—

F UNCTIO NA L DESCRIP TIO N

ABB AbilityTM Knowledge Manager

v9.1
Core System
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TRADEMARKS
Ability, Advant, AdvaBuild, AdvaCommand, AdvaInform, IndustrialIT, 800xA are registered trademarks of ABB Asea Brown Boveri Ltd.
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tered trademarks, and ODBC, Windows, Windows NT, Windows 2000, Windows 2003, Windows 2008, Windows 2012, Windows 2016, Windows 7,
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This publication includes DANGER, WARNING, CAUTION and NOTE information where appropriate to point out safety related or other important
information.
DANGER Hazards which could result in severe personal injury or death.
WARNING Hazards which could result in personal injury.
CAUTION Hazards which could result in equipment or property damage.
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Although DANGER and WARNING hazards are related to personal injury, and CAUTION hazards are associated with equipment or property damage,
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mance leading to personal injury or death. Therefore, comply fully with all DANGER, WARNING and CAUTION notices.

NOTICES AND DISCLAIMERS

ABB may have 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. In no event shall ABB be liable for direct, indirect, special, incidental, or consequen-
tial 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 the 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 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.
The products described or referenced in this document are designed to be connected and to communicate information and data via network in-
terfaces, which should be connected to a secure net-work. It is your sole responsibility to provide and continuously ensure a secure connection
between the products and your network or any other networks that may be connected.
You must establish and maintain appropriate measures (including, but not limited to: the installation of firewalls, application of authentication
measures, encryption of data, and installation of antivirus programs) to protect these products, the network, its system, and interfaces against
security breaches, unauthorized access, interference, intrusion, leakage, and theft of data or information.
ABB performs functionality testing on the products and updates that we release. However, you are ultimately responsible for ensuring that any
product updates or other major system updates (including, but not limited to: code changes, configuration file changes, third-party software
updates or patches, and hardware change out) are compatible with the security measures implemented. You must verify that the system and
associated products function as expected in the environment in which they are deployed.
ABB 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.

Copyright © 2019 ABB. All rights reserved.

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Contents
ABB AbilityTM Knowledge Manager .........................................................................................................................9
Introduction.........................................................................................................................................................................9
ABB AbilityTM Knowledge Manager Solutions ..............................................................................................................9

Architecture ............................................................................................................................................................ 10
Software architecture .....................................................................................................................................................10
User’s interface ........................................................................................................................................................... 11
Application server ......................................................................................................................................................14
Database server..........................................................................................................................................................14
Data collectors ............................................................................................................................................................14
Hardware architecture .................................................................................................................................................... 15
Server hardware.......................................................................................................................................................... 15
Workplace hardware .................................................................................................................................................. 15
Redundant configurations .......................................................................................................................................15

System management ............................................................................................................................................. 16

User management............................................................................................................................................................ 16
User authorization scheme ...................................................................................................................................... 16
Multi user environment .............................................................................................................................................18
Native language support ................................................................................................................................................ 19
System backup/restore ................................................................................................................................................. 20
Full system backup/restore .................................................................................................................................... 20
Database export ........................................................................................................................................................ 20
Database import ....................................................................................................................................................... 20
System Parameters.......................................................................................................................................................... 21
History parameters lifetime of report data ......................................................................................................... 21
Setup of automatic report generation .................................................................................................................. 21
System diagnostic reports.............................................................................................................................................22
Auto print status report ...........................................................................................................................................22
Authorization status report .....................................................................................................................................23
Backup log ...................................................................................................................................................................23
Comments log .............................................................................................................................................................23
Data correction log (data audit log) ..................................................................................................................... 24
Error Log...................................................................................................................................................................... 24
Manual corrections ................................................................................................................................................... 24
Session log .................................................................................................................................................................. 25
Signal value report .................................................................................................................................................... 25
System status report ................................................................................................................................................ 25
Usage dashboard report ......................................................................................................................................... 26

Process data management....................................................................................................................................28

800xA Synchronization services .................................................................................................................................. 28
Using KM trends from 800xA user’s interface.................................................................................................... 28
Opening KM reports from 800xA user’s interface............................................................................................. 28
Configuration of KM aspects and setup .............................................................................................................. 29
Database server and collector functionality ............................................................................................................. 30
Data processing scheme ......................................................................................................................................... 30
Description of secondary log types ....................................................................................................................... 31
Process data management technical summary ..................................................................................................33
Information exchange software .................................................................................................................................. 34
Process control system information exchange software ................................................................................ 34
ISA-95 Equipment model ............................................................................................................................................... 35

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Process data monitoring .......................................................................................................................................36

Process data monitoring technical summary........................................................................................................... 36
Usage ..................................................................................................................................................................................37
Configurable reports ...................................................................................................................................................... 38
Dashboard Reports ................................................................................................................................................... 38
Trends .......................................................................................................................................................................... 39
Process overview report .......................................................................................................................................... 40
Operation report ....................................................................................................................................................... 40
Chart report elements...............................................................................................................................................41
Individual manual entries ........................................................................................................................................ 42
Tabular manual entries ............................................................................................................................................ 43
General SQL report ................................................................................................................................................... 43
URL documents ......................................................................................................................................................... 43
Auto-refreshing option ............................................................................................................................................ 43
Commenting data ........................................................................................................................................................... 44
Concept ....................................................................................................................................................................... 44
User interface ............................................................................................................................................................. 44
Process and production log validation....................................................................................................................... 44
Concept ....................................................................................................................................................................... 44
User interface ............................................................................................................................................................. 45
Period closing................................................................................................................................................................... 46
Concept ....................................................................................................................................................................... 46
Dependents and predecessors .............................................................................................................................. 46
Rules on freezing ....................................................................................................................................................... 46
User interface ..............................................................................................................................................................47
Process and production limits ..................................................................................................................................... 48
Limit object ................................................................................................................................................................ 48
Entering limit values ................................................................................................................................................. 49
Displaying limits on reports.................................................................................................................................... 49
Using limits in calculation functions..................................................................................................................... 50
Calculations, Key Performance Indicators (KPIs), Real-time Performance Indicators (RtPIs) ........................51

Event and alarm management .............................................................................................................................. 52

Technical summary ......................................................................................................................................................... 52
Usage ................................................................................................................................................................................. 52
Event and alarm list ........................................................................................................................................................ 52
Event and alarm statistics report ................................................................................................................................ 53
Event and alarms vs trends ..................................................................................................................................... 53
Event and alarm statistics charts ................................................................................................................................ 54
Peak rate vs average rate......................................................................................................................................... 54
Graphical statistics ................................................................................................................................................... 55

Engineering tools .................................................................................................................................................. 56

ABB AbilityTM KM Toolkit ................................................................................................................................................ 56
Technical summary ................................................................................................................................................... 56
Configuration and usage..........................................................................................................................................57
Online help .................................................................................................................................................................. 58
Calculations ...................................................................................................................................................................... 59
Templates and reports....................................................................................................................................................61
Documenting and sharing configuration .................................................................................................................. 62
Documentation tool.................................................................................................................................................. 62
Configuration data export and import tool ........................................................................................................ 62
XML comparison tool ............................................................................................................................................... 62
Bulk loading tool.............................................................................................................................................................. 62

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Other system extensions.......................................................................................................................................63

Excel Add-In ...................................................................................................................................................................... 63
Technical summary ................................................................................................................................................... 63
Usage ........................................................................................................................................................................... 63
Laboratory equipment information exchange software ....................................................................................... 64
ERP information exchange software .......................................................................................................................... 65

Revision table ........................................................................................................................................................ 66

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Figures
Figure 1: ABB AbilityTM Knowledge Manager overview ....................................................................................................9
Figure 2: Software architecture ..........................................................................................................................................10
Figure 3: User’s web interface start page ........................................................................................................................ 11
Figure 4: User’s web interface opened with Chrome from a mobile phone ............................................................. 11
Figure 5: User’s preferences page...................................................................................................................................... 13
Figure 6: Calendar .................................................................................................................................................................. 13
Figure 7: Process display (mimic) example showing navigator to visually assist history search ........................ 13
Figure 8: Report example ..................................................................................................................................................... 13
Figure 9: Authorization status report showing KM user access groups and their rights ..................................... 16
Figure 10: Viewing configuration changes history with details .................................................................................. 17
Figure 11: Audit Log showing data corrections, deletions, and entries .................................................................... 17
Figure 12: Session Log...........................................................................................................................................................18
Figure 13: Usage dashboard ................................................................................................................................................18
Figure 14: User’s preferences – language selection ....................................................................................................... 19
Figure 15: System Backup Log report ............................................................................................................................... 20
Figure 16: Configuration of automatic report generation............................................................................................ 21
Figure 17: Example of settings for on-event notification..............................................................................................22
Figure 18: Auto-print and e-mail settings overview .......................................................................................................22
Figure 19: Authorization status report ..............................................................................................................................23
Figure 20: Backup log ............................................................................................................................................................23
Figure 21: Comment log ........................................................................................................................................................23
Figure 22: Data correction log (data audit log) .............................................................................................................. 24
Figure 23: System error log ................................................................................................................................................. 24
Figure 24: Log data correction form ................................................................................................................................. 24
Figure 25: Session log .......................................................................................................................................................... 25
Figure 26: Current signal value report .............................................................................................................................. 25
Figure 27: Portion of system status report showing installed version and modules ............................................ 26
Figure 28: Portion of system status report showing license status ......................................................................... 26
Figure 29: Portion of system status report showing delays in data collection ...................................................... 26
Figure 30: Usage dashboard ...............................................................................................................................................27
Figure 31: 800xA Minerals Library’s Faceplate with link to KM trends ..................................................................... 28
Figure 32: 800xA Minerals Library’s pop-up menu with link to a KM report ........................................................... 28
Figure 33: 800xA Minerals Library’s Control Structure showing the KM aspect .................................................... 29
Figure 34: KM Toolkit showing same structure as 800xA Minerals Library’s Control Structure ........................ 29
Figure 35: Data acquisition ................................................................................................................................................. 30
Figure 36: Secondary log types ........................................................................................................................................... 31
Figure 37: Example showing a traditional KM folder structure and the ISA-95 Equipment Model view........... 35
Figure 38: ISA-95 overview .................................................................................................................................................. 35
Figure 39: Dashboards –example of a dashboard showing the Plant Health KPI’s ............................................... 38
Figure 40: Dashboards –example of a dashboard’s configuration using the ISA-95 Equipment Model tree.. 38
Figure 41: Trends –example of a single trend object in light color theme ............................................................... 39
Figure 42: Trends –example of multiple trends with shared time control in dark color theme .......................... 39
Figure 43: Example of process display showing navigator to visually assist history search............................... 40
Figure 44: Example of an operation report ..................................................................................................................... 40
Figure 45: Examples of line, area, bar, stacked bars, pie, and donut charts ............................................................41
Figure 46: Manual Entries – Periodical Signals ............................................................................................................... 42
Figure 47: Manual Entries – Signal on Event ................................................................................................................... 42
Figure 48: Manual Entries – Plant Constants .................................................................................................................. 42
Figure 49: Example of a tabular manual entry (aka log sheets) ................................................................................. 43
Figure 50: General SQL report............................................................................................................................................ 43
Figure 51: Report header example showing the Auto-activate option ..................................................................... 43

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Figure 52: Comments entry dialog .................................................................................................................................... 44

Figure 53: Menu with validation options ......................................................................................................................... 45
Figure 54: Comment log with validation filters.............................................................................................................. 45
Figure 55: Freezing hierarchy.............................................................................................................................................. 46
Figure 56: Menu with freeze options .................................................................................................................................47
Figure 57: Dialog to freeze history data............................................................................................................................47
Figure 58: Data correction log with frozen notification............................................................................................... 48
Figure 59: Limit object ......................................................................................................................................................... 48
Figure 60: Limit configuration field in Logs ................................................................................................................... 48
Figure 61: Limit configuration field in report column properties .............................................................................. 49
Figure 62: Process Limits report........................................................................................................................................ 49
Figure 63: Example of a report showing out of limits values in charts, tables, and gauges ............................... 50
Figure 64: Calculation block diagram (drill down) example ......................................................................................... 51
Figure 65: Event alarm list ................................................................................................................................................... 52
Figure 66: Event and alarm statistics ............................................................................................................................... 53
Figure 67: New trend vs events and alarms..................................................................................................................... 53
Figure 68: Peak rate vs average rate chart (according to EEMUA Guideline, 3rd edition) ..................................... 54
Figure 69: Event and alarm statistics charts in bar (above), pie (middle) and line (below) format ................... 55
Figure 70: Toolkit showing configuration of a log .........................................................................................................57
Figure 71: Toolkit’s online help ........................................................................................................................................... 58
Figure 72: Toolkit preprocessing function and calculated log .................................................................................... 59
Figure 73: Toolkit showing preprocessing module example ....................................................................................... 59
Figure 74: Toolkit showing a calculated Log ................................................................................................................... 60
Figure 75: Toolkit showing a template for operation reports......................................................................................61
Figure 76: Toolkit showing properties for detailed report configuration.................................................................61
Figure 77: Toolkit configuration documentation utility ............................................................................................... 62
Figure 78: KM Excel Add-In usage...................................................................................................................................... 63
Figure 79: SAP Connector .................................................................................................................................................... 65

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LIST OF TABLES
Table 1: User’s interface technical summary.................................................................................................................... 12
Table 2: Log class definition ................................................................................................................................................ 21
Table 3: Log types ..................................................................................................................................................................32
Table 4: Process data management technical summary.............................................................................................. 34
Table 5: Process data monitoring technical summary ................................................................................................. 36
Table 6: KM event and alarm management technical summary................................................................................. 52
Table 7: ABB AbilityTM Toolkit technical summary .......................................................................................................... 56
Table 8: KM Excel Add-In module technical summary................................................................................................... 63
Table 9: Lab equipment information exchange software ............................................................................................ 64

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ABB AbilityTM Knowledge Manager

Introduction
This document describes the core functionality for ABB AbilityTM Knowledge Manager systems.

These core functions provide the bases for additional functionalities like for example PIMS & Downtime or
LIMS applications.

ABB AbilityTM Knowledge Manager Solutions

ABB AbilityTM Knowledge Manager provides a flexible approach to collecting, organizing, and distributing
of production and quality information throughout a processing plant. Using service-oriented architecture
(SOA), ABB AbilityTM Knowledge Manager cover fast data acquisition and network communication, historical
database with plant specific structure as well as reports, trends, graphs, and dashboards through a web-
based user interface.

Figure 1: ABB AbilityTM Knowledge Manager overview

The ABB AbilityTM Knowledge Manager perform process data management on data collected from your pro-
cess via different sources, and through functions and components needed for industry specific process and
quality data warehousing and focused information presentation. They are adapted and expanded to meet
specific requirements and can incorporate up to several hundred users.
ABB AbilityTM Knowledge Manager encompass many uses and plant dependent applications can then be
added, whether they be mineral, cement, phosphate, or aluminum specific. These applications are based on
the Knowledge Manager (KM) common platform. KM provides an essential base for Process, Production and
Downtime Information Management (PIMS), Cement Production Accountant, Statistical Process Control,
Interface to ERP systems such as SAP, Cement Production Scheduling and Quality Management System
(LIMS). All these additional applications further compliment the management of the manufacturing pro-
cess.
The core ABB AbilityTM Knowledge Manager functions are described in the next sections.

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Architecture
Software architecture
The ABB AbilityTM Knowledge Manager have the following SOA architecture:
- User Interface: Web-based user’s workplace (thin client)
- Application Server: Business logic
- Database Server: Persistent data storage
- Data Collector: Data collection from analyzers, PLC’s, historians, etc.

Figure 2: Software architecture

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User’s interface
A web-based user’s interface allows accessing all ABB AbilityTM Knowledge Manager applications.
This user’s workplace, also referred to in the documentation as the KM Personal Assistant, provides com-
prehensive and easy to use interface and graphical tools based on the latest web-browser technology.
Since the user interface is based on standard web browser software, there is no need to install any addi-
tional software on the client PC – a true thin client. With lower installation and maintenance cost, it also
benefits user flexibility: the user can work from any workplace.
The user simply opens a web browser (e.g. Chrome) and enters the main web site on the Knowledge Man-
ager server.

Figure 3: User’s web interface start page

The user interface is adaptable to small screens supporting access from mobile devices like smartphones
and tablets.

Figure 4: User’s web interface opened with Chrome from a mobile phone

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Technical summary

Item Specification
Server application Access to the system’s database

User preferences Language

Date/time format
Color and size of report tree
Alias working mode
Printing options

Workplace application Web browser accessing the application software modules available
in the server side, for example:
- Trends
- Charts
- Reports
- Manual entries
A hierarchical folder-like structure for all reports
User own filters
User own reports
User own online calculations
Point and click date and time selector via calendar
Search through lists
Context sensitive Online Help

Table 1: User’s interface technical summary

Usage

The user interface follows the thin client approach and it allows navigation between different entry screens,
reports, displays and selection of the data range for those.
It uses Windows HTTPS or HTTP for communication with the application server. There is no requirement to
install additional drivers such as ODBC or SQL*Net on the client machines.
All screens and reports are presented as web documents. The formatting information of HTML documents
is included as cascading style sheets both for display on screen and hard copies. HTTPS or HTTP are used to
access the HTML documents from the server.
Graphical display components such as trends and charts are also implemented as HTML documents.
Apart from the reports configured by the system administrator in ABB AbilityTM KM Toolkit (Toolkit), the
users have the facility to create their own trends, dashboards, and reports in their in personal folders.
Below are some examples. See later in the document for a comprehensive set of report examples.

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Figure 5: User’s preferences page

Figure 6: Calendar

Figure 7: Process display (mimic) example showing navigator to visually assist history search

Figure 8: Report example

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Application server
The Application Server provides services such as data consolidation, user authorization, client data access
and scheduled report generation. The services are implemented as a set of objects and server processes.
The Application Server consists of:
- data consolidation that rolls up the primary log data to hourly, shift, daily, monthly, and yearly values
- historical data recording, fetching the primary log information from the data collector nodes and stor-
ing them in the database
- Applications (PIMS, LIMS, Cement Production Accountant, SAP Interface, etc.)
- Web Server for publishing HTML templates
- Business objects providing access services to historical data and configuration information

Database server
The Database Server provides continuous storage for historical logs, application configuration data, sys-
tem error logs and system audit logs. It also supports basic statistical calculations as standard consolida-
tion functions for the data (daily, weekly, monthly AVG, STD, MIN, MAX, etc.).

Data collectors
Data acquisition
The Data Collector fetches the data from the process control systems and lab equipment and stores it in
the historical primary log.
ABB AbilityTM Knowledge Manager are independent of the process control system. Information Exchange
Software to most common process control systems, analyzers, laboratory equipment, etc. is available.
For small and medium size systems the data collector typically resides on the same server machine as data-
base server. Multiple channels and collection speeds are available on the same data collection nodes.
Separate Data Collector nodes (DCN) can be used when:
1. There is a requirement to have data collected remotely from the server (e.g. when the server is in an IT
center as opposed to close to the control system)
2. There is a requirement for raw data buffering outside the server
3. Increased collection and processing load need to be distributed.
In case of a network failure the data collected in a Data Collector Node will be stored until the connection is
reestablished with the Server; the temporary storage capacity is configured during the commissioning
phase and depends of the hardware resources where the Data Collector Node is installed.

OPC DA/HDA back-fill

In normal conditions the online data is read by the OPC DA service until a data loss gap is identified. When
this occurs, the system will obtain the historical data from the corresponding OPC HDA server, while at the
same time continuing to get the online data from the OPC DA server.

Fast data acquisition

The system allows for fast data acquisition. The fast data acquisition protocol can collect data at the speed
of 100ms with the ABB’s VIP (the vendor independent protocol). With a standard OPC interface, the data
acquisition is performed at 1s. This might be limited by vendor specific versions of OPC servers.
For other interfaces, the speed is limited by the vendor’s interface to the control system.

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Hardware architecture
Server hardware
The server runs on a Microsoft Windows operating system and connects towards the client/workplace ma-
chines via a normal office type network.
The server hardware is determined by:
- Requirements to run Microsoft Windows server operating system. Please refer to the Microsoft docu-
mentation and specifications.
- Requirements to run then KM server software. All server software components are native Windows
applications. Therefore, there are no specific hardware requirements other than ensuring enough pro-
cessing power, memory, and data storage for the target application.
For small to medium size systems, all server functions can reside on the same machine.
Data collection can also take place outside the main server machine by making use of Data Collector nodes.
Data Collector nodes gather data and store it in an intermediate database that is replicated regularly to-
wards the main server database.
Data Collector nodes can be located remotely on the same plant from the central server (e.g. physically
close to the process control system or in the laboratory) or even outside the main plant (e.g. on a secondary
plant many kilometers away).
As an additional benefit, the Data Collector node can act as a buffer for cases where for example the com-
munication to remote sites is unreliable or has a low bandwidth.
Communication to process control systems are typically done using the OPC protocol and to laboratory
equipment is commonly done via file transfer protocol. Sometimes the communication takes place over se-
rial ports. If the server runs out of available serial ports, then an external serial I/O server can be used. The
serial I/O server is a device that is equipped with typically up to 16 serial ports and connects to the server
via the TCP/IP network. The device can therefore also be located remotely from the server (e.g. in the labor-
atory).
The minimum requirements for the server machine are specified in a separate document, please contact
ABB for the latest information.

Workplace hardware
Any normal general-purpose office type PC can be used as workplace hardware. The requirements for the
workplace are defined by the ability to run the required standard web-browser software. A workplace ma-
chine typically runs under Windows operating system and is equipped with enough RAM and free hard disk
space.
For configuration and maintenance of the server, the ABB AbilityTM KM Toolkit dedicated application is re-
quired. This application is typically installed in the server and access is given to the responsible administra-
tor or the IT department.
The minimum requirements for other machines running the Toolkit are specified in a separate document,
please contact ABB for the latest information.

Redundant configurations
Redundancy can be provided at multiple levels: with OPC clients connecting to redundant OPC servers, with
redundant DCNs or with the main server running in separate hardware; ultimately it is also possible to split
the main server’s database and application functions in redundant configuration for both components each
running in separate hardware.
The specific setup depends on the chosen level of redundancy and whether the servers are real servers or
virtual machines.
For more details on the latest options for redundant configurations, please contact ABB.

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System management
User management
User authorization scheme
The system supports multilevel user authorization scheme for accessing, modifying, and deleting of all
types of data.
The overall user management is integrated with the local Windows network user management scheme (Ac-
tive Directory) for user identification. This means that users will automatically receive a predefined role for
access at the time they login to their Windows network services. There is no need to login separately for
access to ABB AbilityTM Knowledge Manager.
The user’s authorization scheme has the following main functions:
- Unauthorized persons are not able to see confidential information
- Data is protected against accidental changes or removal
- Changes to data can only be made by authorized persons
- All changes are logged for auditing and tracking purposes:
- Changes to data can be viewed in the system report Data Correction Log (Audit Log)
- Configuration changes are also registered and can be viewed in the Toolkit

Figure 9: Authorization status report showing KM user access groups and their rights

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Figure 10: Viewing configuration changes history with details

Figure 11: Audit Log showing data corrections, deletions, and entries

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Multi user environment

Several persons can use the ABB AbilityTM Knowledge Manager at the same time, at different locations, on
the same modules, reports, displays, data, etc. This means that numerous sessions can be active at the
same time, from different areas, onto the same server. Current and previous sessions can be monitored in
the system report Session Log and usage statistics are available in the Usage Dashboard.

Figure 12: Session Log

Figure 13: Usage dashboard

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Native language support

The standard language for the ABB AbilityTM Knowledge Manager product suites is English.
The Web interface is available in:
- English
- German
- French
- Spanish

Other languages are supported on demand through translation of standard sentences, messages, etc. For
example, it has been also deployed in following languages:
- Chinese
- Czech
- Italian
- Slovak
- Polish
- Portuguese

The Toolkit is available in:

- English
- French
- German
- Spanish

ABB AbilityTM Knowledge Manager supports parallel multi-language: a single server can concurrently serve
clients/workplaces in different languages. Users can choose their preferred language in the User’s Prefer-
ence page.

Figure 14: User’s preferences – language selection

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System backup/restore
There are two types of backup/restore operations that can be performed in a system:
- Full system backup: this is done once during commissioning and is then available for full system re-
store operations. The customer should perform a full system backup at least once every two years to
ensure that the tape data is still within the tape’s storage lifetime specification.
- Database export: This is carried out automatically every day by the purge process and backs-up the
content of the database. When restoring the machine after a system crash, the full system backup
must be reloaded first, and the last valid database export must be reloaded afterwards.

Full system backup/restore

The standard Windows backup and restore utility is used to perform a full system backup and/or restore of
the server computer. Other mechanisms, like other 3rd party backup software tools commercially available
can also be used, if required and maintained by the corresponding customer’s IT or automation depart-
ment.

Database export
If the automatic purging and exporting of the database option has been enabled, then a standard com-
mand file executes cyclically once a day. The purge and export utility is started every day at 00:30 and is re-
sponsible for purging the main Oracle data tables, for computing statistics on Oracle table spaces and for
performing a database export of the data to the tape device or disk.
The purge and export utility can be started manually whenever an extra backup is required.
A Backup Log report is accessible to users, displaying a list of all backups performed so far.

Figure 15: System Backup Log report

Database import
The import utility first stops the ABB AbilityTM Knowledge Manager services, then removes the whole data-
base contents (including tables, views, modules, etc.) and finally recreates the database contents by im-
porting the data stored on disk. There is no automated command to perform this operation. The adminis-
trator has the responsibility of locating the correct tape and restoring the export file.
More information on the Import/Export Utilities can be found in the Administrator guide.

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System Parameters

History parameters lifetime of report data

The system provides the flexibility to group history data into different categories to define their lifetime.
This is done using Log Classes. The Log Class defines for how long the values are stored in your system.
There are 5 different log classes: A, B, C, D, E and L, of which class L is used for Lab data only. They are as-
signed to each log, with class B as the typical default value.
The log class definition is read cyclically by the data acquisition and consolidation tasks. If the number of
defined records is reached, the Data consolidation task will overwrite the oldest record.
The following table shows an example of values for Log Class B:

PeriodType LogClass Number of instances

MINUTE B 1440
HOUR B 336
DAY B 366
WEEK B 52

Table 2: Log class definition

Example: A log of log class B will have its minute-values of the last 24 hours (1440 minutes), its hourly values
of the last 14 days (336 hours) and so on, stored in the database.
A dialog in the Toolkit allows the system administrators to set-up these tables according to their needs.

Setup of automatic report generation

KM Reports can be scheduled for automatic generation using multiple outputs types like, for example: e-
mail, printers, or files.
The automatic generation can be setup as periodic schedules like, for example, every day, or shift, as well as
on-event, for example when an important equipment has stopped, or a quality limit has been violated.
Simple Mail Transfer Protocol (SMTP) server functions of Microsoft Internet Information Server (IIS) allows
to automatically send reports by e-mail.
Microsoft IIS is a module of Internet Explorer that is installed in a Windows Server environment. It gives the
user server-side support for Internet application layer protocols such as HTTP (Hypertext Transfer Proto-
col), FTP (File Transfer Protocol) and SMTP.
The auto-print status report provides a summary of which reports are setup for sending to files, printers, or
as emails (see section on Auto print status report below).

Figure 16: Configuration of automatic report generation

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For on-event notifications following events are supported:

- Process and production limits: violation of limits on consolidated logs
- Quality limits: violation of limits on quality results (requires the LIMS applications)
- Downtime: change of status of running hour and limit check logs configured to record downtimes (re-
quires the PIMS & Downtime applications)

Figure 17: Example of settings for on-event notification

System diagnostic reports

KM provides a broad set of default reports for self-diagnostic to support the administrators monitoring
and evaluating the system’s status:
- Audit trail logs
- System self-diagnostic logs (e.g. errors, current status)
- Notifications status
- Session log
- Backup log
- Current signal value report

Auto print status report

The auto print status report provides detail on the automatic export requests configured and whether they
are currently active or not.
The auto-print definitions allow administrators configuring the system to automatically print, e-mail or ex-
port reports at specified periods of based on certain events.
See section on Setup of automatic report generation above for more details on the required settings.

Figure 18: Auto-print and e-mail settings overview

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Authorization status report

The authorization status report shows an overview of the information on the user groups and their authori-
zation as configured in the Toolkit.

Figure 19: Authorization status report

Backup log
The backup log provides detail on the overnight backups and the events that occurred during the Backup.

Figure 20: Backup log

Comments log
The comments log provides a summary of comments and thread discussions entered plant-wise into the
system. It means that regardless of where the comment was entered a complete list can be seen in this log,
which can be further filtered if required.

Figure 21: Comment log

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Data correction log (data audit log)

Each time you manually correct or enter data in the system, the details are automatically logged and can be
viewed in the data correction log, or data audit log.

Figure 22: Data correction log (data audit log)

Error Log
In the Error Log, information relating to errors in data acquisition and interface processes is displayed.

Figure 23: System error log

Manual corrections
The log data correction form allows correcting or modifying consolidated data. Access to this report is ei-
ther from a tree view, or from a report that shows the data that needs to be corrected.

Figure 24: Log data correction form

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Session log
The session log provides information about all users’ sessions during a selected time period.

Figure 25: Session log

Signal value report

The signal value report shows all signals and their current values and status.

Figure 26: Current signal value report

System status report

The system status report is a pre-configured report. It provides system managers and administrators with
details about the system such as which version and licensed options are installed, which services are run-
ning, the current event list count, how much memory is available and much more.
It provides visual clues for areas of attention like, for example: data collection delays or disk or database
size running small.

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Figure 27: Portion of system status report showing installed version and modules

Figure 28: Portion of system status report showing license status

Figure 29: Portion of system status report showing delays in data collection

Usage dashboard report

The usage dashboard provides statistical information about the system usage and user’s behavior.
For a selected period, you will find, among other details, information like:
- How many sessions were opened?
- How many sessions lasted less and more than 2 minutes?
- How many sessions lasted more than 1 hour?
- How many reports where opened?
- Which ones are the most common web browsers?
- Who are the most common users?
- Which ones are the most common reports?
- How much time do reports take to load?

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The system will detect the following browsers (same as tracked in the Session log): Edge, IE 11, IE 10, IE 9, IE
8, IE 7, IE 6 or less, Chrome, Safari, Firefox. Anything else will be categorized as “Other”.

Figure 30: Usage dashboard

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Process data management

800xA Synchronization services
When an ABB’s 800xA control system (v6 or newer) is available together with ABB’s Minerals Library (v 6.0/2
or newer) the automatic synchronization of signals and logs can be activated so that when changes occur in
the 800xA system they are correspondingly applied in the KM system.
The “master” configuration is kept in 800xA, therefore any changes in the 800xA KM properties will trigger
automatic configuration changes in KM for:
- Creating new items
- Deleting items
- Modifications

Using KM trends from 800xA user’s interface

The Mineral Library’s faceplates will include a shortcut to open directly the KM trends for the selected ob-
ject.
Once a KM Trend is opened the user can add more tags to it by simply dragging and dropping an object
from an 800xA screen.

Figure 31: 800xA Minerals Library’s Faceplate with link to KM trends

Opening KM reports from 800xA user’s interface

Links to KM reports can be setup in 800xA buttons, or as web-links in pop-up menus.

Figure 32: 800xA Minerals Library’s pop-up menu with link to a KM report

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Configuration of KM aspects and setup

The Minerals Library will include the required KM aspects required for the configuration synchronization
and trend links.

Figure 33: 800xA Minerals Library’s Control Structure showing the KM aspect

The configuration will be automatically synchronized towards the KM system, where the objects tree struc-
ture for signals and logs will replicate that one of the Control Structure.

Figure 34: KM Toolkit showing same structure as 800xA Minerals Library’s Control Structure

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Database server and collector functionality

The Knowledge Manager data collection functions are defined by logs. A log defines beside other attributes
the data acquisition processing functions, the function to be applied for consolidation and the identifica-
tion of the data source(s).

Data processing scheme

The Knowledge Manager is based on an Oracle database that provides consistent and always up-to-date
data. This database structure has been optimized in order to minimize the waiting time for the data re-
trieval from database into reports for the user.

Process data is automatically acquired from the process as real time raw data in primary logs (collection of
data entries of same time base pertaining to one specific item), stop logs and maintenance counters.

Stop logs and maintenance counters are needed for downtime management and for troubleshooting and
maintenance work and they are not further compressed or consolidated.

Primary logs are compressed to save space on the hard disk and to speed-up trend display. The compressed
data is stored in the database as compressed logs. In addition, primary logs are used to create secondary
logs for hourly, shift, daily, weekly, monthly, and yearly data. The creation of secondary logs is referred to as
data consolidation process.

Data pre-processing allows arithmetical or logical processing to be carried out on data as it passes from
the control system to the database. This is particularly useful for environmental data or data acquired for
different product types.

When some data cannot be automatically acquired by the database from the process control system, man-
ual data entry capabilities enable the user to enter this data manually into the system.

Occasionally the data acquired from the process control system contains errors. This may be due, for exam-
ple, to incorrectly calibrated measuring equipment. Manual data correction function allows authorized us-
ers to correct these values. The details of the user making the change, the old and new values are recorded
in an audit log.

Figure 35: Data acquisition

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Description of secondary log types

For many logs, one or more control signals can optionally be specified in addition to the actual data source.
Data is acquired only if the control signal is true (e.g. evaluation of minimum or maximum load of a motor
makes only sense if the motor is running). If the control signal is false, the resulting output value is set to
NULL. In this case the consolidation function would not take it into account. The control signal is read at the
same point in time as the value.

Another resulting output is the quality of the output value. If a defined control signal or the value signal is
faulty, the quality of the calculated output goes to zero, otherwise it goes to one. The quality of a log value
is considered.

Figure 36: Secondary log types

The following table describes each of the different log types.

Function
Average Values (AVG)
Calculated Values (CLC)
Counter Values (CTR)
Cumulative Values (CUM)
Description
Logs the average of a value for a time interval
Calculated logs take other logs as inputs and the calcu-
lations on the inputs are defined using Visual Basic
Script
Logs an incremented production/ consumption /en-
ergy value for a time interval
Logs an already consolidated value starting from a
specified period till now (e.g. function “month to date”)

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Function
End of Period (EOP)
First Values (FST)
Integration Values (INT)
Limit Check (LMC)
Last Values (LST)
Moving Average (MAV)
Maximum Values (MAX)
Minimum Values (MIN)
Plant Constant Values (PLC)
Running Hours Values (RHR)
Sort Values (SRT)
Standard Deviation Values (STD)
Status running hours
Stock Value (STK)
[Available with the PIMS & Down-
time module]
Stock Value Calculated (SK2)
[Available with the PIMS & Down-
time module]
Sum (SUM)
Replicated (REP)
[Available with the PIMS & Down-
time module]
Variance Values (VAR)
Generic
Table 3: Log types
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Description
Log function carries out a linear interpretation of the in-
put value from now until a specified period.
Logs the first of a series of values for a time interval
Logs the integrated result of a series of values for a
time interval
Logs the time the value is outside the given limits in a
given period
Logs the last of a series of values for a time interval
Logs the average of a value for up to the last 60
minutes
Logs the maximum of a value for a time interval
Logs the minimum of a value for a time interval
Tracks the value of plant specific, operator alterable co-
efficients such as heat values, energy prices etc.
Logs operating hours for a time interval
Logs the product name
Logs the standard deviation of a series of values for a
time interval
Calculates hours running at different status or condi-
tions
Tracks the content of a stock based on inlet flow and
outlet flow. The actual volume can be manually ad-
justed.
Tracks the content of a stock based on the integrated
inlet flow from the Production and Received fields mi-
nus the integrated outlet flow from the Consumption
and Shipped fields, if the measured value is un-
changed. Otherwise the measured value is tracked.
Logs the integration value of a series of values for a
time interval. Then provides the sum of the parent log
values.
Logs a replica of an already existing log that is consoli-
dated in a remote KM server.
Logs the variance of a series of values for a time interval
The generic function is for a customer's data specific
needs. The behavior of the log is pre-configured in the
background of the system by your commissioning engi-
neer.
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Process data management technical summary
Table below lists the software components inherent to Process Data Management and related functions.
Item
Information exchange software
Data collection
Database functions
Database capacity
Backup facility
User specific calculations
Online data storage
Application Software
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Specification
- Information Exchange Software to control system,
laboratory equipment, ERP systems
- Interface to plant network (TCP/IP)
- Communication between clients and server via
HTTP
- Mechanisms
- Polled, cyclical, multiple frequencies
- Event driven
- Manual entries
- Local, remote
- Buffering in data collectors (store & forward)
- Fast data acquisition from 1s
- Classic data acquisition 1min
- Watchdog
- Successful collection logging
- Data sources:
- OPC servers: UA, DA, AE, HDA
- ERP systems
- Point Historians
- Data collectors
- Process Control Systems: PLC, DCS, OCS, etc.
- Laboratory Control systems: AutoLab, Polab,
etc.
- Sensors, Instruments, Analyzers, …
- Comprehensive set of data consolidation functions
(log types) e.g.: Min, Max, Avg, Std, Moving Avg,
Integrators, Month to Date, Year To Date, Running
hours, Forecast for the End Of Period, etc.
- Data reconciliation functions
- Limited only by server data storage space
- Automatic daily backups
- For example: +, -,*,/,LN, IF, THEN, ELSE, AND, OR
- Primary log limited only by server storage space;
years
- Daily, weekly, monthly, yearly logs 20 years
minimum, depending on availability of data storage
space
- Server business objects for
- Data retrieval
- Data processing
- Data formatting
- Data quality marking
- Data dispatch
- User authorization
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Item Specification
System audit and diagnostic - Graphical view of data references for calculations
- Overview of the current system status
- Recording functions for
- Users access
- Manual entries and corrections
- Plant wise as well as data specific comments
and thread discussions
- Backups and system errors
- Configuration changes

Table 4: Process data management technical summary

Information exchange software

NOTE: New Information Exchange Software packages are constantly being developed on project basis and
integrated to the standard interface list. For the latest list of interfaces please contact ABB.

Process control system information exchange software

OPC UA as well as DA client interfaces are the standard Information Exchange Software.
An automatic data recovery function using OPC UA or HDA servers (where available) is built into the OPC UA
and DA Client interfaces and activated automatically in case the communication between the ABB AbilityTM
Knowledge Manager and the OPC UA or DA source is somehow interrupted.
Client interfaces for reading events and alarms via OPC UA or AE are also available.
Protocol-specific Information Exchange Software to most common process control systems could be availa-
ble on demand. Please contact ABB for more information. The Information Exchange Software for these
cases can be realized by standard serial links or by advanced bus interfaces.
Information Exchange with a Process Control system is usually implemented to run in a polling mode. These
interfaces can typically be implemented with a buffer function: to prevent loss of raw data in the event of
central server maintenance, shutdown, etc., interfaces carry on collecting data from the collected 3rd party
subsystem. Upon restore of the connection with the central server, the buffered data are forwarded retain-
ing collection time stamp (Store & Forward).
Information Exchange Software supports watchdog mechanisms logging quantified successful transmis-
sion. This can be used as additional reassurance information in data processing, report presentation, etc.

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ISA-95 Equipment model

Knowledge Manager incorporates mechanisms to setup an Equipment Model based on the ISA-95 standard.

The Equipment Model helps mapping and adding context to all the data stored in the system.

In Knowledge Manager, the ISA-95 Equipment Tree does more than just serving as a traditional folder hier-
archy where each folder contains either another folder or element (Logs, Signals, Reports, Templates).

The ISA-95 Equipment Tree does work as a hierarchical folder arrangement in which each node in the hierar-
chy contains its own functions.

Here an example of the hierarchy for an enterprise “Plant X”, in which each level has their own properties:

Plant X à Line 1 à Cement Prod à Cement Mill 1

The area Cement Prod has its own property signals, like ActualProduction, or ActualRunTime.

The production unit Cement Mill 1 has its own property signals, like ElectricityConsumption, or Production-
Rate.

In this way ISA-95 helps improving manufacturing information clarity, structure, and consistency independ-
ent of specific engineering implementations.

Figure 37: Example showing a traditional KM folder structure and the ISA-95 Equipment Model view

ISA-95 is the actual standard which became the U.S. ANSI/ISA standard produced by the SP95 (ISA
Standards & Practices Committee No. 95). ISA-95 offers a framework for projects integration and focuses
mainly on their functions.
ISA-95 main tool for bringing together automation & IT groups is the Business To Manufacturing Markup
Language (B2MML), which is implemented into the ISA-95 standard with W3C XML schema. It enables inte-
gration project teams to use ISA-95 during analysis & design, to identify information categories.

Figure 38: ISA-95 overview

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Process data monitoring
Process data monitoring technical summary
Table below lists the core software components inherent to process data monitoring functions.
Item
Workplace user interface
Output
System configuration
System audit and diagnostic
Table 5: Process data monitoring technical summary
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Specification
- Process data
- Dashboard elements
- Trend elements
- Basic dynamic elements for process overview
display (mimics)
- Time-series report tables
- Manual entries
- Manual correction form
- Comment entry
- Process limits
- User specified folders & reports
- User specified filters
- User specified online calculations
- Web browser user interface
- Automatic notifications functions to export reports:
- as e-mail (as mail client)
- as HTML or PDF files
- as output on a printer
- Toolkit
- Bulk Loading Tool
- Graphical view of data references and hierarchy for
calculations
- Overview of current system status
- Recording functions for
- Users access
- Manual entries and corrections
- Plant wise as well as data specific comments and
thread discussions
- Backups and system errors
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Usage

The process data monitoring functions facilitate plant wide information management and allow the user to
- View plant process displays (mimics) with actual and historical data, for example: view the current
status and explore what happened over last 24 hours
- Monitor key operating variables of a process
- Correct erroneous data
- Plot variables against one another in trend displays
- Automatic notifications: printing, exporting, or emailing reports
- Management and visualization of process and production limits

In detail, the process data reporting includes:

- Dashboard reporting elements
- Chart reporting elements
- Time series table reporting elements
- Interactive trends
- Basic calculations, Key Performance Indicators and Real-time Performance Indicators
- Process overview display objects (Mimics)
- URL document links
- Manual entry forms
- Entering of comments for specific data and at system level
- Manual correction, validation and freezing of data
- General SQL report elements

With these functions, the users are supported in information reporting, charting, and trending, as well as
process data management and system administration (see description in previous sections).
An advanced trend solution allows asynchronous data query using http and provides functions for easy
search over extended periods.
Process reports can be viewed showing the values of plant variables for on-the-fly chosen resolution
(hourly, daily values, etc.), over on-the-fly chosen period (hours, shifts, days, x days, weeks, x weeks,
months, x months, years, etc.).
Current signal value report shows the current value and status recorded for all signals configured in the
system.
Manual entry forms allow users entering data manually into the system, when their values cannot be auto-
matically transferred into Knowledge Manager.
The ABB AbilityTM Toolkit is an all-encompassing configuration tool for the production information manage-
ment system. It includes several predefined templates and standard reports containing industry specific
knowledge. See section on ABB AbilityTM KM Toolkit for more detail.

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Configurable reports

Dashboard Reports
A dashboard report is an information management tool that helps visually tracking, analyzing, and display-
ing Key Performance Indicators (KPI), metrics, and other key data points. These screens support monitoring
any data available in the Knowledge Manager system, like for example the health of equipment, plant pro-
duction, or specific process variables. They are only configurable through the web-browser and fully cus-
tomizable to meet the specific needs of any user.

Figure 39: Dashboards –example of a dashboard showing the Plant Health KPI’s

Figure 40: Dashboards –example of a dashboard’s configuration using the ISA-95 Equipment Model tree.

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Trends
Trends offer an interactive report with line charts, providing you with a view of how a set of variables
change over a certain time period.
Trends provide multiple navigation functions like, for example, zooming in/out, changing the time window,
resolution, and scale, or hiding/showing individual lines.
It is also possible to visualize multiple trend charts in the same screen sharing a single time navigation bar.
More advance functions allow for statistical data aggregation, time shifting, and filtering using the legend.

Figure 41: Trends –example of a single trend object in light color theme

Figure 42: Trends –example of multiple trends with shared time control in dark color theme

With the mini trend element, like with the Trend function, it is possible to show recorded data graphically in
process displays. The functionality is similar to the trend function, but the mini trend is limited to two
trend lines and contain less navigation controls – the purpose is to have a small trend display version in-
cluded on reports with other tables and graphs.

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Process overview report

Process overview reports (also known as mimics) show an overview of current status of the plant.
These reports allow users to navigate through time to explore all the values using a scroll bar, and for nu-
meric log elements it is also possible to open a line chart or an interactive trend for further data inspection.
From dynamic elements linked to history data (logs) the users can initiate multiple data management tasks
like: open a line chart or an interactive trend for further data inspection.

Figure 43: Example of process display showing navigator to visually assist history search

Operation report
The operation report is a tabular report, which provides you with detailed information about what has hap-
pened in the process over a certain time period.
These bodies show in rows the time periods and in columns the process and production data. Furthermore,
they support the visual indication of process limits violation, see details in section on Process and pro-
duction limits.
From these reports the users can initiate multiple data management tasks like, among others: open a line
chart or an interactive trend for further data inspection, enter comments, correct values, mark values for
validation.
Operation report tables can be complemented with other report types for more comprehensive infor-
mation.

Figure 44: Example of an operation report

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Chart report elements

Charts such as line, area, pie, donut, bar, and stacked bar charts, can be displayed in any report and are of-
ten included in operation or production reports. See also operation report example further below.

Figure 45: Examples of line, area, bar, stacked bars, pie, and donut charts

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Individual manual entries

The entry form for periodical signals is used to enter data, which will be processed cyclically, e.g. every mi-
nute, like for example to provide the value from an instrument which not yet connected to the system. The
value entered is then stored from the current time and kept until a next entry is provided.

Figure 46: Manual Entries – Periodical Signals

The values entered for the Signal on Event Manual Entry are for a specific point in time, a value as a result of
an event, like for example measuring a silo level. The value entered is stored with the timestamp of the
event, which is provided in the header of the report.

Figure 47: Manual Entries – Signal on Event

If any Plant Constant (PLC) Logs (for example, clinker factor or coal heat value) have been defined in your
system, they can be changed by using a Plant Constant manual entry form. This might be useful for exam-
ple to provide the humidity factor for a material when not available automatically from the laboratory sys-
tem. The value entered is stored for a given period as provided in the header of the report.

Figure 48: Manual Entries – Plant Constants

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Tabular manual entries

Tabular manual entry forms are used to manually enter production data into Knowledge Manager, when
necessary. It is usually on an hourly, shift or daily basis.

Figure 49: Example of a tabular manual entry (aka log sheets)

General SQL report

A general SQL report shows whatever has been defined in an SQL query in a tabular format. It is a project
specific report to display specific data.

Figure 50: General SQL report

URL documents
It is possible to define URL documents, simply by defining a URL link with the address to which one needs
to connect.

Auto-refreshing option
KM reports have a function to refresh automatically on the screen without any user interaction. This is a
configurable option available in operation report headers and provides three modes for: no refresh, refresh
data only on first access, or refresh data periodically.
When the periodical update is setup users will see an additional field allowing them to pause or activate the
updates. The tooltip in this field gives additional information on when the next update will take place.

Figure 51: Report header example showing the Auto-activate option

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Commenting data
Concept
In order to promote collaboration, it is often important to share information among users at multiple loca-
tions and across shifts.
The commenting functions enables just that, by allowing all users to view any comments linked to the data
in the system.
While only authorized users can enter comments, all other users have read-access to view them.

User interface
The comment functionality is available to the users from the pop-up menu on following reports:
- Operation Report and derivatives (e.g. Sample report)
- Production Rep and Production Balancing [Available with the PIMS & Downtime module]
- Daily Weekly [Available with the PIMS & Downtime module]

These reports will indicate which values have comments linked to them, by showing a red triangle in top
right corner.

Figure 52: Comments entry dialog

All comments are stored and can be monitored in the Comment log.

Process and production log validation

Concept
Definitions for plants quality processes (ISO 9001, 14000, 17025) make it necessary to approve reports or
analysis results before publication. To enable this, the Knowledge Manager provides a concept for data vali-
dation, in which data can be validated on cell/log, column, or report level. The validated value can be indi-
cated on reports if so desired.

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User interface
The validation functionality is an extension of comment functionality and is available to the users from the
pop-up menu on following reports:
- Operation Report and derivatives (e.g. Sample report)
- Production Rep and Production Balancing [Available with the PIMS & Downtime module]
- Daily Weekly [Available with the PIMS & Downtime module]

Validated values are indicated with a green triangle in bottom right corner.

Figure 53: Menu with validation options

User can choose to validate single values, columns, rows or the whole report.
There is similar option to undo validations
These reports have a configurable property to show or hide the visual clue for validated data (green trian-
gles) as well as the validate popup menu options.
Selecting the “Comments” option will also show the following information about the validation: user name
and validation time.
A summary of validations can be viewed in the comment log. The log will show when data validations were
made and which user made them. The log will also show any undone validations that may have been made.

Figure 54: Comment log with validation filters

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Period closing
Concept
The concept of period closing, referred to as “data freezing”, has been introduced to further improve data
integrity. Period closing enables a user, typically at month-end after data has been sent to ERP system, to
freeze data for that month as to prevent further changes and data inconsistency between such two sys-
tems. Modification of frozen data is no further allowed.
When a log is frozen it is given a freeze time by the user and the system will only allow to modify the log val-
ues after that time-stamp.

Dependents and predecessors

Logs can be attached to other logs. For a certain log, logs that it depends on are called predecessors, and
logs that depend on it are called dependents.
An example hierarchy is as follows

Figure 55: Freezing hierarchy

In the example, for the INT log there are two predecessors (SRT and PLC) and three dependents (CLC, CLC
and SK2).

Rules on freezing
- If a log is frozen then all predecessor logs are automatically frozen with the same freeze time.
- A log cannot be frozen if a dependent log has a later freeze time.

User rights for freezing

User must have ‘modify’ rights on the log to be frozen, as well as on all predecessors.

Unfreezing
There is no concept of unfreezing. The user simply re-freezes the logs, but with an earlier freeze time.
There is no guarantee that a log that you once froze can be “unfrozen” because of second rule above. This
rule ensures the integrity of data from further “up the tree”.
Unfreezing is not considered a normal operation.

CLC Logs
When a CLC log is frozen its data is evaluated and copied to the database. This means that a CLC log’s con-
figuration may be changed after data freeze without fear of the data changing.

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User interface
The freezing functionality is also an extension to the comment functionality and is available to the users
from the pop-up menu on following reports:
- Operation Report and derivatives (e.g. Sample report)
- Production Rep and Production Balancing [Available with the PIMS & Downtime module]
- Daily Weekly [Available with the PIMS & Downtime module]

Frozen data is marked on reports with a blue triangle in bottom right corner.

Figure 56: Menu with freeze options

Selecting this option opens a dialog with summary of the logs to be frozen, the predecessor logs that will
also be frozen and the dependent logs, along with the freeze time. The user enters the desired freeze time
and clicks freeze.

Figure 57: Dialog to freeze history data

If the user attempts to enter/modify data on a log before the freeze time from any user interface in the
system, then they are given a warning and the data entry does not take place.

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These reports have a configurable property to show or hide the visual clue for frozen data (blue triangles)
as well as the freeze popup menu option.
A history of freeze events can be viewed in the Data Correction Log.

Figure 58: Data correction log with frozen notification

Process and production limits

The process and production limits handling and presentation support users identifying problem areas and
interpret information at a glance.

Limit object
There is a main object type available for configuration in the Toolkit: “Limits”.

Figure 59: Limit object

A limit object is used to set up “process limits” on a log. The behavior is similar to the limits already availa-
ble on LIMS sample measures.
A limit object can be used in two ways:
1. Attached directly to one (or more) logs. In this configuration the limits will be shown automatically on all
reports that support limits for logs.

Figure 60: Limit configuration field in Logs

2. Limits attached directly to a report. It is also possible on some reports to attach the limit object di-
rectly. This can be used to configure limit specific reports, or to override the limits configured on a log. For
example, the column on an operation report has following properties:

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Figure 61: Limit configuration field in report column properties

When configured on a report the limit supports “Before Query”. This is for further flexibility and can be used
to adjust the timestamp of the limits shown, for example if a time-shifted CLC is used in the column.

Sort name and period

The limit object has two properties to indicate if the limit object shall allow different limits per Sort (“Has
Sort”) or per Period (“Has PType”).

Entering limit values

There is a standard system report called “Process Limits” from where users can maintain the process lim-
its:

Figure 62: Process Limits report

Displaying limits on reports

Limits are supported on the following reports bodies:
- Basic charts: line and bars
- Operation
- Gauges charts [Available with the PIMS & Downtime module]
- Production [Available with the PIMS & Downtime module]
- Daily-weekly [Available with the PIMS & Downtime module]
- Spreadsheet [Available with the LIMS module]
- Material balancing [Available with the CPA module]

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Limits can also be used on charts, mimics and from CLC library functions.
Just like the limits in the LIMS module, yellow means inner (L or H) limits breached, orange for middle (LL or
HH) and red for outer (LLL or HHH) limit.

Figure 63: Example of a report showing out of limits values in charts, tables, and gauges

Using limits in calculation functions

For further flexibility the Limit values can be accessed through the CLC functions:
- Stat2.GetLimit
- Stat2.GetOutOfLimitCnt
- and Stat2.GetTarget

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Calculations, Key Performance Indicators (KPIs), Real-time

Performance Indicators (RtPIs)
KPI Overview reports can be built from predefined templates using the Toolkit, so that one can see all infor-
mation at a glance.
Number of KPI’s can be presented in table or graphical format.
Often it is important to analyze how KPI are constructed, where figures come from, why is it so high or low.
The drill down function for calculated values is available to support this analysis.

Figure 64: Calculation block diagram (drill down) example

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Event and alarm management

Technical summary
Table below lists the software components inherent to event and alarm management.

Item Specification
Server Application - KM event and alarm management (EA) business
objects for
- EA Data retrieval
- EA Data processing
- EA Data formatting
- EA Data quality marking
- EA Data dispatch
- KM Configurator
User Application - Extension to all KM workplaces with event and
alarm management Functions
- Event Alarm List
- Event Alarm Statistics

Table 6: KM event and alarm management technical summary

Usage
Internal error messages and events from an underlying control system are stored in KM database.
In the event and alarm list the user can see all occurrences of events (for example: start, stop, change of
value, and exceed of limiting value) and alarms (for example: stop caused by fault, and faulty signals).
Event and alarm statistics report may be used on a periodic basis to analyze priorities of different mainte-
nance works. It will list a ranked order of signals with events or alarms during the selected interval.

Event and alarm list

In the event and alarm list the user can see all occurrences of events (e.g. start, stop, change of value, ex-
ceed of limiting value, etc.) and alarms (e.g. stop caused by fault, faulty signals, etc.).
- Each row contains the event ‘s data. The date and time of the event can be found in the first column.
- Other columns contain the signal name, signal description, event text, event property and the event
reason. The event/alarm duration column is available, and the value is calculated if information for
start and end of an event/alarm is sent by the control system.
- At the bottom of the report, if you have more rows than can be displayed on the page, a navigation bar
is provided, which includes a Go to Page option.

Figure 65: Event alarm list

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Event and alarm statistics report

Event and alarm statistics may be used on a periodic basis to analyze priorities of different maintenance
works. It will list a ranked order of signals with events (e.g. start, stop, change of value, exceed of limit
value, etc.) or alarms (e.g. stop caused by fault, faulty signals, etc.) during the selected interval.
- The output of an Event/Alarm Statistics report consists of a list of alarms or events that matches the
selected criteria, ordered by number of occurrences.
- Each row contains the signal related event and alarm data. The name of the signal can be found in the
first column.
- Other columns contain the signal description, property, reason, and number of events and alarms
within the selected interval, number of events since the last reset and date of last reset.

Figure 66: Event and alarm statistics

Event and alarms vs trends

A line chart provides information about the log values and a table shows the alarms and events produced
for the same period:
- Rows per page value restrict the data fetching of event and alarms
- Clicking on the chart displays the event and alarms for the selected period
- Clicking on a specific alarm will highlight the chart showing a hairline at the selected time

Figure 67: New trend vs events and alarms

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Event and alarm statistics charts

The following chart types are now provided to extend the analysis of event and alarm statistics:
- Peak rate vs average rate: based on the EEMUA 191 Guideline for event and alarm management.
- Graphical statistics as: density distribution in bars, percentage distribution in pie, or trends.
- Trend vs Alarms: showing trend lines aligned with events and alarms around the same period.

Peak rate vs average rate

This chart is based on the EEMUA 191 Guideline for event and alarm management. It supports plotting the
data according to the 2nd and 3rd edition of the guideline.
The diagram plots the following KPIs and indicates the “EEMUA 191 Reference point” (at 6 average rate / 60
peak rate):
- average alarms rate per hour
- peak alarm rate per hour
The more the plotted value gets to the bottom and left axis, the better the alarm system is configured.
Systems with values on the top right area have an unusable alarm system, in which operators are very likely
to ignore alarm notifications.
Five areas of interest are marked in the chart:
- predictive
- robust
- stable
- reactive
- overloaded
It is important checking data over a longer period of at least 30 days.
For the 3rd edition it provides the analysis for steady state and upset state, as defined by the guideline.

Figure 68: Peak rate vs average rate chart (according to EEMUA Guideline, 3rd edition)

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Graphical statistics
A new chart is provided which can be used for plotting the following three types of statistics based on the
event and alarm list:
- density distribution in bars
- percentage distribution in pie
- trend

Figure 69: Event and alarm statistics charts in bar (above), pie (middle) and line (below) format

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Engineering tools
ABB AbilityTM KM Toolkit
ABB AbilityTM Toolkit (Toolkit) is the engineering tool for Knowledge Manager and related ABB AbilityTM
based products and solutions including the Production Accountant, SAP Connector and LIMS, as well as the
optimization solutions suite. See relevant functional description for more information on these solutions.

Technical summary

Item Specification
Server application - Server business objects for
- User authorization
- User management
- Status monitoring
PC client application - Menu driven ALL IN ONE configuration tool for
- User authorization
- Database setup
- Interface definitions
- Signal definitions
- Log definitions
- User specific calculations
- Template building
- Configurations of reports, graphics, entries,
etc.
- Component libraries include element headers and
bodies for
- Basic dynamic elements for process displays
- Lines, boxes, tables
- Multi Trends, Mini Trends
- Lists, tables
- Log sheets, reports
- Single and multiple entry forms
- SPC control charts, Histograms
- X-Y Charts, cross correlation
- Free configurable elements
- Flexible plant specific folder structure
- Efficient searching tools for different components
- Supporting “Drag and Drop” or “Copy and Paste”
- Different type of filters included in headers
element
- Cross references
- Configurable measurement units table
- Property recording in XML format
- Favorite language
- Online help
- Audit trail of configuration changes

Table 7: ABB AbilityTM Toolkit technical summary

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Configuration and usage

ABB AbilityTM Toolkit software allows the user to build displays, report templates, reports, trends manual
entry forms, survey sheets etc. and make them available for PC client users. The Toolkit is a graphical and
menu driven ALL IN ONE tool and it allows the user to view the result during the run time operation.
The Toolkit consists of a comprehensive library of predefined components with presentation graphics, re-
ports, and manual entries. Knowledge Manager Server Software provides business objects for user authori-
zation, user management, status monitoring, data retrieval, data processing, configuration handling, con-
sistency check and enforcement.
The Toolkit additionally allows the user to use various scripting tools for both complex processing and
treatment of data and for design of more complex templates and reports.
Some examples are explained below.

Figure 70: Toolkit showing configuration of a log

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Online help
To make the configuration of Signals, Logs, Templates, Reports, etc. easier on-line help is provided.

Figure 71: Toolkit’s online help

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Calculations
Within the Toolkit there are two options for calculations: either treating signals before data collection or
carrying out more complex calculations on data before it is displayed in reports or trends. This is illustrated
in the exploded view of the ABB AbilityTM Knowledge Manager Software Architecture diagram shown below.
Raw data signals can be acquired either directly by the Database Server or can pass through the prepro-
cessing module.

Figure 72: Toolkit preprocessing function and calculated log

The preprocessing function is used for:

- Conversion of signals not supported by control systems
- Pre-processing of signal values
- Recording of modified and computed signal values
The preprocessing function is the first data collection task to be executed and normally runs once per mi-
nute.

Figure 73: Toolkit showing preprocessing module example

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The second option is the CLC log that carries out a calculation on other logs stored in the database before
these logs are displayed in reports or trends. This calculation maybe arithmetical or logical and is based on
the Visual Basic scripting language.
The Toolkit offers some pre-defined functions for very specific purposes or for setting additional filtering
conditions when querying the database, such as:
- Standard statistical functions (standard deviation, count of values out of limits, fractiles, etc.)
- Manipulation of the default environment parameters (start date, period type, sort name, etc.)
- Maintenance related calculations (mean time between failures, partial stop times, etc.)
Typical usage of the CLC log is to make calculations
- For displaying in reports
- That are dependent on some conditions being true.

Figure 74: Toolkit showing a calculated Log

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Templates and reports

The next step after data collection and logging is the creation of the various templates that will form the
basis of any reports that the user wants to produce.
The Toolkit’s Toolbox contains a range of elements that can be used to create templates: basic elements,
headers, bodies, entries, graphics, etc.
The availability of toolbox elements depends on which software modules are installed.

Figure 75: Toolkit showing a template for operation reports

Template objects can then be used for multiple reports.

The most basic report configuration can be achieved by simply dragging and dropping the required log
onto a report.
Additional layout or data handling properties can be then setup by an user with authorization to use the
Toolkit.

Figure 76: Toolkit showing properties for detailed report configuration

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Documenting and sharing configuration

Documentation tool
The configuration of a KM system can be documented by saving the contents of the KM database into XML
files. This utility is available from Toolkit’s Tools menu. The user can select one, some or all objects.
A tool to show differences between saved configuration files is also available (see section on XML
comparison tool below).

Figure 77: Toolkit configuration documentation utility

Configuration data export and import tool

The tool enables the user to perform easy export and import of KM objects (logs, materials, reports) within
the Toolkit environment.
The user has the option to select some or all the configuration objects for export. Export of any object or
folder is accomplished by simple right click.
The import of an exported configuration or an object is accomplished by a selection from the Toolkit’s
Tools menu.
This export and import utility allows copying of objects from one system to another and enables offline en-
gineering. This feature is particularly interesting to manufacturers with multiple plants or operations and
similar reporting requirement from these plants, for example, for the head office.

XML comparison tool

The user can compare a single XML file against another file, or a whole directory of XML files against an-
other directory with XML files. The compared files can come from the same or different servers. These XML
files can be a result of running the Documenting , or Configuration data export and import .
This utility is available as a standalone executable and can be run directly of a desktop on your PC.

Bulk loading tool

The bulk loading tool enables the project engineer to configure signals and the dependent logs. It also ena-
bles one to bulk pre-configure standard reports such as the mimic overview, operation and production re-
ports and trends. Depending on the project scope, other options are also available.
The Bulk Loader consists basically of two parts:
- Configuration information in Excel
- Bulk Loader, the import tool

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Other system extensions

Excel Add-In
Technical summary
Item Specification
Server application - Access to KM database
User application - KM Excel Add-In for MS-Excel 1
- Providing KM data directly into MS-Excel
spreadsheet
- Favorite language
- Easy selection of tags, time ranges etc. definitions
for data retrieval
- Multiple queries per worksheet
- Bi-directional for updating existing logs
- Bi-directional for entering budget values
- Ad-hoc reduction types
- Insert, split, merge, delete of records
- Online defined calculations on retrieval

Table 8: KM Excel Add-In module technical summary

Usage
KM Excel Add-In provides easy access to KM data for "ad hoc" reporting or any other user specific pur-
poses. Users can select KM data for further study with Excel functions. Selection of data can be done on tag
name, alias, description, etc. and can be done using filters, specifying resolution, setting period start and
end, etc.
The wizard-like interface is easy to use especially designed to support users without the need to write any
programming code or use especial functions.

Figure 78: KM Excel Add-In usage

1
MS-Excel software is not included

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Once the data has been selected, it can be stored as a separate Excel worksheet for easy update/retrieval
at a later stage.

The following functions are available:

- Connection to the Knowledge Manager server via the plant or office networks
- Collection of requested data from the Knowledge Manager server into personal Excel sheets
- Customization of ad-hoc reports and graphs

The Excel Add-In is accessed via a toolbar that is available in Excel after installation of the Excel Add-In
module.

Laboratory equipment information exchange software

It is possible to interface with lab test equipment and analyzers for automatic data collection.
The comprehensive list of analyzer interfaces includes (but is not limited to) scales, presses, granulome-
ters, X-ray analyzers, atomic absorption analyzers, organic carbon analyzers, carbon & sulfur determinators,
Ultra Violet Analyzers and Polab systems and equipment.

Some examples of lab equipment included in the standard information exchange software includes are
listed below.

Type of lab equipment Required software on Data transfer type

lab equipment
Panalytical XRF spectrometer - X46 - File
- Serial link protocol
ARL XRF spectrometer - Compac - File
- Serial link protocol
Oxford XRF spectrometer - Kermit - File
Bruker XRF analyzer - Hostcom - File
POLAB - AMT/AOT - File
Sympatec Granulometer - Helos - Serial link protocol
Cilas Granulometer - Remote Control - Serial link protocol
Module
Others - File transfer protocol
Toni Technik Press, Setting
Walter & Bai Press
Nequel Press
Jobin Yvon ICP
Spectro ICP
Coulter Granulometer
Malvern Granulometer
Minolta Color
Others Any type

Table 9: Lab equipment information exchange software

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ABB has created some more generic interfaces defining how data transfer should occur between the labor-
atory interfaces and the Knowledge Manager system. There are three types of these read-only generic in-
terfaces:
- GenLab file: based on flat files,
- GenLab XML: based on structured XML files, and
- GenLab Scripted: based on structured or unstructured files, providing a framework for reading, script-
ing the parsing of meaningful data fields, and then saving the data into the system.

See the LIMS Functional Description for more detail.

ERP information exchange software

ERP interfaces for Knowledge Manager are available and are being implemented in multiple ERP systems
like Oracle and SAP, among others.
For example, SAP R/3 integration includes bi-directional exchange of information that provides for the inte-
gration of manufacturing production information and the business information from SAP.

Figure 79: SAP Connector

See the SAP Connector Functional Description for more detail.

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Revision table
Rev. ind. Page (P) Description Date
Chapt.(C) Dept. / Init.
Original issue, 3BHS246232 October 2007
ATBA / GPC
01 All Updated for KM 6.1 June 2009
ATBA / SCV
02 P1 New front page April 2010
All Some layout changes ATBA / RC
03 All Updated for KM 7.0 August 2011
ATBA / SCV
04 All Product version renamed from 7.0 to 7.1 February 2012
ATBA / SCV
05 All Updated for KM 8.0 February 2014
ATBA / SCV
06 C 1.2 New image for Solutions Overview October 2014
C 5.3 Included Authorization Status Report and updated System ATBA / SCV
Status Report Figure
C 5.4 Updated chart Figure
C 8.1 Updated template picture
07 All Updated for KM 8.1 May 2015
PAPI / SCV
08 All Updated for KM 8.1sp1 December 2015
PAPI / SCV
09 All Updated for KM 9.0 December 2017
IAPI / SCV
10 All Updated for KM9.1 November 2019
IAPI / SM, SCV

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