AC500 PLC The ideal solution for water Flexibility, reliability & efficiency

AC500 PLC The ideal solution for water Flexibility, reliability & efficiency
PLC water brochure
AC500 PLC
The ideal solution for water
Flexibility, reliability & efficiency
Preface
Clean water for everyone
Challenges in Automation Systems
As the population continues to grow the world is facing a crisis of water resources, we need to ensure that drinking water
continuously meet the needs of population growth. At the
same time sewage treatment capacity needs to be improved
to prevent pollution on the ecological environment.
Flexibility
Systems optimization to upgrade the existing water treatment
plant, and maintain its compatibility and ensure scalability for
a future requirements.
Under the premise to provide users with high-quality drinking
water and effective sewage treatment, we also face many
challenges, such as high energy consumption, changing
climate conditions and restrictions of various laws and regulations. In addition to that, the old water supply facilities and
systems are now unable to meet growing consumer demand.
ABB fully understand customer needs. With our successful
implementation of the global water treatment project experience, we can help improve and upgrade the local water
treatment efficiency and protect your Investment and jointly
overcome the water crisis.
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Reliability
Water is one of the most important resources to sustain our
lives. Automated system must be very reliable to ensure water
quality is always good and correct for safe consumption.
System stability is important even in the event of a failure,
systems should have own monitoring diagnostic for problem
solving functions ensure continuous supply.
Efficiency
In the water treatment industry, automation is the prerequisite
for the effective functioning of the system. A fully automated system also includes information management and its
communication to service external systems such as remote
control and monitoring.
The ideal solution for water
Flexibility, reliability and efficiency
ABB has nearly half a century experience in equipping
thousands of water treatment facilities. It supplies products
and systems for any type of application in the water cycle.
Below are just a few examples, visit our website for more
information.
Urban water distribution
ABB supplied motors, drives, control switchgear and instrumentation to MWA (Metropolitan Waterworks Authority) in
Bangkok, which provides tap water to 11 million people. MWA
owns and operates one of the world’s biggest water treatment plants and more than 30 pumping stations. Electricity
costs amounted to almost 50 percent of MWA’s production
cost. The equipment supplied by ABB helps MWA to achieve
energy savings of more than $10 000/month for a pumping
station.
Industrial water
ABB supplied PLC, drives, motors, transformers and control
panels for the Ras Laffan Common Cooling Water Project,
which supplies vital cooling water to Ras Laffan Industrial City,
one of the world’s fastest-growing industrial export locations.
The cooling water system pumps 833,000 cubic meters of
cooling water an hour to the power plant, LNG trains and
petrochemical facilities.
Sewage
ABB supplied instrumentation, motors and drives for
Singapore’s Changi Water Reclamation Plant project, which
is designed to meet Singapore’s wastewater treatment needs
through the 21st century. The new water reclamation plant will
treat 528 million gallons of used water per day.
Water treatment
ABB supplied motors, drives and instrumentation to Scottish
Water, the fourth-largest water utility in the U.K. Scottish Water operates about 47,000 kilometers of water mains, 48,000
kilometers of sewers, 370 water-treatment works and 1800
wastewater treatment works.
Desalination
ABB has supplied AC500 PLC systems to Middle East
desalination plant. The reverse osmosis (RO) plant, which is
scheduled to go on line in 2010, will produce approximately
100 million cubic meters of fresh water a year.
ABB brochure
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High Availability solution for reliable water supplies
Performance is the key
Most downtime is caused by either human error or device
malfunction which could be avoided with the AC500 High
Availability. Utilising dual CPUs and dual I/Os help reduce any
risk of total system failure thus enhancing system availability.
High Availability - System overview
OPC server
If the retention of critical data and the avoidance of downtime are important to your application then ABB AC500 High
Availability with dedicated large data storage solution is the
ideal solution.
What benefits can you expect from our AC500 High
Availability solution?
−− G reater resource usage with no downtime in Hardware/
Software failure with the dual CPUs and dual communication fieldbus CS31.
−− C ost efficiency and easy system maintenance through the
use of standard hardware.
−− Only standard CPUs required, choose from PM573-ETH to
PM592-ETH to achieve High Availability.
DigiVis500
Supervisory Control
Ethernet
CP400 HMI
Programming Package PS501
Control Builder Plus
ABB Dual I/O bus
(CS31)
Singapore: Deep Tunnel Sewerage System project Is an efficient and cost-effective solution to meet Singapore’s long-term
needs for used water collection, treatment and disposal.
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CP600 HMI
Demand for water is rising at three times the rate of population growth. ABB’s PLC automation solutions help provide more
flexibility, reliability, and efficiency producing clean water while
ABB‘s motors and drives reduce energy consumption in treatment plants. ABB’s instruments help to detect leaks and minimize chemical usage, reducing waste and improving quality at
every step of the process.
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Water supply and waste water treatment
Water supply and waste water treatment
ABB provides Supervisory Control solutions to allow real-time monitoring and control water systems. Because we integrate
plant automation systems and field instrumentation, all the typical parameters (flow, pressure, level and quality) are under control.
DigiVis 500
Supervisory Control
PS501 Control Builder Plus
Programming Station
Industrial Ethernet (Optional Ring Redundancy)
HMI
AC500 PLC
AC500 PLC
HMI
CS31
PROFIBUS
Industrial Ethernet
Electrical Hardwire
ACQ810
MCB
Motor
S500
Remote I/O
Flow
Meter
Temp
Sensor
Soft
Starter
UMC
AC500-XC for extreme conditions:
Extended immunity to hazardous gases and salt mist for water
treatment and desalination plan.
Motor
Extended operating temperature
-30˚c up to +70˚c operating temperature (with de-rating)
Extended operating temperature
-40˚c power up
Operation at high altitudes
Operating altitude up to 4,000m above sea level
Extended EMC requirements
EN 61000-5-45 surge test, EN 61000-4-4 transient/burst immunitity test
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Solutions for water distribution and pumping stations
Water distribution network and pumping stations
ABB provides automation solutions for turnkey projects, including electrical and mechanical scope (pumps, hydromechanical
components). Better management of pumping stations enables a significant saving in energy consumption. That is why ABB
developed a complete range of products and solutions covering the electrical and automation processes and provide this
through value added channels partners and system integrators.
DigiVis 500
Supervisory Control
GSM, GPRS,
3G, SMS
AC500-eCo
AC500 PLC
AC500-eCo
CP600 HMI
ACS800
VSD
CP600 HMI
Push Buttons
S500
Remote I/O
GSM, GPRS,
3G, SMS
GSM, GPRS,
3G, SMS
CP600 HMI
ACS800
VSD
MCBs
ACS800
Motor
Flow
Meter
Motor
Flow
Meter
AC500-XC for extreme conditions:
Extended immunity to hazardous gases and salt mist for water
treatment and desalination plan.
Flow
Meter
Motors
Serial
PROFIBUS
Industrial Ethernet
Electrical Hardwire
Temp
Sensor
Extended operating temperature
-30˚c up to +70˚c operating temperature (with de-rating)
Extended operating temperature
-40˚c power up
Operation at high altitudes
Operating altitude up to 4,000m above sea level
Extended EMC requirements
EN 61000-5-45 surge test, EN 61000-4-4 transient/burst immunitity test
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Condition monitoring for water
Condition monitoring for all water solutions
Items for measuring, machine/motor/pump vibrations, operator inputs, temperature differences, voltages, speeds, water levels,
flows and pressures . The real benefit from condition monitoring is malfunction prediction and identification of irregularities in
system behavior which can significantly improve repair planning and can also prevent additional damage from occuring. ABB‘s
monitoring systems would include vibration monitoring, monitoring of electrical measurements and process quantities (temperatures, pressures, flow etc.) Systems must include continuous measuring, trending and database creation of all measured
data. Repair works based on system reports can reduce the cost of maintenance up to 50 %. Data can be recorded with the
powerful data storage features of the AC500 with internal memory up to 4GB. AC500 can also report via email on the status of
the system.
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Solutions for desalination and industrial treatment
Desalination and industrial treatment
As desalination becomes more essential in water production in those areas where increasing demand outpaces the availability
of natural resources. In some cases combined desalination and power plants are the flexible solution to produce both water and energy. Hybrid desalination plants use two or more different desalination processes in one plant; these plants have a
complex system structure, which allows multiple possibilities for optimization. ABB’s portfolio includes a wide range of products
covering electrical and automation solutions. ABB is the ideal partner for EPC contractors that are looking for engineered ICE
solutions (Instrumentation, Control and electrification) also applicable for pharmaceutical.
DigiVis 500 Supervisory Control
Server
PS501 Control Builder Plus
Programming Station
Industrial Ethernet (Optional Ring Redundancy)
CS31
PROFIBUS
Industrial Ethernet
Electrical Hardwire
Control Devices
AC500-XC for extreme conditions:
Soft Starter
Extended immunity to hazardous gases and salt mist for
water treatment and desalination plan.
Extended operating temperature
-30˚c up to +70˚c operating temperature (with de-rating)
Flow Meter
Extended operating temperature
-40˚c power up
Operation at high altitudes
Operating altitude up to 4,000m above sea level
Extended EMC requirements
EN 61000-5-45 surge test, EN 61000-4-4 transient/burst
immunitity test
Variable
Speed Drive
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Remote Connectivity
Remote communications with AC500 PLCs can be realized in a number of differing ways and we recognize that the ability to
create remote connections to equipment can provide service and maintenance great savings in time and money, not only this
but improved availability and reliability through easier monitoring and diagnostics. With the following communication solutions
we are able to control and monitor, update software or troubleshoot, irrespective of where the equipment is located, by simple
means of remote connection. Being able to connect to a remote site from main control facility or whilst working in a different
location makes a much more efficient and flexible working conditions for support and maintenance personnel. ABB‘s solutions
for remote connectivity use wireless switches, hubs, modems and devices which are available from 3rd party vendors.
Remote Connectivity: SMS Reporting and Alarm Monitoring
Ethernet
WAN
Serial
PROFINET
Control & Monitoring
Programming
Remote I/O
Remote Web Server Connectivity
Modbus TCP
Ethernet
Ethernet
Ethernet
Router
Web Server
Programming
WAN
LAN
Remote Connectivity: Remote Distributed Controlling
Wireless
LAN
Remote I/O
Modbus TCP
Modbus TCP
Hardwire
PROFINET
Flow
Meter
ACS800
Temp
Sensor
Remote Connectivity: Modem Connectivity and Email Functionality
SMS
AC500-XC for extreme conditions:
Extended immunity to hazardous gases and salt mist for water
treatment and desalination plan.
Extended operating temperature
-30˚c up to +70˚c operating temperature (with de-rating)
Serial
Extended operating temperature
-40˚c power up
Flow
Meter
Operation at high altitudes
Operating altitude up to 4,000m above sea level
Hardwire
Hardwire
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Temp
Sensor
Extended EMC requirements
EN 61000-5-45 surge test, EN 61000-4-4 transient/burst
immunitity test
Municipal water treatment is a key process in the water lifecycle,
as it must guarantee a sufficient degree of water quality before
use. ABB‘s portfolio includes a wide range of products and solutions for water and wastewater treament plants with a specific
focus on energy efficiency. These include PLC, motors & drives,
control products and systems, instrumentation and analytics
and complete electrical distribution components.
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AC500 products family
Fields of application
ABB has more than 40 years of experience in producing PLC offering a comprehensive range of scalable PLCs and robust
HMI control panels as well as high-availability solutions. the AC500 PLC platform has achieved significant industry recognition
for delivering high performance, quality and reliability. Our unique family of IP67-rated wireless Input/Output devices extends
PLC solutions for robotics and similar applications. ABB delivers scalable, flexible and efficient ranges of automation components to fulfill all conceivable automation applications including:
Programming software PS501 Control Builder Plus
PS501 Control Builder Plus complies with the IEC61131-3 CoDeSys standard offering all 5 programming languages, extensive function block libraries, a powerful embedded simulation or visualization feature. It also supports a number of languages (e.g. Chinese, English, French, German, Italian, Spanish, etc).
New: New libraries, FTP functions, SMTP server, smart diagnostics and debugging.
AC500
ABB’s powerful flagship PLC offering a wide range of performance levels and scalability within a single, simple concept and where most competitors require multiple product ranges to deliver similar functionality. Web server integrated and IEC 60 870-5-104 remote control protocol.
New: "Extreme Conditions" modules with extended operating temperature, immunity to
vibration and hazardous gases, use at high altitudes, in rainy conditions, etc.
AC500-eCo
Meets the cost-effective demands of the small PLC market whilst offering total inter-operability with
the core AC500 range. A CPU integrating onboard Ethernet.
New functionalities: Web server for all Ethernet versions, up to 10 I/O modules connected to
the CPU, a fast counter up to 50 kHz.
S500 I/O modules
Digital and analog modules can be configured to best meet customer requirements as
well as offering local and/or remote expansion options using most industry standard
communications protocols.
New: "Extreme Conditions" modules and an assortment of PROFINET interface modules.
Control panels
Touchscreen or keypad graphical displays utilizing low cost, user friendly configuration software,
offering extensive libraries and drivers for most PLC platforms and other automation devices.
IP switch function managing High Availability.
New: CP600 range up to 15" available with Panel Builder 600 engineering software or web panel
version.
DigiVis 500
DigiVis 500 software is a simple and easily accessible solution in the development of supervision applications. It offers all the functions that are essential to a secure environment, its functional reliability and dual-display mode will simplify all your supervision operations, keeping interruptions to a minimum.
Wireless interface for sensors and actuators
Factory Automation for high productivity thanks to reliable sensor and actuator networks. Broken
cable and wire issues can be a thing of the past with this solution. Wireless is ideal for machines with
sensors or actuators on moving end effectors.
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Engineering tool
PS501 Control Builder Plus
Diagnosis, Service
Operate, Visualize
Engineering
Tool
Libraries
Programming
Configurator
Programming ABB PLCs and configuring drives with
PS501 Control Builder Plus
For PLC, drives and control panels, there is now one single
smart engineering tool: PS501 Control Builder Plus!
PS501 Control Builder Plus provides:
−−
−−
−−
−−
−−
Powerful programming functionality
Advanced visualization capabilities
Convenient diagnostics and debugging
Easy network and fieldbus connectivity
Remote and bulk update and parameterization of all your
machine devices
Features include:
Powerful IEC 61131-3 and C programming
−− One tool for programming and configuration of PLCs
AC500, AC500-eCo and specific LV drives offered by ABB
−− Programming in all five IEC 61131-3 languages, the only
recognized international standard
−− In addition, PLC functions can now be written in ANSI-C
language and integrated using an external compiler
Advanced visualization
−− Control Builder Plus supports many different kinds of
enhanced visualization built-in
- Integrated visualization when using online
- Standalone visualization used in PC with protection of code
- AC500 web visualization built using Control Builder Plus
- Integrated panel builder software for CP600 series panels
- OPC server integrated with CoDeSys
Convenient diagnostics and debugging
−− Recipe management for simpler production solutions
−− Multiple watch lists for superior overview and for
customized tasks
−− Smart diagnostics and debugging for easier online use
−− Alarm handling for enhanced maintenance and
commissioning
Easy network and Fieldbus connectivity
−− Simple configuration of Fieldbuses and serial connections:
- PROFIBUS DP, CAN, CANopen, Modbus, serial and ABB IO-bus CS31
- DeviceNet with Sycon.net configurator
−− Easy configuration of real-time Ethernet networks:
- PROFINET, EtherCAT,
−− Internet protocol suite includes:
- HTTP (Web server in AC500 CPU)
- SNTP (Time synchronization of CPUs)
- SMTP (Email messages and attachments)
- FTP (File transfers)
- DHCP (Automatic network IP configuration)
- TCP/IP (Standard transmission control and internet protocol)
- UDP/IP (Fast network communication)
- IEC60870-5-104 (Sub station automation protocol)
−− IEC 60870-5-104 (Sub station automation protocol)
Remote and bulk update and parameterization
−− ABB drives connected by Profibus or PROFINET to AC500
can now be remotely parameterized from a single point the PC running PS501 Control Builder Plus
−− Multi-online-change allows to modify and transfer multiple
PLC programs simutaneously
−− Remote firmware updates reduces travel cost and time.
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Scalable PLC AC500
Superial local extention capabilities for I/O and communication
modu
ding
lu
c
in
s
odule
I/O m
n
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Up to
range
-eCo
0
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un
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AC500 CPU: Amazing functionality and industry leading performance with
extensive range of communication modules and industrial interfaces
1 Terminal base:
−− Easy snap-on of CPU and
optional communication
module
−− CPU performance
upgrade is convenient and
fast
−− Pre-wiring of CPU
connections
4
O nboard Ethernet
(optional)
−− Programming via PC
−− Internet protocols (web
server, FTP, e-mail, time
sync and more)
−− IEC 60870-5-104
1
2
5 C OM2 (Sub-D9, RS232/
RS485)
2 C ommunication module:
− − Up to 4 modules in
numerous combinations to
communicate with nearly
everything
4
−− Programming via PC
−− ASCII protocol
−− Modbus-RTU (master or
slave)
5
3
6
6 C OM1 (spring terminal,
RS232/RS485)
3 F ieldBusPlug connector:
−− Slaves for Profibus DP,
CANopen, DeviceNet
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−−
−−
−−
−−
Programming via PC
CS31 bus (master)
ASCII protocol
Modbus-RTU (master or
slave)
Extreme Conditions
AC500-XC
xtended operating temperature
E
– -30°C up to +70°C operating temperature
– -40°C power up
E xtended immunity to vibration
– 4 g root mean square random vibration up to 500Hz
– 2 g sinusoidal vibration up to 500Hz
E xtended immunity to hazardous gases and salt mist
– G3, 3C2 immunity
– Salt mist EN 60068-2-52 / EN 60068-2-11
Use at high altitudes
– Operating altitude up to 4,000m above sea level
E xtended EMC requirements
– EN 61000-4-5 Surge immunity test
– EN 61000-4-4 Transient / burst immunity test
The new AC500-XC series is designed to withstand various
harsh conditions during operations. In many cases, this
makes engineering and operations much more cost-efficient
than before.
General benefit
The major benefit of using AC500-XC is cost saving in
engineering and in operations.
AC500-XC simply works in harsh areas - even if installed in
plain cabinets. Many expensive extras become obsolete:
−−
−−
−−
−−
−−
Sealings at cable entrances and doors
Shock absorbers
HVAC for the panel
Cooling fins and cut-outs
EMC protection.
When HVAC is no longer needed, the energy and
maintenance costs can be kept at a minimum.
So the efforts to design, purchase, install and argue for
expensive housings are fully gone.
Everybody affected with special cabinets or panels will save
time and money thanks to the now possible straight-forward
cabinet design.
Savings in cable infrastructure
Plain components are often placed in buildings for protection,
while the I/O port is needed elsewhere. The required cabling
requires relatively complex Fieldbusses, cables and ducts.
The better way can be the robust AC500-XC, placed at the
point where the I/O is needed. AC500-XC eliminates the cable
hassle.
Benefits for design engineers
Mechanical dimensions and electrical specifications of
connections are the same as for AC500. Panel layouts and
wiring harnesses can be re-used. Mechanical design effort
is mostly as for plain control gear. Time and complexity are
saved.
Benefits for system engineers
The new products are functionally fully compatible with
the proven AC500 series. As important consequence,
configuration, programming and commissioning remain
completely identical with AC500. Software works as before.
PS501 Control Builder Plus is the same engineering tool to be
used.
Benefits for operators
Investments can be kept at minimum due to smaller
engineering efforts. Maintenance and repair efforts are
lower than with special expensive cabinets carrying plain
components.
Product range
Most of AC500 products are available as AC500-XC version.
Example for AC500-XC product
CPU module PM592-ETH-XC with highest speed, most
memory and numerous Internet technologies built-in. AC500-XC products carry the snow symbol.
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ABB Global Contact Directory
The ABB Contact Directory (http://www.abb.com/
contacts/) helps you find local contacts for ABB products
in your country.
Please select the relevant product group from the
dropdown menu to the right or from the page.
PAP GB
www.abb.com/plc
As part of its on-going product improvement, ABB
reserves the right to modify the characteristics or the
products described in this document. The information
given is not-contractual. For further details please
contact the ABB company marketing these products
in your country.
1SBC 125 046 B0201 - AC500 PLC ideal solution for water ABB Automation Products GmbH
Wallstadter Str. 59
68526 Ladenburg, Germany
Tel. :+49 62 21 / 701-1444
Fax :+49 62 21 / 701-1361
E-Mail : [email protected]
Printed in Germany
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(08.2011)
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