download to Simulation Controller ...................................................... 113
A.3.6 Running in a Simulation Controller ...................................................... 113
A.3.7 Restrictions Concerning Hardware Simulation .................................... 114
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Table of Contents
A.4 Download .......................................................................................................... 114

A.4.1 General Download ............................................................................... 114
A.4.2 Download New Project to Controller .................................................... 117
A.4.3 Download Project to Selected Controllers ........................................... 118
A.4.4 Difference Report ................................................................................. 120
A.4.5 Re-Authentication ................................................................................ 122
A.4.6 Compiler Switches ............................................................................... 123
A.5 Application Restart Mode .................................................................................. 125
A.5.1 Warm Restart ....................................................................................... 125
A.5.2 Cold Restart ......................................................................................... 126
A.5.3 Variable values in Download mode ...................................................... 127
A.5.4 Variable values in Test mode ............................................................... 128
A.5.5 Power Failure .......................................................................................129
Appendix B License Management

B.1 Introduction ....................................................................................................... 131
B.2 Control Builder Licenses ................................................................................... 132
B.2.1 Loop Check License ............................................................................ 132
B.3 Controller Capacity Points (CCP) .....................................................................132
B.3.1 CCP Calculation Rules ........................................................................ 132
B.4 Library Licenses ................................................................................................ 134
B.5 Checking Licenses for a Controller ................................................................... 135
B.6 Combined AC 800M High Integrity Controller ................................................... 136
Appendix C SIL Certified Applications

C.1 Introduction ....................................................................................................... 137
C.1.1 SIL Information can be Disregarded by Non-SIL Users ....................... 137
C.2 SIL Applications ................................................................................................ 137
C.2.1 Setting SIL-Levels ................................................................................138
C.2.2 Restricted SIL-Level .............................................................................140
C.3 High Integrity Controllers ...................................................................................140
C.3.1 Downloading an Application ................................................................ 141
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Table of Contents
Appendix D Communication Cables

D.1 Connecting Control Builder PC to a Controller ..................................................143
Revision History ..................................................................................................... 145
Index .......................................................................................................................... 147
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The System 800xA Safety AC 800M High Integrity Safety Manual (3BNP004865*)
must be read completely by users of 800xA High Integrity. The recommendations
and requirements found in the safety manual must be considered and implemented
during all phases of the life cycle.
Any security measures described in this user manual, for example, for user access,
password security, network security, firewalls, virus protection, and so on, represent
possible steps that a user of an 800xA System may want to consider based on a risk
assessment for a particular application and installation. This risk assessment, as well
as the proper implementation, configuration, installation, operation, administration,
and maintenance of all relevant security related equipment, software, and procedures,
are the responsibility of the user of the system.
Welcome to Control Builder Professional for AC 800M. This manual is produced for
anyone intending to use the programming tool Control Builder for the first time. It is
focused on getting you quickly started and acquainted with the product. Therefore, as
much 'in-depth' information as possible has been separated from the main sections and
placed in appendices instead.
If this is your first time working with the programming tool, it is recommended that you
start by reading Section 1 Introduction and then work yourself through each section.
The sections are organized in this manner:
Section 1 Introduction, gives you an overview of the product Control Builder.
Section 2 Control Builder User Interface is a brief introduction to the Control Builder’s
core interface Project Explorer.
Section 3 MyDoors Project, encourages you to build a small project example to get
yourself acquainted with the Control Builder environment.
Section 4 Hardware Configuration, teaches you how to add hardware units to your project.
Section 5 Connecting the Controller and Go Online, starts with the prerequisites for
connecting a controller (correct firmware and system identity) and then guide you through
downloading a project and Go online.
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User Manual Conventions
Section 6 View Live Data in Plant Explorer will introduce you to the Plant Explorer interface
and help you studying how variable values from MyDoors project are transferred from
a controller, via an OPC Server, up as live data in a Workplace.
User Manual Conventions

Microsoft Windows conventions as defined in the Microsoft Manual of Style are normally
used for the standard presentation of material when entering text, key sequences,
prompts, messages, menu items, screen elements, and so on.
Warning, Caution, Information, and Tip Icons

This user manual includes Warning, Caution, and Information where appropriate to
point out safety related or other important information. It also includes Tip to point out
useful hints to the reader. The corresponding symbols should be interpreted as follows:
Electrical warning icon indicates the presence of a hazard that could result in electrical
shock.
Warning icon indicates the presence of a hazard that could result in personal injury.
Caution icon indicates important information or warning related to the concept

discussed in the text. It might indicate the presence of a hazard that could result in
corruption of software 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 certain function.
Although Warning hazards are related to personal injury, and Caution hazards are
associated with equipment or property damage, it should be understood that operation
of damaged equipment could, under certain operational conditions, result in degraded
process performance leading to personal injury or death. Therefore, fully comply with
all Warning and Caution notices.
3BSE041880-610 A 12
Terminology
Terminology
A complete and comprehensive list of terms is included in System 800xA Terminology
and Acronyms (3BSE089190*). The listing includes terms and definitions that apply to
the 800xA System where the usage is different from commonly accepted industry standard
definitions.
Released User Manuals and Release Notes

A complete list of all User Manuals and Release Notes applicable to System 800xA is
provided in System 800xA Released User Documents (3BUA000263*).
System 800xA Released User Documents (3BUA000263*) is updated each time a
document is updated or a new document is released.
It is in pdf format and is provided in the following ways:
• Included on the documentation media provided with the system and published to
ABB Library and myABB/My Control System portal when released as part of a major
or minor release or System Revision.
• Published to ABB Library and myABB/My Control System portal when a User Manual
or Release Note is updated in between any of the release cycles listed in the first
bullet.
3BSE041880-610 A 13
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1 Introduction
1.1 General
1 Introduction
1.1 General
Control Builder Professional (CB Professional) is a programming tool for creating control
solutions when using the AC 800M hardware.
The Control Builder comes with type solutions for simple logic control, device control,
opened and closed loop control, alarm handling, packaged as libraries.
It provides different wizard functions for e.g. configuration of IEC61850 devices (electrical
integration), uploading hardware configuration from Ethernet based I/O, and generating
hardware definition files,
It also provides support for multi-user engineering and an evaluation mode for testing,
and evaluating new applications against a running application.
Control Builder supports five different programming languages according to IEC 61131-3.
They are Function Block Diagram (FBD), Structured Text (ST), Instruction List (IL), Ladder
Diagram (LD), and Sequential Function Chart (SFC).
In addition to these, Control Builder supports creation of logic using Diagrams (which
use the Function Diagram (FD) language) and Control Modules using Control Module
Diagrams (CMD). Other useful functionality are configuring High Integrity controllers for
SIL applications, online debugger, test and simulation mode.
1.2 Product Overview

Control Builder is a fully integrated control system function in the 800xA system. It provides
tools for programming applications and configure hardware units from the AC 800M
family. It is accessed through the Project Explorer interface.
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1 Introduction
Figure 1.1: Project Explorer and Plant Explorer are two separate interfaces for building
and maintaining control projects.
This manual gives an introduction to the Project Explorer interface. Once you are familiar
with the basics within this user manual, you are advised to look up the manual Control
AC 800M Configuration (3BSE035980*) which describes more thoroughly the 800xA
programming functions that can be accessed through the Project Explorer.
An introduction to the Plant Explorer can be found in the manual, Operator Workplace,
Configuration (3BSE030322*).
1.2.1 ABB Start Menu

ABB Start menu is a tool to access the installed ABB applications. It has shortcuts under
different folders in a tree structure. The user can open the relevant folder and click the
appropriate menu item to launch the required ABB application.
3BSE041880-610 A 16
1 Introduction
Figure 1.2: ABB Start Menu
It is possible to pin the Start Menu tool to the taskbar for an easy access of the tool.
1.2.2 Project Explorer

The main user interface is called the Project Explorer and this is where you create and
build your projects. A project contains the entire configuration needed for a AC 800M
based control solution, including control applications and hardware settings. Context
menus are helpful while configuring hardware units or creating Diagrams etc. You
right-click an object to open its corresponding context menu.
Both the software (diagrams, programs, functions, and so on) and the hardware (the
actual hardware connected to the controller) are modelled in a project. The relationships
are visualized in Figure 1.3.
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1 Introduction
PM860/TP830 DO810 DI810
Figure 1.3: Project Explorer and actual hardware setup.
1.2.3 Libraries
Control Builder is delivered with an extensive set of predefined type solutions stored in
libraries. These include data types, functions, function block types, control module types,
and diagram types, which can be used in your projects.
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1 Introduction
All standard libraries are included during the installation and are available in your projects.
The installation provides the following libraries:
• The Basic library. It contains basic building blocks for AC 800M control software like
data types, function block types, and control module types, with extended
functionality, designed by ABB.
The contents inside the Basic library can be categorized as follows: IEC 61131-3
Function Block Types, Other Function Block Types and Control Module Types.
• The Communication Libraries. They include function blocks for MMS, ModBus RTU,
Modbus TCP, Foundation Fieldbus HSE, SattBus, COMLI, UDP and TCP,
MOD5-to-MOD5 (MTM), Siemens 3964R protocols, and IOCommLib for PROFINET.
• The Control Libraries. They include single PID control and cascade PID control
function blocks, control modules, etc.
• The Binary Process Libraries, contain types for controlling motors, valves, ABB
Drives and Insum Devices. Most types in these libraries are templates, that is, you
can copy and modify them to fit your particular process.
• The Alarm and Event Library contain function blocks for alarm and event detection,
and alarm printouts on a local printer.
• The Signal Libraries contain types for adding supervision, alarm handling and error
handling to I/O signals, and also for the overview and forcing of boolean and real
signals.
• The Burner Library contain function block types, which are used for defining logic
for Burner control.
A complete list of libraries delivered with the installation can be found in the manual
Control AC 800M Binary and Analog Handling (3BSE035981*).
Hardware Libraries
An extensive set of predefined hardware types, stored in standard hardware libraries,
are delivered with Control Builder. These hardware types can be used in your projects
when configuring the controller hardware.
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1 Introduction
All standard hardware libraries are included during the installation and are available in
your projects. The installation provides the following libraries:
• The basic hardware libraries. They contain basic hardware types for controller
hardware, such as types for AC 800M, CPUs, Ethernet communication link, Com
port, ModuleBus etc.
• PROFIBUS and PROFInet hardware libraries. They contain hardware types for
PROFIBUS and PROFInet communication interfaces, ABB Drives, and ABB Panel
800.
• Communication hardware libraries. They contain hardware types for the
communication interfaces Foundation Fieldbus HSE, MasterBus 300,
Modbus TCP, IEC 61850, PROFIBUS, PROFINET IO, MOD5, AF 100, EtherNet/IP
and DeviceNet, INSUM, DriveBus, RS-232C, and UDP and TCP.
• Hardware libraries for serial communication protocols. They contain hardware types
for SerialProtocol, COMLI, ModBus and Siemens 3964R.
• Hardware libraries for I/O Systems. They include hardware types for I/O
communication interfaces, I/O adapters, and I/O units; S100 (incl. S100 Rack), S200,
S800, S900, and Select I/O.
1.2.4 Control Builder Functions

The Control Builder is used to create control solutions. The solutions are created within
control builder projects, and several levels of structuring are available inside one project.
A project in Control Builder can handle up to 32 controllers where each controller can
configure 32 tasks. Each controller can connect up to 32 applications, where each
application can handle 128 diagrams and 64 programs at the most. Several Control
Builder PCs can be used together in a multi-user environment.
It is possible to create self-defined libraries containing data types, function block types
etc. which can be used in any project.
Besides function block types, your Control Builder can also handle control modules and
diagrams, which are components for object-oriented (and graphical) programming.
For more information see also Appendix Functions and Settings.
1.2.5 Manuals
All online manuals exist as pdf files. The files are stored on your local disk after installation.
Online manuals can be accessed from ABB Start Menu > ABB System 800xA > .....
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1 Introduction
This manual, Getting Started introduces you to the basic functions necessary to create
and download a small control project to a controller. The installation provide a number
of additional online manuals in pdf format:
• The manual Control AC 800M Configuration (3BSE035980*) describes the basic
functions in Control Builder.
• The manual Control AC 800M Planning (3BSE043732*) describes design issues
and programming languages.
• The Safety Manual AC 800M High Integrity (3BNP004865*) describes processes
and rules that apply when creating SIL certified applications for AC 800M High
Integrity controllers.
• The manual Control AC 800M Binary and Analog Handling (3BSE035981*), describes
the Control Builder standard libraries and how to use them to build complex
automation solutions.
• The Control AC 800M Controller Hardware (3BSE036351*) manual describes how
to install and configure AC 800M and AC 800M High Integrity controllers, together
with AC 800M control software.
• There is also pdf versions of fieldbus and I/O manuals, that is, documentation
regarding FOUNDATION Fieldbus, PROFIBUS, PROFINET IO, AF 100, EtherNet/IP
and DeviceNet, TRIO, Satt IO, S200 I/O, S800 I/O, and S900 I/O.
1.2.6 Online Help

Control Builder Online Help can be accessed in the following ways:
• Context-sensitive help. Select an object in e.g. Project Explorer and press F1. (If
you press F1 in Plant Explorer, you will open general Plant Explorer help.) Another
way to use context-sensitive help is to push the Help button in dialogs. The online
help is started and the relevant topic is selected.
• Via menu command Help>Help Topics. This will bring up online help with the
Control Builder topic selected.
• Via menu command Help>Help About (browser/editor) This will bring up online
help with the topic for the current browser/editor selected.
• Via menu command Help>Show Help About... This will bring up a dialog where
other help files can be reached. This could be either user specific help files or help
files for installed hardware libraries.
3BSE041880-610 A 21
1 Introduction
1.3 Before You Begin
Once the online help window has been opened, it is possible to navigate to other topics
via links in the help topics or via the different tabs in the help window:
• Contents: The table of contents lists all help topics in a structured way. Navigate
to the relevant topic and select it.
• Index: The index table lists interesting keywords. Scroll through the list or use the
search field to find the keyword you want to view. Double-click on the keyword and
the relevant topic is displayed.
• Search: The text search goes through all topics and shows all the matches, based
on the text you enter. For better results, enter the specific text that is relevant to the
concept that you are searching.
Note that it is not always possible to find information about a single object by entering
its name, for example “CI860” or “Level6CC”. Try searching for the category instead,
for example “I/O units” or “data types”. This will normally take you to a list of objects
or units, from which you can jump to the one you are interested in.
If you are looking for information about a specific library object, or information about
a specific hardware unit, the easiest way to find this information is to select the object
in Project Explorer and press F1. Control Builder will then take you to the right topic.

This manual assumes that your 800xA system has been installed and configured. The
installation procedure is described in the System 800xA Getting Started (2PAA111708*)
manual.
Three software licenses – Control Builder, SoftController, and Library License

are required. For more information on licenses, see Appendix B.
You need to install OPC Server for AC 800M in order to subscribe to live controller
data in Plant Explorer.
1.3.1 Configuration
Before you start, you should have the answer to the following questions:
• Should your engineering workplace consist of a single workplace (single user) or a
number of workplaces (multiple users)?
• Should your engineering workplace contain single/multiple environments?
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1 Introduction
The System Installer will help you:

• Create a system and give it a name.
• Choose whether to run aspect and connectivity servers on the same PC, or
separately.
• Define the number of environments.
• Prepare your system for RNRP configuration (if network redundancy is desired).
• Add System Extensions.
• Start the aspect server(s).
• Start the system.
Refer to the System Installer described in the System 800xA Getting Started
(2PAA111708*) manual.
1.3.2 Configure OPC Server

For information on how to configure an OPC Server, refer to the
AC 800M OPC Server (3BSE035983*) manual. You can read how to connect the OPC
Server in subsection OPC Server on page 101.
3BSE041880-610 A 23
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2.1 Introduction
2.1 Introduction
The core interface of Control Builder is the Project Explorer. After getting familiarized
with Project Explorer in this section, you can refer to
Section 3 MyDoors Project, to create a new project and its logic.
2.1.1 About Project and its Objects

In a Control Builder project, the available objects for creating control logic are applications,
diagrams, programs, control modules, and function blocks.
The following list describes the hierarchy of these and their usage, in descending order:
• An automation system might contain a number of control networks representing
different parts of a large plant.
• Within each control network, you can create a number of projects.
• A project is the top level software unit and it contains the configuration data for
libraries, applications, connected hardware, etc. It also groups libraries, applications
and the connected hardware in an hierarchical tree structure in Project Explorer.
• Each application contains diagrams, programs, or control modules, and additional
objects (data types, function block types, control module types, diagram types) that
are used within the application.
• Each diagram, program, or control module is connected to a task, which decides
how often each of them is executed. It is also possible to connect individual function
blocks and control modules, which are used to build the objects, to different tasks.
A complete control network is only represented in Plant Explorer, and not in Project
Explorer. Therefore the control network is not illustrated here in Figure 2.1. The sequence
below shows the steps from creating a new project to a download. As you can see, a
Project is the highest level object in Control Builder, whereas a diagram, program, or
control module is an alternative to handle code below inside an application.
3BSE041880-610 A 25
2.1 Introduction
Figure 2.1: Sequence for building a project and making a download to the controllers
2.1.2 About Entities and Reservation

Several users can work at the same time with a Control Builder project. To avoid that
different users edit the same object properties at the same time, you have to reserve the
relevant object, for example a project or an application, before you can modify its
properties. This ensures that only one user can modify an object at a time.
When ready, you release the reservation. Now, it is possible for another user to reserve
and modify the object.
3BSE041880-610 A 26
2.1 Introduction
However, only some objects, so-called entities, can be reserved. An entity is a set of
objects and aspects that is reserved as a single unit.
• Examples of objects that are reservable entities: projects, libraries, applications,
diagrams, diagram types, control module types, function block types, controllers,
and hardware units (where this has been defined for the corresponding hardware
type).
• Examples of objects that not are reservable on their own: programs and datatypes.
These are contained within the objects above and are reserved when those objects
are reserved. A program is e.g. reserved when the application it resides in is
reserved.
For more information on entities and reservation of entities, refer to the manual Control
AC 800M Configuration (3BSE035980*).
2.1.3 About Environments

Environments require a separate license and are not available to all users. The Project
Explorer will only show information on environments when they are used.
Environments provide isolated engineering. Since different environments can have

different contents, you can modify a control application without affecting the running
application.
When you create a new project, or open an existing one, you must first select the relevant
environment. The Control Builder project will then be opened in that environment. When
you modify an object in one environment, the changes will only be visible in that
environment. However, users working in the same environment will see each others
changes.
You can also transfer the changes from one environment to another. This process is
called deploy.
The two basic environments are:
• Engineering Environment is used for engineering tasks, for example to modify a
project, or an application.
• Production Environment is used to compile and download a project (or a single
application) to the controller and go online.
For more information, refer to the System 800xA, Configuration (3BDS011222*) and
to the Control AC 800M Configuration (3BSE035980*) manuals.
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2.2 Project Templates
2.2 Project Templates

When a new project is to be created, the Control Builder provides a set of predefined
templates. These templates contain predefined initial setup data, suitable for different
kind of projects.
The following project templates are available in the Control Builder:
• AC800M
– For normal use, and for running non-SIL applications.
• AC800M_HighIntegrity_SM811
– For running non-SIL, SIL1-2, and SIL3 applications.
• AC800M_HighIntegrity_SM812
– For running non-SIL, SIL1-2, and SIL3 applications.
• EmptyProject1
– Rarely used, and has a minimum configuration with initial data only under the
Libraries folder.
• LoopCheckController
– For loop check purposes. See manual Select I/O Configure and Check Ethernet
I/O Getting Started (9ARD148917*) for more information.
• SoftController
– For development use, and for simulating non-SIL applications without a
controller.
• SoftController_HI
– For development use, and for simulating SIL applications without a controller.
• AC800M_SelectIO
– For running SelectIO and for non-SIL applications.
• AC800M_HighIntegrity_SelectIO
– For running SelectIO, non-SIL, SIL1-2 and SIL3 applications.
SIL stands for "Safety Integrity Level". For more information see Appendix C.
1. An empty project template contains only the compulsory system firmware functions, with no additional
application or hardware functions.
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2.3 Project Explorer

The Project Explorer is the main browser in the Control Builder programming tool. It
displays the currently active control project, and can be used for creating and deleting
the different objects in the project as well as be used for navigation to different editors
where the objects can be modified.
Only one project can be opened at a time in the Project Explorer, although all the
projects can be viewed in the Plant Explorer.
Title bar
Menu bar
Toolbar
Project Explorer pane
Message pane
Figure 2.2: Project Explorer
2.3.1 Title Bar, Menu Bar and Toolbar

The title bar of the Control Builder shows the name of the current project, the status of
the project (Offline, TestMode, or Online), and the name of the 800xA system.
The menu bar contains the drop-down menus: File, Edit, View, Tools, Window, and Help.
When the menu items on the menus are dimmed, they cannot be accessed (the function
is not allowed in the current context).
The toolbar contains icons that serve as shortcuts to the most common Control Builder
functions, such as Download, Reserve, and Online help.
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2.3.2 Project Explorer Pane

The Project Explorer pane contains three main folders, see Figure 2.3.
• The Libraries folder, see Libraries Folder on page 30.
• The Applications folder, see Applications Folder on page 32.
• The Controllers folder, see Controllers Folder on page 34.
Libraries Folder
Applications Folder
Controllers Folder
Figure 2.3: The Project Explorer pane, showing the three main folders Libraries,
Applications, and Controllers.
2.3.3 Libraries Folder

When a project is created, the Libraries folder contains the System folder (containing
firmware functions that can be used throughout the applications), and two libraries that
are always connected to a project: the BasicLib and the IconLib.
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Besides these three libraries, the Libraries folder also contains the Hardware folder with
the library containing the basic hardware types:
• BasicHWLib (if AC800M, EmptyProject, or SoftController template is used for creating
the project).
• BasicHIHwLib (if AC800M_HighIntegrity or SoftController_HI template is used for
creating the project).
After the project is created, both standard libraries and user-defined libraries can be
created or inserted into the Libraries folder and the Hardware folder.
When a new library is created, the subfolders – Data Types, Diagram Types, Control
Module Types, and Function Block Types – are not visible since they do not contain
any objects.
Right-click the library to open the context menu, and go to New which displays the
option to create the different types (see Figure 2.4). Once the types are created, they
are displayed under the corresponding subfolders in the library.
Figure 2.4: Creating types under a library
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A library can only be added to an application if it has first been added to the Libraries
folder. A hardware unit (type) can only be connected in a controller configuration if the
corresponding hardware library is added to the Hardware folder.
Libraries can only be added to the Libraries and Hardware folders if they exist in the
Library Structure in Plant Explorer.
For more information on libraries and library handling, see the manual Control
AC 800M Configuration (3BSE035980*) and the manual Control AC 800M Binary
and Analog Handling (3BSE035981*).
2.3.4 Applications Folder

The Applications folder holds all code that is downloaded to the controller(s).
This code is stored as programs, control modules, single control modules or diagrams.
The chosen method depends on the requirements of the particular application.
The Applications folder contains applications and other application folders.
To create a new application folder under the Applications folder, right click the Applications
folder and select New Folder (see Figure 2.5). The new application folder can in turn
contain both applications and application folders.
Figure 2.5: Creating a new application folder inside the Applications folder
The application folders helps to structure or group the applications in the Project Explorer.
It is also possible to move applications and application folders in the folder structure
using the drag-and-drop operation.
The Connected Libraries folder under the application contains all libraries that are
connected to the particular application. To connect a library to an application, right click
the Connected Libraries folder, select Connect Library, and select the required library
from the drop down list.
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The types that can be created under the application are Data Types, Diagram Types,
Function Block Types, Control Module Types. The created types can be used in the
application. If a library is connected to the application, the types from that library can
also be used in the application.
In the application, the code is organized in any of the following folders:
• Control Modules
• Diagrams
• Programs
For more information, refer to the manual Control AC 800M Configuration (3BSE035980*).
The Diagrams folder in the default application contains three diagrams. These three
diagrams are connected to three default tasks, see Controllers Folder on page 34. You
can change these task connections, as well as add your own tasks and diagrams.
When a new application is created, the subfolders – Data Types, Control Module
Types, Diagram Types, Function Block Types, Control Modules, Diagrams, and
Programs – are not visible because they do not contain any objects.
Right-click the application to open the context menu, and go to New, which displays
the option to create the different types, control modules, diagrams, and programs
(see Figure 2.6). Once these are created, they are displayed under the corresponding
subfolders in the application.
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Figure 2.6: Creating types, control modules, diagrams, or programs under an application.
From the objects in the Applications folder, a number of software editors can be
opened, see Editors on page 38.
To check the code for errors, click the Check icon on the toolbar. If there are errors in
the project, these are indicated by a red triangle next to the object (in Offline mode). The
descriptions of the errors are displayed in the Check tab of the message pane.
2.3.5 Controllers Folder

The Controllers folder contains all the controllers that belong to the project.
Each controller has a Connected Applications folder, containing the application(s) running
in the controller. The controller also has a Connected Libraries folder, containing all the
hardware libraries to be used when configuring the controller.
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To connect an application to the controller, right-click the Connected Applications folder,

select Connect Application, and select the application.
To connect a hardware library to the controller, right-click the Connected Libraries folder,
select Connect Library, and select the hardware library.
Only hardware libraries that are added to the project can be connected to a controller
(see Libraries Folder on page 30).
For each controller there is a hardware folder where a CPU unit is located. Other units,
such as I/O units and communication interface units can be added to this hardware
folder. The controller structure mirrors the physical structure, which means that all ports
and buses have their own corresponding unit (icon) in Project Explorer.
For more information about hardware configuration and the Controllers folder, see
Section 4 Hardware Configuration.
The Controllers folder also contains a Tasks sub-folder and an Access Variables container.
The Tasks folder contains tasks that are used to control the execution of your applications.
By default, the Tasks folder contains three tasks: Fast, Normal, and Slow. However, you
can add the tasks you need for your applications.
For more information on tasks and task execution, see the manual Control AC 800M
Configuration (3BSE035980*).
Double-clicking the Tasks folder will display a task overview. Double-clicking an individual
task will display the Task Properties dialog for that particular task.
From objects in the Controllers folder (CPU units, I/O units, communication ports,
communication interfaces, etc.), a number of hardware editors can be opened, see
Editors on page 38.
2.3.6 Drag-and-Drop in Project Explorer

Some objects can be dragged and then dropped to other objects in the Project Explorer.
Table 2.1 shows the supported operations.
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Table 2.1: Supported Drag-and-Drop Operations Within Project Explorer

Drag Source Drop Target Operation
Library Application or another Connects the library to the application or the target
library library.
The library is then visible in the Connected Libraries
folder in the target application or library.
Hardware Library Controller Connects the hardware library to the controller.
The hardware library is then visible in the Connected
Libraries folder in the target controller.
Application Controller Assigns the application to the Controller.
The application is then visible in the Connected
Applications folder in the target controller.
Application Task This results in two operations:
• Assigns the application to the corresponding
controller.
• Connects the application to the task.
The application is then visible in the Connected
Applications folder in the corresponding controller and
the task name is shown after the application name.
Application Application Folder Moves the application to the target application folder.
Application Folder Application Folder Moves the application folder and its contents to the
target application folder.
Hardware unit Hardware object or Moves a hardware unit from one location to another. If
another hardware unit the Ctrl key is pressed during the operation it will be a
copy of the hardware unit that is moved, i.e. the original
unit remains at its location.
Dragging Objects in Project Explorer and Dropping in Another Window

It is also possible to drag objects in the Project Explorer and drop them in other windows.
All objects can be dragged to an arbitrary text input field or text editor. When the object
is dropped, the current name of the object becomes the text input. This helps in deriving
names for variables, parameters, and function blocks, from the existing object names.
It is also possible to drag a type, e.g. a function block type, and drop it in the drawing
area of a diagram. An instance of the function block type is then created in the graphical
pane and its declaration is added to the declaration grid.
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Figure 2.7: Object created in diagram as a result of dragging a type and dropping it in
the drawing area
2.3.7 Context Menus

Context menus can be used to edit the properties of various objects. Context menus are
displayed by right-clicking an object in Project Explorer.
Unless you have reserved an entity, parts of the Project Explorer will be read-only,
for example, some context menu items will be disabled, and dialog boxes may be
read-only.
2.3.8 Reservation Status

Entity icons can indicate reservation status, see Figure 2.3. For example:
• indicates that an application is not reserved by anyone.
• indicates that an application is reserved by you.
• indicates that an application is reserved by another user.
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2.3.9 Message Pane

See the location of the message pane in Figure 2.2. The message pane contains three
tabs:
• Description, shows a description of the selected type or hardware object.
• Check, shows the result of a code check, including error messages.
• Message, showing messages resulting from events in Control Builder, such as
compiling and loading a new project.
2.3.10 Editors
Control Builder contains a number of editors. The editors can be accessed from Project
Explorer and from Plant Explorer. To access an editor, right-click the object (it could be
a controller, a hardware unit, an application, a diagram, a program, or a type) and select
Editor from the context menu.
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Figure 2.8: Diagram Editor with declaration pane, code pane, and message pane
Among many things, editors are used to declare variables, create control logic, and
connecting to I/O channels.
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2.3.11 Refresh Project

The Refresh function loads the latest stored user code and can be used on the following
levels: project, library, application and controller.
To refresh a project: In Project Explorer (with your project open), right-click the project
icon and select Refresh Project in the context menu. The Project will load correct
information from the storage.
To refresh a library, application, or controller: In Project Explorer (with the control project
active), expand Library, Application or Controller and select Refresh. The Project will
load correct information from the storage.
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3 MyDoors Project
3.1 Introduction
3 MyDoors Project
3.1 Introduction
This section helps you to build a small project and get yourself familiar with Control
Builder. The guidelines that come with this example suggests that you build a project
called MyDoors that simulates the entrance to a store. While working with the MyDoors
project, you will learn about diagrams and declaration of variables and function blocks
in diagrams, and much more.
Control Builder comes with a ready-made project example called ShopDoors installed
on your local disk, see Ready-made Projects for CB Professional on page 109 for
locating the ShopDoors example or any other Control Builder examples.
If you do not have access to an AC 800M controller or IO modules, you can still follow
this example with a SoftController. Look for SoftController specific instructions
throughout MyDoors project example.
The SoftController is a test and debugging tool used for basic program tests. Execution
of specific functions differs between SoftController and a hardware controller in several
aspects, for example, execution performance, floating point precision (64 versus 32
bit), communication capabilities and so on.
After finishing your study of the MyDoors project, you are advised to continue with the
remaining sections in this manual.
3.2 Building a Shop Door Project

At the end of the MyDoors project, you will test your application in the Control Builder
Test mode. By doing so, the Control Builder helps you to verify, in a secure way, how
variable values and conditions are changing during a diagram execution.
Before you create your project and start writing code, take a brief moment and study the
given specifications and the suggested variable definitions below.
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3.2.1 Specifications
This project will simulate the entrance to a store. The following specifications are given:
• The entrance consists of two sliding doors that open when a customer activates a
photocell.
• Each door is opened and closed by its own motor.
• The doors return to default position (closed) five seconds after the last activation of
the photocell. Consequently, several customers arriving one after the other will
extend the time the door remains open.
• The number of customers is recorded for statistics. Manual reset of this counter
should be possible.
• The total number of times the doors have opened since they were last serviced
should be recorded.
• Each opening of the doors should increment a counter. When the counter reaches
a preset limit, a flag should indicate that service is required. Manual reset of the flag
should be possible.
3.2.2 Defined Variables

• Photocell
The photocell has two states, active and inactive, typically represented by a Boolean
variable. In this project, a Boolean variable named Photo_Cell (true = active, false
= inactive) is used.
• Door motors
The entrance itself consists of two doors facing each other. Each door is opened
by a motor controlled by Boolean signals (Motor_1 and Motor_2). The time the
doors should remain open is declared in a variable DoorsOpen_Time of type Time.
• Number of customers
Each time the photocell is activated, a counter representing the total number of
customers entering the shop should be incremented. The counter, Customers_Qty,
is of type Integer.
• Reset the counter on certain dates
On certain dates, the shop manager records the total number of customers up to
that date, and resets the counter. Consequently, a Boolean variable Reset_Counter
is declared, which resets the counter.
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3 MyDoors Project
• Door service intervals

The doors should have regular service intervals, approximately after every 10,000
openings; you also need to keep a record of the number of openings from the
previous service. The record is represented as the variable Openings_Freq of
type Dint.
• Time for service

When the counter reaches the upper limit defined by Openings_Total of type Dint,
a flag (Service_Req of type Boolean) is set, indicating that service is required.
This flag can be accessed by all controllers in the network. Manual reset of the
service counter is activated using a Boolean variable Serviced. The doors should
continue to work even if service is not performed.
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3 MyDoors Project
3.2.3 Creating MyDoors Project

Start the Control Builder from the Windows Start menu or from the ABB Start Menu
app, described in ABB Start Menu on page 16.
The Control Builder starts and opens the Project Explorer interface.
1. From the Project Explorer, select File > New Project, or click the icon. A New
Project window opens.
2. Select the AC800M template and type MyDoors in the Name field.
Figure 3.1: Standard templates for building a project.
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3 MyDoors Project
3. Click OK. Project Explorer creates and opens MyDoors project.
Figure 3.2: MyDoors project opened in Project Explorer.
The Libraries folder contains the standard libraries Basic library (BasicLib), Icon library
(IconLib) and Basic hardware library (BasicHwLib).
The System library is always automatically inserted into a project. It contains basic
data types and firmware functions. The System library cannot be removed from the
project or changed by the user.
When you create a new project, the default application (Application_1) and the default
controller (Controller_1) are automatically reserved.
3.2.4 Diagrams
In Control Builder, the control logic can be created in diagrams, which are created under
an application. The diagrams use a graphical programming language.
The diagram editor allows mixing of functions, function blocks, control modules, and
other diagrams, and allows graphical connection between the blocks to achieve a
particular logic.
In this example project, you are going to create the logic in a diagram.
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3 MyDoors Project
In the MyDoors project, expand Application_1 to view the Diagrams folder and the three
default diagrams.
Open the Diagram editor for Diagram2.
3.2.5 Variables and Signals

There are different types of variables in Control Builder for storing and computing values
(local, communication, global, and access variables).
The local variables are the most frequently used in Control Builder. As their name applies,
the local variables belongs to the local code inside a function block, control module,
diagram or program.
Communication variables are used to communicate between applications in the same
controller or between different controllers in the network. The name of the communication
variable must be unique within the network. Within an aspect directory, Control Builder
automatically finds the referenced communication variables. If the communication variable
is accessed from another aspect directory then the IP address needs to be specified.
Signals are used for connecting a variable to an I/O channel. If a signal is declared in a
diagram and also in a hardware unit below a controller, the link between the local variable
in the diagram and the I/O channel will be automatically set up when the project is
downloaded to the controller.
In this example, you will declare 10 local variables, one communication variable, and
three signals in the editor for Diagram2.
Declare Variables and Signals

1. Double-click Diagram2 to open the corresponding Diagram editor.
2. If the editor is opened in Read-only mode, Diagram2 needs to be reserved before
editing is possible. Click on the Reserve icon and then click OK in the Reserve
dialog.
Figure 3.3: The Reserve icon is the fourth from the left.
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3 MyDoors Project
3. The Diagram editor is divided into three panes: the declaration pane, the code pane,
and the message pane.
Figure 3.4: The editor for Diagram2.
4. Select the Variables tab, and place the cursor in the upper left-hand cell in the
declaration pane and type Photo_Cell.
5. Move one cell to the right by pressing the tab key. The default values retain and
hidden are automatically shown in the “Start Attribute” and “Attributes” columns.
The default setting retain means that the variable will keep its value at a warm
restart. The default setting hidden means that the variable is not visible as an OPC
variable.
6. Type BoolIO in the “Data Type” column.
7. Skip the “Initial Value” column. Since BoolIO is a structured data type it is not relevant
to enter any initial value. The initial values defined in the data type definition will be
applied.
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3 MyDoors Project
8. Skip the “I/O address” and “Access Variables” read-only columns. The I/O address
will be automatically filled in later when connecting variables to I/O channels.
9. The last column “Description” is reserved for you to use freely. Your first row should
now look like this:
Figure 3.5: Declaration of the Boolean variable Photo_Cell
10. Prepare the code pane by changing the name of page 1. At first the code pane only
has one diagram page, but many pages can be added. To make navigation easier
it is possible to set a textual name on a page in addition to just numbers 1, 2, 3 and
so on. To do this, click in the code pane background and press F2. Set the page
name to Motors_Doors:
Figure 3.6: Setting a textual name for page 1
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3 MyDoors Project
11. The next step is to insert a declared variable in the code pane by drag and drop.
First go to the declaration pane and select the Photo_Cell cell in the Name column.
Then drag and drop (keep left mouse button down while moving the cursor) the
variable name in the code pane.
Figure 3.7: Variable is displayed as graphical object in the code pane after the drag
and drop operation.
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3 MyDoors Project
12. Declare the next variable Motor_1 and use the option to declare a signal with the
same name. Right click the code pane and select New > Variable. In the New
Variable dialog enter Motor_1 as name and BoolIO as data type. Use the option to
declare a signal at the same time. In the New Variable dialog mark the Add signal
check box and change Direction to out. Fill in the remaining values according to
the dialog below and click OK.
Figure 3.8: New Variable dialog with optional signal added.
The new variable, Motor_1 gets inserted as a graphical object in the code pane. It
also appears as a variable in the Declaration Pane:
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3 MyDoors Project
Figure 3.9: Motor_1 variable declaration.
Furthermore, Motor_1 appears as a signal in the Declaration Pane with path to the
corresponding variable:
Figure 3.10: Motor_1 signal declaration.
13. Declare the next variable Motor_2 by the same method. Add signal also for Motor_2.
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3 MyDoors Project
14. Declare the remaining variables in the declaration pane, row 4 to row 8:
Figure 3.11: Declaration of the remaining variables.
Note the attribute constant of the variable Openings_Total. You can either explicitly
type “constant”, or scroll through the available formats using Alt-key together with the
up and down arrow keys, or press CTRL+J to display the list of attributes and then
select constant.
15. Select the Communication Variables tab in the Diagram editor, and declare the
Service_Req communication variable:
Figure 3.12: Declaration of the communication variable Service_Req
16. Select the Signals tab. The Signal tab already show the Motor_1 and Motor_2
signals added by previous steps. Place the cursor in the left-hand cell on row 3 in
the declaration pane and type Photo_Cell. The Path defines the variable that will
be linked to an I/O channel. Set the cursor in Path column on row 3 and press Ctrl+J.
Double click on the Photo_Cell variable name shown in the entry assistance dialog.
Fill in the remaining values:
Figure 3.13: Signal declarations
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3 MyDoors Project
17. Click Check to check for errors.
18. Click Save to save the all editing changes.

The editing changes that are made in the editor only exist in memory until the user
makes a Save. Then, the changes are stored to persistent media.
3.2.6 Create Logic for Door Timer and Counters

Timers and counters in Control Builder are normally represented as function block types
and located in the Basic library. This example will declare one Timer (TOf), and two
Counters (CTU) from the Basic library.
The creation of logic in the diagram editor involves inserting and connecting the graphical
objects, which can be also be moved freely in the code pane.
Logic on first page - Timer function block

Make sure the diagram editor for Diagram2 is open. The default code block (named
Code) is the FD (Function Diagram) code block, which is a graphical editor (with visible
grids) for adding graphical objects.
The diagram code block – Code – consists of one default page. It is possible to add
several diagram pages so that the code block logic can be structured. Logic that belongs
together can be put on a separate diagram page.
The purpose of the logic on the first diagram page is to react on photocell activation and
then open the doors by activating the two door motors. When five seconds have passed
the doors shall be closed again. To implement this a Timer Off (TOf) function block shall
be used.
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3 MyDoors Project
To start creating the logic in the editor for Diagram2:

1. In the Motors_Doors diagram page background, right-click to open the context
menu, and select New > Object. The New Object dialog opens.
Figure 3.14: Opening the New Object dialog
2. In the New Object dialog, select the TOf function block type from any of the two
tabs:
• The List tab contains alphabetical list of all objects available in the inserted
libraries in Project Explorer. Select TOf (Timer Off).
• The Tree tab displays a tree structure to navigate to the required object.
Go to Connected Libraries > BasicLib > Function Block Types, and select
TOf.
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3 MyDoors Project
3. After selecting TOf, enter OpenDoors in the Name field:
Figure 3.15: New Object dialog.
4. Click Insert, and then click Close to close the dialog. The OpenDoors function block
is inserted in the code pane and also in the declaration pane.
For more information about the TOf and the CTU function blocks, open the Control
Builder Online Help. Simply place the cursor in the Function Block Type cell (for
example TOf), and press F1.
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3 MyDoors Project
5. In the declaration pane for Function Blocks, add the description ‘Timer for Motor’
for the OpenDoors function block.
Figure 3.16: OpenDoors function block declaration.
6. The triangle in the lower right corner of the OpenDoors graphical block indicates
that not all ports are shown. Make all ports visible by selecting the OpenDoors block
in the code pane and then clicking on the Show All Ports tool bar button:
Figure 3.17: Tool bar buttons for changing port visibility. The left button means Show
All Ports as visible in tool tip.
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3 MyDoors Project
7. A variable can be created directly from a block port. This shall be done for the PT
and ET ports of the OpenDoors block. Do this by right-clicking on the PT port and
selecting the Add Variable... command in the context menu. The New Variable
dialog will be shown and suggest a variable name based on the block and port
names, and a data type based on the port data type. Enter 'T#5s' as Initial value
and 'Time duration that doors should be opened' as Description and then click OK.
Figure 3.18: The New Variable dialog opened from the PT port of the OpenDoors
function block.
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3 MyDoors Project
8. Repeat for the ET port of the OpenDoors block. Leave the Initial value empty and
enter 'Elapsed time after photo cell has been activated' as Description and then
click OK. If necessary, adjust the position of the created variable objects by dragging
them. Now the code block shall look like this:
Figure 3.19: The logic after creating variables directly from the PT and ET ports.
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3 MyDoors Project
9. Make a graphical connection between the Photo_Cell variable and the In port of
the OpenDoors function block. Do this by clicking on the right port on the Photo_Cell
variable object and while keeping the left mouse button pressed down, start moving
the cursor. An uncompleted connection is shown:
Figure 3.20: Making a graphical connection.
Move the cursor to the In port of the OpenDoors function block and release the
mouse button. If the two ports involved are of the same data type the graphical
connection is simply completed. But in this case, the source port is of BoolIO data
type, which is a structured data type, and the destination port is of bool data type,
which is a simple data type. Therefore a Select Component dialog will be shown:
Figure 3.21: The Select Component dialog.
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3 MyDoors Project
The dialog shows the components that match the data type of the destination port.
Select the Value component and click OK.
10. Repeat this for the Motor_1 and Motor_2 variables. Select the left hand port of the
variable objects and make a graphical connection to the Q port of the OpenDoors
function block. For both variables, select the Value component and click OK in the
Select Component dialog. After this is done the logic shall look like this:
Figure 3.22: The logic after making graphical component connections.
The graphical connection has a label showing which component is used.

The output Q parameter is a Boolean signal, which represents the status on the
door position (open or closed) and is passed on to the motors. For both doors to
open, the Q signal must be passed to both motors.

The Check command makes a validation of the declarations and the code. If any
warnings or errors are detected, these will be listed in message pane, in the Check
tab. If everything is OK, the message pane just shows '0 Errors, 0 warnings'. If error
messages are displayed it is possible to navigate to the error source by
double-clicking on the error message.
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3 MyDoors Project
Logic on second page - first Counter function block

The purpose of the logic on the second diagram page is to record the number of
customers that have passed the photocell. It should also be possible to reset the counter.
To implement this a Up-Counter (CTU) function block shall be used.
1. Add a diagram page, by selecting Insert > New Page or, right-click on the code
pane background and select Pages > Add New Page. Rename the new page as
Number_of_customers.
2. Open the Number_of_customers page. In the code pane, right-click and select New
> Object from the context menu. The New Object dialog opens.
3. Select CTU from the list and enter Customer_Count_Up in the Name field. Click
Insert and close the dialog.
4. A Customer_Count_Up function block is created in the code pane. Add the
description in the declaration pane according to figure below:
Figure 3.23: Declare CTU function block in Number_of_customers page
5. Add variables in the code pane by selecting Insert... in the background area context
menu. Select the variables Photo_Cell, Reset_Counter, and Customers_Qty
(multiple select in the list by using Control key down while clicking) and then click
the Insert button. Close the Insert dialog. Move the Customers_Qty variable to a
position to the right of the CTU block. Move the Photo_Cell and Reset_Counter
variables to a position to the left of the CTU block.
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3 MyDoors Project
6. Graphically connect the variables to the Customer_Count_Up function block. For

the Photo_Cell variable use the Value component. The resulting logic shall look
like this:
Figure 3.24: Variable connections to Customer_Count_Up function block
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3 MyDoors Project
Logic on third page - second Counter function block

The purpose of the logic on the third page is to record the number of times the doors
have been opened, and when a limit is reached raise a flag to indicate that service is
needed. It should be possible to reset the 'service required' flag. To implement this a
Up-Counter (CTU) function block shall be used.
1. Add a third page, by selecting Insert > New Page or, right-click on the code pane
background and select Pages > Add New Page. Rename the new page as
Service_On_Doors.
2. Open the Service_On_Doors page. In the code pane, right-click and select New >
Object from the context menu. The New Object dialog opens.
3. Select CTU from the list and enter Service_Count_Doors in the Name field. Click
Insert and close the dialog.
4. A Service_Count_Doors function block is created in the code pane. Add the
description in the declaration pane according to figure below:
Figure 3.25: CTU function block on Service_On_Doors page
5. Add variables in the code pane by selecting Insert... in the background area context
menu. Insert the Serviced, Openings_Total, Service_Req, and Openings_Freq
variables. Move the Service_Req and Openings_Freq variables to the right of the
CTU block.
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3 MyDoors Project
6. Graphically connect the variables to the Service_Count_Doors function block:
Figure 3.26: Variable connections to Service_Count_Doors Function Block Type
7. The CU parameter shall be connected to the Q port of the OpenDoors function block
on diagram page 1. It is possible to make graphical connections to object on other
pages by the use of page connectors. Go to diagram page 1 and left click on the Q
port. The port becomes marked:
Figure 3.27: The Q port of the OpenDoors object is selected on page 1.
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3 MyDoors Project
8. Go back to diagram page 3 and right click on the CU port of the

Service_Count_Doors function block. Select the Connect to Previous Selection
command:
Figure 3.28: Completing the connection by using the Connect to Previous Selection
context menu command.
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3 MyDoors Project
9. This will create the graphical connection to the object on diagram page 1 with page
connectors shown on diagram pages 1 and 3:
Figure 3.29: On page 1 the page connector on the right hand side shows that the
graphical connection goes to the CU port on the Service_Count_Doors object on
page 3.
Figure 3.30: On page 3 the page connector on the left hand side shows that the
graphical connection comes from Q port of the OpenDoors object on page 1.
It is possible to navigate to source/destination page by double-clicking on the page

connector object.
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3 MyDoors Project

If an error message is displayed in the message pane, double-click the error line and
you will jump directly to the error location in the code. You will also find a brief
description in the message pane, explaining the type of error that has occurred.
11. Click Save and Close .
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3 MyDoors Project
3.2.7 Testing MyDoors Project

Before downloading the application to a controller and going online, it is often necessary
to first test the application in an offline mode and confirm that everything is working
properly. This mode is called the Test Mode and means basically that Control Builder
will compile and execute the code locally in the PC as if it was downloaded to an AC 800M
controller.
The test mode is an easy way to try out the application many times. However, external
communication will be disabled during the test mode, thus reading and writing variables
connected to IO units cannot be validated in test mode.
The communication variable cannot be tested in Test Mode.
Before running the diagram in Test mode, there is an option to enable the Difference
Report window. However, the Difference Report function is not important for this
example since it does not generate a report in Test mode.
For details on how to enable this function, see Difference Report on page 120. This
example assumes that the Difference Report has the default setting (not enabled).
1. In Project Explorer, click Test Mode . The Test Mode Analysis window opens.
2. Click Cold Restart All.
3. Click Continue.
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3 MyDoors Project
4. Double-click Diagram2 to display the editor.

5. Open Motors_Doorspage. All variables in Diagram2 are listed in the upper pane
and the diagram appears in the lower pane, see Figure 3.31.
Figure 3.31: The Diagram editor in Test mode.
Analyzing the Code During Diagram Executions

As you can see, test mode helps you test and analyze your project without yet having
any hardware configured in the Project Explorer tree. You can change the variable
values and study the diagram response.
While analyzing the variable conditions, the following instructions will ask you to
right-click a variable and change its value. The variable values can be right-clicked
from either the declaration pane or directly in the code pane.
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3 MyDoors Project
Figure 3.32: Changing online value for a variable in the declaration pane.
Figure 3.33: Changing online value for a variable component in the code pane.
1. Right-click Photo_Cell and select On in the context menu.

Note that the motors change to True (start) and the number of openings since last
service increases by one, as does the number of customers.
2. Right-click Photo_Cell and select Off in context menu.
Simulating that no customer is activating the photocell. Note how the clock starts
and counts up to five seconds at which point the motors are set to False (stop) and
the doors close.
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3 MyDoors Project
3. Right-click Photo_Cell and select On, then QUICKLY select Off again.
Simulating that a customer has activated the photocell. Both the number of openings
is increased and customers increase.
4. Wait until the doors close. Right-click Photo_Cell and QUICKLY select On, Off,
On, Off, On, Off.
Simulating that three customers are passing the photocell one by one. Notice that
the clock starts when the first customer passes the photocell and resets to 0 when
the next customer passes. Consequently, the opening time is extended for a new
period of 5 seconds, and so on. Note also that the number of times the doors open
only increases by one, whereas the number of customers is increased by three. You
should have three openings of the doors and five customers registered.
5. In the variables list, right-click Reset_Counter and select On, then select Off again.
Reset the customer counter.
6. Activate the photocell so the number of openings (Openings_Freq) passes
Openings_Total. Service_Req will then become True.
7. Right-click Serviced and select On, then select Off again.
Study the reaction of the counters and flags. Note that the variable Openings_Freq
resets.
8. Close Diagram editor.
9. From Control Builder Menu bar, select Tools > Stop Test Mode.
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4.1 Configure Hardware
This section teaches you how to add or remove hardware units from the tree structure
in the Project Explorer. It covers the necessary steps for building a software model that
represents a limited part of a hardware configuration in the plant.

Study the hardware configuration in Figure 4.1. Assume an AC 800M controller, together
with six I/O modules. We are going to add two of them (DO814 and DI810) to the tree
structure in Project Explorer. The modules are placed at positions 1 respective 2.
AC 800M DO814 DI810

pos. No. 1 pos. No. 2
Figure 4.1: Hardware position for IO modules (for example DO814 at position 1 and
DI810 at position 2).
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4.1.1 Changing a CPU Unit

You must have the same CPU unit connected in Project Explorer as in the physical
controller, otherwise you cannot download your application to the Controller. However,
if you run with a SoftController with hardware simulation, the choice of CPU models is
optional.
In this example, a default CPU PM860 will be replaced with a CPU PM864.
To replace a CPU:
1. Expand Controllers > Controller_1 > Hardware AC 800M until you see the PM860
/ TP830 item in the Project Explorer tree.
2. Right-click the PM860 / TP830 item and select Replace Unit in the context menu.
A ‘Replace’ window opens.
3. Expand Connected Libraries and select, for example PM864/TP830.
Figure 4.2: Replace Hardware Unit dialog
4. Click Replace and then Yes to accept the change.
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4.1.2 Adding the IO Modules DO814 and DI810

The S800 IO modules are represented in Control Builder as hardware types located in
the hardware library S800IOModulebusHwLib. Thus, before adding the IO modules
you must first insert the hardware library to your project. Once the library has been
inserted to your project you can connect it to your hardware configuration and then
access the IO modules and add them to your controller configuration.
To insert and connect a hardware library:
1. Expand Libraries folder, until you see Hardware folder in the Project Explorer tree.
Hardware Folder
Figure 4.3: The hardware folder located inside Libraries folder in the Project Explorer.
Among the hardware libraries listed under the Hardware folder, the
S800IoModulebusHwLib library contains S800 IO units for the Modulebus.
2. Expand Controllers > Controller_1 until you see the Connected Libraries folder
in the Project Explorer tree.
3. Right-click the Connected Libraries folder, select Connect Library, and select
S800IoModulebusHwLib from the window.
4. Click OK.
Adding the IO modules from the hardware library:
1. Expand Controllers > Controller_1 > Hardware AC 800M > PM864/TP830 until
you see the ModuleBus item in the Project Explorer tree.
2. Right-click the ModuleBus item and select Insert Unit in the context menu. A ‘Insert
Unit for ModuleBus’ window opens.
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3. Expand Connected Libraries > S800Io ModulebusHwLib > Hardware types and
select DO814.
Figure 4.4: Insert Hardware Unit dialog
4. Keep default position 1 from Position drop-down menu and click Insert.
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5. Scroll up-down in the list and select DI810.

6. Keep default position 2 from Position drop-down menu and click OK.
When you have added the two IO modules, your “hardware tree” should look like
the configuration in Figure 4.5.
Figure 4.5: Hardware setup (Project Explorer).
To remove a hardware unit, right-click the object in the tree structure and select
Delete.
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4.2 Connect Signals to I/O Channels

Communication between I/O channels and code is established by the use of signals. A
signal in Diagram2 has a path that points to a variable in the diagram. When a signal
with the same name is added for an I/O channel, the link between the variable and the
I/O channel is automatically resolved when the project is compiled and downloaded to
the controller.
In this section the MyDoors project shall be configured using signals so that:
• The variable Photo_Cell is linked to the fist input I/O channel of the DI810 I/O module.
• The variable Motor_1 is linked to the first output I/O channel of the DO814 I/O
module.
• The variable Motor_2 is linked to the second output I/O channel of the DO814 I/O
module.
4.2.1 Configure Photo Cell Signal for Input I/O Channel

Under the Controllers in Project Explorer:
1. Double-click DI810 I/O module. The DI810 hardware editor opens.
2. Select the Connections tab and place the cursor in the first empty white cell (the
Signal column).
3. Type Ctrl + J to open the entry assistance.
Figure 4.6: The entry assistance shows the available signals with direction 'in'.
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4. Double click on Photo_Cell.

5. Press the ENTER key. The Photo_Cell variable has been connected to the first
channel in DI810 by use of the Photo_Cell signal.
Figure 4.7: The signal added to the first I/O channel.
4.2.2 Configure Motor Signals for Output I/O Channels

From the Controllers in Project Explorer:
1. Double-click the DO814 I/O module. The hardware editor for DO814 opens.
2. Select the Connections tab and place the cursor in the first empty white cell (the
Signal column).
3. Type Ctrl + J to open the entry assistance.
Figure 4.8: The entry assistance shows the available signals with direction 'out'.
4. Double click on Motor_1. Press the ENTER key. Focus is moved to the second row.
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5. Type Ctrl + J to open the entry assistance again, this time select Motor_2.
6. The motor variables in Diagram2 have now been connected to the D0814 I/O
channels by use of the corresponding signals.
Figure 4.9: The signals added to the first two I/O channels.
7. Click Check for errors.
4.2.3 Reading I/O addresses from the Application

An easy way to read the I/O address is to open (in this case) Diagram2 in the diagram
editor, select the Variables tab and check the column labeled I/O Address. Here you
will find the address for the photocell and the motors.
Figure 4.10: The I/O Address column shows how variables are connected to I/O channels.
Changes made to I/O connections in the hardware editor will be reflected in both editors.
Your project has now been tested offline and the hardware configuration is complete.
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4.3 Ethernet I/O Wizard
4.2.4 Releasing Reservations

Since you have finished the configuration, you can release any reservations.
1. Right-click MyDoors, and select Release Reservation.
2. The displayed dialog box is used to release reserved entities. In this example, the
default selection is sufficient. However, you can enter a comment.
Figure 4.11: Releasing reservations.
3. Click OK. The reservations are released.

If you use environments, continue by deploying the configuration. Otherwise, you are
ready to proceed with Section 5 Connecting the Controller and Go Online.
4.3 Ethernet I/O Wizard

For I/O connected on Ethernet, there is a tool for scanning for I/O modules and populating
the hardware tree. It can also be used as a loop check tool. This is not described in this
manual. Please refer to Select I/O Configure and Check Ethernet I/O Getting Started
(9ARD148917*) for more information.
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5.1 Firmware Upgrade
This section contains the prerequisites for connecting a controller and the general
procedure for downloading a project to the controller.
If you have created a project according to Section 3 MyDoors Project and then followed
the instructions in Section 4 Hardware Configuration, you can continue with downloading
the application in MyDoors project to a controller.
If you do not have access to a controller or IO modules, you can still follow this example
by using a SoftController. If you prefer to run with a SoftController; jump directly to the
subsection, Setting the System Identity in Control Builder on page 91.

The controller firmware and Control Builder must be of compatible versions. If you are
unsure, perform the steps in this section.
Firmware can only be upgraded when the controller has no application and no previous
hardware configuration. If the controller already has an application and hardware
configuration; you have to first reset the controller to remove all old applications and
configuration information.
Firmware upgrade can be performed from the control builder via the Ethernet network
(see the Control Builder Online Help). In case of network failure the serial line upgrade
procedure is always available.
Serial Firmware Upgrade Tool cannot be used for firmware upgrade of PM891. The
firmware upgrade of PM891 can be done using an SD card or from the Remote
System dialog in Control Builder.
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5.1.1 Firmware Upgrade via the Serial Cable (TK212A)

1. Connect the serial cable between the Control Builder PC and the controller, as
specified in Table 5.1. For the type of cable, see Appendix Communication Cables.
Table 5.1: Cable connection for the Controller.
Controller Tool Port Connector Cable Name

AC 800M COM 4 RJ 45 TK212A
No program capable of blocking the selected COM port, is to be running during

upgrade procedure. This applies in particular to the MMS Server program.
2. Turn on the power to the Controller.

3. Select ABB Start Menu > ABB System 800xA > Engineering > Utilities > Serial
Firmware Upgrade. The dialog as in Figure 5.1 appears.
Figure 5.1: The Serial Firmware Upgrade dialog.
4. Select Settings > COM Port from the drop-down menu. Make sure the settings
correspond to the physical COM port, on the PC to which your cable is connected.
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5. Click Connect and then press the Init push-button on the Controller until the Run
LED starts to blink. Wait about a minute until a message appears. If connection was
successful, a confirmation text will occur in the Firmware Version text field (Figure
5.2).
Figure 5.2: A Firmware version displayed in the text field.
In the event of an error message “Connection failed”, you must check the cables and
repeat these steps again.
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5.2 Setting IP Addresses
6. Select Firmware version2 from the drop-down menu and click Upgrade. File
transmission starts to the controller. This operation may takes a few minutes. A
confirmation window opens when the controller is upgraded, see Figure 5.3.
Figure 5.3: The Serial Firmware Upgrade window.
7. Click OK.
8. Click Exit.
9. Press the Init push-button on the Controller until the Run LED starts to blink.

A unique controller IP address must be set in order to avoid conflict with other devices
on the Control Network. This subsection guides you to assign an IP address for your
controller via the serial cable (TK212A) without being connected to the network.
Furthermore, you will be instructed to setup the PC machine running your Control Builder.
However, these instructions are strictly Microsoft Windows specific. A configuring tool,
named IP Config, is used to set the IP address for the Controller.
5.2.1 Setting IP Address for Controller

If you performed Firmware Upgrade on page 83, you can skip the preparations (identical
instructions) and go directly to Starting the IP Config Tool on page 88.
2. The firmware version must be supported by the installed Control Builder version.
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Preparations
Connecting the cable between the Control Builder and the Controller are exactly the
same as described in Firmware Upgrade on page 83.
1. Connect a serial cable between the Control Builder PC and the Controller, as
specified in Table 5.2. For the type of cable, see Appendix Communication Cables.
Table 5.2: Cable connection for the AC 800M Controller.
Controller Tool Port1 Connector Cable Name

AC 800M COM 4 RJ 45 TK212A
1. The tool port COM4 is part of controllers PM85x, PM86x and PM891.
2. Turn on the power to Controller.
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Starting the IP Config Tool

1. Select ABB Start Menu > ABB System 800xA > Engineering > Utilities >
IPConfig. An IP Config dialog opens.
Figure 5.4: The IP Config dialog box.
2. From the dialog menu Settings, select the Com port connected to the controller.
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3. Click Connect and then press the Init push-button on the Controller until the Run
LED starts to blink. Wait about a minute until the default IP address appears, see
Figure 5.5.
Figure 5.5: The IP Config dialog box with factory default setting.
In the event of an error message “Connection failed”, you must check the cables and
repeat these steps again.
4. Enter a unique IP address (obtainable from your Control Network Administrator).

Example: IP address 172.16.84.124, see Figure 5.6.
Figure 5.6: IP Config window for setting unique IP address.
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5. Set Subnetmask 255.255.252.0 and then click Apply. The new address will be sent
to the Controller and an IP Config window re-opens, see Figure 5.7.
Figure 5.7: IP Config confirmation dialog window.
6. Click OK.
7. Click Exit.
8. Press the Init push-button on the controller until the Run LED starts to blink. The
new IP address is not valid until the controller has been restarted.
5.2.2 Setting IP Address for PC

To setup the IP address (in Windows) for the Control Builder PC:
1. Go to Control Panel > Network and Sharing Center.
2. Click Change Adapter Settings.
You must setup the correct order of network adapters in the Control Builder PC; the
Control Builder will use the IP address of the last network adaptor. Hence, the Control
Network adaptor must come last.
3. Right-click Local Area Connection and select Properties. The Local Area
Connection Properties dialog opens.
4. Select Internet Protocol Version 4 (TCP/IPv4) and click Properties. An ‘Internet
Protocol Version 4 (TCP/IPv4) Properties’ dialog opens.
5. Select Use the following IP address.
The PC and controller NetID must be the same for the first three positions (start from
left to right). For example, if the Controller has the IP address 172.16.84.124, then
the PC must have the IP address 172.16.84.Q. The number represented by Q must
not be same as the Controller; thus not 124, 0 nor 255 in this example.
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5.3 Download Project via Ethernet
6. Enter an IP address, in this example (172.16.84.120) and then enter sub net mask
(255.255.252.0).
The number 120 in this example is arbitrary; you may choose any number in range
of (1-254) except number 124 for obvious reasons in this example.
Refer to the System 800xA Network Configuration (3BSE034463*) for a recommended

set of addresses to use for nodes in the 800xA System.
7. Click OK, and close the Local Area Connection Properties dialog.
8. Connect a network cable. The port and channel positions are shown in Table 5.3.
To check that the IP configuration works; open the command prompt window and
ping the Controller. In this example write the following command: ping 172.16.84.124.
If the Controller is to be connected to a PC via a switch or hub, then a straight-through

Ethernet cable should be used. If there is a direct connection between the Controller
and the PC, then use a cross-over Ethernet cable.
Table 5.3: Channel positions for connecting the Ethernet cable in the Controller.
Controller Communication Interface Position Channel

AC 800M Built-in - CN1
CN2 port on the Controller must not be connected to the same network as CN1. This
port is used for connecting the Controller to a secondary (redundant) network.

Provided that you have downloaded firmware upgrade (Serial Firmware Upgrade) and
given IP addresses, you should have contact with the controller.
This also means that you are ready to download projects to the Controller and Go Online.
For downloading to an AC 800M HI controller, see Downloading an Application on page
141
5.3.1 Setting the System Identity in Control Builder

In order to download projects to the controller you must first set the system identity in
Project Explorer.
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Setting the IP Address for Controller

1. In the Project Explorer, expand Controllers.
Figure 5.8: The Controllers expanded in Project Explorer.
2. This time the controller is not reserved. Right-click Controller_1 and select Reserve.
3. The displayed dialog box is used to reserve relevant entities. In this example, the
default selection is sufficient. However, you can enter a comment.
Figure 5.9: Reserving the controller.
4. Click OK. The controller is reserved.

5. Right-click Controller_1 and select Properties > System Identity from the context
menu. The System Identity window opens.
Figure 5.10: The System Identity window for setting the IP address.
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6. Enter the actual IP address of your controller and click OK. The System Identity
window closes.
If you run with a SoftController then type in your computer IP address and finish
with colon and the digit 2. Example: 10.46.35.117:2
When the computer is started without network connection, the Control Builder and
SoftController get the IP addresses 127.0.0.1 and 127.0.0.1:2 respectively (irrespective
of fixed IP addresses in the computer). These addresses can be used in the project.
But, without network connection, it is not recommended to use the fixed addresses
in the computer, such as 172.16.84.123:2, because when it is used in the project and
a downloaded to the SoftController, it results in a crash.
7. Expand Hardware AC 800M until you find 1 Ethernet. Right-click the Ethernet icon
(at position 1) and select Editor. The editor opens.
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8. Select the Settings tab (lower left corner, see Figure 5.11) and enter the IP address
in the IP address Value field.
Figure 5.11: IP address for controller Ethernet port at position 1.
Note that the IP address of the first Ethernet port has to be the same as the IP address
of the Controller (system identity). The second Ethernet port (at position 2) is only
used if the controller is connected to a redundant network.

10. You are now ready with all necessary configuration changes, and can release the
reservation of the controller.
Right-click Controller_1, and select Release Reservation.
11. In this example, the default selection is sufficient. Click OK. The reservation is
released.
5.3.2 Downloading the Project to the Controller

When you have tested your project and ensured that there are no errors, you are ready
to download your application to the Controller.
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If you run with a SoftController; go to Downloading to the SoftController on page 96.
Downloading to the Controller

The following instructions address the project MyDoors, which was previously created
in Section 3 MyDoors Project. However, these instructions are common for downloading
any project application.
1. Make sure MyDoors project is in Offline mode.
2. Click the toolbar button Download Project and Go Online . The Online analysis
window opens.
Figure 5.12: Online Analysis Dialog
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3. Click Continue.
4. In the Task Analysis dialog, click to accept the download.
Figure 5.13: Task Analysis Dialog
You should now be online.
Downloading to the SoftController

Make sure that your (MyDoors) project is in Offline mode (not running in test mode).
1. Enable the Hardware Simulation feature in Control Builder. See Simulation on page
111.
2. In Project Explorer, expand the Controllers folder.
3. Right-click Controller_1 and select Simulate Hardware from context menu.
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4. Next, you must start the SoftController. Select SoftController in the ABB Start Menu
app, described in ABB Start Menu on page 16.
The SoftController panel opens:
Figure 5.14: The Soft Controller panel.
5. In Soft Controller panel, Click the Start button. The SoftController starts and the
Status field changes to Started.
6. In Project Explorer, click the toolbar button Download Project and Go Online .
The Online analysis window opens.
7. Click Cold Restart All.
8. Click Continue. You should now be online.
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5.4 Test the Diagram Online
5.4 Test the Diagram Online

This subsection describes how to run the diagram online by forcing the variable Photo
cell that is connected to the IO unit DI810 in MyDoors project example.
The forcing function can be used to activate/deactivate an I/O.
1. In Project Explorer, right-click Diagram2 and select Online Editor to open the online
editor.
2. Right-click I/O module DI810 and select Editor.
3. Click the box in the Forced column. Change the variable Photo_Cell value to 1
(true), return quickly to 0 (false) and inspect the motor’s values in the online editor
(values will change to 1 for five seconds and then return to 0). Previously, you
changed the variable Photo_Cell values in the online editor to start and stop the
motors. Now, you are using the I/Os to control the motors.
4. Close all editors.
5. Click the icon to go to Offline mode.
5.4.1 Forcing I/O Values

In online mode, an I/O channel can be forced to a certain value from Control Builder.
The forcing of I/O values is not possible with High Integrity controllers.
• When an input I/O channel is forced, the value that is passed from I/O units to the
application is set to the forced value, no matter what the real value from the external
device is.
• When an output I/O channel is forced, the value that is passed to the external device
is set to the forced value, no matter what the real value from the application is.
This can be used for both testing and fault-finding purposes, as well as to control the
process.
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5.5 What's Next?
5.5 What's Next?

You have almost reached the end of getting you started with Control Builder. You should
proceed next with Section 6 View Live Data in Plant Explorer. However, as mentioned
before in the beginning of this manual, these sections help you to get started with Control
Builder.
The subsequent appendices in this manual also contain useful information that you might
need in your daily work with the Control Builder. Control Builder also comes with an
extensive set of online manuals presenting in detail the many functions and design issues
for building applications. You will be well prepared and experienced with Control Builder
and the Project Explorer after referring these manuals.
Furthermore, most of your decision-making that comes via context menus and editors
in Project Explorer can be explained and decided from the Control Builder Online Help.
To activate the online help, press the F1 key.
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6.1 OPC Server
This section is intended to introduce you to the Plant Explorer interface. It is the last and
final section with the example MyDoors. You have learned how to test an application
locally in Control Builder. Furthermore after configuring an AC 800M controller with S800
IO units you have downloaded the application to the controller and then study how to
control the motors online via I/O. Finally this section will help you studying how the
variable values from MyDoors project appears as live data from the controller. This is
especially interesting since these values will illustrating the same variables that otherwise
would be connected to faceplates in an Operators Workplace.
6.1 OPC Server

6.1.1 Setting up Variable Communication
Normally, before you create a project you should setup a control network and connect
an OPC Server to communicate between the controller and the Operator's Workplace.
However, because of the project (MyDoor) that you created previously in Project Explorer,
Control Builder has already made a control network for you in Plant Explorer. Thus, the
only thing left is configure the OPC Data Source Definition aspect and then connecting
the OPC Server to the controller before subscribing live data from the controller.
This subsection assumes that the OPC Server has already been installed and that
you have the MyDoors project downloaded and running in a controller. For information
on how to configure an OPC Server, see the System 800xA Getting Started
(2PAA111708*) manual.
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6.1 OPC Server
Connecting the OPC Server to a Controller

From the Windows Start menu:
1. Select ABB Start Menu > ABB System 800xA > Control and IO > OPC Server
for AC 800M > OPC Server for AC 800M.
2. In the IP text field, enter the controller IP address and click Connect.
If your controller is a SoftController, the IP address is the IP address of your PC, with
the suffix ":2". For example, if the PC has the IP address 172.16.37.35, the IP address
of the SoftController will be 172.16.37.35:2
To retrieve the computer IP address:
a. In the Windows Search, type cmd and select Command Prompt from the list.
b. A Command Prompt window is displayed.
c. Type ipconfig and press Enter. The IP address is displayed.
d. Write down the IP address and close the DOS window.
The OPC Server should be up and running:
Figure 6.1: The OPC Server Configuration Panel connected to a Soft Controller
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6.2 Plant Explorer
6.2 Plant Explorer

6.2.1 Starting the Plant Explorer
From the ABB Start Menu select ABB System 800xA > System > Workplace. The
ABB Workplace Login window opens.
Figure 6.2: ABB Workplace Login window.
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6.2 Plant Explorer
1. Select Plant Explorer Workplace and click Open. The Plant Explorer opens.
To access the Plant Explorer Workplace from the desktop, select Plant Explorer
Workplace and click Create Desktop Shortcut (see Figure 6.2).
2. Select Control Structure from the drop-down menu.
Figure 6.3: Control Structure view. Note that Control Network and MyDoors project
have been added to the Control Structure by Control Builder.
Configure OPC Server in 800xA System

OPC Server for AC 800M must also be configured in the 800xA System:
1. In the Control Structure, select the Control Network icon. An aspect list opens.
2. In the aspect list, click the OPC Data Source Definition aspect. The Aspect preview
pane opens.
3. Click New. A ‘New Service Group’ window opens.
4. Click Add. An ‘Add Service Provider’ window opens and lists the PC network names.
5. Click OK.
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6.2 Plant Explorer
6.2.2 Subscribing Controller Data

Make sure you are in the Control Structure, see Figure 6.3.
1. Expand MyDoors > Applications > Application_1 > Diagrams until you see
Diagram2.
2. Select the control aspect for Diagram2. It is the aspect Diagram in the aspect pane.
The aspect preview pane will open.
Control aspect for Diagram2

Figure 6.4: Diagram1 and the control aspect Diagram
3. Select the Property View tab in the Aspect preview pane.

4. Check Subscribe for live data. Live controller data is now presented in the Aspect
preview pane:
Figure 6.5: Aspect preview pane with live controller data.
6.2.3 Navigating between Project Explorer and Plant Explorer

Many of the objects that are shown in the Project Explorer tree view in Control Builder
are also shown in the Plant Explorer, mainly in the Library Structure view and Control
Structure view. There are some navigation commands that make engineering easier
when working in these two tools.
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6.2 Plant Explorer
Navigate from Project Explorer to Plant Explorer

1. Open the context menu by right clicking on the object in Project Explorer.
Figure 6.6: Navigation command in the context menu of the Diagram1 object.
2. Select the Go to Object in Plant Explorer command.
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6.2 Plant Explorer
3. The Plant Explorer will open and the corresponding object is selected in the tree
view:
Figure 6.7: Diagram1 object selected in the Control Structure of the Plant Explorer
Workplace.
Navigate from Plant Explorer to Project Explorer

In the context menu for a Control Builder object in the Plant Explorer there are two
navigation commands:
Figure 6.8: Navigation commands in the Plant Explorer
The Project Explorer command will open the Project Explorer and the corresponding
object will be selected in the tree view.
The Diagram Editor command will open the editor for the diagram.
Note that these commands are not available for all objects in Plant Explorer. The
commands are only visible if the object exists in Control Builder.
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A Functions and Settings
A.1 Ready-made Projects for CB Professional
Appendix A Functions and Settings
This section describes some of the functions that are specific to Control Builder. It will
also provide guidelines for different settings and configuration issues typical to working
with control software for AC 800M. A more detailed description for these topics can be
found in the manual Control AC 800M Configuration (3BSE035980*).
A.1 Ready-made Projects for CB Professional

The 800xA system comes with a number of examples that are designed to help you
understand how to use various parts of the system and the standard libraries. All these
examples are installed as (afw) files in the folder
Program Files (x86)/ABB Industrial IT/Engineer IT /
Control Builder M Professional/Examples.
• An alarm and event example (AlarmSimple_M.afw),
• A number of control loop examples (ControlExamples.afw),
• A group start example (GroupStartExample1.afw),
• A supervision example (AreaExampleProject.afw)
• An INSUM example (INSUMExample.afw),
• A basic shop door example in ST and FD languages (ShopDoors_ST.afw and
ShopDoors_FD.afw),
• A tutorial (Tutorial_03.afw).
A.1.1 Import an Example to 800xA

Before you can use any of these examples that have been storage on your disk, you
must first import them to the Plant Explorer workplace.
If Environments are enabled, the files are imported to the Engineering Environment
(default settings).
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A.2 Testing
To import an example:
1. Click the icon (Launch Import Export tool) in the Plant Explorer tool bar.
2. On the File menu, select Open. The Open Import/Export File dialog is displayed.
3. Browse to the file you want to import, select it and click Open. The Import/Export
window opens.
It is also possible to open the Import/Export window by double-clicking the .afw file
of the example project from the folder. In this case, ignore Step 1 to Step 3.
4. On the Actions menu, select Import All. A project, containing the example, is created
under a separate Control Network.
5. In the Control Structure, drag the project icon from the Control Network that was
created to your “ordinary” Control Network and drop it.
6. Delete the Control Network that was created.
You can now study the example like any other control project.
A.2 Testing
Test mode can be used for offline testing of applications. Executing code in Test mode
means that the code will be compiled and executed locally in the PC. You can use the
online editors to view variables and application execution. The execution time will be
much faster than executing code online, and you do not need a controller. However,
external communication is disabled during test mode.
Test mode is enabled from the Tools menu in Project Explorer (select Test Mode).
If the project includes several controllers, you will be asked to choose which controller
to start the test mode with. See also Download Project to Selected Controllers on page
118. When Test mode is selected, a version check is performed and the Test Mode
Analysis dialog displays the present applications and controller configurations. Different
restart options will be offered in the Analysis dialog, a more defined presentation can be
found in Application Restart Mode on page 125.
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A.3 Simulation
A.3 Simulation
Simulation means that the code is downloaded and executed in a simulation controller.
Simulation can be done either in a SoftController, or in a simulation controller.
SoftController requires a separate software license.
Simulation can be used to test your applications without connecting them to the physical
environment, and to make sure they work and behave as expected.
When an application is simulated, all I/O copying is cancelled. This means that you
need to write corresponding code for I/O responses. For more information see Running
in a Simulation Controller on page 113.
You are advised to read the subsection Restrictions Concerning Hardware Simulation
on page 114, before you start simulating the hardware.
Select Tools > Setup > Station > Application Download to open the
Setup - Application Download dialog (see Figure A.1).
Figure A.1: Application Download with default settings
Set the parameter HWSimulationAllowed to true, to allow hardware simulation.
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A.3 Simulation
A.3.1 Simulation Controllers

Applications written for another product type may be tested in a simulation controller.
The normal copying of I/O-channel data to and from any “real” I/O-module can be replaced
by simulated I/O values.
I/O values can be simulated in a number of ways, from simply using logged data, to
using advanced process simulations. Since there is no I/O copying in a simulated
controller, it is possible to write simulated values directly to I/O variables.
Simulation controllers are always marked with a “Simulated” flag ( ), to eliminate the
risk of downloading simulation code to a production controller.
A simulation controller accepts a controller configuration even if it does not match its
family and type. The following hardware simulation combinations are possible:
Table A.1: Matrix of controllers that can be used for simulation

Type of controller to be SoftController (HI
AC 800M SoftController
simulated Mode)
AC 800M Yes Yes No
AC 800M HI No No Yes
Note that an AC 800M High Integrity controller can never be used for simulation
purposes. An AC 800M High Integrity controller can only be simulated in a
SoftController High Integrity (SoftController HI).
A.3.2 Applications in Simulation Controllers

Normally, applications that are to be simulated should have a “Simulated” mark.
However, it is always possible to run applications that do not have the “Simulated” mark
in a simulation controller. The main purpose of the “Simulated” mark on applications is
to prevent the application from being downloaded to a controller that is not intended for
simulation.
A.3.3 Mark Controller for Simulation

To mark the controller “simulated”, right-click the controller and select
Properties > Simulate Hardware in the context menu.
All hardware units belonging to the simulation controller will automatically be
simulated-marked, including hardware units such as communication interfaces on the
controller’s CEX-bus. When a controller is set in simulated mode the icons in the Project
Explorer's hardware tree will be exchanged with special simulation icons (with a red "S").
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A.3 Simulation
A.3.4 Mark Application for Simulation

To mark the application “simulated”, right-click the application in the Project Explorer,
and select Properties > Simulated.
If the application is simulated-marked, all programs, control modules, function blocks
etc. will be simulated, even if they are not simulated-marked. If a simulated-marked
program, control module, or function block is used in an application, then the application
itself must be simulated-marked as well. It is the simulated-mark on the application that
is important.
The simulate-mark on a program may be a way to indicate where, for example, a

simulate marked function block is used.
A.3.5 Download to Simulation Controller

To download the hardware configuration and the simulated-marked application to the
simulation controller, select Tools > Download Project and Go Online. See also Difference
Report on page 120.
Before download, the controller has to be reset, or already be simulated-marked. To
reset the controller, press the controller’s INIT button in more than 3 seconds, or
temporarily disconnect battery and power supply from the controller.
A simulated-marked application or object can only be downloaded to a simulation
controller. But, an application without simulation mark can be downloaded to a simulation
controller.
A.3.6 Running in a Simulation Controller

When an application is running in a simulation controller, value and status of I/O variables
can be set. The status can be set both on module and channel level.
To test the application in the simulated hardware environment, you can for example use
the forcing function to change variable values (that will normally be connected real
I/O-channel values). Right-click the I/O module and select Editor, and in the Status tab,
check the box in the Forced column and change the desired variable value. See Figure
A.2. Note the word “Simulated” in the title bar.
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A.4 Download
Figure A.2: Variable values can be forced to simulate I/O channel values.
The online editor can for example be used to inspect the result of changed variable
values for a simulated program.
A.3.7 Restrictions Concerning Hardware Simulation

The hardware simulation functionality is intended for use in a separate testing Control
Network. Thus, the hardware simulation controllers shall never be run on the same
Control Network as the real production controllers.
If the hardware simulation controllers are located on the same Control Network as
the production controllers, either the production controllers may receive unintentional
downloads or the future downloads to the production controllers may be affected.
There is also a chance of the simulated data being sent to the production controllers,
along with the real data. If there is an IP address conflict, the simulated data can also
be interpreted as real data by the controllers.
A.4 Download
This section describes download and the checks and reports associated with download.
A.4.1 General Download

When you select Tools > Download Project and Go Online, the project in Control Builder
will be downloaded to the controller and Control Builder will enter Online mode.
Version and Online Analysis

During the version check, the project in the Control Builder is analyzed and compared
with the project downloaded in the controller (if any).
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A.4 Download
The version check will detect if:

• project versions are identical, and neither the application nor the controller
configuration has been changed, then the project will not be downloaded. The effect
will be same as going online without download.
• there is no project version mismatch, but the application or controller configuration
has been changed, then the changed parts will be downloaded, following the general
procedure described in the following.
• the project in the controller contains an application that is not part of the project to
be downloaded, but has been downloaded as part of the same project, then this
application will be deleted during the download process.
• there is another project in the controller, different from the one to be downloaded,
you will have to delete the project and restart the controller, before you can download
the new project. See Download New Project to Controller on page 117.
The Online Analysis dialog displays the present applications and controller configurations,
and whether or not they have been changed in the Control Builder. An application or
controller configuration is considered changed if the version in the Control Builder is
different from the version running in the controller.
Compilation
Compilation is performed in Control Builder. If any warnings or errors are detected during
the compilation, a Compilation Summary dialog shows a summary of the warnings and
errors. You can then choose (if there are no errors) to continue or cancel the compilation.
Compiler switches can be used to set extra restrictions for the code. For more
information, see Compiler Switches on page 123.
Change Analysis
Control Builder will perform a change analysis if you have changed:
• variables, function blocks, or control modules,
• data types, function block types or control module types,
• libraries,
• applications.
The change analysis is performed, before downloading, to check the possibility of
maintaining variable values after restart.
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A.4 Download
The change analysis detects mismatches between the application version in the controller
and the application version to be downloaded.
A mismatch can occur if:
• A variable has been assigned another data type,
• A variable, function block or control module has been renamed,
• A data type, function block type or control module type is missing, has been renamed,
or has been moved to another library,
• A library has been given a new name (this will result in a mismatch for all data types,
function blocks types and control module types from this library),
• An application has been renamed (this will result in a mismatch for all data types
and variables, function blocks and control modules in the application).
For variables with attributes Retain or ColdRetain, the change analysis is performed in
the following way:
1. All data types, function block types, and control module types, which existed before
the change, are checked for name matching.
2. All variables, function blocks, and control modules are checked for name and type
matching.
If the change analysis detects mismatches, Control Builder cannot determine how to
retain variable values. A warning dialog will display information about detected
mismatches. You may then have to guide Control Builder and correct mismatching
names, by giving the renamed object the new name (click Rename in the dialog).
Download and Go Online

The changed parts of the project (application and/or controller configuration) are
downloaded to the controller(s). The controller(s) will stop the running application(s),
and restart with the new/changed versions, and with variable values maintained
(depending on the type of attribute and restart).
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A.4 Download
After download is completed, Control Builder enters Online mode. In Online mode, Control
Builder communicates with the controller(s), and you can view variables and application
execution in the controller(s) using online editors. Furthermore, you can issue operations
to the controller.
If the message “Download aborted. See the controller log for further information.”
appears during download, an error has been detected in the downloaded controller
configuration. A common cause is that there is not enough controller memory. You
may find details in the controller log. If the controller is still running, you can try to
compile and download again. See the manual Control AC 800M Configuration
(3BSE035980*) for how to locate the log file.
A.4.2 Download New Project to Controller

When you select Tools > Download Project and Go Online, the Confirm Deletion of
Project dialog is displayed if there is another project in the controller. To reset and restart
the controller, click Complete Reset in the dialog. See Figure A.3.
Another way to reset and restart the controller is to press controller’s INIT button for
more than 3 seconds.
Figure A.3: Confirm Deletion of Project dialog
When downloading to a High Integrity controller, a complete reset cannot be done

from this dialog. The Complete Reset button will be dimmed.
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A.4 Download
The controller will then be reset, all existing applications in the controller will be deleted,
and the controller will be restarted. The download of the new project can then be continued
(as described in General Download on page 114.)
A.4.3 Download Project to Selected Controllers

For a project that contains more than one controller, it is possible to choose which
controllers to download and go online with. In this way, certain applications and controller
configurations can be excluded from the download, and you can go online with only a
sub-set of the project to a selected controller. This reduces the compilation time.
When working in a multi-user environment, one user can work with some parts of the
project, while other users are working with other parts. If the other parts of the project
cannot be compiled since they are not finished, the user will still be able to go online
with parts that are finished.
If an application is connected to several controllers, it is not possible to select only

one controller. The remaining controllers will be added automatically.
If you select Tools > Download Project and Go Online for a project with more than one
controller, the Selection of Controllers dialog will be displayed. For example, in Figure
A.4, “Controller_2” and “Controller_3” cannot be separately selected or excluded since
one application is connected to both these controllers.
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A.4 Download
Figure A.4: Selective of Controllers dialog
Another way to select a specific controller is to right-click the controller in Project Explorer,
and select Download and Online Mode.
The Selective Download function is by default enabled, but can be disabled by selecting
Tools > Setup > Station > Application Download, and in the Setup dialog setting the
parameter SuppressOnlineSelectionDialog to true.
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A.4 Download
Selecting an Application to Download

Besides connecting several applications to one controller and download them, you can
also select just one of these applications for download. This is convenient when some
parts, for example in Application_1 are not ready but everything in Application_2 is
finished and ready for testing. If both applications are connected to Controller_1, you
will be giving a chance to select if both applications should be downloaded or just
Application_2.
1. Click Continue-button in Figure A.4, an Online Analysis window will open.
2. Select the application to be downloaded. See the example in Figure A.5.
Fi 63 C d li i ll O l A li i 2 ill b
Figure A.5: Connected applications to a controller. Only Application 2 will be
downloaded.
A.4.4 Difference Report

Difference report shows the difference between data downloaded to the controller and
the data present in Control Builder. The tree view shows the parts of the application that
have changed. By clicking an item in the tree, you can display the present controller
code, and the new code beside. Differences are also indicated by colors (the color coding
is explained on the status bar at the bottom of the report window).
If the Difference Report function is enabled, it will display:
• Difference report,
• Source code report.
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A.4 Download
Based on the information presented in the reports you can either accept or reject the
changes that is if you want the download to be carried out or cancelled.
The function is enabled/disabled from the root (Project icon) at the top of the Project
Explorer tree structure.
Right-click the Project Icon (e.g. MyDoors in Figure 3.2) and select Settings > Project
Settings from the context menu. The click on the Difference Report Settings item in the
tree view in the left part of the Project Settings dialog.
Figure A.6: The Difference Report Settings part or the Project Settings dialog.
To enable the difference report, select the Enable Difference Report check box and
click OK.
The Difference Report function is always enabled when downloading any application
to a High Integrity controller.
Difference Report Before Download

If the difference report setting is enabled, the Difference Report Before Download dialog
(as shown in Figure A.7) appears before the download of the application to the controller.
Click to accept the download.
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A.4 Download
Figure A.7: Example of a Difference Report Before Download
A.4.5 Re-Authentication
The Re-Authenticate function is used to ensure that a user is authorized to download a
project. If the function is enabled, a dialog is shown and you will be asked to enter name
and password before the download is carried out.
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A.4 Download
Figure A.8: Re-authenticate dialog
Disable/Enable Re-Authenticate function

1. Select Tools > Setup > Station > Application Download.
A ‘Setup Application Download’ dialog opens.
2. Set the parameter ReauthenticateDL to true/false. The function is enabled per
Control Builder station.
A.4.6 Compiler Switches

Configurable switches in the compiler allow you to introduce extra restrictions on code.
The restrictions are divided into:
• Global restrictions
• SIL restrictions
Global restrictions are valid for all code.
SIL restrictions are valid only for code marked SIL1-2 and SIL3. For SIL1-2 and SIL3
code, there are also mandatory restrictions, which cannot be changed.
A restriction can have the values:
• Allowed
• Warning
• Error
Mandatory SIL1-2 and SIL3 restrictions are always errors.
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A.4 Download
The restrictions are checked during the check of each type, and also during the
compilation. If you change a restriction, the project will be re-compiled when you perform
a download of the project, and the code will be validated with the new restriction.
Restrictions makes it possible to warn against or forbid things that may result in complex
code and thereby errors. For example, to check the usage of Instruction List language,
you can change the corresponding switch from “Allowed” to “Warning”, and you will get
a compilation warning if there is any IL code in the project. Another example is when a
new library is imported, you can then turn all switches from “Warning” to “Error” to check
the quality of the new library.
Compiler switches are configured in the Compiler Switches dialog, which is displayed if
you; right-click the Project Icon (e.g. MyDoors in Figure 3.2) and select Settings >
Compiler Switches from the context menu. A ‘Compiler switches’ window will open.
Figure A.9: Compiler switches dialog
It is possible to exclude a library from a certain restriction, provided that the restriction
is a warning. If a library is excluded, no checks are performed on the restriction for any
type in that library. For example, if a new external library results in many warnings, you
may want to filter out acceptable warnings to make it easier to read other warnings. Click
Options in Compiler Switches dialog, and in the expanded dialog select the library to
exclude from the selected restriction.
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A.5 Application Restart Mode
Figure A.10: Compiler switches, excluding library from restriction.

Variables can be given the attributes retain or cold retain. Depending on the attributes
specified for the variables, the values of the attributes are either maintained or lost upon
warm restart, cold restart, and power failure. Control Builder sets the attribute retain on
all variables by default.
It is also possible to specify an initial value for a variable. The initial value is used if the
value of the variable is not maintained after a restart or power failure.
For more information about variables, attributes and values, see the manual Control
AC 800M Configuration (3BSE035980*).
A.5.1 Warm Restart

A warm restart is performed after a download of application changes and after a power
failure (provided that it is backed up by the battery in the controller).
3BSE041880-610 A 125
At warm restart, only variables with the attribute retain or coldretain are retained. The
values are retained from the current version of the application running in the controller
to the new version, based on name matching.
All other variables are set to their initial value, if such values have been given. Otherwise
the values of the variables are set to the default values of the data types. The default
value is “false” for boolean, 0 (zero) for integer, and so on.
It is possible to force a cold restart after a download, even if a warm restart is

proposed.
After a power fail, instead of doing a warm restart of the application SIL3 applications
are restarted using cold retain marked values saved in the controller periodically with
a cycle time set by the user.
A.5.2 Cold Restart

A cold restart is always performed after the first download. It is also possible to order a
forced cold restart after a download (in the Online Analysis dialog, select the application
and select Cold Restart, or click Cold Restart All to perform a cold restart of all
applications).
A short (less than 3 seconds) push on the controller’s INIT button also results in a
cold restart.
At cold restart, only variables with the attribute cold retain are retained. The values from
the aspect server are only used when downloading from Control Builder using cold
restart. All other variables are set to their initial value, if such values have been given.
Otherwise the values of the variables are set to the default values of the data types.
Cold Retain Values

Control Builder normally saves cold retain values when going from Online to Offline
mode. The saving is enabled/disabled, via Tools > Setup > Station > System Variables,
and the parameter SaveColdRetainOnOfflineTransfer.
In Online mode, you can order Control Builder to save cold retain values by selecting
Tools > Save “ColdRetain” Values.
3BSE041880-610 A 126
The OPC server can also be configured to save cold retain values, either manually (the
values are saved when you click Save) or automatically (the values are saved periodically
with a cycle time set by you).
When you need to setup the saving of cold retain values, consult OPC Server online
help and the manual AC 800M OPC Server (3BSE035983*).
A.5.3 Variable values in Download mode

Depending on which mode Control Builder enters Online mode, a cold or warm restart
will affect variable values differently. See Table A.2, Table A.3, and Table A.4.
Initial Restart
Table A.2 shows how a initial restart affects variable values when Download mode is
started.
Table A.2: Initial restart, starting values
Variable attribute Starting value

ColdRetain Initial value
Retain Initial value
Other Initial value
Cold Restart
Table A.3 shows how a cold restart affects variable values when Download mode is
started.
Table A.3: Cold restart, starting values

ColdRetain Cold retain value
Retain Initial value (if any)
Other Initial value (if any)
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Warm Restart
Table A.4 shows how a cold restart affects variable values when Download mode is
started.
Table A.4: Warm restart, starting values

ColdRetain Retain value
Retain Retain value
A.5.4 Variable values in Test mode

Initial Restart
The variable values are similar as in Download mode, see Table A.2.
Cold Restart
The variable values are similar as in Download mode, see Table A.3.
Warm Restart
The Warm restart mode can only be selected if the Control Builder previously was in
Test mode. The variable values are similar to Warm restart variable values in Download
mode if the control builder was not in the Test mode previously, see Table A.4.
Warm Restart of the application is performed after the power failure. The restart values
of the variables are as shown in Table A.5.
Table A.5: Warm restart: starting values

ColdRetain Last test session
Retain Last test session
Compilation is performed in Control Builder. You can choose (if there are no errors) to
continue or cancel the compilation. If compilation warnings or errors are detected, the
Compilation Summary dialog will display a summary of the warnings or errors.
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A.5.5 Power Failure

A power failure, in combination with low battery capacity in the controller, means that
the controller will be completely reset, that is, empty. Or by pressing the controller’s INIT
button for more than 3 seconds it will have the same effect. You will then have to download
the project again.
If you remove the power source (battery) during a power fail, all error logs
will be lost.
In these cases, only variables with the attribute cold retain can be retained. All other
variables are set to their initial values, if such values has been given. Otherwise the
values of the variables are set to the default values of the data types.
3BSE041880-610 A 129
3BSE041880-610 A 130
B License Management
B.1 Introduction
Appendix B License Management
B.1 Introduction
License Management comprises of the following three licenses:
• Control Builder license
– A license that controls the number of currently active Control Builder clients,
see Control Builder Licenses on page 132.
• SoftControl license
– Each started Soft Controller instance should have one license each. Several
Soft Controllers can be started on the same PC.
• Library license
– For using the libraries – TCPHwLib, UDPHwLib, and BurnerLib – separate
licenses are required, see Library Licenses on page 134.
• Loop check license
– For using the loop check tool, see manualSelect I/O Configure and Check
Ethernet I/O Getting Started (9ARD148917*).
Information regarding licensing errors and what happens when licenses need to be
extended (the system will start showing messages that licenses are missing, so called
system wide annoyance mode) etc. can be found in the manual Control AC 800M
Configuration (3BSE035980*) (in the Maintenance and Trouble-Shooting section).
3BSE041880-610 A 131
B.2 Control Builder Licenses
B.2 Control Builder Licenses

A Control Builder license is included when purchasing an engineering workplace.
When you open or create a new control project, Control Builder checks for a ‘free’ Control
Builder license. If the server cannot find one, a dialog will tell you that the action was
denied.
You cannot open or create a new control project without a Control Builder license.
B.2.1 Loop Check License

A loop check license is required to download to a loop check controller and use the loop
check tool. See Select I/O Configure and Check Ethernet I/O Getting Started
(9ARD148917*) for more information.
B.3 Controller Capacity Points (CCP)

When applications are downloaded to controllers, the total CCP count is calculated.
The total CCP count is calculated by checking the CPU type of the controllers that
participated in the download. Other installed hardware units (like IO modules, drives,
INSUM units, and so on) are not checked for calculating the CCP.
The following restrictions apply to CCP count calculation for controllers (PM8xx):
• Controllers with the Simulate Hardware state is excluded from CCP calculation.
• Redundant PM8xx is counted as single PM8xx.
B.3.1 CCP Calculation Rules

Each CPU type has a unique Controller Capacity Points (CCP) figure that relates to the
capacity for the controller. Table B.1 provides the CCP for each type of controller.
Table B.1: CCP for each controller type
Controller Type CCP

PM851 13
PM856 25
PM857 25
3BSE041880-610 A 132
B.3 Controller Capacity Points (CCP)
Table B.1: CCP for each controller type

(Continued)
Controller Type CCP
PM858 30
PM860 40
PM861 50
PM862 58
PM863 67
PM864 67
PM865 67
PM866 100
PM867 100
PM891 150
SoftController 0
See Checking Licenses for a Controller on page 135.

In a Control Builder project, if an application is downloaded to a controller, the CCP
count for this controller is always included in all subsequent downloads. This happens
even though this controller is not selected in the subsequent downloads. To remove
the CCP count for this particular controller (if this controller is no longer used), remove
it from the Control Builder project and proceed with the download to the other
controllers.
3BSE041880-610 A 133
B.4 Library Licenses
B.4 Library Licenses

The libraries – TCPHwLib, UDPHwLib, and BurnerLib – require separate licenses. These
licenses are checked after the download of the project to the controller, in any of the
following cases:
• The TCPHwLib is added to the Connected Libraries folder under required controller
in Controllers folder.
• The UDPHwLib is added to the Connected Libraries folder under required controller
in Controllers folder.
• The BurnerLib is added to the Connected Libraries folder under the required
application in Applications folder.
See also Checking Licenses for a Controller on page 135.
3BSE041880-610 A 134
B.5 Checking Licenses for a Controller
B.5 Checking Licenses for a Controller

To check the required CCP Count and Library Licenses for a controller that participated
in the download:
1. In Plant Explorer, go to Control Structure, go to the project and then select the
controller. The Controller aspect will be displayed in the aspect pane.
Controller in the Control Structure Controller aspect

Figure B.1: (Left) Selected controller in the Control Structure. (Right) The Controller
aspect for the selected controller (Controller_1).
3BSE041880-610 A 135
B.6 Combined AC 800M High Integrity Controller
2. Click the Controller aspect and select the Licensing tab in the aspect preview pane.
The current downloaded CCP value for the selected controller, and the Library
Licenses are displayed (see Figure B.2).
The Required points is validated against the actual licenses available.
If the controller has not been downloaded or if it is in Simulate Hardware state, the
tab displays information about this condition, and no CCP values or Library Licenses
are displayed.
Figure B.2: Example of the Licensing tab in the Controller aspect of the selected
controller
The Licensing tab in Figure B.2 shows the required Controller Capacity Points (CCP)
count and Library Licenses for only the selected controller to which the application
is downloaded. To calculate the total CCP count, open the Controller aspect of each
controller that participated in the download, and add the CCP counts.
B.6 Combined AC 800M High Integrity Controller

An AC 800M High Integrity controller can be used to run both non-SIL and SIL applications
at the same time. If the non-SIL application uses more than the limited functionality listed
below, it is considered to be a combined PA/Safety controller.
• Connect only to Unit Status on hardware units, i.e. no variables or signals connected
to I/O channels.
• Only using standard libraries System, BasicLib, IconLib, and/or AlarmEventLib,
hence the usage of e.g. SystemDiagnostics is allowed
A combined PA/Safety controller requires an additional license. For further additional
information, please contact your local ABB vendor.
3BSE041880-610 A 136
C SIL Certified Applications
C.1 Introduction
Appendix C SIL Certified Applications
C.1 Introduction
SIL stands for “Safety Integrity Level”, as specified in the standard IEC-61508. To run
SIL certified AC 800M applications, you need a SIL certified AC 800M High Integrity
controller.
It is also possible to run non-SIL applications in a High Integrity controller.
The Safety Manual, AC 800M High Integrity (3BNP004865*) contains guidelines and
safety considerations related to all safety life-cycle phases of an AC 800M High Integrity
controller.
C.1.1 SIL Information can be Disregarded by Non-SIL Users

Part of the information given in this manual applies to SIL applications only. If so, this
will be indicated. If you do not run any SIL applications and do not have an AC 800M
High Integrity controller, you can disregard any SIL-specific information.
For information on restrictions regarding SIL applications and High Integrity controllers,
see online help and the manual Control AC 800M Configuration (3BSE035980*).
C.2 SIL Applications

A SIL application is always marked with a SIL icon when shown in the programming
interface.
3BSE041880-610 A 137
SIL application
2
3
Figure C.1: SIL application in Project Explorer.
When an AC 800M High Integrity controller is used, there is always an additional standard
library, as well as two additional applications (see Figure C.1):
• VMTLib (1) is the Virtual Machine Test library, containing types used when running
the VMT application.
• VMT_Controller_1 (2) is an application used to make sure that the HI controller
works properly. The name of this application is made up of the prefix VMT_ and the
name of the controller, which is called HI_23 in our example.
• CTA (3) is the Compiler Test Application, used to make sure that the compiler works
properly.
Never delete the above libraries and applications if you run a High Integrity controller.
The VMT library, the VMT application, and the CTA application are needed to make
sure that the High Integrity controller and compiler work properly.
A SIL application may only use library types that are SIL certified. SIL certified library
types are marked with SIL icons in the programming interface. The compiler will also
check for constructs in your code (for example, loops) that are not allowed according to
the SIL standard. If a SIL-marked application contains not allowed types, objects or
constructs, it cannot be downloaded due to compilation errors.
C.2.1 Setting SIL-Levels

You can set Non-SIL, SIL1-2, and SIL3 for the Safety Level on Function Blocks, Control
Modules, SingleControlModules, Programs, Diagrams, Applications, and Tasks according
to the requirement.
3BSE041880-610 A 138
Right-click on the object (except for tasks where the setting is performed in the Task
Dialog), select Properties, and then select Safety Level as shown in Figure C.2. Select
the required SIL Level.
Figure C.2: Setting SIL-Level
The SIL-level is displayed as a black number on top of the icon for the intended object.
If no number is displayed the level is Non-SIL. This marking is also available on Functions.
3BSE041880-610 A 139
C.3 High Integrity Controllers
C.2.2 Restricted SIL-Level

It is not allowed to use output parameters from Function Blocks or Control Modules
marked with Non-SIL in the parameter description in a way that can influence the safety
function of a SIL classified application. If such code affects an output from a SIL3
application, it might result in a Safety Shutdown.
Some of the objects and functions in standard libraries have a restricted SIL-marking
icon in the project tree in the Control Builder project explorer. These functions are allowed
to be used in a SIL application with few restrictions. Using a restricted object or function
to affect I/O or to be used in peer-to-peer communication might result in a malfunctioning
application or a safety shutdown. Restricted objects and functions must not be used as
a part of the critical loop for a safety function.
The color of the SIL-digit in the icon is grey on a restricted object and function, compared
to the black digit on regular SIL-classified objects and functions. Examples of Restricted
icons is as shown in the figure below.

An AC 800M High Integrity (HI) controller consists of a PM857, PM863, PM865, or PM867
processor unit and a number of HI-specific objects that are added to the hardware tree,
see Figure C.3.
3BSE041880-610 A 140
Figure C.3: AC 800M High Integrity controller.
The following objects are only added for a HI controller:

• SM81X (1) is a module that supervises the function of the controller.
• The VMT task (2) is used to run the VMT application. Note that the VMT application
is connected to HI controllers automatically, and should not be removed.
• The VMT application (3) (see previous subsection) is automatically connected to
the controller.
In addition to the objects listed above, a High Integrity controller also has HI-specific
firmware, which makes sure that the controller works as specified in the
SIL1-2 and SIL3 standard.
C.3.1 Downloading an Application

Access Enable must be set to (ON) before downloading to an AC 800M HI controller,
no matter if the applications are non-SIL or SIL marked.
3BSE041880-610 A 141
3BSE041880-610 A 142
D Communication Cables
D.1 Connecting Control Builder PC to a Controller
Appendix D Communication Cables
Serial communication between Control Builder and the AC 800M controller is done by
using the TK212A cable.
Connect the DB9 Female connector to a Control Builder PC COM port, thus the RJ45
(8P8C) plug to the AC 800M controller COM4 port. The Figure D.1 illustrates the TK212A
pin-out configuration.
D.1 Connecting Control Builder PC to a Controller

2 3
5 4
5 5
DB9 Female 3 6 RJ45 plug
Control Builder PC 4 2 AC 800M Controller
1 7
6 1
7 8
8
Braid
Shield Shield
Figure D.1: Cable TK212A Pinout configuration.
3BSE041880-610 A 143
3BSE041880-610 A 144
Revision History
Revision History
Revision History
This section provides information on the revision history of this User Manual.
The revision index of this User Manual is not related to the 800xA 6.1 System Revision.
Revision History
The following table lists the revision history of this User Manual.
Revision
Description Date
Index
A Published for 800xA 6.1 November 2018
3BSE041880-610 A 145
3BSE041880-610 A 146
Index
Index
A
Analysis D
changes, 115 Diagram, 45–46
online, 114 Diagram editor, 47
version, 114 add new object, 54
Application, 25 add new variable, 50, 57
CTA, 138 changing online value, 70
folder, 32 graphical connection between objects, 59
restart mode, 125 graphical connection between pages, 64
SIL, 137 in test mode, 69
page connectors, 66
C page name, 48
Change analysis, 115 panes, 39
Cold restart, 126 port visibility, 56
variable values, 127 Download
Communication cables change analysis, 115
cross-over ethernet cable, 91 go online, 116
serial connection to controller, 143 new project, 117
straight-through ethernet cable, 91 re-authenticate, 122
Communication variable, 46 simulated applications, 120
declaration, 52 to selected controller(s), 118
Compilation, 115 via Ethernet, 91
Compiler Test Application (CTA), 138 Drag-and-drop, 35
Configure
hardware, 73 E
IP address for controller, 93 Entity, 26
OPC server, 23, 104 Environment, 27
system, 23 deploy, 27
Context-sensitive help, 21 Ethernet
Controller cables, 91
configure IP address, 93 configure IP address for controller, 93
High Integrity, 140 ports on controller, 91
Create logic
counters, 53 F
timers, 53 Firmware upgrade
CTA application, 138 via Ethernet, 83
Firmware Upgrade
3BSE041880-610 A 147
Index
via serial cable, 84 declare variable and signals, 46

Folder MyDorrs project
application, 32 creating the project, 44
applications, 32 testing, 68
controllers, 34
libraries, 30 O
Forcing I/O values, 98 Online analysis, 95, 97
Online help, 21
H contents, 22
Hardware context-sensitive help, 21
configuration, 73 help topics, 21
Hardware Libraries, 19 index, 22
High Integrity controller, 140 search, 22
show help about..., 21
I Online mode, 95, 97
INIT button, 126 forcing I/O, 98
IP address, 86, 89 OPC Server, 101
IPConfig, 86 configure, 23
configure in 800xA system, 104
L variable communication, 101
Libraries, 18
Alarm and event library, 19 P
Basic library, 19 Power failure, 129
Binary process libraries, 19 Project
Burner library, 19 download, 95
Communication libraries, 19 object, 25
Control Libraries, 19 refresh, 40
Signal libraries, 19 templates, 28
Standard libraries, 18 Project Explorer, 17
License, 131 drag-and-drop, 35
explorer pane, 30
M message pane, 38
Manuals, 20
safety manual, 21, 137 R
Message pane Re-authentication, 122
diagram editor, 39, 47 Refresh, 40
Project Explorer, 38 Release reservation, 26, 81
ModuleBus, 75 Reservation, 26
MyDoors project, 41 status indications, 37
create logic (first page), 53 Reserve object, 27
create logic (second page), 61
create logic (third page), 63
3BSE041880-610 A 148
Index
S TK212A cable, 84, 143

Safety Manual, 21, 137
Signals, 46 V
connect to I/O channels, 78 Variable values
declaration in POU editor, 52 at cold restart, 127
SIL, 137 at warm restart, 128
Standard libraries, 18 Version
System configuration, 23 analysis, 114
System extensions, 23 Virtual Machine Test (VMT), 138
T W
Test mode, 68, 110 Warm restart, 125
variable values, 128
3BSE041880-610 A 149
3BSE041880-610 A 150
www.abb.com/800xA 800xA is a registered or pending trademark We reserve all rights to this document
of ABB. All rights to other trademarks reside and the items and images it contains.
www.abb.com/controlsystems with their respective owners. The reproduction, disclosure to third parties
or the use of the content of this document
We reserve the right to make technical – including parts thereof – are prohibited
changes to the products or modify the without ABB’s prior written permission.
3BSE041880-610 A
contents of this document without prior

notice. With regard to purchase orders, Copyright © 2019 ABB.
the agreed particulars shall prevail. All rights reserved.
ABB does not assume any responsibility
for any errors or incomplete information in
this document.

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SYSTEM VERSION 6.

ABB Ability™ System 800xA

ABB Ability™ System 800xA

Document Number: 3BSE041880-610

Trace back information Main Publication:

Copyright © 2019 by ABB.

About this User Manual

2 Control Builder User Interface

2.3.2 Project Explorer Pane .......................................................................... 30

5 Connecting the Controller and Go Online

6 View Live Data in Plant Explorer

Appendix A Functions and Settings

A.4 Download .......................................................................................................... 114

Appendix B License Management

Appendix C SIL Certified Applications

Appendix D Communication Cables

Revision History ..................................................................................................... 145

Index .......................................................................................................................... 147

About this User Manual

User Manual Conventions

Warning, Caution, Information, and Tip Icons

Caution icon indicates important information or warning related to the concept

Information icon alerts the reader to pertinent facts and conditions.

Released User Manuals and Release Notes

1.2 Product Overview

1.2.1 ABB Start Menu

Figure 1.2: ABB Start Menu

1.2.2 Project Explorer

PM860/TP830 DO810 DI810

Figure 1.3: Project Explorer and actual hardware setup.

1.2.4 Control Builder Functions

1.2.6 Online Help

1.3 Before You Begin

Three software licenses – Control Builder, SoftController, and Library License

The System Installer will help you:

1.3.2 Configure OPC Server

2 Control Builder User Interface

2.1.1 About Project and its Objects

2.1.2 About Entities and Reservation

2.1.3 About Environments

Environments provide isolated engineering. Since different environments can have

2.2 Project Templates

2.3 Project Explorer

Project Explorer pane

Figure 2.2: Project Explorer

2.3.1 Title Bar, Menu Bar and Toolbar

2.3.2 Project Explorer Pane

2.3.3 Libraries Folder

Figure 2.4: Creating types under a library

2.3.4 Applications Folder

2.3.5 Controllers Folder

To connect an application to the controller, right-click the Connected Applications folder,

2.3.6 Drag-and-Drop in Project Explorer

Table 2.1: Supported Drag-and-Drop Operations Within Project Explorer

Dragging Objects in Project Explorer and Dropping in Another Window

2.3.7 Context Menus

2.3.8 Reservation Status

• indicates that an application is not reserved by anyone.

• indicates that an application is reserved by you.