VERSION 6.1.

Compact Product Suite

Compact Control Builder AC 800M
Getting Started
VERSION 6.1.0

Compact Product Suite

Compact Control Builder AC 800M
Getting Started

Document Number: 3BSE041584-610

Document Revision: A
Release: November 2019

Trace back information Main Publication:

Tool version: 5.2.025
Build date: 2019-11-12 at 11:03:13
Domain: ABBPA
Workspace, version, checked in: 800xA Main, a316, 2019-11-12
Master: ix-412668-AC 800M Getting Started.xml
Recipe: ix-363495-6.1_Compact AC 800M Getting Started.rcp
PDF stylesheet: ix-406351-PDF-Stylesheet.xml
Customer stylesheet: ix-315380-CustomerStylesheet.xml
Notice
This document contains information about one or more ABB products and may include a description of or a reference
to one or more standards that may be generally relevant to the ABB products. The presence of any such description of
a standard or reference to a standard is not a representation that all of the ABB products referenced in this document
support all of the features of the described or referenced standard. In order to determine the specific features supported
by a particular ABB product, the reader should consult the product specifications for the particular ABB product.

ABB may have one or more patents or pending patent applications protecting the intellectual property in the ABB
products described in this document.

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

Products described or referenced in this document are designed to be connected, and to communicate information and
data via a secure network. It is the sole responsibility of the system/product owner to provide and continuously ensure
a secure connection between the product and the system network and/or any other networks that may be connected.

The system/product owners must establish and maintain appropriate measures, including, but not limited to, the
installation of firewalls, application of authentication measures, encryption of data, installation of antivirus programs,
and so on, to protect the system, its products and networks, against security breaches, unauthorized access, interference,
intrusion, leakage, and/or theft of data or information.

ABB Ltd and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized
access, interference, intrusion, leakage and/or theft of data or information.

ABB verifies the function of released products and updates. However system/product owners are ultimately responsible
to ensure that any system update (including but not limited to code changes, configuration file changes, third-party
software updates or patches, hardware change out, and so on) is compatible with the security measures implemented.
The system/product owners must verify that the system and associated products function as expected in the environment
they are deployed.

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

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

The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed
only in accordance with the terms of such license. This product meets the requirements specified in EMC Directive
2014/30/EU and in Low Voltage Directive 2014/35/EU.

Trademarks
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.

Copyright © 2019 by ABB. All rights reserved.

Table of Contents

Table of Contents

About this User Manual

User Manual Conventions ................................................................................. 11
Warning, Caution, Information, and Tip Icons ...................................... 12

1 Introduction
1.1 General ............................................................................................................. 13
1.2 Product Overview .............................................................................................. 13
1.2.1 ABB Start Menu ................................................................................... 14
1.2.2 Project Explorer ................................................................................... 15
1.2.3 Libraries ............................................................................................... 16
1.2.4 Control Builder Functions .................................................................... 17
1.2.5 Multi-User Engineering ........................................................................ 19
1.2.6 Manuals ............................................................................................... 19
1.2.7 Online Help .......................................................................................... 21

2 Installing Software
2.1 Installation Prerequisites ................................................................................... 24
2.2 Step-by-Step Instructions .................................................................................. 24
2.2.1 Installing the Software .......................................................................... 25
2.2.2 Coexistence with Previous Versions .................................................... 27

3 Control Builder User Interface

3.1 Introduction ....................................................................................................... 29
3.1.1 About Project and its Objects .............................................................. 29
3.2 Project Templates .............................................................................................. 31
3.3 Project Explorer ................................................................................................. 31
3.3.1 Title Bar, Menu Bar and Toolbar .......................................................... 32
3.3.2 Project Explorer Pane .......................................................................... 32

3BSE041584-610 A 5
Table of Contents

3.3.3 Libraries Folder .................................................................................... 33

3.3.4 Applications Folder .............................................................................. 36
3.3.5 Controllers Folder ................................................................................ 39
3.3.6 Drag-and-Drop in Project Explorer ...................................................... 39
3.3.7 Context Menus ..................................................................................... 41
3.3.8 Message Pane ..................................................................................... 41
3.3.9 Editors .................................................................................................. 41
3.3.10 Refresh Project .................................................................................... 43

4 MyDoors Project
4.1 Introduction ....................................................................................................... 45
4.2 Building a Shop Door Project ............................................................................ 45
4.2.1 Specifications ....................................................................................... 46
4.2.2 Defined Variables ................................................................................. 46
4.2.3 Creating MyDoors Project .................................................................... 48
4.2.4 Diagrams .............................................................................................. 49
4.2.5 Variables and Signals .......................................................................... 50
4.2.6 Create Logic for Door Timer and Counters .......................................... 57
4.2.7 Testing MyDoors Project ...................................................................... 72

5 Hardware Configuration
5.1 Configure Hardware .......................................................................................... 77
5.1.1 Changing a CPU Unit .......................................................................... 78
5.1.2 Adding the IO Modules DO814 and DI810 .......................................... 79
5.2 Connect Signals to I/O Channels ...................................................................... 82
5.2.1 Configure Photo Cell Signal for Input I/O Channel .............................. 82
5.2.2 Configure Motor Signals for Output I/O Channels ............................... 83
5.2.3 Reading I/O addresses from the Application ....................................... 84
5.3 Ethernet I/O Wizard ........................................................................................... 84

6 Connecting the Controller and Go Online

6.1 Firmware Upgrade ............................................................................................ 85
6.1.1 Firmware Upgrade via the Serial Cable (TK212A) .............................. 86

3BSE041584-610 A 6
Table of Contents

6.2 Setting IP Addresses ......................................................................................... 88

6.2.1 Setting IP Address for Controller ......................................................... 88
6.2.2 Setting IP Address for PC .................................................................... 92
6.3 Download Project via Ethernet .......................................................................... 93
6.3.1 Setting the System Identity in Control Builder ..................................... 93
6.3.2 Downloading the Project to the Controller ........................................... 95
6.4 Test the Diagram Online .................................................................................... 99
6.4.1 Forcing I/O Values ............................................................................... 99
6.5 What's Next? ..................................................................................................... 100

Appendix A Functions and Settings

A.1 Product Settings for Compact Control Builder .................................................. 101
A.1.1 File Locations .......................................................................................101
A.1.2 Language ............................................................................................. 102
A.1.3 License .................................................................................................103
A.2 Multi-User Configuration ................................................................................... 104
A.2.1 Creating a Shared Project Folder ....................................................... 104
A.2.2 Setting Up Compact Control Builder Stations ...................................... 108
A.2.3 Setting Up OPC Server ........................................................................ 109
A.2.4 Configuration Example ........................................................................ 113
A.2.5 Guide lines for Multi-User Engineering ................................................ 114
A.3 Project Examples in Compact Control Builder .................................................. 114
A.3.1 Opening a Project Example (Read Only) .............................................115
A.3.2 Preparing the ShopDoors Example for a Project ................................. 116
A.3.3 Opening a Project ................................................................................ 117
A.4 Testing ............................................................................................................... 117
A.5 Simulation ......................................................................................................... 118
A.5.1 Simulation Controllers ..........................................................................119
A.5.2 Applications in Simulation Controllers ................................................. 119
A.5.3 Mark Controller for Simulation ............................................................. 119
A.5.4 Mark Application for Simulation ........................................................... 119
A.5.5 Download to Simulation Controller ...................................................... 120
A.5.6 Running in a Simulation Controller ...................................................... 120

3BSE041584-610 A 7
Table of Contents

A.5.7 Restrictions Concerning Hardware Simulation .................................... 121

A.6 Download .......................................................................................................... 121
A.6.1 General Download ............................................................................... 121
A.6.2 Download New Project to Controller .................................................... 123
A.6.3 Download Project to Selected Controllers ........................................... 124
A.6.4 Difference Report ................................................................................. 126
A.6.5 Compiler Switches ............................................................................... 128
A.7 Application Restart Mode .................................................................................. 130
A.7.1 Warm Restart ....................................................................................... 131
A.7.2 Cold Restart ......................................................................................... 131
A.7.3 Variable values in Download mode ...................................................... 132
A.7.4 Variable values in Test mode ............................................................... 133
A.7.5 Power Failure .......................................................................................134

Appendix B Network Redundancy

B.1 Setting Up Redundant Network .........................................................................135
B.1.1 Two Separate Redundant Networks .................................................... 135
B.1.2 Decide IP Addresses ........................................................................... 138
B.1.3 Setup Using the IPConfig Tool ............................................................. 139
B.1.4 Configure PLC Ports from Project Explorer ......................................... 140
B.1.5 Configure PC Ports in Windows .......................................................... 140
B.1.6 Download Project and Go Online ........................................................ 141
B.1.7 Setting Clock Synchronization using the CNCP Protocol .................... 141
B.2 Design ............................................................................................................... 143
B.2.1 IP Address ........................................................................................... 143
B.2.2 Separating Client/Server and Control Network .................................... 145
B.2.3 Summary of Configuration Steps ......................................................... 147

Appendix C Upgrade
C.1 Save Application and Configuration Data ......................................................... 151
C.2 Save Gain Schedule Settings in PidAdvancedCC ............................................ 152
C.3 Remove Products ..............................................................................................156
C.4 Install Products ..................................................................................................156

3BSE041584-610 A 8
Table of Contents

C.5 Restore Application and Configuration Data .................................................... 157

C.5.1 OPC Server for AC 800M .................................................................... 157
C.5.2 Compact Control Builder ......................................................................157
C.5.3 Upgrade PLC Firmware ....................................................................... 159
C.5.4 Downloading the Project ...................................................................... 159
C.5.5 Compatibility Issues ............................................................................ 159

Appendix D Communication Cables

D.1 Connecting Control Builder PC to a Controller ..................................................177

Revision History ..................................................................................................... 179

Index .......................................................................................................................... 181

3BSE041584-610 A 9
3BSE041584-610 A 10
About this User Manual
User Manual Conventions

About this User Manual

Welcome to Compact Control Builder 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 3 Control Builder User Interface is a brief introduction to the Control Builder’s
core interface Project Explorer.
Section 4 MyDoors Project, encourages you to build a small project example to get
yourself acquainted with the Control Builder environment.
Section 5 Hardware Configuration, teaches you how to add hardware units to your project.
Section 6 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.

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.

3BSE041584-610 A 11
About this User Manual
User Manual Conventions

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.

Required action icon indicates actions that are required for the product or system to
function as intended.

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.

3BSE041584-610 A 12
1 Introduction
1.1 General

1 Introduction

1.1 General
Compact Control Builder 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. 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 online debugger, test and simulation
mode.

1.2 Product Overview

Compact Control Builder is a fully integrated application that runs on:
• Windows 8.1 Update 1 64 bit
• Windows 10 64 bit
• Windows Server 2012 R2 Update 1
• Windows Server 2016
Besides the operating system requirements, the minimum software requirements are:
• Microsoft Word 2010, 2013, or 2016. Required for creating project documentation.

3BSE041584-610 A 13
1 Introduction
1.2 Product Overview

Control Builder provides tools for programming applications and configure hardware
units from the AC 800M family. It is accessed through the Project Explorer interface.
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 Compact
Control Builder AC 800M Configuration (3BSE040935*) which describes more thoroughly
the 800xA programming functions that can be accessed through the Project Explorer.

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.

Figure 1.1: ABB Start Menu

It is possible to pin the Start Menu tool to the taskbar for an easy access of the tool.

3BSE041584-610 A 14
1 Introduction
1.2 Product Overview

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 1.2.

PM860/TP830 DO810 DI810

Figure 1.2: Project Explorer and actual hardware setup.

3BSE041584-610 A 15
1 Introduction
1.2 Product Overview

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.
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, 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.

A complete list of libraries delivered with the installation can be found in the manual
Compact Control Builder AC 800M Binary and Analog Handling (3BSE041488*).

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.

3BSE041584-610 A 16
1 Introduction
1.2 Product Overview

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.

Main Compact Control Builder Functions

• Backup/Restore
• Create/change/insert libraries
• Create/change/use data types, function block types and control module types
• Difference report (between previous/new application)

3BSE041584-610 A 17
1 Introduction
1.2 Product Overview

• Downloading projects and go online

• Multi-user engineering
• Search and Navigation Tool
• Testing projects offline

Functions in 800xA
Additional functionality for building DCS type of control solutions can be used by the
Control Builder M Professional, available in the ABB 800xA DCS system.
The 800xA Control Builder (the Control Builder Professional) adds the following functions
to the set of functions available in Compact Control Builder:
• Online Upgrade.
• Load Evaluate Go.
• Batch handling.
• Audit Trail.
• SFC Viewer.
• High Integrity Controller for SIL applications.
• CI860 for FF HSE, and CI862 for TRIO I/O.
• Information routing via HART protocol.
• User access control. Possibility to control a user’s authority to perform different
operations and tasks.
• Loop check tool.

The additional functions from 800xA are not included in the Compact Control Builder
AC 800M.

It is possible to migrate Compact Control Builder solutions to 800xA systems, and

the PLC projects can be opened in the Control Builder Professional.

For more information see also Appendix Functions and Settings.

3BSE041584-610 A 18
1 Introduction
1.2 Product Overview

1.2.5 Multi-User Engineering

Compact Control Builder supports multi-user engineering with a maximum of 32 separate
engineering workplaces. In a multi-user configuration, all Control Builder PCs and the
OPC Server must have access to the common project file(s). This means that a common
Project folder must be created on a shared network server.
The network server can be placed anywhere in the network; in a Control Builder PC, in
an OPC Server PC, or located as a stand-alone file server.

Control Builder and/or OPC Server Control Builder station

From shared network
drive

To OPC Client

Ethernet

PLC Controller PLC Controller

Figure 1.3: Programmers can share the same project. Multi-user engineering stores
projects on a shared network drive

1.2.6 Manuals
All online manuals exist as pdf files. The files are stored on your local disk after installation.
Online manuals can be accessed from the Project Explorer. Select Help > Manuals >.

3BSE041584-610 A 19
1 Introduction
1.2 Product Overview

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 Compact Control Builder AC 800M Configuration (3BSE040935*)
describes the basic functions in Control Builder.
• The manual Compact Control Builder AC 800M Planning (3BSE044222*) describes
design issues and programming languages.
• The manual Compact Control Builder AC 800M Binary and Analog Handling
(3BSE041488*), describes the Control Builder standard libraries and how to use
them to build complex automation solutions.
• 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.

Full-Text Search
The Figure 1.4 shows Full-Text search window. The link on the page opens the
full-text index file CCB_Manuals_Catalog_file.pdx of the Compact Control Builder.
manuals. Use the Search command of this full-text catalog index file to search the entire
set of documents quickly.

3BSE041584-610 A 20
1 Introduction
1.2 Product Overview
Compact Control Builder AC 800M Page 1 of 2

—
Compact Control Builder AC 800M Manuals

Search All Manuals

To search all manuals for textual content, click here

This link opens the full-text index file CCB_Manuals_Catalog_file.pdx, of the CCB manuals. Use the Search command of this full-text
search the entire set of documents quickly.

Browse for Manuals

You can browse for a manual in the alphabetical listing below. Click a title to open the corresponding manual.

Compact Control Builder AC 800M Manuals

Compact Control Builder AC 800M - Getting Started (3BSE041584*)

Compact Control Builder AC 800M - Planning (3BSE044222*)

Compact Control Builder AC 800M - Configuration (3BSE040935*)

Compact Control Builder AC 800M - Binary and Analog Handling (3BSE041488*)

Compact Control Builder AC 800M - Product Guide (3BSE041586*)

AC 800M Manuals

AC 800M - DriveBus (2PAA113566*)

AC 800M - PROFIBUS DP Installation (3BDS009029*)

AC 800M - PROFIBUS DP Configuration (3BDS009030*)

Figure 1.4: Full-Text Search Window
AC 800M - PROFINET IO Configuration (3BDS021515*)

AC 800M - Communication Protocols (3BSE035982*)

1.2.7 Online Help
AC 800M - OPC Server (3BSE035983*)

Control
AC 800M -Builder Online(3BSE036351*)
Controller Hardware Help can be accessed in the following ways:
AC 800M - Interfacing SATT I/O (3BSE042821*)
• Context-sensitive help. Select an object in e.g. Project Explorer and press F1.
AC 800M - Library Object Style Guide (3BSE042835*)
Another way to use context-sensitive help is to push the Help button in dialogs. The
AC 800M - Ethernet/IP
online help is DeviceNet
started Configuration
and the (9ARD000014*)
relevant topic is selected.
AC 800M - IEC 61850 Configuration for CI868 (9ARD171385*)
• Via menu command Help>Help Topics. This will bring up online help with the
Advant Fieldbus 100 - Installation, Configuration and Operation (3BSE000506*)
Control Builder topic selected.
I/O Manuals
• Via menu command Help>Help About (browser/editor) This will bring up online
S200 I/O - Hardware (3BSE021356*)
help with the topic for the current browser/editor selected.
S200L I/O and I/O 200C - Hardware (3BSE021357*)

• Via menu command Help>Show Help About... This will bring up a dialog where
S800 I/O - Getting Started (3BSE020923*)

other help files can be reached. This could be either user specific help files or help
S800 I/O - Modules and Termination Units (3BSE020924*)

S800files for installed

I/O - Fieldbus hardware
Communication libraries.
Interface for PROFIBUS DP/DPV1 (3BSE020926*)

S800 I/O - Modules and Termination Units with Intrinsic Safety Interface (3BSE020927*)

S900 I/O - Communication Interface for PROFIBUS DP CI920A V2.1 (2PAA107375*)

S900AI/O - Installation Guide S-N-System SA920 CI920A (3BDD010421*)

3BSE041584-610 21
S900 I/O - Digital I/O Modules DO910 and DX910 (3BDD010423*)
1 Introduction
1.2 Product Overview

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.

3BSE041584-610 A 22
2 Installing Software

2 Installing Software

This section explains how to install and start up a single-user configuration, which means
a Compact Control Builder and an OPC Server installed together on the same PC station.
The delivered software consists of three parts -
the ABB Common 3rd Party Install kit, the Compact Control Builder AC 800M, and the
OPC Server for AC 800M. Each of these is installed with the help of installation wizards.
• The first installation wizard installs the common 3rd party software required to work
with ABB Compact Control Builder AC 800M. This is different from the software
mentioned in Product Overview on page 13.
• The second installation wizard installs Compact Control Builder, Base Software for
SoftController, MMS Server, RNRP, and User Documentation.
• The third installation wizard installs OPC Server for AC 800M, MMS Server, and
RNRP.

Run the Compact Control Builder installation before running the OPC Server
installation.

The Compact Control Builder opens the projects stored in a project folder which is
created during the installation.
If the project folder path is changed in a recent installation, the previous projects
cannot be found by the Control Builder. This problem is solved by either changing
the project folder path back to previous location, or copying the previous projects
from the Windows explorer into the current Project folder location.

3BSE041584-610 A 23
2 Installing Software
2.1 Installation Prerequisites

2.1 Installation Prerequisites

Before installing the Compact Control Builder on a PC that has Windows installed:
• Install all the other software that conforms to the minimum software requirement for
Compact Control Builder. See Product Overview on page 13.
• Login to Windows, with Administrator privileges.
• Remove previous Control Builder versions from the PC1. This also includes other
products that comes with a Compact Control Builder installation (for example, OPC
Server for AC 800M).
Do not install Compact Control Builder on a PC that already has Control Builder
Professional installed. A Compact Control Builder and a Control Builder Professional
cannot coexist in a PC.

2.2 Step-by-Step Instructions

Install the delivered software from the media it was delivered on, as the software products
cannot be run from e.g. a DVD or a network drive.

1. Go to Control Panel > Programs and Features to remove the old version.

3BSE041584-610 A 24
2 Installing Software
2.2 Step-by-Step Instructions

2.2.1 Installing the Software

1. Login as Administrator in Windows.
2. Insert the installation media. After a few seconds the Welcome dialog appears as
shown in Figure 2.1. If the dialog does not appear, start the file Startme.bat, located
in the root directory of the installation media.

Figure 2.1: The Welcome dialog of the installation process

The installation dialog contains the following buttons:

• The Release Notes button provides the latest information.
• The Getting Started button brings up this manual.

3BSE041584-610 A 25
2 Installing Software
2.2 Step-by-Step Instructions

• The Install Software button activates the installation procedure. The Install Software
dialog opens as shown in Figure 2.2.
• The Exit button quits the installation procedure.

Figure 2.2: Install Software dialog

Installing the ABB Common 3rd Party Software

These required common 3rd party software components must be installed before installing
the Compact Control Builder and OPC Server.
1. In the Install Software dialog, click ABB Common 3rd Party Install to start the
Installation Wizard.
2. Follow the installation instructions that is displayed in the wizard. This installation
does not include the requirements mentioned in Product Overview on page 13.

3BSE041584-610 A 26
2 Installing Software
2.2 Step-by-Step Instructions

Installing the Compact Control Builder

If you intend to install both the Compact Control Builder and the OPC Server for
AC 800M on the same computer, then start with the Compact Control Builder
installation. The OPC Server installation needs to read the Control Builder settings
that are created during the Compact Control Builder installation.
1. In the Install Software dialog, click Compact Control Builder AC 800M to start the
Installation Wizard.
2. Follow the installation instructions that is displayed in the wizard.
If any project saved from the previous version need to be used through upgrade, you
have to extend the installation after this installation is completed (see Coexistence
with Previous Versions on page 27).

If the installation procedure is interrupted, all the previously installed components

belonging to this installation are rolled back.

Installing the OPC Server for AC 800M

1. In the Install Software dialog, click OPC Server for AC 800M, to start the Installation
Wizard.
2. Follow the installation instructions that is displayed in the wizard.
Running the OPC Server on the same PC as the Compact Control Builder does not
require further settings.

For more information about setting up an OPC Server for multi-user engineering, see
Setting Up OPC Server on page 109.

License Key
The products in the Compact Suite requires a valid license key. How to get a license
key is described in Compact Control Builder AC 800M Product Guide (3BSE041586*).
The license key is entered using the Setup Wizard of any of the products. This is e.g.
described in Product Settings for Compact Control Builder on page 101. Without a valid
license key, the products will be running in demo mode.

2.2.2 Coexistence with Previous Versions

The Compact Control Builder projects saved from previous versions can be upgraded
and used with the new installed version.

3BSE041584-610 A 27
2 Installing Software
2.2 Step-by-Step Instructions

This is possible only if the required Compact Control Builder options are installed:
1. To include coexistence, change the installed features. From the Control Panel,
select Programs and Features, right-click ABB Compact Control Builder
AC 800M, and select Change. Select the Modify option. The Custom Setup dialog
is displayed.

Figure 2.3: Custom Setup dialog with coexistence options

2. Select the version(s) for coexistence. For example, if any project saved in Compact
Control Builder 5.1.1 need to be used, select AC 800M Coexistence 5.1.1.
3. Click Next to proceed with the installation.

3BSE041584-610 A 28
3 Control Builder User Interface
3.1 Introduction

3 Control Builder User Interface

3.1 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 4 MyDoors Project, to create a new project and its logic.

3.1.1 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.
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.

3BSE041584-610 A 29
3 Control Builder User Interface
3.1 Introduction

Figure 3.1: Sequence for building a project and making a download to the controllers

3BSE041584-610 A 30
3 Control Builder User Interface
3.2 Project Templates

3.2 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.
• EmptyProject2
– Rarely used, and has a minimum configuration with initial data only under the
Libraries folder.
• SoftController
– For development use, and for simulating non-SIL applications without a
controller.

3.3 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.

2. An empty project template contains only the compulsory system firmware functions, with no additional
application or hardware functions.

3BSE041584-610 A 31
3 Control Builder User Interface
3.3 Project Explorer

Title bar

Menu bar

Tool bar

Project
Explorer

Message
pane

Figure 3.2: Project Explorer

3.3.1 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 and Online help.

3.3.2 Project Explorer Pane

The Project Explorer pane contains three main folders, see Figure 3.3.
• The Libraries folder, see Libraries Folder on page 33.
• The Applications folder, see Applications Folder on page 36.
• The Controllers folder, see Controllers Folder on page 39.

3BSE041584-610 A 32
3 Control Builder User Interface
3.3 Project Explorer

Libraries

Applications

Controllers

Figure 3.3: The Project Explorer pane, showing the three main folders Libraries,
Applications, and Controllers.

3.3.3 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.

3BSE041584-610 A 33
3 Control Builder User Interface
3.3 Project Explorer

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).
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 3.4). Once the types are created, they
are displayed under the corresponding subfolders in the library.

3BSE041584-610 A 34
3 Control Builder User Interface
3.3 Project Explorer

Figure 3.4: Creating types under a library

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.
For more information on libraries and library handling, see the manual Compact
Control Builder AC 800M Configuration (3BSE040935*) and the manual Compact
Control Builder AC 800M Binary and Analog Handling (3BSE041488*).

3BSE041584-610 A 35
3 Control Builder User Interface
3.3 Project Explorer

3.3.4 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 3.5). The new application folder can in turn
contain both applications and application folders.

Figure 3.5: 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.
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

3BSE041584-610 A 36
3 Control Builder User Interface
3.3 Project Explorer

For more information, refer to the manual Compact Control Builder AC 800M Configuration
(3BSE040935*).
The Diagrams folder in the default application contains three diagrams. These three
diagrams are connected to three default tasks, see Controllers Folder on page 39. 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 3.6). Once these are created, they are displayed under the corresponding
subfolders in the application.

3BSE041584-610 A 37
3 Control Builder User Interface
3.3 Project Explorer

Figure 3.6: 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 41.

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.

3BSE041584-610 A 38
3 Control Builder User Interface
3.3 Project Explorer

3.3.5 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.
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 33).

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 5 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 Compact Control
Builder AC 800M Configuration (3BSE040935*).

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 41.

3.3.6 Drag-and-Drop in Project Explorer

Some objects can be dragged and then dropped to other objects in the Project Explorer.
Table 3.1 shows the supported operations.

3BSE041584-610 A 39
3 Control Builder User Interface
3.3 Project Explorer

Table 3.1: 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.

3BSE041584-610 A 40
3 Control Builder User Interface
3.3 Project Explorer

Figure 3.7: Object created in diagram as a result of dragging a type and dropping it in
the drawing area

3.3.7 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.

3.3.8 Message Pane

See the location of the message pane in Figure 3.2. 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.

3.3.9 Editors
Control Builder contains a number of editors. The editors can be accessed from Project
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.

3BSE041584-610 A 41
3 Control Builder User Interface
3.3 Project Explorer

Figure 3.8: 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.

3BSE041584-610 A 42
3 Control Builder User Interface
3.3 Project Explorer

3.3.10 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.

3BSE041584-610 A 43
3BSE041584-610 A 44
4 MyDoors Project
4.1 Introduction

4 MyDoors Project

4.1 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 Project Examples in Compact Control Builder on page 114 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.

4.2 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.

3BSE041584-610 A 45
4 MyDoors Project
4.2 Building a Shop Door Project

4.2.1 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.

4.2.2 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.

3BSE041584-610 A 46
4 MyDoors Project
4.2 Building a Shop Door 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.

3BSE041584-610 A 47
4 MyDoors Project
4.2 Building a Shop Door Project

4.2.3 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 14.
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 4.1: Standard templates for building a project.

3BSE041584-610 A 48
4 MyDoors Project
4.2 Building a Shop Door Project

3. Click OK. Project Explorer creates and opens MyDoors project.

Figure 4.2: 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.

4.2.4 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.
In the MyDoors project, expand Application_1 to view the Diagrams folder and the three
default diagrams.
Open the Diagram editor for Diagram2.

3BSE041584-610 A 49
4 MyDoors Project
4.2 Building a Shop Door Project

4.2.5 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.
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.

3BSE041584-610 A 50
4 MyDoors Project
4.2 Building a Shop Door Project

Declare Variables and Signals

1. Double-click Diagram2 to open the corresponding Diagram editor.
2. The Diagram editor is divided into three panes: the declaration pane, the code pane,
and the message pane.

Figure 4.3: The editor for Diagram2.

3. Select the Variables tab, and place the cursor in the upper left-hand cell in the
declaration pane and type Photo_Cell.
4. 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.
5. Type BoolIO in the “Data Type” column.

3BSE041584-610 A 51
4 MyDoors Project
4.2 Building a Shop Door Project

6. 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.
7. 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.
8. The last column “Description” is reserved for you to use freely. Your first row should
now look like this:

Figure 4.4: Declaration of the Boolean variable Photo_Cell

9. 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 4.5: Setting a textual name for page 1

3BSE041584-610 A 52
4 MyDoors Project
4.2 Building a Shop Door Project

10. 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 4.6: Variable is displayed as graphical object in the code pane after the drag
and drop operation.

3BSE041584-610 A 53
4 MyDoors Project
4.2 Building a Shop Door Project

11. 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 4.7: 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:

3BSE041584-610 A 54
4 MyDoors Project
4.2 Building a Shop Door Project

Figure 4.8: Motor_1 variable declaration.

Furthermore, Motor_1 appears as a signal in the Declaration Pane with path to the
corresponding variable:

Figure 4.9: Motor_1 signal declaration.

12. Declare the next variable Motor_2 by the same method. Add signal also for Motor_2.

3BSE041584-610 A 55
4 MyDoors Project
4.2 Building a Shop Door Project

13. Declare the remaining variables in the declaration pane, row 4 to row 8:

Figure 4.10: 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.
14. Select the Communication Variables tab in the Diagram editor, and declare the
Service_Req communication variable:

Figure 4.11: Declaration of the communication variable Service_Req

15. 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 4.12: Signal declarations

3BSE041584-610 A 56
4 MyDoors Project
4.2 Building a Shop Door Project

16. Click Check to check for errors.

17. 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.

4.2.6 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.

3BSE041584-610 A 57
4 MyDoors Project
4.2 Building a Shop Door 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 4.13: 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.

3BSE041584-610 A 58
4 MyDoors Project
4.2 Building a Shop Door Project

3. After selecting TOf, enter OpenDoors in the Name field:

Figure 4.14: 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.

3BSE041584-610 A 59
4 MyDoors Project
4.2 Building a Shop Door Project

5. In the declaration pane for Function Blocks, add the description ‘Timer for Motor’
for the OpenDoors function block.

Figure 4.15: 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 4.16: Tool bar buttons for changing port visibility. The left button means Show
All Ports as visible in tool tip.

3BSE041584-610 A 60
4 MyDoors Project
4.2 Building a Shop Door 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 4.17: The New Variable dialog opened from the PT port of the OpenDoors
function block.

3BSE041584-610 A 61
4 MyDoors Project
4.2 Building a Shop Door 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 4.18: The logic after creating variables directly from the PT and ET ports.

3BSE041584-610 A 62
4 MyDoors Project
4.2 Building a Shop Door 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 4.19: 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 4.20: The Select Component dialog.

3BSE041584-610 A 63
4 MyDoors Project
4.2 Building a Shop Door 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 4.21: 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.

11. Click Check to check for errors.

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.

12. Click Save to save the all editing changes.

3BSE041584-610 A 64
4 MyDoors Project
4.2 Building a Shop Door 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 4.22: 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.

3BSE041584-610 A 65
4 MyDoors Project
4.2 Building a Shop Door 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 4.23: Variable connections to Customer_Count_Up function block

7. Click Check to check for errors.

8. Click Save to save the all editing changes.

3BSE041584-610 A 66
4 MyDoors Project
4.2 Building a Shop Door 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 4.24: 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.

3BSE041584-610 A 67
4 MyDoors Project
4.2 Building a Shop Door Project

6. Graphically connect the variables to the Service_Count_Doors function block:

Figure 4.25: 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 4.26: The Q port of the OpenDoors object is selected on page 1.

3BSE041584-610 A 68
4 MyDoors Project
4.2 Building a Shop Door 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 4.27: Completing the connection by using the Connect to Previous Selection
context menu command.

3BSE041584-610 A 69
4 MyDoors Project
4.2 Building a Shop Door 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 4.28: 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 4.29: 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.

3BSE041584-610 A 70
4 MyDoors Project
4.2 Building a Shop Door Project

10. Click Check to check for errors.

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 .

3BSE041584-610 A 71
4 MyDoors Project
4.2 Building a Shop Door Project

4.2.7 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 126. 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.

3BSE041584-610 A 72
4 MyDoors Project
4.2 Building a Shop Door 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 4.30.

Figure 4.30: 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.

3BSE041584-610 A 73
4 MyDoors Project
4.2 Building a Shop Door Project

Figure 4.31: Changing online value for a variable in the declaration pane.

Figure 4.32: 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.

3BSE041584-610 A 74
4 MyDoors Project
4.2 Building a Shop Door 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.

3BSE041584-610 A 75
3BSE041584-610 A 76
5 Hardware Configuration
5.1 Configure Hardware

5 Hardware Configuration

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.

5.1 Configure Hardware

Study the hardware configuration in Figure 5.1. 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 5.1: Hardware position for IO modules (for example DO814 at position 1 and
DI810 at position 2).

3BSE041584-610 A 77
5 Hardware Configuration
5.1 Configure Hardware

5.1.1 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 5.2: Replace Hardware Unit dialog

4. Click Replace and then Yes to accept the change.

3BSE041584-610 A 78
5 Hardware Configuration
5.1 Configure Hardware

5.1.2 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 5.3: 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.

3BSE041584-610 A 79
5 Hardware Configuration
5.1 Configure Hardware

3. Expand Connected Libraries > S800Io ModulebusHwLib > Hardware types and
select DO814.

Figure 5.4: Insert Hardware Unit dialog

4. Keep default position 1 from Position drop-down menu and click Insert.

3BSE041584-610 A 80
5 Hardware Configuration
5.1 Configure Hardware

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 5.5.

Figure 5.5: Hardware setup (Project Explorer).

To remove a hardware unit, right-click the object in the tree structure and select
Delete.

3BSE041584-610 A 81
5 Hardware Configuration
5.2 Connect Signals to I/O Channels

5.2 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.

5.2.1 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 5.6: The entry assistance shows the available signals with direction 'in'.

3BSE041584-610 A 82
5 Hardware Configuration
5.2 Connect Signals to I/O Channels

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 5.7: The signal added to the first I/O channel.

6. Click Save and Close .

5.2.2 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 5.8: 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.

3BSE041584-610 A 83
5 Hardware Configuration
5.3 Ethernet I/O Wizard

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 5.9: The signals added to the first two I/O channels.

7. Click Check for errors.

8. Click Save and Close .

5.2.3 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 5.10: 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.

5.3 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. 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.

3BSE041584-610 A 84
6 Connecting the Controller and Go Online
6.1 Firmware Upgrade

6 Connecting the Controller and Go Online

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 4 MyDoors Project and then followed
the instructions in Section 5 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 93.

6.1 Firmware Upgrade

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.

3BSE041584-610 A 85
6 Connecting the Controller and Go Online
6.1 Firmware Upgrade

6.1.1 Firmware Upgrade via the Serial Cable (TK212A)

1. Connect the serial cable between the Control Builder PC and the controller, as
specified in Table 6.1. For the type of cable, see Appendix Communication Cables.

Table 6.1: 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 6.1 appears.

Figure 6.1: 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.

3BSE041584-610 A 86
6 Connecting the Controller and Go Online
6.1 Firmware Upgrade

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
6.2).

Figure 6.2: 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.

3BSE041584-610 A 87
6 Connecting the Controller and Go Online
6.2 Setting IP Addresses

6. Select Firmware version3 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 6.3.

Figure 6.3: 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.

6.2 Setting IP Addresses

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.

6.2.1 Setting IP Address for Controller

If you performed Firmware Upgrade on page 85, you can skip the preparations (identical
instructions) and go directly to Starting the IP Config Tool on page 90.

3. The firmware version must be supported by the installed Control Builder version.

3BSE041584-610 A 88
6 Connecting the Controller and Go Online
6.2 Setting IP Addresses

Preparations
Connecting the cable between the Control Builder and the Controller are exactly the
same as described in Firmware Upgrade on page 85.
1. Connect a serial cable between the Control Builder PC and the Controller, as
specified in Table 6.2. For the type of cable, see Appendix Communication Cables.

Table 6.2: 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.

3BSE041584-610 A 89
6 Connecting the Controller and Go Online
6.2 Setting IP Addresses

Starting the IP Config Tool

1. Select ABB Start Menu > ABB System 800xA > Engineering > Utilities >
IPConfig. An IP Config dialog opens.

Figure 6.4: The IP Config dialog box.

2. From the dialog menu Settings, select the Com port connected to the controller.

3BSE041584-610 A 90
6 Connecting the Controller and Go Online
6.2 Setting IP Addresses

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 6.5.

Figure 6.5: 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 6.6.

Figure 6.6: IP Config window for setting unique IP address.

3BSE041584-610 A 91
6 Connecting the Controller and Go Online
6.2 Setting IP Addresses

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 6.7.

Figure 6.7: 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.

6.2.2 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.

3BSE041584-610 A 92
6 Connecting the Controller and Go Online
6.3 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 6.3.

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 6.3: 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.

6.3 Download Project via Ethernet

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.

6.3.1 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.

3BSE041584-610 A 93
6 Connecting the Controller and Go Online
6.3 Download Project via Ethernet

Setting the IP Address for Controller

1. In the Project Explorer, expand Controllers.

Figure 6.8: The Controllers expanded in Project Explorer.

2. Right-click Controller_1 and select Properties > System Identity from the context
menu. The System Identity window opens.

Figure 6.9: The System Identity window for setting the IP address.

3. 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.
4. Expand Hardware AC 800M until you find 1 Ethernet. Right-click the Ethernet icon
(at position 1) and select Editor. The editor opens.

3BSE041584-610 A 94
6 Connecting the Controller and Go Online
6.3 Download Project via Ethernet

5. Select the Settings tab (lower left corner, see Figure 6.10) and enter the IP address
in the IP address Value field.

Figure 6.10: 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.

6. Click Save and Close .

6.3.2 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.
If you run with a SoftController; go to Downloading to the SoftController on page 97.

3BSE041584-610 A 95
6 Connecting the Controller and Go Online
6.3 Download Project via Ethernet

Downloading to the Controller

The following instructions address the project MyDoors, which was previously created
in Section 4 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 6.11: Online Analysis Dialog

3BSE041584-610 A 96
6 Connecting the Controller and Go Online
6.3 Download Project via Ethernet

3. Click Continue.

4. In the Task Analysis dialog, click to accept the download.

Figure 6.12: 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
118.
2. In Project Explorer, expand the Controllers folder.
3. Right-click Controller_1 and select Simulate Hardware from context menu.

3BSE041584-610 A 97
6 Connecting the Controller and Go Online
6.3 Download Project via Ethernet

4. Next, you must start the SoftController. Select SoftController in the ABB Start Menu
app, described in ABB Start Menu on page 14.
The SoftController panel opens:

Figure 6.13: 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.

3BSE041584-610 A 98
6 Connecting the Controller and Go Online
6.4 Test the Diagram Online

6.4 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.

6.4.1 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.

3BSE041584-610 A 99
6 Connecting the Controller and Go Online
6.5 What's Next?

6.5 What's Next?

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.

3BSE041584-610 A 100
A Functions and Settings
A.1 Product Settings for Compact Control Builder

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 Compact Control Builder AC 800M Configuration (3BSE040935*).

A.1 Product Settings for Compact Control Builder

From ABB Start Menu select ABB Compact Product Suite > Utilities > Setup Wizard
Control Builder M.
All Setup Wizard dialog boxes contain a System Information button. Click this button
to open a log file on screen containing all available Wizard settings. It also contains a
list of system environment variables.

A.1.1 File Locations

Compact Control Builder has three file locations which can be managed by the Setup
Wizard. The Working folder and the MMS server working folder are handled by the
system, thus should never be modified. The Project folder should only be changed, if
the Compact Control Builder station should be part of a multi-user configuration.

3BSE041584-610 A 101
A Functions and Settings
A.1 Product Settings for Compact Control Builder

Figure A.1: The Product setting dialog for File Locations

• Working folder; contains Compact Control Builder station log files, settings etc.
• MMS Server working folder; contains MMS Server log files.
• Project folder; contains projects.
Clicking Use Default Settings, resets the manual settings to the general default settings.

How to change the file location for the Project Folder, see Multi-User Configuration
on page 104.

A.1.2 Language
The language to be used for the programming tool is selected under the Language tab.
By default, the installation program selects English.

3BSE041584-610 A 102
A Functions and Settings
A.1 Product Settings for Compact Control Builder

Figure A.2: The Product setting dialog for Language

A.1.3 License
A valid license key shall be entered here. It will be valid for Compact Control Builder,
Soft Controller, and OPC Server. If no valid license key is entered, the products will be
running in demo mode.

Figure A.3: The Product setting dialog for License

3BSE041584-610 A 103
A Functions and Settings
A.2 Multi-User Configuration

A.2 Multi-User Configuration

The Compact Control Builder must be installed on every PC before setting up a multi-user
environment. The OPC Server can be installed on one of the Compact Control Builder
stations or on a standalone PC. All PCs must be connected to the same network.
A multi-user configuration requires that all Compact Control Builder stations and an OPC
Server have access to the common project files1. During multi-user engineering, all
Control Builder stations must write/read engineering changes to the common project
files located in a shared project folder.
The OPC Server reads run-time data directly from the PLC over the network, by accessing
the configuration data located in the common project folder. Thus, the project folder must
be both shared and placed on a network server, before the team starts multi-user
engineering.
Multi-user configuration consists of the following sections:
• Creating a Shared Project Folder on page 104.
• Setting Up Compact Control Builder Stations on page 108.
• Setting Up OPC Server on page 109.
• Configuration Example on page 113.
• Guide lines for Multi-User Engineering on page 114.

A.2.1 Creating a Shared Project Folder

Select a PC station as the network File server (from now on MyServer). Start Windows
and login with administrator role.
1. Create a project folder (from now on AC800Mprojects) on MyServer.
2. In Windows Explorer, right-click AC800Mprojects and select Properties from the
context menu. A Properties dialog opens.

1. A Compact Control Builder project contains several files. These project files hold configuration data for
libraries, applications, hardware, project constants etc.

3BSE041584-610 A 104
A Functions and Settings
A.2 Multi-User Configuration

3. Select the Sharing tab.

Figure A.4: Properties dialog with the Sharing tab active.

4. Click Advanced Sharing... to open the Advanced Sharing dialog.

3BSE041584-610 A 105
A Functions and Settings
A.2 Multi-User Configuration

5. Select the Share this folder check box.

Select this
checkbox

Figure A.5: Advanced Sharing dialog

6. Click Permissions to open the Permissions for AC800Mprojects dialog.

3BSE041584-610 A 106
A Functions and Settings
A.2 Multi-User Configuration

7. Select the Everyone group, and select the Allow checkbox corresponding to Change.

Select this
checkbox

Figure A.6: Permissions for Everyone

8. Click Apply and OK.

9. Click OK.
10. Click Apply in the Properties dialog.
It is preferable to create a new user group (for example MyTeam) in Windows and
add the project members to MyTeam group. Then, select the permission as Change
for MyTeam, instead of for Everyone.

3BSE041584-610 A 107
A Functions and Settings
A.2 Multi-User Configuration

A.2.2 Setting Up Compact Control Builder Stations

Ensure that the Compact Control Builder is installed and the PC station is connected to
Ethernet. For installation instructions see Section 2 Installing Software.
1. Start the Setup Wizard according to Product Settings for Compact Control Builder
on page 101.
2. Select Project Folder on File Locations, and click Modify to open the Modify Working
Folder dialog.

Figure A.7: Modify Project Folder dialog for opening the shared project folder

Type the path in the Folder Path field as in Figure A.7. The path must be specified
with an UNC path that contains the server name and the shared folder name
\\MyServer\AC800Mprojects.
Exclude the ABB Industrial IT Data folder and any used shared network disk from a
virus scan, if the files are scanned at access. Configure the anti-virus program to
scan these files and folders on demand or at a scheduled scan.
3. Type the UNC path to the shared AC800Mprojects folder in the Folder Path field.

3BSE041584-610 A 108
A Functions and Settings
A.2 Multi-User Configuration

4. Click OK to close the Modify Project Folder dialog.

Figure A.8: The new file location for the common project folder.

For more information about the differences between the Working folder and Project
folder, see File Locations on page 101.

5. Click Apply to save the new folder name.

6. Click Close to close the Setup Wizard.
7. Repeat these steps for all Compact Control Builder stations.

A.2.3 Setting Up OPC Server

An OPC Server configuration for multi-user engineering requires the following:
• The path to the common project folder. This path is to be specified under the tab
‘File Locations’ in the Setup Wizard.
• A Service Account.

3BSE041584-610 A 109
A Functions and Settings
A.2 Multi-User Configuration

Ensure that the OPC Server is installed. For installation instructions see Installing the
OPC Server for AC 800M on page 27.
1. From the ABB Start Menu select ABB Compact Product Suite > OPC Server for
AC 800M > Setup Wizard OPC Server for AC 800M.

Figure A.9: Setup Wizard for OPC Server.

2. Select Project Folder on the File Locations tab and click Modify to open the
Project Folder dialog.

Figure A.10: The Modify Project Folder dialog for opening the shared project folder

Type the path in the Folder Path Product Setting field as in Figure A.10.
The path must be specified with an UNC path that contains the server name and the
shared folder name \\MyServer\AC800Mprojects.
3. Enter the path to the shared AC800Mprojects folder.

3BSE041584-610 A 110
A Functions and Settings
A.2 Multi-User Configuration

4. Click OK to close the Modify Project Folder dialog.

Figure A.11: An example of a path to a shared project folder located on a network

server.

5. Select the topic Service Account.

Figure A.12: The Service Account topic for OPC server showing the current login
name

3BSE041584-610 A 111
A Functions and Settings
A.2 Multi-User Configuration

Choosing the Service Account

The choice between 'Local System Account' and 'This Account' depends on the OPC
Server location and the other software products that are installed on the same PC (as
the OPC Server). The two account options are:
• Local System Account cannot read from/write to a network file server. The project
folder must be created locally on the same PC as the OPC server runs. This is
irrespective of the user that is logged in.
• If a network file server holds the project folder the OPC service must run with This
Account and the User account (user, password) must have change privileges to
the project folder.

Communication Failure between OPC Server and the OPC Panel

If a communication failure occurs between the OPC Server and the OPC Panel, then a
pop-up menu appears with the message 'Access denied', and the OPC Panel stops
responding. In such a scenario, proceed with the following steps:
1. In Windows, search for the OPCServerPanel.exe file2.
2. Right-click OPCServerPanel.exe and select Run as in the context menu.
3. Select the OPC Server user account (with administrator role) for running the OPC
Server Panel application.
For more information about setting up user account in Windows, refer to Windows User
Documentation.
1. Click Close to close the Setup Wizard.

Create a small project in one of the Compact Control Builder stations and verify that
the project can be opened from all the other Compact Control Builder stations.

2. Normally located at C:\Program Files (x86)\ABB Industrial IT\Control IT\OPC Server for AC 800M\Bin\

3BSE041584-610 A 112
A Functions and Settings
A.2 Multi-User Configuration

A.2.4 Configuration Example

Assume the following network configuration:
• The OPC Server is installed on a PC together with an operator interface. The OPC
Server has the Project folder path set to the File Server.
– OPC Server copies the configuration data from the project folder to its own local
working folder. It uses the configuration data to translate the live data traffic
from the PLC.
– OPC Server writes cold retain values to the shared project folder. This is one
of the reasons to set the permission Change in Windows.
• If Local System Account (see Figure 5.) has been selected previously in the Setup
Wizard, only members of MyTeam group should login to the PC machine, or the
OPC Server is interrupted.
• If This Account (see Figure 5.) has been selected previously in the Setup Wizard,
any user including an operator can login to the PC machine without interrupting the
OPC Server traffic.
• Two Compact Control Builder stations with their project folder shared on the network
File Server.
• One File Server with the shared project folder AC800Mprojects. The figure below
shows this multi-user configuration.

Operator
interface \\MyServer\AC800Mprojects
Compact Compact
OPC Server Control Builder Control Builder File Server
(MyServer)

Writes Cold retain values Ethernet

to File Server

PLC MyTeam Group with Change

Copy necessary project files permission in Windows
and Paste them in the Working folder

Figure A.13: An example of a multi-user configuration

3BSE041584-610 A 113
A Functions and Settings
A.3 Project Examples in Compact Control Builder

A.2.5 Guide lines for Multi-User Engineering

A project contains a number of files, whereas every member in a multi-user environment
has a decisive impact on these project files. This means that a project folder shared by
several Compact Control Builders may be subjected to multiple changes at the same
time.
To avoid unwanted read/write results on the project files, follow these guidelines:
1. Several members may work with different libraries etc. without difficulties, but always
strive to assign one member to a specific library, application or PLC at the time.
2. If several members must work with the same library or application, then allow only
one member to work with a specific Type (Program, Function block type etc.) at the
time.
3. Allow only one member to work with control modules in an application at the same
time.
4. If several members must work with a specific PLC, then permit only one member
to work with a specific Hardware unit, Task or Access variables, at the same time.

If a rename operation affects several files, Control Builder shows the alert message
and displays the corresponding files before proceeding with the rename operation.

A.3 Project Examples in Compact Control Builder

The Compact Control Builder comes with a number of examples that are designed to
help you understand how to use various parts of the product and the standard libraries.
All these examples are installed as (read-only) files in the folder
Program Files (x86)/ABB Industrial IT/Engineer IT /Compact Control Builder
AC 800M/Examples. All the examples are Read-only, which means they cannot be
altered. To study these, see Opening a Project Example (Read Only) on page 115.
• An alarm and event example (AlarmSimple_M),
• A number of control loop examples (ControlExamples),
• A group start example (GroupStartExample1),
• A basic shop door example in ST and FD languages (ShopDoors_ST and
ShopDoors_FD),

• A tutorial (Tutorial_03).

3BSE041584-610 A 114
A Functions and Settings
A.3 Project Examples in Compact Control Builder

If these are used as a template or a skeleton for other projects, then the project needs
to be copied and the projects attribute changed from read only in Preparing the ShopDoors
Example for a Project on page 116.

A.3.1 Opening a Project Example (Read Only)

1. From the Project Explorer, select File > Open Project. An Open Project window
opens
2. In the Open Project window, select Examples files in the Go to folder drop-down
list, or navigate manually to the Examples folder in the Compact Control Builder
installation folder, typically, C:\Program Files (x86)\ABB Industrial IT\Engineer
IT\Compact Control Builder AC 800M).
3. Open e.g. the ShopDoors_FD folder and select ShopDoors_FD.prj.

Figure A.14: Selecting ShopDoors_FD project (Read Only)

4. Click Open. The ShopDoors example opens as read-only in the Project Explorer.

3BSE041584-610 A 115
A Functions and Settings
A.3 Project Examples in Compact Control Builder

A.3.2 Preparing the ShopDoors Example for a Project

From the disk where Compact Control Builder3 is installed:
1. Start the Search tool in Windows and search for ShopDoors_FD.prj. The project file
is located inside the example folder for the ShopDoors project.
2. Copy the complete ShopDoors_FD folder into the Projects folder4.
3. Right-click the ShopDoors_FD folder and select Properties from the context menu.
4. Clear the folders properties Attribute Read-only. Apply changes to the folder, sub
folder and files.
5. Follow the next steps under Opening a Project on page 117, to open the converted
ShopDoors_FD project.

3. Compact Control Builder is normally installed on the Local Disk (C:)

4. The Projects folder is normally located at; C:\ABB Industrial IT Data\Engineer IT Data\ Control Builder
AC 800M\Projects

3BSE041584-610 A 116
A Functions and Settings
A.4 Testing

A.3.3 Opening a Project

1. From the Project Explorer, select File > Open Project. An Open Project window
opens.

Figure A.15: The Open Project window

2. Select the ShopDoors_FD folder and click Open. The project ShopDoors_FD folder
opens.
3. Select the ShopDoors_FD.prj file and click Open. The Project Explorer opens the
ShopDoors_FD project.

A.4 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
124. 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 130.

3BSE041584-610 A 117
A Functions and Settings
A.5 Simulation

A.5 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 120.
You are advised to read the subsection Restrictions Concerning Hardware Simulation
on page 121, before you start simulating the hardware.
Select Tools > Setup > Station > Application Download to open the
Setup - Application Download dialog (see Figure A.16).

Figure A.16: Application Download with default settings

Set the parameter HWSimulationAllowed to true, to allow hardware simulation.

3BSE041584-610 A 118
A Functions and Settings
A.5 Simulation

A.5.1 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.5.2 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.5.3 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").

A.5.4 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.

3BSE041584-610 A 119
A Functions and Settings
A.5 Simulation

A.5.5 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 126.
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.5.6 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.17. Note the word “Simulated” in the title bar.

Figure A.17: 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.

3BSE041584-610 A 120
A Functions and Settings
A.6 Download

A.5.7 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.6 Download
This section describes download and the checks and reports associated with download.

A.6.1 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).
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 123.

3BSE041584-610 A 121
A Functions and Settings
A.6 Download

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 128.

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.
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).

3BSE041584-610 A 122
A Functions and Settings
A.6 Download

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).
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 Compact Control Builder AC 800M
Configuration (3BSE040935*) for how to locate the log file.

A.6.2 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.18.

Another way to reset and restart the controller is to press controller’s INIT button for
more than 3 seconds.

3BSE041584-610 A 123
A Functions and Settings
A.6 Download

Figure A.18: 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.

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 121.)

A.6.3 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.

3BSE041584-610 A 124
A Functions and Settings
A.6 Download

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.19, “Controller_2” and “Controller_3” cannot be separately selected or excluded since
one application is connected to both these controllers.

Figure A.19: 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.

3BSE041584-610 A 125
A Functions and Settings
A.6 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.19, an Online Analysis window will open.
2. Select the application to be downloaded. See the example in Figure A.20.

Fi 63 C d li i ll O l A li i 2 ill b
Figure A.20: Connected applications to a controller. Only Application 2 will be
downloaded.

A.6.4 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.

3BSE041584-610 A 126
A Functions and Settings
A.6 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 4.2) 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.21: 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.22) appears before the download of the application to the controller.
Click to accept the download.

3BSE041584-610 A 127
A Functions and Settings
A.6 Download

Figure A.22: Example of a Difference Report Before Download

A.6.5 Compiler Switches

Configurable switches in the compiler allow you to introduce extra restrictions on code.
Global restrictions are valid for all code.
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 4.2) and select Settings >
Compiler Switches from the context menu. A ‘Compiler switches’ window will open.

3BSE041584-610 A 128
A Functions and Settings
A.6 Download

Figure A.23: 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.

3BSE041584-610 A 129
A Functions and Settings
A.7 Application Restart Mode

Figure A.24: Compiler switches, excluding library from restriction.

A.7 Application Restart Mode

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 Compact
Control Builder AC 800M Configuration (3BSE040935*).

3BSE041584-610 A 130
A Functions and Settings
A.7 Application Restart Mode

A.7.1 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).
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.

A.7.2 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. 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.
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*).

3BSE041584-610 A 131
A Functions and Settings
A.7 Application Restart Mode

A.7.3 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.1, Table A.2, and Table A.3.

Initial Restart
Table A.1 shows how a initial restart affects variable values when Download mode is
started.

Table A.1: Initial restart, starting values

Variable attribute Starting value

ColdRetain Initial value
Retain Initial value
Other Initial value

Cold Restart
Table A.2 shows how a cold restart affects variable values when Download mode is
started.

Table A.2: Cold restart, starting values

Variable attribute Starting value

ColdRetain Cold retain value
Retain Initial value (if any)
Other Initial value (if any)

Warm Restart
Table A.3 shows how a cold restart affects variable values when Download mode is
started.

3BSE041584-610 A 132
A Functions and Settings
A.7 Application Restart Mode

Table A.3: Warm restart, starting values

Variable attribute Starting value

ColdRetain Retain value
Retain Retain value
Other Initial value (if any)

A.7.4 Variable values in Test mode

Initial Restart
The variable values are similar as in Download mode, see Table A.1.

Cold Restart
The variable values are similar as in Download mode, see Table A.2.

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.3.
Warm Restart of the application is performed after the power failure. The restart values
of the variables are as shown in Table A.4.

Table A.4: Warm restart: starting values

Variable attribute Starting value

ColdRetain Last test session
Retain Last test session
Other Initial value (if any)

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.

3BSE041584-610 A 133
A Functions and Settings
A.7 Application Restart Mode

A.7.5 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.

3BSE041584-610 A 134
B Network Redundancy
B.1 Setting Up Redundant Network

Appendix B Network Redundancy

The information given in this Appendix applies only to users who intend to setup
Redundant Networks.

For more information about Redundant Networks and clock synchronization, refer to the
online help and the AC 800M Communication Protocols (3BSE035982*) manual (in
particular, the MMS section in the manual).

B.1 Setting Up Redundant Network

The following example explains how to set up two separate redundant networks with the
so called implicit IP addressing method. It also explains configuring IP addresses for the
two PLCs and two PCs. The following sub-sections have step-by-step instructions which
can be applied in the projects. After completing this example, the user must be able to
add another PLC or Compact Control Builder station.

B.1.1 Two Separate Redundant Networks

The example consists of PLC_1 and PLC_2 on one redundant Control Network, and
PC_1 with a Control Builder on another redundant Client/Server Network. PC_2, with
for example an OPC Server to access the right network components, connects the two
separate redundant networks according to the figure below.

3BSE041584-610 A 135
B Network Redundancy
B.1 Setting Up Redundant Network

PC_1 with Control Builder and

two Ethernet boards
P=172.16.4.1
S=172.17.4.1

Client/Server Network
Primary (P)
Secondary (S)
PC_2 with, for example an OPC Server and
four Ethernet boards
P=172.16.4.2 P=172.16.0.3
S=172.17.4.2 S=172.17.0.3

Control Network
Primary (P)
Secondary (S)
P=172.16.0.1 P=172.16.0.2
S=172.17.0.1 S=172.17.0.2

P=IP address in the primary network

S=IP address in the secondary network PLC_1 PLC_2

Figure B.1: Redundant Control Network and redundant Client/Server Network

3BSE041584-610 A 136
B Network Redundancy
B.1 Setting Up Redundant Network

Changing in RNRP Setup Wizard

Run the RNRP Setup Wizard for PC_2, otherwise the routing from PC_1, via PC_2, to
the PLCs does not work.
1. Right-click the ABB RNRP-icon located in the system tray. Normally located at the
lower right-side of the Windows desktop. The RNRP Wizard opens.
2. Make sure the Base Parameters tab are active.

Base Parameters
Tab

Parameter

Figure B.2: RNRP Wizard

3BSE041584-610 A 137
B Network Redundancy
B.1 Setting Up Redundant Network

3. Select the Enable TCP/IP forwarding parameter and click the Modify button. A
value dialog opens.

Figure B.3: Parameter dialog for changing parameter values

4. Change the parameter value to 1 instead of the default value 0 and click OK.
5. Click Close to close the RNRP Wizard.

B.1.2 Decide IP Addresses

First the IP addresses must be decided, and then the IP subnet mask to use for each
Ethernet connection port. These redundant networks must have two IP addresses for
each PLC and in PC_1 with the Control Builder. In PC_2, with the OPC Server, four IP
addresses are required to the four ports in the Ethernet PC boards.
In this example, select the IP addresses displayed in Table B.1 below and in Figure B.1
as follows.

Subnet mask
Use the following subnet mask for all IP addresses: 255.255.252.0.

3BSE041584-610 A 138
B Network Redundancy
B.1 Setting Up Redundant Network

IP addresses (X.Y.Z.Q)
• Use the recommended IP addresses in the X.Y. positions of X.Y.Z.Q for both
redundant networks; 172.16.Z.Q for the primary network, and 172.17.Z.Q for the
secondary network.
• Due to the subnet mask value, select the Z. position of X.Y.Z.Q as a multiple of four.
Choose two values between; 172.16.0.Q, 172.16.4.Q, 172.16.8.Q, 172.16.12.Q etc.
up to 172.16.124.Q. Note that the Z. value must also be different for Control Network
and Client/Server Network.
• Select the Q position of X.Y.Z.Q as a free serial number in the range 1 - 254, for
each node on each separate network. Thus one serial Q number for the primary
and the secondary network ports of each PLC and PC.

Table B.1: Selected settings of the IP addresses with the 255.255.252.0 subnet
mask.

PC_1 with PC_2 with

PLC_1 PLC_2 Control OPC
Network
(X.Y.Z.Q) (X.Y.Z.Q) Builder M Server
(X.Y.Z.Q) (X.Y.Z.Q)
Primary Control Network 172.16.0.1 172.16.0.2 - 172.16.0.3
Secondary Control Network 172.17.0.1 172.17.0.2 - 172.17.0.3
Primary Client/Server - - 172.16.4.1 172.16.4.2
Network
Secondary Client/Server - - 172.17.4.1 172.17.4.2
Network

B.1.3 Setup Using the IPConfig Tool

To get initial access to the PLCs, assign them with a first primary IP address.
1. Connect a PC, running the program IPConfig tool, to the PLC_1 Tool port (via a
serial cable).
2. Follow IPConfig online help instructions and set the primary IP address to 172.16.0.1
(see Table B.1).
3. Repeat Step 1 and Step 2, for PLC_2.

3BSE041584-610 A 139
B Network Redundancy
B.1 Setting Up Redundant Network

B.1.4 Configure PLC Ports from Project Explorer

1. In the Project Explorer of PC_1, configure the project with PLC_1 and PLC_2.
2. In PLC_1, double-click Ethernet port number 1 to open its editor.
3. In the editor Settings tab, set the IP address parameter to 172.16.0.1 (see Table
B.1), and the IP subnet mask to 255.255.252.0.
No other parameter setting is required.
4. Repeat step 2 and 3 for Ethernet port number 2 of PLC_1, set its IP address to
172.17.0.1 (see Table B.1).
5. From Ethernet port number 2, select Settings tab and set the Enable Ethernet
channel parameter to true (Figure B.4).

Change the parameter from false to true

Figure B.4: Hardware editor for Ethernet port no. 2 in Project Explorer

6. Repeat step 2 to 5 for PLC_2.

B.1.5 Configure PC Ports in Windows

Configure the Ethernet board ports for PC_1 and PC_2, using the following steps:
1. In PC_1, go to Control Panel (> Network and Internet5) > Network and Sharing
Center.
2. Click Change adapter settings.
3. Right-click the network adapter and select Properties. The Properties dialog for the
adapter is displayed.
4. In the Connect Using drop-down list, select the Ethernet board that is to be connected
to the primary network.
5. Select Internet Protocol Version 4 (TCP/IPv4) and click Properties. The Internet
Protocol Version 4 (TCP/IPv4) Properties dialog is displayed.

5. The path in the parenthesis depends on the Control Panel view by Category.

3BSE041584-610 A 140
B Network Redundancy
B.1 Setting Up Redundant Network

6. Select Use the following IP address and enter the IP address (172.16.4.1 for the
primary network in PC_1, see Table B.1), and the subnet mask 255.255.252.0. Click
OK.
7. Repeat steps 1 to 7 for the secondary network (using the IP address 172.16.4.2).
8. Click OK.
9. For PC_2, repeat steps 1 to 9 for all four Ethernet boards to be configured.
10. Click OK. The PC IP addresses and subnet masks have now been set for all Ethernet
ports connected to the two networks.

B.1.6 Download Project and Go Online

When all IP addresses and subnet masks are set, download the project and go online
in the Control Builder. After a while, redundant network communication is enabled.

B.1.7 Setting Clock Synchronization using the CNCP Protocol

This subsection describes how to setup a clock synchronization using the CNCP protocol.
CNCP offers relative clock synchronization down to milliseconds, which means that the
real time clocks in the controllers will never be more than a few milliseconds apart. Hence,
absolute time will not necessarily be totally correct. See also the AC 800M Communication
Protocols (3BSE035982*) manual for other available clock synchronization methods.

CNCP requires that RNRP is properly configured in the PLCs.

When using AC 800M controllers, CNCP is the recommended protocol for time
synchronization to all nodes on the Control Network that support CNCP.

Configure the CNCP clock master

Assign one controller to be the clock master (any type of controller is adequate). From
the Project Explorer tree:
1. Right-click the assigned PM unit and select Editor from the context menu. The
hardware editor opens.
2. Select the Settings tab and locate the following parameters.

3BSE041584-610 A 141
B Network Redundancy
B.1 Setting Up Redundant Network

3. Set the following (four) parameters according to Figure B.5. The setting
CS Time Set Enabled can be set to True if local time source is used.

The parameter settings

Figure B.5: CNCP master settings in the hardware editor

4. Save the settings and close the editor (Ctrl+U).

5. Perform a download to the (clock master) controller.
The CNCP Clock Master periodically sends time updates to the clock slaves with multicast
messages.

Configure the CNCP clock slaves

Assign all the other controllers to be clock slaves (they should all be configured in the
same way). From the Project Explorer tree:
1. Right-click the PM unit and select Editor from the context menu. The hardware
editor opens.
2. Select the Settings tab and locate the following parameters.
3. Set the following (four) parameters according to Figure B.6. The setting
CS Time Set Enabled can be set to True if local time source is used.

The parameter settings

Figure B.6: CNCP slave settings in the hardware editor

3BSE041584-610 A 142
B Network Redundancy
B.2 Design

4. Save the settings and close the editor (Ctrl+U).

5. Perform a download to the (clock slave) controller.

B.2 Design
B.2.1 IP Address
A communication channel IP address is a 32-bit word (4×8 bits) that can be entered as
a string X.Y.Z.Q of four decimal numbers 0-255, separated by periods. The IP standard
uses the terms NetID and HostID. The subnet mask specifies the boundary between the
NetID part and the HostID part of the IP address (the zero bits indicate the HostID part).
Depending on the value of X, IP addresses are divided mainly into three classes, A–C:

Table B.2: IP address classes.

IP address
XXXXXXXX.YYYYYYYY.ZZZZZZZZ.QQQQQQQQ
in bit format

Class A NetID HostID

Class B NetID HostID
Class C NetID HostID

Figure B.7:

Value Possible host Default subnet

Class NetID HostID
of X IP addresses mask
A 1-126 X Y.Z.Q X.0.0.1-X.255.255.254 255.0.0.0
B 128-191 X.Y Z.Q X.Y.0.1-X.Y.255.254 255.255.0.0
C 192-223 X.Y.Z Q X.Y.Z.1-X.Y.Z.254 255.255.255.0

3BSE041584-610 A 143
B Network Redundancy
B.2 Design

The Redundant Network Routing Protocol (RNRP) developed by ABB handles alternative
paths between nodes and automatically adapts to topology changes. RNRP uses more
terms than the standard IP, namely network area and node number. By selecting
225.255.252.0 as the subnet mask, the last 10 bits constitute the node number (i.e. host
ID, 0-1023). Note that the largest permitted node number is 500. The remaining NetID
part is used for network ID (16 bits), local flag (1 bit), and network area number (5 bits).
The last two bits of the network ID make up the path number, where 0 indicates the
primary network and 1 the redundant secondary network.
Consequently, RNRP requires a different interpretation of the IP address to the IP
standard.
It is recommended that the RNRP interpretation of the IP address be used. If the decimal
numbers are converted to binary numbers, the address can be interpreted as follows:
XXXXXXXX.XXXXXXPP.LAAAAANN.NNNNNNNN
Each position represents a binary digit (0 or 1). The different parts of the address signify
the following:

Table B.3: IP address converted into binary.

Number of
Binary number IP term RNRP term
bits
XXXXXXXX.XXXXXXPP 16 Network ID Network ID
LAAAAA Subnetwork ID
PP 2 Path number
L 1 Local flag
AAAAA 5 Network area
number
NNNNNNNNNN 10 Host ID Node number

The subnet mask sets the boundary between the host ID part and the subnet ID part
and is selected as 11111111.11111111.11111100.00000000 (=255.255.252.0 in decimal
notation).
The network ID must be identical for all nodes on the same network. It is recommended
that an address be selected from the private IP address space, which has the following
advantages:

3BSE041584-610 A 144
B Network Redundancy
B.2 Design

• There is no requirement to apply to the licensing authorities for an IP address.

• Some protection is gained against illegal access, since private addresses are not
permitted on the public Internet.
• The firm connection between IP and RNRP parameters reduces the risk of
inconsistency.
The following primary network IP addresses are recommended (class B):
172.16.0.0
172.20.0.0
172.24.0.0
or 172.28.0.0
By converting the second decimal number into binary, the path number is converted to
0 (see also Table B.1 and Table B.3).

Example 1:
Convert the subnet ID 11111111.11111111.11111100.00000000 to decimal.
By writing the first part in groups of four binary digits (1111), the hexadecimal equivalent
is FF. The decimal equivalent is 255. The second part is identical, that is, 255. The third
part 1111 1100 equals FC (hexadecimal) and 252 (decimal). The fourth part equals 0 in
both decimal and hexadecimal notation. Consequently the subnet ID is written
255.255.252.0 in decimal notation.

Example 2:
IP address 192.168.255.25 written in binary notation:
It can be written C0.A8.FF.19 in hexadecimal form, which means
11000000.10101000.11111111.00011001 in binary notation.

B.2.2 Separating Client/Server and Control Network

The Control Network must be protected from foreign traffic that can be a security risk
and also cause undesired load on both the nodes and network. To avoid these risks the
Control Network should be physically separated from the Internet and protected by
servers and/or fire walls. In large configurations such separation may also be desirable
between the Control Network and client/server networks.

3BSE041584-610 A 145
B Network Redundancy
B.2 Design

Client Node and Server Node

In a large network topology, only nodes with real-time communication requirements may
be connected to the Control Network. Client nodes (such as engineering stations, operator
stations, etc.) not belonging to the Control Network may go through a server node that
performs authority control and can disable routing (transfers) to nodes on the Control
Network.

Internet
Service
Provider
Internet
Client nodes
Client nodes Fire wall

Client/server networks
Client/Server

Server node Client node Server node

Control Network

Control Network

Figure B.8: Separation of Control Network and client/server networks

It is, however, possible to have client nodes such as operator stations and engineering
stations connected directly to the Control Network. If such a client needs access to the
client/server network, a separate network connection is possible.
Traffic other than that between Compact Control Builder products may jeopardize
performance.
Only IP traffic generated by IndustrialIT products is allowed to reach the PLCs on the
Control Network.

3BSE041584-610 A 146
B Network Redundancy
B.2 Design

B.2.3 Summary of Configuration Steps

1. Specify network ID (IP address and subnet mask).
2. Split the control network into network areas.
3. Specify local network areas.
4. Specify network area numbers.
5. Assign path numbers.
6. Decide which devices should run the routing functionality.
7. Assign IP addresses to each device.
8. Assign redundant functionality to each system.

3BSE041584-610 A 147
3BSE041584-610 A 148
C Upgrade

Appendix C Upgrade

This appendix covers only the upgrade from 5.0.2, 5.1.0, 5.1.1, and 6.0.0 to
Compact Control Builder 6.1.0.

It is not possible to upgrade a project created in Control Builder Professional to

Compact Control Builder 6.1.0.

Figure C.1 shows the possible options for upgrade to Compact Control Builder version
6.1.0.

3BSE041584-610 A 149
C Upgrade

Advant Control Control Builder Control Builder Control Builder

Builder 1.x/y M Professional M Professional M Professional
2.x/y 3.0/x 3.1/x

Compact Control Builder

Control Builder M Professional
4.0.0-x 3.2/x

Compact Compact Compact

Control Builder Control Builder Control Builder
4.1.0-x 5.0.0-x 5.0.1-x

Compact Compact
Control Builder Control Builder
5.1.x-y 5.0.2-x

Compact
Control Builder
6.0.x-y

Compact Control Builder 6.1.0-0

(This version)

Figure C.1: Upgrade options for Compact Control Builder

3BSE041584-610 A 150
C Upgrade
C.1 Save Application and Configuration Data

C.1 Save Application and Configuration Data

The application and configuration data must be saved on a safe media before upgrading,
if the upgrade involves change of Windows version. It is also possible to take a backup
of the entire project (which saves the application and configuration data) and restore it
in the new version.
To save the application and configuration data:
1. Open the project in the Compact Control Builder.
2. Go to the Online mode.
3. From Control Builder menu bar, select Tools > Save ColdRetain Values. Failure
to make new files can cause some or all Cold Retain marked variables to revert to
older values after upgrading.
4. Go to Offline mode.
5. From Control Builder menu bar, select Tools > Maintenance >
Project Backup, select Complete backup as the option, and save the project to a
safe media.
6. Repeat the procedure for each Control Builder project.
7. From the OPC Server Configuration window, select
File > Save Configuration.
The OPC configurations are saved in:
...\ABB Industrial IT Data\Control IT Data\OPC Server for
AC 800M\Files.

8. Copy the following OPC Server files from the OPC Server to a safe media:
• systemsetup.sys, located in:
...\ABB Industrial IT Data\Control IT Data\
OPC Server for AC 800M

• Configuration files (*.cfg), located in:

...\ABB Industrial IT Data\Control IT Data\
OPC Server for AC 800M\Files

3BSE041584-610 A 151
C Upgrade
C.2 Save Gain Schedule Settings in PidAdvancedCC

C.2 Save Gain Schedule Settings in PidAdvancedCC

Before upgrade, Gain Schedule Settings in PidAdvancedCC must be saved. This is only
necessary for upgrades from Compact Control Builder 5.1.x-y and Compact Control
Builder 5.0.2-x to Compact Control Builder 6.0.x-y or Compact Control Builder 6.1.0-0
(This version). The reason is that some internal Function Block types in
ControlAdvancedLib have changed names in version 6.0.x-y and onwards.
After an upgrade this will lead to the loss of cold retain values in the Gain Scheduling
table of the PidAdvancedCC Control Module instances. The user is notified about the
cold retain mismatch in the Change Analysis. See Figure C.2 and Figure C.3.

Figure C.2: Change Analysis

3BSE041584-610 A 152
C Upgrade
C.2 Save Gain Schedule Settings in PidAdvancedCC

Figure C.3: Change Analysis

The following Gain Scheduling values (inside the red boxes) are affected and will be
lost. See Figure C.4 and Figure C.5.

3BSE041584-610 A 153
C Upgrade
C.2 Save Gain Schedule Settings in PidAdvancedCC

Figure C.4: Interaction Window - Gain Scheduling window

3BSE041584-610 A 154
C Upgrade
C.2 Save Gain Schedule Settings in PidAdvancedCC

Figure C.5: Interaction Window - Edit window

Before an upgrade make a hardcopy of all Gain Schedule settings, i.e. main interaction
window and Edit window(s) of the PidAdvancedCC Control module instances. Note that
for every set of variables a hardcopy shall be made of each “Edit” window(s). After project
upgrade the Gain Scheduling variables shall be manually entered either from Control
Builder or from a Workplace in order to retain the Gain Schedule settings.

3BSE041584-610 A 155
C Upgrade
C.3 Remove Products

C.3 Remove Products

Stop all third party OPC Clients and shut down the Control Builder on all nodes.
In order to upgrade, the previous version or revision must be removed before installing
the new version. If several products (that is, Control Builder and OPC Server,
SoftController, User Documentation, Firmware and RNRP) are installed on the same
PC, all should be removed before the new versions are installed.
The following services must be manually stopped before the products are
removed/upgraded:
• MMS Server for AC 800M.
• OPC Server for AC 800M.
• RNRP Service.

It also applies for any other service that automatically starts any of above services.

The RNRP Service should be stopped in the Windows Services Overview, which is found
at Control Panel > System and Security > Administrative Tools > Services.
When the PC is upgraded to a new Windows version, the existing Control Builder
projects (made in the previous version) may be deleted from the local disc.
In case of re-install of Control Builder on the same Windows version, no existing
projects will be deleted from disc when the Control Builder version is removed. In this
case, the new Control Builder will be able to open the projects left on disc.

C.4 Install Products

Install the Compact Control Builder 6.1.0 products by follow the instructions given in
Section 2 Installing Software.
Make sure to install the needed coexistence features. See Coexistence with Previous
Versions on page 27. For example, if a project saved in Compact Control Builder 5.0.2
is to be upgraded, select AC 800M Coexistence 5.0.2.

3BSE041584-610 A 156
C Upgrade
C.5 Restore Application and Configuration Data

C.5 Restore Application and Configuration Data

C.5.1 OPC Server for AC 800M
1. Restore the previously saved systemsetup.sys file to the following location:
ABB Industrial IT Data\Control IT Data\OPC Server for AC 800M

2. Restore the configuration files (*.cfg) to the Files folder in the same location.

C.5.2 Compact Control Builder

1. From Compact Control Builder menu bar, select Tools > Maintenance >
Restore, select Complete restore as the option, and restore the project from the
safe media to a new folder in the following destination:
...\ABB Industrial IT Data\Engineer IT Data\
Compact Control Builder AC 800M\Projects

2. Repeat the procedure for each Control Builder project.

3. Ensure that all the files in the Projects folder are not marked as Read-only (especially,
if the files have been stored on a CD-ROM).
4. Upgrade the 5.0.2, 5.1.0, 5.1.1 or 6.0.0 projects to Compact Control Builder 6.1.0
by performing one of the following two methods:
• Open the project in Compact Control Builder 6.1.0.
• In Compact Control Builder 6.1.0, select Tools > Maintenance > Upgrade
Project.

3BSE041584-610 A 157
C Upgrade
C.5 Restore Application and Configuration Data

Upgrade by Opening the Project

1. Open the 5.0.2, 5.1.0, 5.1.1 or 6.0.0 project in Compact Control Builder 6.1.0 by
selecting the option
File > Open Project.
2. If the project needs to be upgraded, a dialog pops-up and informs the user about
the upgrade of project to the current version.
During the upgrade, a check is made for the version of BasicHwLib. If any old version
is connected to the project, the user is asked if the old libraries shall be kept or
replaced by the newest library in the system
When the BasicHWLib is replaced, the firmware in the controllers also needs to be
upgraded.
If other hardware libraries exist in newer major versions and the versions are
dependent on the BasicHwLib version, then they are also replaced if the user selects
to replace BasicHwLib. This is the case for the new versions of
CI-HwLibraries delivered in Compact Control Builder 6.1.0.

Upgrade by Selecting the Upgrade Project Option

Libraries, Applications, and Controllers originally placed in folders different from the
project folder will not be upgraded if the project backup on safe media are restored
using Windows Explorer.
1. From the Compact Control Builder, select Tools > Maintenance >
Upgrade Project.
2. Browse to the project file (*.prj) and click Open.
The ‘Save Upgraded Project As’ dialog opens.
3. Select location and click Save in the project folder.
4. Wait for the upgrade to finish.
a. During the upgrade process, some messages may be displayed. Read the
messages and choose among the available options.
b. The upgrade may take up to 30 minutes. The Compact Control Builder may
stop responding during that time. If the process is interrupted, it must be
restarted. The Windows Task Manager can be used to supervise the
completeness.
5. Repeat Step 1. to Step 4. for all other projects.

3BSE041584-610 A 158
C Upgrade
C.5 Restore Application and Configuration Data

C.5.3 Upgrade PLC Firmware

Upgrade PLC firmware to the new version in order to be compatible with other products
of version 6.1.0. Firmware in all communication interfaces must also be upgraded to the
latest version, refer to Firmware Upgrade on page 85.

C.5.4 Downloading the Project

Before handling a download, refer to the compatibility issues given in Table C.1 on
page 160.

C.5.5 Compatibility Issues

CCB 5.0.2 to 6.1 Compatibility Issues

Table C.1 lists and describes Compact Control Builder compatibility issues, including
solutions to the issues, when upgrading from version 5.0.2 to 6.1.0.

3BSE041584-610 A 159
C Upgrade
C.5 Restore Application and Configuration Data

Table C.1: CCB Version 5.0.2 to 6.1 Compatibility Issues

Application Issue Solution

Mixing formal and Prior to Compact Control Correct the code to use either
informal parameter Builder 5.1 it was allowed formal or informal parameter
passing in a function call to mix formal and informal passing for all parameters in the
is not allowed. parameter passing in a function call.
function call.
The Control Builder
compiler in Compact
Control Builder 6.0 gives
a compile error for mixed
parameter passing.
Allowed:
AddSuffix( String :=
StrVar, Suffix := StrSuffix
);
or
AddSuffix( StrVar,
StrSuffix );
Not allowed:
AddSuffix( String :=
StrVar, StrSuffix );
Writing to components of If a function block has a Correct the code to not use this
a structured function parameter p1 with illegal construction.
block parameter with direction [in] of a
direction [in] via control structured data type, it
module parameter is was possible to write to
prohibited. its components by
connecting it to a control
module that writes to the
parameter. This is
prohibited in compact
control builder 6.0

3BSE041584-610 A 160
C Upgrade
C.5 Restore Application and Configuration Data

Table C.1: CCB Version 5.0.2 to 6.1 Compatibility Issues

(Continued)
Application Issue Solution
New attributes for Some new attributes For detailed information on the
function block, control have been introduced in new attributes and their
module, and data types compact control builder consequences, refer to Compact
have been introduced. 5.1 that affect function Control Builder AC 800M
block, control module, Configuration (3BSE040935*).
and data types.
For example:
- Direction attribute on
control module
parameters.
- Reverse and ISP
attribute on datatype
components.
CI851 and CI852 are no It will no longer be CI851 should be replaced with
longer supported possible to perform CI854 instead.
co-existence downloads
to old controllers with
firmware that supports
CI851 and CI852. CI851
and CI852 related HWD
files will emit warnings
due to removed syntax.
ABBDrvFenaCI871HwLib To solve the problem with If any workaround is configured
1.0-3 negative values like in the 61131 application e.g. to
ABBDrvRetaCI871HwLib unsupported negative survive the negative speed value
1.0-6 speed, all I/O-channels issue, these workarounds must
instead of Status and be removed when using the
Command have been updated Library versions.
changed to operate the See Product Bulletin
data to and from the drive 3BSE047421D0166 for details as
as signed instead of well.
unsigned Integer value.

3BSE041584-610 A 161
C Upgrade
C.5 Restore Application and Configuration Data

Table C.1: CCB Version 5.0.2 to 6.1 Compatibility Issues

(Continued)
Application Issue Solution
ABBDrvFenaCI871HwLib These libraries have been If the intention is to continue
version 1 moved to AC 800M running with co-existence the
CI868IEC61850HwLib Classic system extension. Classic Library Extension has to
version 2 See System 800xA be installed. A message will
Release Notes New appear to inform the user during
CI871PROFINETHwLib
Functions and known upgrade.
version 1
Problems (2PAA111899*)
S900IoCI854HwLib for current versions of the
version 1 libraries.
CI871PROFINETHwLib When upgrading from Ensure that the value of "Red.
version 2 PROFINET IO Feature Ethernet recovery time” is set to
Pack 1.2. The maximum <= 1726 ms. Otherwise a
value for "Red. Ethernet download might get blocked.
recovery time” has been
decreased.
SignalReal FB To prevent that the out Before an upgrade it is advisable
signal from a SignalReal to check the configured ranges
with an extremely high in for SignalReal objects so that the
value freezes, a limitation limitation of Out values does not
of the out value has been affect the application program.
implemented. The out
value can now not
exceed the signal range
with more than 10 times.
Outmax=(Max-Min)*10+Max
and
Outmin=-[(Max-Min)*10+Min].

3BSE041584-610 A 162
C Upgrade
C.5 Restore Application and Configuration Data

Table C.1: CCB Version 5.0.2 to 6.1 Compatibility Issues

(Continued)
Application Issue Solution
Hidden FB types If a hidden function block Create a new function block to
type from an ABB replace the hidden block before
Standard Library has upgrading.
been used this will now
generate a compilation
error. A new function
block to replace the
hidden block must be
created before upgrading
before upgrading.
MinReached and The MinReached and User-defined control modules or
MaxReached MaxReached function blocks with Control
components of a Control Connection parameters may need
Connection are now set to be revised accordingly.
when the value goes
above/below the
respective range limit,
and not as earlier when
they were set at or
above/below the limit.
Parameter name change On control modules If there was a textual connection
in PidAdvancedCC and PidAdvancedCC and to the ERF parameter it will be
PidC PidC, the parameter ERF removed during upgrade and has
has changed name to to be manually added.
EBV, External back
value.

3BSE041584-610 A 163
C Upgrade
C.5 Restore Application and Configuration Data

Table C.1: CCB Version 5.0.2 to 6.1 Compatibility Issues

(Continued)
Application Issue Solution
Hardware types created During upgrade of Save the hardware units after the
with DIW projects created in channel name change.
version 5.1.0 or earlier,
I/O connections may be
lost. The problem only
affects hardware types
created with Device
Import Wizard, and only
channels for which the
channel name has been
changed. During project
upgrade, hardware units
that have not been saved
after the channel name
change will lose variable
connections for these
channels.
Hardware tree If hardware modules at Re-name the modules before
the same level do not upgrade.
have unique names a
compilation warning will
be given due to duplicate
instance name.

3BSE041584-610 A 164
C Upgrade
C.5 Restore Application and Configuration Data

Table C.1: CCB Version 5.0.2 to 6.1 Compatibility Issues

(Continued)
Application Issue Solution
Update output signals The setting, Update Select the default value manually.
first output signals first, is not
allowed for AC 800M HI
controllers PM857,
PM863 and PM867. This
will lead to a compilation
error if it was selected in
the Task properties dialog
for the controller.
Execution order The compiler switch for Resolve the loops.
sorting loops can no
longer be set to Allowed.
If the value is set to
Allowed, it will be
changed to warning after
upgrade.

CCB 5.1.0 to 6.1 Compatibility Issues

Table C.2 lists and describes Compact Control Builder compatibility issues, including
solutions to the issues, when upgrading from version 5.1.0 to 6.1.0.

Table C.2: CCB 5.1.0 to 6.1 Compatibility Issues

Component/Function Issue Solution

When upgrading from 5.1:
CI851 and CI852 are no It will no longer be CI851 should be replaced with
longer supported possible to perform CI854 instead.
co-existence downloads
to old controllers with
firmware that supports
CI851 and CI852. CI851
and CI852 related HWD
files will emit warnings
due to removed syntax.

3BSE041584-610 A 165
C Upgrade
C.5 Restore Application and Configuration Data

Table C.2: CCB 5.1.0 to 6.1 Compatibility Issues

(Continued)
Component/Function Issue Solution
ABBDrvFenaCI871HwLib To solve the problem with If any workaround is configured
1.0-3 negative values like in the 61131 application e.g. to
ABBDrvRetaCI871HwLib unsupported negative survive the negative speed value
1.0-6 speed, all I/O-channels issue, these workarounds must
instead of Status and be removed when using the
Command have been updated Library versions.
changed to operate the See Product Bulletin
data to and from the drive 3BSE047421D0166 for details as
as signed instead of well.
unsigned Integer value.
ABBDrvFenaCI871HwLib These libraries have been If the intention is to continue
version 1 moved to AC 800M running with co-existence the
CI868IEC61850HwLib Classic system extension. Classic Library Extension has to
version 2 See System 800xA be installed. A message will
Release Notes New appear to inform the user during
CI871PROFINETHwLib
Functions and known upgrade.
version 1
Problems (2PAA111899*)
S900IoCI854HwLib for current versions of the
version 1 libraries.
CI871PROFINETHwLib The maximum value for Ensure that the value of "Red.
version 2 "Red. Ethernet recovery Ethernet recovery time” is set to
time” has been <= 1726 ms. Otherwise a
decreased. download might get blocked.
CI871PROFINETHwLib Some settings have Configured values will be taken
version 2 changed names. Disable from existing configuration and
diagnosis alarms -> converted to new definition
Diagnosis, Disable automatically. The configured
process alarms (SOE) -> functionality will not change.
Process alarms (SOE)

3BSE041584-610 A 166
C Upgrade
C.5 Restore Application and Configuration Data

Table C.2: CCB 5.1.0 to 6.1 Compatibility Issues

(Continued)
Component/Function Issue Solution
SignalReal FB To prevent that the out Before an upgrade it is advisable
signal from a SignalReal to check the configured ranges
with an extremely high in for SignalReal objects so that the
value freezes, a limitation limitation of Out values does not
of the out value has been affect the application program.
implemented. The out
value can now not
exceed the signal range
with more than 10 times.
Outmax=(Max-Min)*10+Max
and
Outmin=-[(Max-Min)*10+Min].
Hidden FB types If a hidden function block Create a new function block to
type from an ABB replace the hidden block before
Standard Library has upgrading.
been used this will now
generate a compilation
error. A new function
block to replace the
hidden block must be
created before upgrading
before upgrading.
MinReached and The MinReached and User-defined control modules or
MaxReached MaxReached function blocks with Control
components of a Control Connection parameters may need
Connection are now set to be revised accordingly.
when the value goes
above/below the
respective range limit,
and not as earlier when
they were set at or
above/below the limit.

3BSE041584-610 A 167
C Upgrade
C.5 Restore Application and Configuration Data

Table C.2: CCB 5.1.0 to 6.1 Compatibility Issues

(Continued)
Component/Function Issue Solution
Parameter name change On control modules If there was a textual connection
in PidAdvancedCC and PidAdvancedCC and to the ERF parameter it will be
PidC PidC, the parameter ERF removed during upgrade and has
has changed name to to be manually added.
EBV, External back
value.
Hardware types created During project upgrade Save the hardware units after the
with DIW from version 5.1.0 or channel name change.
earlier, variable
connections may be lost
during project upgrade.
The problem only affects
hardware types created
with DIW, and only
channels for which the
channel name has been
changed.
Hardware tree If hardware modules at Re-name the modules before
the same level do not upgrade.
have unique names a
compilation warning will
be given due to duplicate
instance name.
Update output signals The setting, Update Select the default value manually.
first output signals first, is not
allowed for AC 800M HI
controllers PM857,
PM863 and PM867. This
will lead to a compilation
error if it was selected in
the Task properties dialog
for the controller.

3BSE041584-610 A 168
C Upgrade
C.5 Restore Application and Configuration Data

Table C.2: CCB 5.1.0 to 6.1 Compatibility Issues

(Continued)
Component/Function Issue Solution
Execution order The compiler switch for Resolve the loops.
sorting loops can no
longer be set to Allowed.
If the value is set to
Allowed, it will be
changed to warning after
upgrade.
When upgrading from 5.1.1:
CI851 and CI852 are no It will no longer be CI851 should be replaced with
longer supported. possible to perform CI854 instead.
co-existence downloads
to old controllers with
firmware that supports
CI851 and CI852. CI851
and CI852 related HWD
files will emit warnings
due to removed syntax.
Restriction to configure In previous release of This configuration is now
CV Ack Group to Access 5.1.1 it was possible to restricted with a compiler check.
Variables with direction configure Acknowledge
out groups for communication
variables used for
communication within the
same task and also for
communication variables
having direction out.
These configurations has
no effect and the
configuration is not
relevant.
Name change from ERF On control modules The function is still the same if the
to EBV PidAdvancedCC and EBV parameter is connected. If
PidC, the parameter ERF connected the EBV value is used
has changed name to instead of the backward value in
EBV, External back the Control Connection in the
value. controller output parameter.

3BSE041584-610 A 169
C Upgrade
C.5 Restore Application and Configuration Data

Table C.2: CCB 5.1.0 to 6.1 Compatibility Issues

(Continued)
Component/Function Issue Solution
ABBDrvFenaCI871HwLib To solve the problem with If any workaround is configured
1.0-3 negative values like in the 61131 application e.g. to
ABBDrvRetaCI871HwLib unsupported negative survive the negative speed value
1.0-6 speed, all I/O-channels issue, these workarounds must
instead of Status and be removed when using the
ABBDrvFpbaCI854HwLib
Command have been updated Library versions.
1.0-2
changed to operate the See Product Bulletin
data to and from the drive 3BSE047421D0166 for details as
as signed instead of well.
unsigned Integer value.
ABBDrvFenaCI871HwLib These libraries have been If the intention is to continue
1-0-3.afw moved to AC 800M running with co-existence the
CI868IEC61850HwLib Classic system extension. Classic Library Extension has to
2-20-0.afw See System 800xA be installed. A message will
Release Notes New appear to inform the user during
CI871PROFINETHwLib
Functions and known upgrade.
1-10-10.afw
Problems (2PAA111899*)
S900IoCI854HwLib for current versions of the
1-1-2.afw libraries.
CI871PROFINETHwLib The maximum value for Ensure that the value of "Red.
version 2 "Red. Ethernet recovery Ethernet recovery time” is set to
time” has been <= 1726 ms. Otherwise a
decreased. download might get blocked.
CI871PROFINETHwLib Some settings have Configured values will be taken
version 2 changed names. Disable from existing configuration and
diagnosis alarms -> converted to new definition
Diagnosis, Disable automatically. The configured
process alarms (SOE) -> functionality will not change.
Process alarms (SOE)

3BSE041584-610 A 170
C Upgrade
C.5 Restore Application and Configuration Data

Table C.2: CCB 5.1.0 to 6.1 Compatibility Issues

(Continued)
Component/Function Issue Solution
SignalReal FB To prevent that the out Before an upgrade it is advisable
signal from a SignalReal to check the configured ranges
with an extremely high in for SignalReal objects so that the
value freezes, a limitation limitation of Out values does not
of the out value has been affect the application program.
implemented. The out
value can now not
exceed the signal range
with more than 10 times.
Outmax=(Max-Min)*10+Max
and
Outmin=-[(Max-Min)*10+Min].
Hidden FB types If a function block, not Create a new function block to
belonging to the ABB replace the hidden block before
Standard Libraries, upgrading.
includes a hidden
function block from
standard libraries there
will be a compilation error
since the function block
has been removed.
MinReached and The MinReached and User-defined control modules or
MaxReached MaxReached function blocks with Control
components of a Control Connection parameters may need
Connection are now set to be revised accordingly.
when the value goes
above/below the
respective range limit,
and not as earlier when
they were set at or
above/below the limit.

3BSE041584-610 A 171
C Upgrade
C.5 Restore Application and Configuration Data

Table C.2: CCB 5.1.0 to 6.1 Compatibility Issues

(Continued)
Component/Function Issue Solution
Hardware types created During project upgrade Save the hardware units after the
with DIW from version 5.1.0 or channel name change.
earlier, variable
connections may be lost
during project upgrade.
The problem only affects
hardware types created
with DIW, and only
channels for which the
channel name has been
changed.
Hardware tree If hardware modules at Re-name the modules before
the same level do not upgrade.
have unique names a
compilation warning will
be given due to duplicate
instance name.
Execution order The compiler switch for Resolve the loops.
sorting loops can no
longer be set to Allowed.
If the value is set to
Allowed, it will be
changed to warning after
upgrade.

CCB 6.0.x to 6.1 Compatibility Issues

Table C.3 lists and describes Compact Control Builder compatibility issues, including
solutions to the issues, when updating from version 6.0.x to 6.1.0.

3BSE041584-610 A 172
C Upgrade
C.5 Restore Application and Configuration Data

Table C.3: CCB Version 6.0.x to 6.1 Compatibility Issues

Component/Function Issue Solution

When upgrading from 6.0.x:
CI851 and CI852 are no It will no longer be possible to CI851 should be replaced
longer supported. perform co-existence with CI854 instead.
downloads to old controllers
with firmware that supports
CI851 and CI852. CI851 and
CI852 related HWD files will
emit warnings due to removed
syntax.
ABBDrvFenaCI871HwLib These libraries have been If the intention is to continue
version 1 moved to AC 800M Classic running with co-existence
CI868IEC61850HwLib system extension. See System the Classic Library
version 2 800xA Release Notes New Extension has to be
Functions and known installed. A message will
CI871PROFINETHwLib
Problems (2PAA111899*) for appear to inform the user
version 1
current versions of the during upgrade.
S900IoCI854HwLib libraries.
version 1
CI871PROFINETHwLib The maximum value for "Red. Ensure that the value of
version 2 Ethernet recovery time” has "Red. Ethernet recovery
been decreased. time” is set to <= 1726 ms.
Otherwise a download might
get blocked.
CI871PROFINETHwLib Some settings have changed Configured values will be
version 2 names. Disable diagnosis taken from existing
alarms -> Diagnosis, Disable configuration and converted
process alarms (SOE) -> to new definition
Process alarms (SOE) automatically. The
configured functionality will
not change.

3BSE041584-610 A 173
C Upgrade
C.5 Restore Application and Configuration Data

Table C.3: CCB Version 6.0.x to 6.1 Compatibility Issues

(Continued)
Component/Function Issue Solution
SignalReal FB To prevent that the out signal Before an upgrade it is
from a SignalReal with an advisable to check the
extremely high in value configured ranges for
freezes, a limitation of the out SignalReal objects so that
value has been implemented. the limitation of Out values
The out value can now not does not affect the
exceed the signal range with application program.
more than 10 times.
Outmax=(Max-Min)*10+Max
and
Outmin=-[(Max-Min)*10+Min].
Hidden FB types If a hidden function block type Create a new function block
from an ABB Standard Library to replace the hidden block
has been used this will now before upgrading.
generate a compilation error.
A new function block to replace
the hidden block must be
created before upgrading
before upgrading.
MinReached and The MinReached and User-defined control
MaxReached MaxReached components of modules or function blocks
a Control Connection are now with Control Connection
set when the value goes parameters may need to be
above/below the respective revised accordingly.
range limit, and not as earlier
when they were set at or
above/below the limit.
Parameter name change On control modules If there was a textual
in PidAdvancedCC and PidAdvancedCC and PidC, the connection to the ERF
PidC parameter ERF has changed parameter it will be removed
name to EBV, External back during upgrade and has to
value. be manually added.

3BSE041584-610 A 174
C Upgrade
C.5 Restore Application and Configuration Data

Table C.3: CCB Version 6.0.x to 6.1 Compatibility Issues

(Continued)
Component/Function Issue Solution
Hardware tree If hardware modules at the Re-name the modules
same level do not have unique before upgrade.
names a compilation warning
will be given due to duplicate
instance name.
Execution order The compiler switch for sorting Resolve the loops.
loops can no longer be set to
Allowed. If the value is set to
Allowed, it will be changed to
warning after upgrade.

3BSE041584-610 A 175
3BSE041584-610 A 176
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.

3BSE041584-610 A 177
3BSE041584-610 A 178
Revision History
Revision History

Revision History

This section provides information on the revision history of this User Manual.

Revision History
The following table lists the revision history of this User Manual.

Revision
Description Date
Index
A Published for Compact Control Builder AC 800M 6.1.0-0 November 2019

3BSE041584-610 A 179
3BSE041584-610 A 180
Index

Index
A Configure
ABB Common 3rd Party Install, 23 hardware, 77
addresses IP address for controller, 94
convert, 144 Context-sensitive help, 21
Analysis Controller
changes, 122 configure IP address, 94
online, 121 Control Network, 145
version, 121 convert
Application, 29 addresses, 144
folder, 36 Copying files to safe media
restart mode, 130 OPC server for AC 800M
SV 4.1 or SV 5.0.2 to SV 6.0., 151
C Create logic
CCB 4.1 or CCB 5.0.2 to CCB 6.0.0 counters, 57
Copying files to safe media timers, 57
OPC server for AC 800M, 151
Change analysis, 122 D
class A Diagram, 49
IP address, 143 Diagram editor, 51
class B add new object, 58
IP address, 143 add new variable, 54, 61
class C changing online value, 74
IP address, 143 graphical connection between objects, 63
client graphical connection between pages, 68
node, 146 in test mode, 73
client/server networks, 145 page connectors, 70
Cold restart, 131 page name, 52
variable values, 132 panes, 42
Communication cables port visibility, 60
cross-over ethernet cable, 93 Download
serial connection to controller, 177 change analysis, 122
straight-through ethernet cable, 93 go online, 123
Communication variable, 50 new project, 123
declaration, 56 simulated applications, 126
Compilation, 122 to selected controller(s), 124
configuration via Ethernet, 93
MMS, 147 Drag-and-drop, 39

3BSE041584-610 A 181
Index

E select, 102
Enable Ethernet channel, 140 Libraries, 16
Ethernet Alarm and event library, 16
cables, 93 Basic library, 16
configure IP address for controller, 94 Binary process libraries, 16
ports on controller, 93 Communication libraries, 16
Control Libraries, 16
F Signal libraries, 16
File Location Standard libraries, 16
select, 101 License Key, 27, 103
File server, 104 local flag, 144
Firmware upgrade
via Ethernet, 85 M
Firmware Upgrade Manuals, 19
via serial cable, 86 Message pane
Folder diagram editor, 42, 51
application, 36 Project Explorer, 41
applications, 36 MMS
controllers, 39 configuration, 147
libraries, 33 ModuleBus, 79
Forcing I/O values, 99 multi-user configuration, 19
MyDoors project, 45
H create logic (first page), 57
Hardware create logic (second page), 65
configuration, 77 create logic (third page), 67
Hardware Libraries, 16 declare variable and signals, 51
HostID, 143 MyDorrs project
host ID creating the project, 48
IP address, 144 testing, 72

I N
implicit IP addressing, 135 NetID, 143
INIT button, 131 network area, 144
IP address, 88, 91 network ID, 144
class A, 143 node
class B, 143 client, 146
class C, 143 server, 146
host ID, 144 node number, 144
IPConfig, 88 RNRP, 144

L O
Language Online analysis, 96, 98

3BSE041584-610 A 182
Index

Online help, 21 parameters, 144

contents, 22 path number, 144
context-sensitive help, 21 RNRP-icon, 137
help topics, 21 RNRP Service, 156
index, 22 RNRP Setup Wizard, 137
search, 22
show help about..., 21 S
Online mode, 96, 98 Selecting
forcing I/O, 99 file location, 101
OPC Server, 23 language, 102
OPC server for AC 800M server
Copying files to safe media node, 146
SV 4.1 or SV 5.0.2 to SV 6.0., 151 Service Account, 111
Setup Wizard, 101
P Signals, 50
parameters connect to I/O channels, 82
RNRP, 144 declaration in POU editor, 56
path number single-user configuration, 23
RNRP, 144 Standard libraries, 16
permission Full Control, 107 subnetwork ID, 144
PLC Control Builder, 23
Power failure, 134 T
Project Test mode, 72, 117
download, 96 TK212A cable, 86, 177
object, 29
refresh, 43 U
templates, 31 upgrading projects, 149
Project Explorer, 15
drag-and-drop, 39 V
explorer pane, 32 Variable values
message pane, 41 at cold restart, 132
Project folder, 19, 101 at warm restart, 132
Version
R analysis, 121
real-time communication, 146
Refresh, 43 W
RNRP Warm restart, 131
node number, 144 variable values, 132

3BSE041584-610 A 183
3BSE041584-610 A 184
www.abb.com/compactproductsuite 800xA is a registered or pending trademark We reserve all rights to this document and
of ABB. All rights to other trademarks reside the items and images it contains. The
www.abb.com/controlsystems with their respective owners. 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.
3BSE041584-610 A

contents of this document without prior

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