Program Conversion between Advant Master and ABB 800xA

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Supervisor:
Dr. Loványi István
Department of Control Engineering and Information Technology

The extension of industrial process control systems or switching between an old system and a new one arises the still unsolved problem of portability of controller applications. Creating applications according to the standard IEC 61131-3 helps the case of portability, although in most cases, the standard is implemented in a system-specific way only or not at all. The situation is the same with ABB’s System 800xA and one of its predecessor, Advant Master. The great number of the old system’s controllers still in use, the demand to switch to the new system fast, and the favoring of cost-effective solutions bring up the opportunity of program conversion that plays as an alternative to rewriting programs.

In my thesis, I introduce and compare the distributed control systems Advant Master and System 800xA, detailing their programming languages and opportunities, as well as their differences and extensions to the standard IEC 61131-3. I shortly describe the drives of cold rolling mill technology used in aluminium industry and the ABB DCS600 motor controller. The exchange of the old system’s controller AC450 to AC800M made necessary to convert the drive control application. In the following I give a detailed description considering the steps of conversion and two methods for the implementation of program conversion. The changing of the application affects the operator displays, therefor I grant the steps for their modification. Then I detail the testing of the converted application, which was carried out in laboratory conditions. Lastly, I review the steps of putting the application into operation and the testing on the live system. At the end of my thesis I point out the future usability and the further development opportunities of the conversion methods.

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