Specifying the ABB SPIET800 interface unit is the first step; its correct integration into an Advant OCS or MOD 300 system is what delivers value. This guide provides a practical, step-by-step overview for system designers and technicians, covering the key considerations for hardware configuration, station addressing, I/O module setup, and commissioning of a remote station based on the SPIET800.
Pre-Design: System Architecture Planning
Before procurement and installation, a clear design is essential.
1. Define the I/O List and Module Configuration
Create a detailed list of all field signals (inputs and outputs) that will be assigned to the remote station. This list will determine the number and types of S800 I/O modules needed (e.g., DI810, AI810, AO810, DO810).
2. Determine the Station Address
Each SPIET800 unit on the MasterBus 300 (MB300) network must have a unique station address. This address is set manually on the module using rotary switches or DIP switches. Plan the addressing scheme for the entire network to avoid conflicts.
3. Redundancy Requirement
Decide if the application requires a redundant SPIET800 configuration. This is critical for processes where loss of the I/O link would lead to a safety risk or significant production loss. Redundancy requires specific wiring and configuration.
Step 1: Hardware Configuration and Wiring
Warning: All installation must be performed by qualified personnel following local safety regulations. Power must be disconnected during installation.
1. Rack Assembly and Module Installation
- Mount the S800 station baseplate (e.g., a TU810 terminal unit) on a DIN rail.
- Insert the SPIET800 interface unit into its designated slot (usually slot 1).
- Insert the required S800 I/O modules into the subsequent slots. The modules are typically keyed to prevent incorrect insertion.
2. Fieldbus Wiring (MB300)
The MB300 network is a serial bus that requires proper termination.
- Topology: It is a daisy-chained bus. The cable runs from the master communication module in the central controller to the first SPIET800 station, then to the next, and so on.
- Termination: The bus must be terminated at both physical ends with a termination resistor (usually 120 Ohm) to prevent signal reflections. The SPIET800 modules may have built-in terminators that can be enabled via a switch.
- Cabling: Use a shielded, twisted-pair cable designed for industrial fieldbuses. Ensure the shield is grounded at one end only.
3. Power Supply Connections
The S800 station requires a stable power supply.
- Provide a redundant power supply if possible. The power supply modules often slot into the baseplate.
- Connect the auxiliary power to the terminal unit.
4. Field Wiring to I/O Modules
Wire the field devices (sensors, actuators) to the channels of the respective S800 I/O modules. Use shielded cables for analog signals and separate them from power cables to minimize noise.
Step 2: Software Configuration
The remote I/O station must be configured within the central engineering tool, typically ABB's Advant Station or a similar environment for the MOD 300 system.
1. Hardware Declaration
In the project's hardware configuration, you need to:
- Add the remote station to the MB300 network.
- Assign it the same address that was set on the hardware DIP switches.
- Define the modules in the station, slot by slot, exactly as they are physically installed (e.g., Slot 1: SPIET800, Slot 2: AI810, Slot 3: AO810, etc.).
2. I/O Channel Configuration
For each channel on each I/O module, configure:
- Signal Type: For analog modules, define the type (4-20mA, 0-10V, RTD, etc.).
- Scaling: Define the engineering units (e.g., 4mA = 0 Bar, 20mA = 100 Bar).
- Alarming: Set up high and low alarms for process variables.
- Filtering: Apply digital filtering to smooth noisy signals.
3. Data Mapping
Link the configured I/O channels to variables in the control logic (e.g., to the Process Variable (PV) of a PID controller). This is how the main controller knows which physical point it is reading or writing to.
Step 3: Commissioning and Testing
- Station Address Verification: Double-check that the hardware address on the SPIET800 matches the address configured in the software.
- Bus Termination Check: Verify that the bus is properly terminated at both ends.
- Power Up: Apply power to the central controller and then to the remote I/O station.
- Status LEDs: Observe the LEDs on the SPIET800. A "COM" or "OK" LED should indicate successful communication with the master controller.
- I/O Loop Checking: This is the most critical step. Force a field input (e.g., short a DI) and verify that the correct value appears in the control system. Similarly, command an output from the HMI and verify that the field device activates.
Conclusion
Integrating the ABB SPIET800 requires careful hardware planning, precise addressing, and correct software configuration. By following this structured approach—from system design and hardware installation to software mapping and rigorous testing—you can reliably deploy this robust interface unit to create a high-performance, distributed control architecture that is the hallmark of a well-engineered industrial automation system.
