Compact Control Builder Training

Chapter 3 Getting Started

TABLE OF CONTENTS

Chapter 3 Getting Started ....................................................................................................................................................... 1

3.1 General Information...................................................................................................................................................... 2
3.1.1 Objective ............................................................................................................................................................... 2
3.1.2 Legend................................................................................................................................................................... 2
3.1.3 Reference Documentation ...................................................................................................................................... 2
3.2 Compact Control Builder Installation ............................................................................................................................ 3
3.2.1 Requirements ......................................................................................................................................................... 3
3.2.2 Software ................................................................................................................................................................ 3
3.2.3 Installation of Compact Control Builder ................................................................................................................. 4
3.2.4 Install AC 800PEC Control Builder Extension ........................................................................................................ 5
3.3 Functional Design Specification.................................................................................................................................... 7
3.3.1 Purpose.................................................................................................................................................................. 7
3.3.2 Scope / Requirements............................................................................................................................................. 7
3.3.3 Process Description................................................................................................................................................ 8
3.3.4 Equipment List....................................................................................................................................................... 8
3.3.5 Instrument List....................................................................................................................................................... 9
3.3.6 P&ID Drawing..................................................................................................................................................... 10

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3.1 General Information

3.1.1 Objective
On completion of this chapter you will be able to:
Install the Compact Control Builder AC800M
Interpret P&ID and Functional Design Specification

3.1.2 Legend
> Indicates when you go from one menu to a sub-menu
Italic Indicates object and file names
“ “ Indicates dialog box buttons, tabs, menus etc.
Bold Indicates important topics
Indicates start/explanation of student activity

3.1.3 Reference Documentation

3BSE041584 Industrial IT 800xA – Compact Control Builder AC 800M
Getting Started - Introduction and Installation
3BHS349821 AC 800PEC SW Compatibility

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3.2 Compact Control Builder Installation

3.2.1 Requirements
Compact Control Builder is a fully integrated Windows XP Professional and Windows
2003 Server application. The minimum requirements are besides the operating system
Windows XP Professional and Windows 2003 Server:
Microsoft Word 2000, 2002 or 2003 (for creating project documentation)
Acrobat Reader version 4.0 or later (required to read online manuals)

3.2.2 Software
The PEC Firmware Release must match the version of the Compact Control Builder.
More information is available at the document “AC 800PEC SW Compatibility”

The software for the Compact Control Builder delivered on the CD is divided in two
parts – 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 wizard contains Compact Control Builder, Base Software for
SoftController, and User Documentation.
The second wizard contains OPC Server for AC 800M.You must first run the
Compact Control Builder installation before running the OPC Server installation.

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3.2.3 Installation of Compact Control Builder

Skim through the following check-list before installing your Software:
Either Windows XP Professional or Windows 2003 Server installed
Administrator privilege for the login to Windows
Remove previous Control Builder versions from the PC. This also includes other
products that comes with a Compact Control Builder installation (for example,
OPC Server for AC 800M).

1. Log in as Administrator in Windows.

2. Insert the CD into the drive. After a few seconds the Welcome dialog window will
appear. If the dialog box does not appear, start the file Startme.bat, located in the
root directory of the CD.

3. Click the “Install software” button. A software installation window opens.

Installing the Compact Control Builder

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4. Click the “Compact Control Builder AC800M” button. The Installation Wizard
starts. Follow the on-screen installation instructions.

Using the “Cancel” button in any of the installation Wizard dialogs will interrupt
the installation. When installation procedure is interrupted, all previously installed
components will be disregarded.

Installing the OPC Server for AC 800M

5. Click the “OPC Server for AC 800M” button. The Installation Wizard starts.

6. Follow the on-screen installation instructions. Running the OPC Server on the
same PC as the Compact Control Builder does not require further settings.

7. Click “Back” and then “Exit” to close the dialog box.

3.2.4 Install AC 800PEC Control Builder Extension

Install the AC800PEC Control Builder Extension

Choose Compact Control Builder

Please note that a new folder was added to the Compact Control Builder:

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Also a new environment variable “SL_REDIRECT_FLASH” has been created:

It will redirect the data for the compact flash to the folder c:\temp. The flash utility
will use it and send this data to the flash memory of the PEC.

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3.3 Functional Design Specification

3.3.1 Purpose
The purpose of this document is to provide a Functional Design Specification for
designing and implementing a complete project like in the industrial world.
During the course you will build up this configuration, step by step, via the different
exercises that have been prepared for you.
You will learn about programming the AC800M controller itself and also how to
connect the controller to I/O systems.

3.3.2 Scope / Requirements

The Compact Control Builder is required to control a stirred reactor with the ability to
process several liquid raw materials. This document describes the requirements for the
control of the process for the following categories:
Automatic Control
Operate the reactor with a fully automated sequence to do the following main steps:
Filling the vessel with a certain quantity of raw material
Heating the content up to a certain temperature
Mixing starts after the reactor is filled and stops when draining is completed
Draining the complete content

Manual Control
Each device shall be able to operate via faceplate.

Interlocks
Draining and filling at the same time must be prevented.
Heating and cooling at the same time needs to be blocked.
Temperature control and mixing at the same time must be allowed.

Process Alarms / Limits

Shut-off the heater if the temperature comes close to the design temperature of the
vessel (130°C).
Close the inlet block valve V1 if the overflow signal LSH2 becomes active.

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3.3.3 Process Description

Raw material is fed into the vessel and the quantity is measured by flow meter FT1.
As a second check the level measurement LT1 of the tank can be used.
The temperature TT1 of the liquid is controlled with on-off control using a heater and
a cooler. The liquid will be heated up at the beginning to start the reaction.
The agitator M1 is used to mix the material and keep the reaction going. It is speed
controlled to allow smooth mixing of high viscous material.
At the end of the reaction the liquid is cooled down and drained.

3.3.4 Equipment List

Filling System
It consists of two block valves, V1 and V5. The bypass valve V5 is capable of
delivering only 40% of the total possible flow into the vessel.
Additionally the valve V3 is a control valve, whose position can be set between fully
closed (0%) and fully open (100%). When the control valve is set to 100% and the
bypass valve V5 is closed, the flow will be 100%.
Opening both block valves only will result in a flow of 40%, if the control valve V3 is
fully closed (0%).
A flow transmitter FT1 is provided which measures the flow from the inlet system into
the vessel.

Cooler
The cooler is supplied with cooling water through the pump P1 to cool down the
vessel temperature.
One digital output is used to start the pump and the fan simultaneously. The motor
circuitry provides one feedback signal for running indication.

Heater
One digital output is used to start the heater. The power circuitry provides one
feedback signal for running indication.

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Agitator Motor M1
The agitator is variable speed controlled. One digital output is used to start the motor.
The motor circuitry provides one signal for motor running indication.
The motor current is monitored by the current transmitter IT1.
The speed ST1 of the motor may be controlled by a 0-20mA reference signal as a set
point for the frequency converter.
A pulse is generated as a digital input which indicates rotational speed. The shaft
creates one equal pulse per rotation.
NOTE! The motor needs a minimum speed set point of 10% to
start running and the main contactor must be active.

Draining System
The draining system is identical to the filling system, but using different tag names.

3.3.5 Instrument List

A list of all I/O signals in the project is available in a separate document called
“Training Equipment”.
Block Valves V1 / V2 / V5 / V6
Each valve provides two dry contact limit switches for valve OPEN and CLOSED
indications.
All block valves are 24 VDC solenoid operated and fail closed.

Flow Control Valves V3 / V4

The control valves are fail-closed, air operated, valves and requires a 0-20mA
reference signal for operation.

Level Switches LSL1 / LSH1 / LSH2

The tank has three level switches to indicate:
- Tank empty = 1.5% level
- Tank filled = 100% level
- Tank overflow = 102% level

Level Transmitter LT1

It provides indication of the level in the vessel.

Temperate Transmitter TT1

It provides indication of the liquid temperature in the vessel, measured at the bottom
of the tank. The temperature is controlled by the heater and cooler.

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3.3.6 P&ID Drawing

FIC
1
IT
1
FT
1
V3 ST
M1 1
LSH
2

LSH
V1 V5 1

LT
1

COOLER HEATER
P1 LSL
1

TT
1 FT FIC
2 2

V4

V6 V2

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