PCP 4.

x Training

1 – PCP System
Table of Contents
1 – PCP System.................................................................................................................1
1.1 General Information.............................................................................................2
1.1.1 Objectives.....................................................................................................2
1.1.2 Reference Documents.................................................................................2
1.2 System Overview................................................................................................3
1.2.1 Introduction..................................................................................................3
1.2.2 Data Acquisition...........................................................................................4
1.2.3 Architecture..................................................................................................4
1.2.4 Calculations..................................................................................................5
1.2.5 Human System Interface..............................................................................5
1.2.6 Process Control............................................................................................7
1.2.7 Alarm Management......................................................................................8
1.2.8 Trending.......................................................................................................9
1.2.9 Historian.....................................................................................................10
1.2.10 Reporting....................................................................................................11
1.3 PCP architecture...............................................................................................12
1.3.1 Server / Client Structure.............................................................................12
1.3.2 Internal architecture...................................................................................13
1.3.3 Functional architecture...............................................................................17
1.3.3.1 On-line and Off-line parts..........................................................................17
1.3.4 Configuration overview...............................................................................18
1.4 Installation and initial setup...............................................................................19
1.4.1 Preparation before installation...................................................................19
1.4.2 Installation..................................................................................................19
1.4.3 Post Installation Setup...............................................................................24
1.4.4 License.......................................................................................................29
1.4.4.1 License installation....................................................................................29
1.5 User Login.........................................................................................................34
1.5.1 Users configuration....................................................................................36

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1.1 General Information

1.1.1 Objectives

On completion of this chapter you will be able to:

 Tell how Process Control Portal fits into a Control System

 Describe the network structure in a PCP application
 Describe the functionality of most components
 Explain the Client / Server principles

1.1.2 Reference Documents

The content of this manual is for Training purpose only.

The goal is to give students knowledge about subjects and a guide on how to deal with
them, therefore it is not granted that all details are continuously updated.
For precise and updated information refer to the manuals in next table.

Code Description

9AKK1011D1381 Ver. 3.2 Installation Manual

9AKK1011D1382 Ver. 3.2 Configuration Manual

9AKK1011D1383 Ver. 3.2 User Manual

9AKK1011D1384 Ver. 3.2 Display Builder Manual

9AKK1011D1385 Ver. 3.2 Application Program Interface

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1.2 System Overview

1.2.1 Introduction

The powerful features of distributed data acquisition and control system and the latest
generation of field proven hardware and software platforms are combined in a flexible
and open Client-Server architecture to provide plant information and human interface
capabilities.
Monitoring and real-time optimization tools are provided for both utility and industrial
processes.
In addition to standard configuration facilities, open system design, flexible hardware
platform and client-server software architecture offer easy adaptation to any specific
user requirements.
ABB PS&S can provide customized application and engineering services as a part of
standard product support.

Supervision and management functions are provided in an integrated hardware and

software environment which:

 Communicates process data via MS-Windows displays or printouts to operation,

engineering and technical personnel
.

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 Provides powerful historical data archives and data retrieval utilities.

 Provides operator interface for process control.
 Interfaces with user or third party supplied software packages for management,
maintenance, artificial intelligence, modeling and other applications.
 Provides scanner suite to interface standard market hardware for data
acquisition.
 Interfaces Symphony modules for data acquisition and preprocessing.

1.2.2 Data Acquisition

Plant and process data are gathered from field devices and/or other data servers via:

 Ethernet TCP/IP
 OPC (AC800F, AC800M, DCI System Six, third party OPC devices)
 IEC870-5-101/103/104
 ODBC
 Generic Serial Link Protocols ( Modbus, Modbus RTU, Modbus TCP)
 Siemens Teleperm (through XU device)
 General Electric Mark V / VI (through GSM Protocol)
 SPABUS
 Parallel SCSI or serial RS232
(Modbus, Symphony proprietary protocol)

Server processes data acquired from the plant to provide diagnostic checks
(reasonability limits, open circuit, loss of power, rate of change, etc.), numeric filtering
(smoothing), alarm checking (with the capability of alarm inhibition and variable alarm
limits), and bad quality management. Multiple interfaces, executing through parallel
communication channels, assure high-speed data transfer to the server, while providing
fault tolerance through modularity.

1.2.3 Architecture

A wide range of platforms running the Microsoft Windows 2000/2003/XP operating

systems can run standard Process Control Portal software.
The basic PCP product offering includes:
 Standard or specific field interface.
 Server with CPU, memory and disk size depending on the specific application
requirements.
 Clients for Human System Interface.
 Support for wide range of printers and hard copy devices.
 Magnetic media or optical disk for long term recording.
 Multi-master/Redundancy.

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Standard hardware interfaces and protocols are used to connect local and geographical
networks, in order to make the system "open" and take advantage of distributed
architectures and functions.

1.2.4 Calculations

The calculation subsystem provides a mechanism to easily perform custom calculations

on acquired process data without programming.
Calculations, cyclically processed or scheduled upon pre-defined events, produce
results stored in the database as calculated tags. Calculated tags can be displayed on
the clients, as well as recorded by the Historian processor and referenced within reports.
The user can define the calculations by specifying formulas, using arithmetic, algebraic,
logical operators and a wide range of functions (e.g. mathematical functions, file access
functions, functions related to time, steam and gas properties)

1.2.5 Human System Interface

The client provides an interactive man-machine interface for the operation or

management personnel to access plant data.
Multiple operator windows can be deployed in different locations in the plant by using
multiple clients; each equipped with QWERTY keyboard and mouse/trackball.
Printers/plotters support can be added to complement the CRT’s functionality by
providing hard copy printouts of process information.
Process Control Portal provides a complete color full-graphic information system based
on MS-Windows.

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Displays may include real time data, such as process variables, digital inputs and
outputs, as well as historical data and information from user generated files. The
information may be presented using different formats such as alphanumeric, text string,
bar charts, dynamic symbols, trends, all according to user requirements.
Color, shape and blink can be assigned to dynamic elements of the display according to
associated quality flags (e.g. acknowledged / unacknowledged alarms, etc.).
The dynamic process data is updated at a rate of once per second. The entire system is
optimized to produce fast display retrieval and use minimal resources for data
refreshing.
The operator interface includes a full range of operator security features that can bound
access to programs, function keys, displays or individual fields, depending on operator
access rights. Security access is based on user name and password.
A powerful interactive graphic display builder with a basic shape library, a full range of
graphic commands to draw the display background and a library of dynamic elements to
specify process control information is provided to create application displays. The
number of supported displays is limited only by the available disk space.

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1.2.6 Process Control

Pop-up control faceplates allow the operator to control the process directly from plant
mimic displays. A single element can be controlled directly from the plant display.
A single pop-up or multiple pop-ups can be kept on top of the mimic during control
phases.
Control faceplates can be customized and created using the standard onboard display
builder.

Predefined graphic pages, named pegboards, allow the simultaneous control of multiple
field devices.
Custom application programs can be implemented to change controller modes, set
points, control outputs, ratios and/or switch positions through an application
programming interface.
This approach can be used to directly output the results of advanced control,
optimization or scheduling algorithms.

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1.2.7 Alarm Management

Alarm limits can be associated with any variable created by the various subsystems
(Process I/O, Calculation, User programs). If these limits are exceeded, alarm messages
can be issued to the
operator station and loggers. Multiple limits per point can be defined, in order to monitor
high/low alarm and pre-alarm (warning) conditions.
Individual alarm messages or alarm messages within a alarm page can be
acknowledged.

Alarm information is presented to the operator both in chronological alarm summary

format and dynamically on the process displays.
A general overview of the plant conditions is continuously displayed in the icon toolbar
through an alarm summary panel, which represents the status (normal or alarm
condition) of the major plant sections or areas.
Clicking on a alarm tile of the alarm summary panel, the chronological alarm page of the
relevant area is displayed.

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1.2.8 Trending

The trend display feature provides the ability to graphically display both current and
historical data. Any tag can be trended as real time data without being defined for
historical storage.

The trend presentation can be arranged in different formats and can be presented as a
window inside other displays. If needed, the Real Time presentation automatically takes
into account the historical archive in order to present the oldest data.

Variables to be trended and display attributes are dynamically defined by the user. The
fields that may be entered by the operator include process variable identification,
minimum and maximum value for scaling the Y axis, start time, time span and color.

All trend displays support pan and zoom functions that are addressed by the operator
just pressing a single key. A drag cursor allows to scan values on the trend curves.

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1.2.9 Historian

The historical processor automatically saves data from field and calculated data in a
buffer called "Playback" in order to provide the capability of a very detailed medium-term
history for all tags. Compression algorithms are applied to the “Playback” buffer to
provide a more extensive history of the plant.
Historical data may be used for plot displays, trend logs, calculations or user written
applications for which standard functions are provided to access the data.

By default, the Playback buffer holds 24 hours of data. To keep a medium term history of
the plant, the Playback buffer is automatically saved on hard disk. By default, up to 10
days of data are kept on the hard disk and can be explored using standard access
interfaces. The 10 saved
Playback buffers are managed as a circular buffer.

Utilities are provided to manage Playback buffers and save them for a permanent off-line
history of the plant. Restore utilities are also provided. An automatic saving utility is
provided.

For long-term recording, the historical trend processor samples user-selected tags at
established intervals. Sampled data are processed to generate the datum to be saved in
the historical database. Instantaneous value, average, minimum, maximum, minimum
and total value, etc. can be defined.
Historical trend groups can be configured to define tags involved in the historical
processing. Standard utilities allow to retrieve and display historical data in trend curve
or table format.

Utilities are provided to manage the historical data files and to save/retrieve data to/from
permanent external storage.

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1.2.10 Reporting

Process Control Portal provides full flexibility for formatting of reports using the standard
MS tools, which are fed by the DDE or OLE2/COM interface.

To format a standard report, the user simply creates an Excel spreadsheet using a
library of built-in functions to access databases.

Reports may be printed on demand or scheduled automatically by time of day to the

nearest minute. Reports may be scheduled daily, weekly, monthly or at specified
intervals during the day. Each report can be printed and/or saved to disk, in order to
maintain a complete plant history.

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1.3 PCP architecture

.

1.3.1 Server / Client Structure

PCP is based on a Server / Client structure, a modern architecture that allows flexibility
of use, a good system management and better reliability than other architectures

Monitor
Interface
Keyboard

Mouse / Trackball

Client

Server

The Server part ( a software process ) includes the Application Software Configuration
( Process Tags, Graphic pages etc ) and is bound to communicate to the controllers
using a specific interface depending on the type of controllers.

The Client part gets information from the Server and and drives the peripherals, such as
mouse/trackball, monitor, keyboard.
A Client represents a physical Workplace.
Connecting more than one client to a Server you can use many workplaces with only
one Server configured.

This solution is not wise, because in case of fault of the Server or even of the Interface,
all Clients will be out of order.
It is always advisable to have at least two Servers with a desired number of Clients.

With consideration to the following figure:

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Server 1 Client 1 Client 2 Server 2

Ethernet

With such architecture we can suppose a behaviour as follows:

Normally Client 1 connects Server 1 and Client 2 connects Server 2.
In case of fault of Server 1 both Clients connect Server 2.
In case of fault of Server 2 both Clients connect Server 1.

Note that in real applications the computer hosting a Server also usually includes a
Client .

1.3.2 Internal architecture

PCP resides on a tree of folders starting from one named “Process Control Portal”.
During installation you will be asked for the installation path and presented a default,
what before “Process Control Portal” can be modified ( Figure 1.3.2-1 ).

Application engineers must learn and remember very well some of the folders included
in the tree:

 The folder \Config is the placeholder for most configurations ( Figure 1.3.2-2).

 The folder \Display is the placeholder for graphics ( Figure 1.3.2-3).

Some folders are important for PCP itself and should not be touched:

 \Process Control Portal\bin holds all PCP Application files.

 \Process Control Portal\data holds working data.

The remaining folders will be used or not depending on the application.

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Figure 1.3.2-1 Process Control Portal folders

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Figure 1.3.2-2 \Process Control Portal\config folders

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Figure 1.3.2-3 \Process Control Portal\display folders

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1.3.3 Functional architecture

To understand how PCP works, the best way is to consider PCP as a black box split in
two parts: on-line and off-line.

The on-line part is based on the folder \Process Control Portal\data.

The off-line part is mainly based on the folder \Process Control Portal\config.

1.3.3.1 On-line and Off-line parts

The folder \Process Control Portal\config is the repository of off-line

configuration, it includes files prepared for the necessary configuration of PCP.
In order to make these configuration became active the information must be
transferred to the on-line part.
This is a manual action called Import or Build.

Most configuration activities can also be performed on-line. It is possible to

transfer this configuration to the repository \Process Control Portal\config using a
manual action called Export or Unbuild.

On-line configuration
PCP

On-line part

\Process Control Portal\data

Import or Build Export or Unbuild

Off-line part
\Process Control Portal\config

Off-line configuration

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1.3.4 Configuration overview

PCP databases are mainly loaded by a set of (at least one) DBF or XLS files. The
content of these files is processed and loaded in the PCP data files by running a build
procedure. These files are located, unless differently specified, in the CONFIG folder
and its sub-folders.

PCP is mainly off-line customized editing a set of files. They are commonly named
DECK files or DECKs. These files are located, unless differently specified, in the DECK
folder.
The content of DECK files is processed and loaded in the PCP data files by running a
build procedure.
Database configuration and system customizations are separated activities. They can be
performed in different time and, with some restrictions, in whatever order.
Each operation can be performed separately from the others. Only changing the system
sizes or rebuilding the file system requires a complete build procedure. A single DECK
can be processed to change a specific configuration. Restrictions in the sequence of
processing take place when DECKs have some relationship.

System configuration parameters are defined into the MS-Windows Registry. Creating or
modifying these parameters is the first step in configuring PCP. Values of these symbols
will be used to size global commons,
data files, to select options and roughly customize the PCP application.
PCP installation sets a default value for each configuration parameter in order to allow
correct operation without any change. The parameters are located in
Hkey_Local_Machine\Software\ABB\Process Control Portal registry key of the MS-
Windows Registry.
PCP supplies a utility, named SysSetup, which allows viewing and modifying the
configuration parameters.
The SysSetup process only interfaces the PCP registry set.
When select the Registry button, the process dialog window changes. The tree of
registry folders is displayed on the left side of the dialog window. On the right side of the
dialog window the registry items are listed once the registry folder, has been selected.

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1.4 Installation and initial setup

To install / upgrade PCP first locate the folder where the distribution Kit was loaded.
This can be a folder on the Hard drive or a CD or any other distribution media.

1.4.1 Preparation before installation

Prior to install Process Control Software, some additional software must be installed on
your computer. This software is also included in the PCP installation CD.

1 – Adobe Acrobat Reader 7.0

2 – DOTNETFX 1.1
3 – DOTNETFX 2.0 ( for Win 2000 Microsoft Installer 3.0 is required )
4 – SOAPDSK 3.0

1.4.2 Installation

If it is an upgrade from previous release, first stop PCP execution, then proceed.
If it is a new installation, proceed as follows.

Login as Administrator.
Click on Start > Run

Browse for the installation Kit and select Setup.exe.

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Click OK.

Click Next in the InstallShield Wizard .

Answer Yes to the license agreement.
The next window will be:

Enter a User Name and a Company name.

In the next window select the installation path. A default one is proposed.

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In the next window you can select the features you want to install.

For the course leave the default selection ( all features ).

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A progress window will appear.

Click “Finish” in the next window.

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Click Finish.
In the next InstallShield Wizard window select Yes to restart the computer. Click Finish.

After reboot, the installation will proceed to a second phase.

The window will close on Setup completion.

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1.4.3 Post Installation Setup

Now the basic installation part is complete.

To perform the post installation sequence:

Click :
Start > Programs > ABB Industrial IT > Process Control Portal > System Setup

The System Setup main window will appear.

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Run Windows Explorer and open the folder \Process Control Portal\config\setup.

Verify that a file named Menu.dbf exists.

Copy this file to the folder \Process Control Portal\config\menu\

Open again the folder \Process Control Portal\config\setup.

Verify that a file named Menu.dbf exists.

Copy this file to the folder \Process Control Portal\config\users\

On the left pane of the System Setup window select expand Build Data Base.

Select Build All.

This procedure will create and initialize all files in the folder \Process Control Portal\data.

After you click Build All the right part of the window will populate with check boxes and fill
in blank areas. Do not mind of them for this procedure, only check the box “Echo” that
allows to follow the sequence.

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Click on the button “Import”. A dialog will ask to continue or not. Click OK.

At the end of the procedure you will read Build All completed.

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The next step was meant to register all necessary files just installed.

On the left part of the System Setup window, expand Client and Server.

Click on General Setup.

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Do not take care of the check boxes at this level ( leave the default as it is ).

Click on the button Go.

After a while a dialog will inform tha the step completed.

Click OK.

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1.4.4 License

A license must be installed in all PCP Servers. Servers are responsible to manage a
number of clients. Clients do not need a local license. When the maximum number of
clients allowed for a Server is reached, the Server will not accept any additional
connection.

Licenses are locked to a Machine ID, usually a Hardware Key ( Dongle ) to connect to
the parallel port of the PC. It is also possible to use the MAC address of the Ethernet
card of the PC.

The user can receive the license on a Excel form or text file or both.

1.4.4.1 License installation

On the left pane of System Setup window click on License Entry.

Fill the blanks with data from the Excel form or get data from the .DAT file.

The next figure is an example of Excel form.

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For the course, click on the button Add from File.

In the next dialog locate the DAT file, in the case the folder \KIT.

Click Open. The fill in blanks will populate.

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Click Validate.

Click OK.
Click Save.

Click OK.
Click Test Checkout.

Click OK.

Repeat the sequence just done for Basic Features also for Drivers and
Application.
Close the System Setup window.

Now PCP is ready for use.

To start PCP:
Start > Programs > ABB Industrial IT > Process Control Portal > Start
Process Control portal

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A dialog indicating the startup progress will appear.

Defaults also include a sound during PCP startup.

The command Start Process Control Portal will start both Server and Client.

The command for the Client only is Process Control Portal Explorer.

After few seconds on the task bar of the computer there will be the indication that
PCP ( Server ) is running.

The workplace ( PCP Explorer ) will appear after a while.

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PCP Server is running

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1.5 User Login

Access to Process Control Portal is submitted to access rights policies.
The security system of PCP is based on “Users”.
Each User has its own “Password”.

By default three Users are installed in PCP.

More Users can be added to the system to accomplish specific requirements.
The three Users are:

User Password
SYSMGR PRIV
ENGINEER LEVEL1
OPERATOR LEVEL0

At startup PCP starts with a “default” user, one of the three available.

The default choice is “OPERATOR”, but it is possible to define a different default user
setting a specific register.
The register is located in the registry system in the folder:
\Process Control Portal\APPS\TntExplorer.
The name of the register is: DefaultUser. To access the register:
Start > Programs > ABB Industrial IT > Process Control Portal > System Setup.

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In the left pane of the System Setup window expand Registry.

Expand APPS and select TntExplorer.

To modify the register double click on DefaulUser in the right pane.

Type in the name of the User you want at startup, then click OK to close the window.
Next time TntExplorer will start, it will use the new User.

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1.5.1 Users configuration

Users and Passwords can be configured Off-Line or On-Line.

To configure a new User or modify an existing one On-Line, click on “Configuration” in
the menu bar of PCP Workplace.
To be allowed to do it you must first login as privileged user ( i.e. SYSMGR ).
From the drop down menu select “Security”. You will access the security Database.

To modify an existing user in the list, double click on it.

To configure a new user click on the icon “New” or on “Configure > New Item”.

In both cases the User configuration window will appear.

The window includes three tabs.

The “General” tab allows some generic parameters to be defined.

Very important ones are the password ( not readable ) and the language ( English or
National ).

The tab “Security” is the very one that defines “Rights”.

There is concept of “Levels” or “Layers” on security rights.
Level 16 is the highest one. A user can access any object with an equal or lower level.

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There is also the concept of “Groups”.

Groups refer to a “geographical” distribution of rights.
Groups must be declared accessible ( checked in the tab ) to be accessed.

The two panes “Tag Operations” and “Privileges” in practice define “what” you can do.
Security groups and the tab “Clients” define “where” you can do what allowed before.

When the configuration completes click OK to close the window.

Users can also be configured On-Line using the Security Database.

A DBF file must be prepared and imported using the Database Builder or System Setup.

Passwords written in this file are readable.

It is also possible to Export to a DBF file the Security Database.

In this case passwords in the resulting file are not readable ( encrypted ).

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