T568-02 Freelance System Architecture - RevC

Freelance Training
Chapter 2 Freelance System Architecture
TABLE OF CONTENTS
Chapter 2 Freelance System Architecture ............................................................................................................................... 1

2.1 General Information ..................................................................................................................................................... 2
2.1.1 Objectives.............................................................................................................................................................. 2
2.1.2 Legend .................................................................................................................................................................. 2
2.1.3 Referenced Documentation .................................................................................................................................... 2
2.2 Introduction of the ABB IndustrialIT Concept ................................................................................................................ 3
2.3 Freelance System Components ..................................................................................................................................... 3
2.3.1 Engineering tool Control Builder F (CBF) .............................................................................................................. 4
2.3.2 System Overview with DigiVis .............................................................................................................................. 5
2.3.3 Controller Types and I/Os ...................................................................................................................................... 8
2.3.4 Emulator...............................................................................................................................................................18
2.3.5 Gateway ...............................................................................................................................................................20
2.3.6 OPC - Gateway.....................................................................................................................................................23
2.4 System Overview 800xA Operations............................................................................................................................24
2.5 Redundant Controller Architecture...............................................................................................................................26
2.6 Communication protocol .............................................................................................................................................27
2.6.1 AC 800F IP-Address Settings................................................................................................................................27
2.6.2 AC 700F IP-Address Settings................................................................................................................................28
2.7 Redundancy ................................................................................................................................................................28
2.7.1 Standard setting ....................................................................................................................................................29
2.7.2 Special setting.......................................................................................................................................................30
2.7.3 Ethernet modules ..................................................................................................................................................30
2.8 Freelance system data ..................................................................................................................................................31
2.9 CPU PM 783F Detail Data...........................................................................................................................................32
2.10 System Requirements (Operating System)..................................................................................................................32
2.11 Considerations for Disks and File System...................................................................................................................32
2.12 Recommended PC Equipment....................................................................................................................................33
2.13 Introduction to Freelance Add On Tools.....................................................................................................................34
2.13.1 PGIM 800F.........................................................................................................................................................34
2.13.2 Control Builder F Viewer ....................................................................................................................................35
2.13.3 Security Lock......................................................................................................................................................36
2.13.4 DigiBrowse.........................................................................................................................................................36
2.13.5 Bulk Data Manager .............................................................................................................................................37
2.14 Licensing...................................................................................................................................................................38
2.14.1 AC 800F Product Structure .................................................................................................................................38
2.14.2 EngineerIT ...........................................................................................................................................................39
2.14.3 ControlIT .............................................................................................................................................................41
Chapter 2 - 1
T568-02 Freelance System Architecture - RevC
2.1 General Information
2.1.1 Objectives
On completion of this chapter you will be able to:
• Give an overview about ABB Industrial IT concept
• Describe the network structure in the Freelance architecture
• Describe the functionality of major components
• Recall Freelance Add On Tools
• Outline the Freelance licensing model
2.1.2 Legend
> Indicates when you go from one menu to a sub-menu
Italic Indicates object and file names
“ “ Indicates dialog box buttons, tabs, menus etc.
Bold Indicates important topics
Indicates start/explanation of student activity
2.1.3 Referenced Documentation

3BDD012501R0501 AC 800F Mounting and Installation Instructions
2PAA103858R0201 AC 700F Mounting and Installation Instructions
3BDD012560R0403 Freelance Getting Started
3BDD012513R0401 Security Lock Engineering Manual
3BDD012601R0301 DigiBrowse Operators Manual
Chapter 2 - 2
Freelance Training
2.2 Introduction of the ABB IndustrialIT Concept

Industrial IT is ABB’s commitment to open interoperability of automation and power
solutions and services that leverages the ABB portfolio, 3rd party products and the
relevant standards. The underlying technology supports integrated solutions that
translate into measurable value by increasing productivity, reducing total cost of
ownership and reducing risk and increasing safety - the core values of Industrial IT.
The Freelance system is Industrial IT certified.
2.3 Freelance System Components

Freelance is divided into an operator level and a process level. The operator level
contains the functions for operation and observation, archives and logs, trends and
alarms. Open-loop and closed-loop control functions are processed in the controllers.
One engineering station and several operator stations can be installed at the operator
level. The Control Builder F engineering station is used to configure and commission
the system. Usually, portable equipment such as laptops, which allow configuration
both in the office and on site, is used. The operator level PCs can also be used as
engineering station. A permanent connection to the engineering system is not
necessary.
Engineering Operation Gateways Archive

Control Builder F DigiVis OPC/Trend Server PGIM 800F
Ethernet TCP/IP
Controller
AC 800F AC 800F AC 700F
redundant
PROFIBUS
Remote I/O
Rack-IO
S800 S900 S700
Rack-based
Foundation Controller
Fieldbus
Chapter 2 - 3
2.3.1 Engineering tool Control Builder F (CBF)

The Control Builder F software is running on a unique PC or Laptop in a Freelance
system. The CBF software package is necessary for configuring the automation
functions as well as the operator interface DigiVis. CBF performs configuration and
program compilation based on the IEC 61131-3 standard. The Freelance system can be
configured online, while Freelance is connected to the CBF-PC, or offline. CBF is also
a high-performance tool for commissioning the process. The following features are
offered with Control Builder F:
• Single software tool for configuration of the automation functions, field bus
devices and operator interface DigiVis
• Graphical configuration according to IEC 61131-3 for
o Function block diagram (FBD)
o Instruction List (IL)
o Ladder diagram (LD)
o Sequential function chart (SFC)
o Structured text (ST)
• Function block library with more then 220 tried and tested functions
• Macro library containing more then 200 graphic symbols
• Cross-reference function allowing variables and program points to be found
easily
• Uniform system-wide documentation of the entire user application
• Password protection on many levels
• Import and export functionality of programs and part of programs
• Testing and simulation of user programs using a soft controller (controller
emulator)
User defined Function Blocks

Programs AC 800F
User tasks list
Sequential Function Chart
Program List
Task cycle = 1 sec
Instruction list
Structured Text
Function Block Diagram
System tasks list

Common Display Pool
Operator station
OPC Gateway
DDE Gateway
Project Pool
Chapter 2 - 4
Freelance Training
2.3.2 System Overview with DigiVis
The operator level DigiVis originating from the control system Freelance is based on
the Microsoft operating system Windows XP SP3. DigiVis is to be created very fast
by its simple structures. The objects necessary for the operation are configured and
commissioned with the engineering Tool Control Builder F. Freelance allows to
configure up to 100 operator stations for operation and observation. A maximum of 10
operator stations can be assigned to a process station, because there is a limit of
connects for a process station. Per connection a maximum number of 1400 Byte data
is possible.
Chapter 2 - 5
Message Line
Tool Bar
System Display
(Module Diagnostics)
Group Display
SFC Display
Message list
DigiVis allows to operate the automated process either with mouse or keyboard.
DigiVis offers the following process operation features:
• Faceplate library for Freelance controllers
• Standardized displays such as Group display, Trend displays, SFC displays,

System display
• Quick and direct access to tags for operation
• System diagnostics
• Message management and logging
Chapter 2 - 6
Freelance Training
• Trend display and trend archiving

• Customized graphic displays
• Customized Faceplates
Chapter 2 - 7
2.3.3 Controller Types and I/Os
2.3.3.1 AC 800F
At the process level, a Freelance system can consist of several process stations that are
connected with I/O units. You have the option of running these process stations either
redundantly (CPU redundancy, field bus module redundancy) or without redundancy.
Modular plug-in input/output modules are used in accordance with the type and
quantity of process signals. With AC 800F, field bus-compliant components such as
remote I/O or field devices can be connected.
The AC 800F has a modular structure. The CPU is designed as a backplane to which
various modules power supply units, Ethernet or field bus modules can be attached in
line with the application. On the field bus side, modules for PROFIBUS-DPV1,
FOUNDATION Field bus HSE, MODBUS (master/slave, RTU or ASCII), IEC
60870-5-101 and CAN for Freelance Rack I/O are available. The field bus line and the
connected PROFIBUS slaves are entirely configured and parameterized using the
Control Builder F engineering tool. No further external tools are needed for
configuration.
PROFIBUS slaves can be integrated into the system using a GSD1 file or FDT/DTM2.
In the case of FOUNDATION Field bus, configuration takes place using CFF3 or DD4
files. This allows field bus parameterization even without connected field devices.
Also Freelance Rack I/O can be connected to the AC 800F, in which case a CAN
module is used. This allows you to operate five I/O racks, with a total ofaround 1000
I/Os, for each AC 800F. The I/O racks are equipped with a link module and up to nine
I/O modules and can be mounted separately at a distance of up to 400 m from the AC
800F.
The field bus module for PROFIBUS DP enables connection of remote I/O units such
as the S700, S800 or S900.
Whereas the S700 and S800 are generally used in process automation, the S900 is
preferred, due to its extended channel diagnostics and intrinsic safety, in the chemicals
segment and in areas where explosion protection is required.
Chapter 2 - 8
Freelance Training
2.3.3.2 AC 700F
The AC 700F process station consists of a CPU module, which can be extended with
up to eight I/O modules and one Profibus module. The following modules are
available:
• PM 783F CPU module
• CM 722F Profibus module
• AI 723F Analog input module
• AI 731F Analog input module (Thermocouple)
• AO 723F Analog output module
• AX 722F Analog I/O module
• DC 732F Digital I/O module
• DX 731F Digital I/O module
• DX 722F Digital I/O module
The CPU module PM 783F is the data-processing module of the AC 700F process
station. To the left of the CPU module one Profibus module CM 722F can be
connected. If the Profibus module is not used the dummy coupler module TA 724F
has to be connected to protect the coupler slot. Next to Profibus the AC 700F process
station supports Modbus Master/Slave. The Modbus interface is placed at the CPU
module, so no special module is needed. I/O modules can be connected right of the
CPU module. The PM 783F module works with a Motorola Power PC (MPC8247).
The application data are battery-backed in a 2 MB SRAM.
2.3.3.2.1 Profibus module CM 722F

The Profibus module CM 722F works as a Profibus master and allows the
configuration of other Profibus devices as the S700, S800 or S900 Remote I/O. As the
AC 800F, the AC 700F process station supports the configuration of GSD and DTM
based Profibus slaves.
2.3.3.2.2 Analog input module AI 723F

The analog input module AI 723F has 16 analog inputs for current, voltage or
temperature. The range can be selected for the corresponding input. The following
ranges are available:
Chapter 2 - 9
2.3.3.2.3 Analog input module AI 731F (Thermocouple)

The analog input module AI 731F (Thermocouple) has 8 analog inputs for current,
voltage or temperature. The range can be selected for the corresponding input. The
following ranges are available:
Chapter 2 - 10
Freelance Training
Chapter 2 - 11
2.3.3.2.4 Analog output module AO 723F

The analog output module AO 723F has 16 analog outputs for current or voltage. The
range can be selected for the corresponding output. The following ranges are
available:
2.3.3.2.5 Analog input/output module AX 722F

The analog input/output module AX 722F provides eight analog inputs for current,
voltage or temperature and eight analog outputs for current or voltage. The range can
be selected for the corresponding input. The following ranges are available:
For outputs O0 to O3 both Current and Voltage output configuration is possible. For
O4 to O7 only voltage output configuration is possible. The range can be selected for
the corresponding output. The following ranges are available:
Chapter 2 - 12
Freelance Training
2.3.3.2.6 Digital input/output module DC 732F

The digital input/output module DC 732F is designed for connecting 16 binary 24 V
DC input signals and 16 binary 24 V DC output signals.
2.3.3.2.7 Digital input/output module DX 731F

The digital input/output module DX 731F is designed for connecting 8 digital 230V
AC input signals or 4 relay output (2-wire).
2.3.3.2.8 Digital input/output module DX 722F

The digital input/output module DX 722F is designed for connecting 8 digital 24V DC
input signals or 8 relay output 2-wire.
Chapter 2 - 13
2.3.3.3 S700
The S700 Remote I/O consists of a digital input/output module DC 705F which works
together with the Field Bus Plug (a Profibus connector) as Profibus slave. It can be
extended with up to seven further I/O modules. Next to the I/O modules of the AC
700F controller the following modules are available:
• DC 705F Digital I/O module (FBP Interface module)
• AC 722F Analog I/O module
• AX 721F Analog I/O module
• DI 724F Digital input module
• DA 701F Digital/Analog I/O module
• CD 722F Frequency Input Module
Chapter 2 - 14
Freelance Training
2.3.3.3.1 DC 705F Digital I/O module (FBP Interface module)

DC input signals and 8 configurable digital input/output signals. Further it contains the
interface to the Profibus fieldbus.
2.3.3.3.2 AC 722F Analog I/O module

The analog input/output module AC 722F provides eight analog inputs for current,
voltage or temperature and eight analog outputs for current or voltage. The range can
For outputs O0 to O3 both Current and Voltage output configuration is possible. For
O4 to O7 only voltage output configuration is possible. The range can be selected for
the corresponding output. The following ranges are available:
2.3.3.3.3 AX 721F Analog I/O module

The analog input/output module AX 722F provides four analog inputs for current,
voltage or temperature and four analog outputs for current or voltage. The range can
Chapter 2 - 15
For outputs Current and Voltage output configuration is possible. The range can be
selected for the corresponding output.
2.3.3.3.4 DC 722F Digital I/O module

DC input/output signals.
2.3.3.3.5 DC 723F Digital I/O module

DC input/output signals.
2.3.3.3.6 DI 724F Digital input module

The digital input module DI 724F is designed for connecting 32 binary 24 V DC input
signals.
2.3.3.3.7 DA 701F Digital/Analog input/output module

The digital analog input/output module DA 701F is designed for connecting 4
configurable analog inputs and 2 configurable analog outputs.
Chapter 2 - 16
Freelance Training
2.3.3.3.8 CD 722F Frequency Input Module

The encoder and PWM module CD 722F is designed for connecting 2 integrated 5 V
power supplies for the encoders, 2 PWM outputs, 2 digital 24 V DC input signals and
8 configurable 24V DC digital inputs/output signals.
Chapter 2 - 17
2.3.4 Emulator
The Soft Controller (Emulator) is downloaded from the Freelance setup CD as shown
below.
To start an instance of the Emulator, select Internet Explorer and type “http://localhost:8888”
The Emulator administrator page will be displayed as shown above. Enter the resource
ID in the Station ID (shown as 100 in the example above), and then click on “Start
Resource ID
Controller”
When the Emulator has been started the window will appear as below.
Chapter 2 - 18
Freelance Training
Further instances can be started in the same way.
2.3.4.1 Adding an Emulator to the Hardware Structure.

In the Hardware structure, select “Insert > Emulator”.
Allocate the resource from the project tree.
The Emulator Icon will then look as shown below.
Chapter 2 - 19
In the taskbar select “Hardware structure > Network “ and check that the Resource ID
is set as the Station ID on the emulator, and the IP address corresponds to that on
which the emulator is running.
It can be seen in the project tree that the process station has now been allocated to the
Emulator.
Further instances of the Emulator can be started and resources allocated as required.
NOTE! An emulator cannot be assigned to a process station that
has been configured as a redundant station.
2.3.5 Gateway
The gateway stations D-GS are used to make data from the Freelance system available
to other systems. In principle, all the data from the Freelance system can be read and
written via a gateway station. In addition to each gateway station in a Freelance
system, the appropriate server software from the add-on packages a OPC Server F,
trend server, DDE and Maestro UX must also be installed in the network.
(If, for example, a gateway station of OPC gateway type is configured in a Freelance
system, then the OPC Server F software must be installed on a PC that is linked on the
network with the Freelance process stations.)
For each gateway station it is configured which tags and variables are available to the
other system for reading and/or writing via the gateway.
Correlation to a physical station is carried out in the hardware structure. An assigned
gateway station is represented by the label GWY. In the course of commissioning, the
data specified is made available to the other stations by loading the gateway station.
The following gateway types are available:
• DCP gateway
Chapter 2 - 20
Freelance Training
A DCP gateway is used for coupling the Maestro UX control system. It runs on a
CPU module DCP 02GWY or DCP 10GWY which is installed in any process
station rack.
• Redundant DCP gateway

A redundant DCP gateway is used for coupling the Maestro UX control system. It
runs on two CPU modules DCP 10GWY which are installed in any process
station racks
• DDE gateway
A DDE gateway runs on a PC, on which DDE is installed.
• OPC gateway
The OPC gateway runs a PC, on which an OPC-Server F is installed.
Chapter 2 - 21
• UNI gateway
The gateway type UNI gateway is intended for DMS API use.
Chapter 2 - 22
Freelance Training
2.3.6 OPC - Gateway

Freelance provides an OPC gateway (server), which allows OPC clients to access data
and alarms from the Freelance process stations. From Version 7.1 upwards, the OPC
server also allows access to the DPV1 parameters and user parameters of PROFIBUS
and HART devices. In the case of HART devices, this is only possible if they are
connected to a S900 unit. For V8.2 and higher, the parameters of FOUNDATION
Fieldbus devices can also be accessed. It is possible to limit access to this data at the
OPC gateway such that an OPC client cannot see certain process points and variables
at all, can only read other process points and variables, or has both read and write
access to certain process points and variables.
The DigiVis operator station has a built-in OPC DA client and from Version 9.2 also a
OPC AE client, which permits you to access data from external OPC servers. Using
this, for example, data from a SIEMENS control unit can be integrated into a custom
graphic in DigiVis.
As several OPC gateways can be used in the Freelance system, server redundancy can
be established using OPC clients that support this function.
The Trend Server option provides a special OPC gateway that is used by the DigiVis
operator stations for user-defined trend displays. Access to the Trend Server is fixed to
“read only”, and all trend variables are automatically available. There is one trend
server per Freelance system.
Chapter 2 - 23
2.4 System Overview 800xA Operations
Workplaces W2003 Server
WXP Aspect
Server
CBF CBF
Connectivity
WXP WXP Server
W2003 Server
Project 1 Project 2
The application of 800xA Operations as human system interface is recommended if

elevated requirements are placed at serving and observing. The possibilities of the
multi window technique are given, as well as a user-defined reporting management or
the call of object-oriented aspects by a context menu.
800xA Operations is running on the operating system Windows 2003 server and
Windows XP. Thereby a Client/Server structure for the human system interface is
given.
Chapter 2 - 24
Freelance Training
The connection to AC 800F process stations is made by OPC gateways, which are
configured in CBF. From the view of 800xA Operations the process data is
transmitted by OPC servers.
Chapter 2 - 25
2.5 Redundant Controller Architecture

The technology has proven its worth in industrial use over several years and meets the
highest of requirements regarding availability. The hardware can be structured
redundantly at all levels.
Including the redundant field bus device gateways, network redundancy, controller
redundancy and, last but not least, redundant operator interfaces.
S800 I/O
Chapter 2 - 26
Freelance Training
2.6 Communication protocol
2.6.1 AC 800F IP-Address Settings
The Freelance system use standard Ethernet and TCP/IP protocol to communicate
between its’ nodes, therefore the first step is to setup the IP addresses of the AC 800F
controllers and the PCs.
The setting of IP address of PCs is well known, we concentrate on setting IP address
for the AC 800F controller.
For Freelance system, there are two different methods of setting the IP address:
1. Standard setting which require to setup all the IP addresses with the same format
as:
172.16.1.X (here X stands for the last number of IP address)
and to setup the subnet mask as:
255.255.240.0
2. Non- Standard setting which allows you to setup any IP address and subnet mask
for Freelance system nodes.
Chapter 2 - 27
2.6.2 AC 700F IP-Address Settings

An AC 700F process station that is being used for the first time is not assigned any
valid IP parameters (IP-address, Subnet-mask, and Gateway). When the controller is
switched “ON” it waits for the IP parameters. The message “IPAddr” is displayed in
the LCD display. There are 2 methods for setting an IP address for an AC 700F
process station:
• Setting the IP address using the LCD display and the function keys
• Input of the IP parameters through the diagnostic interface.
Hold CFG during

ESC Startup à
enter Configure Mode
Reset R/S
Batt
888888 ETH
FBP
Ser
IO-Bus Diag
CFG OK é
R/S
Batt
IPAddr ETH
FBP R/S
Batt
42 ETH
FBP
ê
Ser Ser
IO-Bus Diag IO-Bus Diag
ê é ESC OK
Press OK to save
SAvE
ETH
R/S
Batt
FBP
Ser
changes or ESC to
IO-Bus Diag cancel
OK
Configure
Hold RUN during RUN ESC Res.- ID, CPU Load or
Startup à starts the Free Text
Controller in Stop
Mode R/S: Stop
Id
R/S
Batt
StArt ETH
FBP
Ser
R/S
Batt
7
ETH
FBP
Ser
IO-Bus Diag IO-Bus Diag
2.7 Redundancy
Two AC 800F can be linked to enable operation in redundancy mode. In addition to
the Ethernet module in slot E1 for normal network communication a second Ethernet
module is present in slot E2. A point-to-point connection called the Redundancy link
is set up between the Ethernet modules in the E2 slots of the two AC 800F.
Chapter 2 - 28
Freelance Training
2.7.1 Standard setting

In redundancy mode, two Ethernet modules plugged in slots E1 and E2 are needed.
The Ethernet module in slot E1 is used for communication with system bus DigiNet S.
The instructions for setting up the module in the standard or special case apply to this
module as well.
The second Ethernet module (slot E2) is connected to the redundant AC 800F. In this
case, the coding switch on the Ethernet module must be set to position F.
Chapter 2 - 29
2.7.2 Special setting
2.7.3 Ethernet modules

The system bus of the AC 800F is based upon the widespread Ethernet standard.
The following transmission media are available:
• 10Base2 Thin coaxial cable
• 10Base5 Thick coaxial cable
• 10BaseT Twisted pair cable
• 100Base T or FF/HSE Twisted pair cable
• 10BaseFL Fiber optic cable
You can find a more detailed description in 3BDD012501R0401 AC 800F Mounting

and Installation Instructions.
Chapter 2 - 30
Freelance Training
2.8 Freelance system data

Process station Ambient conditions
Functions: Operating conditions:
§ Analog value processing § Ambient temperature: 0...50 °C, 0...60 °C
§ Binary value processing § for AC 800F
§ Closed-loop control § No fan required
§ Open-loop control, standard and § Permitted relative humidity: ≤ 75% annual average,
§ freely programmable § no condensation; ≤ 95% for 30 days a year
§ Logic and arithmetic processing
§ Trend acquisition
§ Disturbance course log
§ Modbus coupling (master and slave)
§ Send and receive blocks
§ Phase logic interface (DigiBatch)
Task execution: Mechanical features:

§ Cyclical processing with selectable cycle times from 5 ms § Shock: 30 g/18 ms / 18 shocks
§ Fastest-possible processing (PLC mode) § Vibrations: 3x5 cycles, 2 g/0.15 mm/5...150 Hz
Operator station
Process interface constructed in racks: Functions:
§ Flexible rack positioning § Plant-specific graphics:
§ Front-panel connection technique (code able blocks § Single displays with mini trend display
§ and screw terminals) § Standardized displays:
§ Replaceable during operation § Overview display
§ Group display
§ SFC display
§ Trend display
§ Time scheduler display
§ System display
§ Faceplates
§ Message list and operator hint list
§ System diagnosis
§ Control aspect (shows configuration)
§ Archiving
§ Logging
Process interface for AC 800F: Display:
§ Flexible rack positioning for field bus modules § Display update: approx. 1 s
§ Replaceable during operation § Display build-up time: 1...2 s
Signal update for the rack modules: Capacity per operator station:
§ Binary signals: selectable from 2 ms § Max. 1 overview display
§ Analog signals: selectable from 10 ms § Max. 96 group displays
§ Max. 42 trend displays
§ Max. 12 logs
§ Max. 2000 messages in the message list at any
one time, further messages only stored
temporarily in the process stations.
§ Number of graphic displays depends on hard
disk capacity
Power supply
Alternating voltage:
§ 230 V, (-15%...+10%)
§ 115 V, (-15%...+10%)
§ Direct voltage: 24 V, (-20%...+35%)
§ Interruption: < 20 ms without function disturbance
Electromagnetic compatibility (EMC):
§ Radio interference suppression according to EN 55022 and EN 55014
§ Interference immunity according to IEC 801, EN 60801 and VDE 0843
§ Security level 3 and NAMUR industrial standard
Chapter 2 - 31
2.9 CPU PM 783F Detail Data

CPU PM 783F
Processor Motorola Power PC (MPC8247)
Program memory (Battery backed up) 2 MB SRAM
Internal memory 8 MB SDRAM, 4 MB FLASH ROM
Max. number of I/O Modules 8
Data backup source Lithium Battery
Real-time clock (with battery back-up) Yes
Multitasking Program execution
- cyclic (Equidistant) 8 Tasks
- cyclic (As fast as possible) 1 Task
- Event driven (Upon any of these "Run, Stop, Warm start, Cold start, Error"
events->)
Serial interface “SER” (COM1)
- Physical link: -configurable for RS-232 or RS-485 (from 1200 bps to 38400 bps)
- Connection: -pluggable terminal block, spring connection
- Usage: -as Modbus ASCII/ RTU (Master/Slave),
Serial interface “DIAG (COM2) - RS-232
- Physical link: - SUB-D Female connector
- Connection: - for programming/ diagnostics
- Usage:
Onboard network interface 1 x 10/ 100 MBPS, Ethernet (RJ45)
LEDs, LCD display, 8 function keys for RUN/STOP switch-over, status displays and diagnosis
Certifications CE, GL, cUL
2.10 System Requirements (Operating System)

Freelance use the operating system Microsoft ® Windows XP Professional SP3.
Freelance OPC Server F and Trend Server can also be run under the Microsoft ®
Windows operating system 2003 Server. For coupling with 800xA also Microsoft ®
Windows operating system 2008 Server is supported.
2.11 Considerations for Disks and File System

Disks
It is generally recommended that you use the Microsoft ® Windows default location,
the program folder on the boot disk, for installation.
Fragmentation
Make sure the file system is in a consistent state at all times. Defragmentation
software should be executed manually on a regular basis using the built-in
defragmentation software.
File System
The Freelance system requires a NTFS file system. A FAT32 partition will also be
required if you are using the Symantec Ghost utility for backup locally.
Chapter 2 - 32
Freelance Training
2.12 Recommended PC Equipment
Hardware Requirements
Control Builder F
Hard disk for installation 500 MB free disk space
Hard disk for operation 10 GB free disk space
Operating system Microsoft ® Windows XP Prof. SP3
Speed ≥ 2 GHz
RAM 1 GB
Ethernet card with support Interface BNC/AUI/TP
DigiVis
Hard disk for operation ≥ 2 GB free disk space
Recommended for archiving ≥ 80 GB (depending on configuration)
Speed ≥ 2 GHz
RAM 1 GB
Graphics card for dual monitor Matrox Millenium P650
Matrox Extio F1400
ATI Fire GL V3100
Nvidia Quadro FX540
Ethernet card with supp. Interface BNC/AUI/TP
OPC Server F
Hard disk for operation ≥ 2 GB free disk space
Microsoft ® Windows 2003 or 2008
Server (for 800xA Connectivity)
Speed ≥ 2 GHz
RAM 1 GB
Ethernet card with supp. Interface BNC/AUI/TP
Chapter 2 - 33
2.13 Introduction to Freelance Add On Tools
2.13.1 PGIM 800F

PGIM 800F is a Process Information Management System (PIMS) for Freelance
800F. It is a software tool to acquire, archive and centrally evaluate all Freelance
process data using the Freelance OPC server connection.
PGIM 800F for Freelance basically cooperates with two node types:
• PGIM 800F Server
Communicates with Freelance controllers and provides real-time data access
between PGIM 800F and the control network via standard OPC DA/AE interfaces.
Single and redundant servers are provided.
• PGIM 800F Client
The client software runs on Digivis or a separate PC. Up to five clients are supported.
PGIM 800F server can be run in a Windows® 2003 Sever environment. The PGIM
800F client software runs in Windows® 2003 or Windows® XP Professional
environment.
PGIM 800F offers a Freelance system-wide architecture that performs these
Functions:
- Collecting, archiving and consolidating data from one Freelance System.
- Visualizing process parameters with a convenient user interface for office network.
- Making data available to other evaluating applications (e.g. for performance
calculation, operation schedule optimization, Microsoft® Excel reporting).
- Delivering process parameters and status variables to maintenance and financial
systems (via Microsoft® Excel)
Chapter 2 - 34
Freelance Training
2.13.2 Control Builder F Viewer

CBF Viewer is a separate auxiliary program to display function block diagrams,
transitions and actions from an SFC. It can be called up via context menu of the
selected tag in DigiVis.
CBF Viewer is available in two license modes. The light version shows only function
block diagrams. The full version mode supports multiple diagnostics and
commissioning functionalities.
CBF Viewer supports the following views:
Function block diagram (FBD), Instruction list (IL), Ladder diagram (LD), Structured
text (ST), Sequential function charts (SFC), Project tree, Variable list, Tag list,
Message list, Hardware tree and Parameter list.
Chapter 2 - 35
2.13.3 Security Lock

SecurityLock is a separate auxiliary program for the compact control system
Freelance. It provides access control for configuration with Control Builder F and for
operation and observation with DigiVis. The access control system can be
implemented for an entire Freelance system with a single SecurityLock license.
It is possible, even without SecurityLock, to specify during configuration with Control
Builder F whether or not the operator at an operator station is allowed, for example, to
alter a controller set-point. This specification has influence for every operator on the
operator station.
In contrast, with SecurityLock, it is possible to give operator a permission to operate a
controller but not operator B.
In a system with SecurityLock installed, users are required to login before using
DigiVis or Control Builder F.
Technical Limitations:
Number of access groups (user profiles) max. 16
Number of users: max.1000
On the Engineering Station
• Installing SecurityLock on engineering station (PC with Control Builder F)
• Assign groups to project with Control Builder F (Project Tree > Edit > User
groups)
• Using Control Builder F, specify the project rights of each group in the tag list and
in the project tree.
On the Operator Stations
• Installing SecurityLock on the operator stations (PCs with DigiVis)
• Determine the groups and their system rights with SecurityLock. (If necessary by
copying the file DIGIMAT.UID via network from the engineering station to the
control station).
• Add user and assign to the groups.
Security Lock and DigiVis
If the optional Security Lock program for DigiVis is installed, an open or closed
padlock icon is shown in each display, indicating whether the logged-on user has the
right to operate this display or not.
Padlock icon:
Open padlock = operation enabled
Closed padlock = operation disabled
2.13.4 DigiBrowse
DigiBrowse is an additional program for the Freelance System.
Chapter 2 - 36
Freelance Training
DigiBrowse permits viewing archived trend and log files without DigiVis. The data
can be presented in graphic form or as tables. The graphic presentation can be scaled
as desired, to facilitate examination of particular past process events. In addition, it is
possible to convert the data to ASCII format, making it readable by other programs,
such as, for example, data base or spread sheet programs.
If DigiBrowse is installed on a PC connected to the DigiNet S system bus, files
archived at the operator stations are transferred with FTP (File Transfer Protocol) to
this PC and connected via DigiNet S. The transfer of archive files from the different
operator stations is automatic, manual or event-driven, as configured in Control
Builder F.
2.13.5 Bulk Data Manager

Freelance Bulk Data Manager (BDM) is a offline bulk engineering tool that allows
manipulation of small or large application entities through Microsoft Excel during
engineering with Control Builder F. Key functionalities comprise of Import / Export
of Tag and Variable lists, replication of program typicals, function block parameter
configuration etc.
BDM is a useful tool for application engineers, project engineers and related
personnel involved in developing medium or large process applications for process
plants.
The tool is available with Freelance 9.2 software and is installed by default at the
Engineering station by the Freelance setup. The package also includes standard excel
templates with default settings for Function block parameter filters.
Chapter 2 - 37
2.14 Licensing
In order to offer market-appropriate functions and features, structure and pricing, the
system is divided into base parts and options. In addition scaling of tags, logs, etc. is
made to further optimize a system for a specific application.
When needed, expansions can be purchased and the system grows with the customer’s
needs.
It is important to recognize that installation is separate from licensing. Installation is
never prevented due to lack of licensing. However, a license is required in order to use
the corresponding applications.
2.14.1 AC 800F Product Structure
EngineerIT
Control Builder F
(Standard, Professional)
ControlIT
Control SW
(Basic, Advanced)
Chapter 2 - 38
Freelance Training
2.14.2 EngineerIT
The options of all Freelance controllers have been grouped in kits that are scalable
through the number of I/Os. As a result, the licenses of each controller can be adapted
to the customer’s needs.
The following Control Builder F versions are available:
• Control Builder F Standard
• Control Builder F Professional
All Control Builder F versions support the following functions:
• Configuration and commissioning of user programs
• Tree view of the programs for convenient program overview and selection
• IEC 61131-3 programming (FBD, IL, LD, ST, SFC)
• Graphical hardware configuration
• Integral Field bus configuration for PROFIBUS DP/PA and FOUNDATION Field
bus
• IEC 61131-3 data types and user-defined (structured) data types
• Project-wide variables and function block lists
• Online cross-reference
• Efficient plausibility check
• Extensive online help
Chapter 2 - 39
2.14.2.1 Control Builder F Standard

Control Builder F Standard supports:
• Tag names of max. 16 characters (so far special Control Builder F option)
• User function blocks (runtime license)
• Unlimited No. of programs
• Max. 100 Clients like OS and/or Gateways (DDE, OPC)
• Max. 10 Connections between Controllers and Clients like local OS and/or
Gateways.
• Max. 10 controller
• Max. 9 User-Task per Controller
2.14.2.2 Control Builder F Professional

Control Builder F Professional supports all functions of Control Builder F Standard
and additionally provides the following features:
• Access protection (Security Lock)
• User function blocks (engineering license)
• FDT/DTM support
• Tag Type Library
Chapter 2 - 40
Freelance Training
2.14.3 ControlIT
ControlIT offers two license types.
• Basic control software license
• Advanced software license
The license functionality can be adapted to the customer’s needs for every controller,
and the number of I/Os can be extended in steps of 50.
2.14.3.1 Basic Control Software License

The Basic control software license includes the following function block libraries:
• IEC 61131-3, digital and analog value processing
• controllers ( without self-tuning)
• integration of field busses (PROFIBUS DP/PA, FOUNDATION Fieldbus)
• DigiVis support
The options for the Basic Control Software License are:
• Serial Package (Modbus Master, Modbus Slave, Sartorius scales interface,
Protronic coupling)
• Tune (PID self-tuning)
• Sequence of Events (with Rack I/O)
• Batch Function Block Package (PLI, FPX)
• Interbus (only for upgrade of existing Interbus couplings)
• Telecontrol Library (IEC 60870-5-101)
• DMS-API
• Maestro-UX Coupling
Chapter 2 - 41
2.14.3.2 Advanced Control Software License

It includes the function block libraries of the Basic license and additionally contains
the following function block libraries and functionality.
• Serial Package (Modbus Master, Mosbus Slave, Sartorius balance interface,
Protronic coupling)
• Tune (PID self-tuning)
• Sequence of Events
• Maestro-UX Coupling
When you extend your Basic license to an Advanced one at a later time, you can
continue to use the existing options for the Basic license. Additionally, all options
of the Advanced license are available
In addition, the following options are provided:
• Batch Function Block Package (PLI, FPX)
• Interbus (only for upgrade of existing Interbus couplings)
• Telecontrol Library (IEC 60870-5-101)
• DMS-API
The following control software options are available for Basic and Advanced licenses
• Open Communication Package (DDE, OPC)
• Trend Server
Besides the Control Builder F engineering program all controllers/process stations
with the respective number of used I/Os and the options must be licensed. All used
OPC DA Items are counted as OPC signals. Used OPC DA Items are those that are
configured in the Variable List or Tag List (instantiated tags).
As a rule, only a project checked as OK correctly indicates the actually required
number of I/O licenses.
NOTE! If the number of I/Os used in a project exceeds the
number of licensed I/Os, it will not be possible for the
project to pass the plausibility check. As a result, you
cannot download the software configuration into the
process station.
You can find a more detailed information in.3BDD0125690R0403 Freelance Getting
Started.
Chapter 2 - 42

T568-02 Freelance System Architecture - RevC

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Freelance Training

Chapter 2 Freelance System Architecture

Chapter 2 Freelance System Architecture ............................................................................................................................... 1

2.1 General Information

2.1.3 Referenced Documentation

2.2 Introduction of the ABB IndustrialIT Concept

2.3 Freelance System Components

Engineering Operation Gateways Archive

2.3.1 Engineering tool Control Builder F (CBF)

User defined Function Blocks

Task cycle = 1 sec

Function Block Diagram

System tasks list

2.3.2 System Overview with DigiVis

• Standardized displays such as Group display, Trend displays, SFC displays,

• Trend display and trend archiving

2.3.3 Controller Types and I/Os

2.3.3.2.1 Profibus module CM 722F

2.3.3.2.2 Analog input module AI 723F

2.3.3.2.3 Analog input module AI 731F (Thermocouple)

2.3.3.2.4 Analog output module AO 723F

2.3.3.2.5 Analog input/output module AX 722F

2.3.3.2.6 Digital input/output module DC 732F

2.3.3.2.7 Digital input/output module DX 731F

2.3.3.2.8 Digital input/output module DX 722F

2.3.3.3.1 DC 705F Digital I/O module (FBP Interface module)

2.3.3.3.2 AC 722F Analog I/O module

2.3.3.3.3 AX 721F Analog I/O module

2.3.3.3.4 DC 722F Digital I/O module

2.3.3.3.5 DC 723F Digital I/O module

2.3.3.3.6 DI 724F Digital input module

2.3.3.3.7 DA 701F Digital/Analog input/output module

2.3.3.3.8 CD 722F Frequency Input Module

Further instances can be started in the same way.

2.3.4.1 Adding an Emulator to the Hardware Structure.

Allocate the resource from the project tree.

The Emulator Icon will then look as shown below.

• Redundant DCP gateway

2.3.6 OPC - Gateway

2.4 System Overview 800xA Operations

Workplaces W2003 Server

The application of 800xA Operations as human system interface is recommended if

2.5 Redundant Controller Architecture

2.6 Communication protocol

2.6.1 AC 800F IP-Address Settings

2.6.2 AC 700F IP-Address Settings

Hold CFG during

2.7.1 Standard setting

2.7.2 Special setting

2.7.3 Ethernet modules

You can find a more detailed description in 3BDD012501R0401 AC 800F Mounting

2.8 Freelance system data

Task execution: Mechanical features:

2.9 CPU PM 783F Detail Data

2.10 System Requirements (Operating System)

2.11 Considerations for Disks and File System

2.12 Recommended PC Equipment

2.13 Introduction to Freelance Add On Tools

2.13.1 PGIM 800F

2.13.2 Control Builder F Viewer

2.13.3 Security Lock

2.13.5 Bulk Data Manager

2.14.1 AC 800F Product Structure

2.14.2.1 Control Builder F Standard