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ABB University Switzerland

Course Program 2006 Part 7


Technology and Solutions
Industrial Automation and Minerals Applications

A B B U N IBVAE SRISCI TCY


O US W
R SI ET SZ E R L A N D

Switzerland

ABB Switzerland Ltd


LC Industrial Automation and
Minerals Applications
Divison ATB
Segelhofstrasse 9P
Postfach
CH-5405 Baden 5 Daettwil
Switzerland
Phone +41 58 586 88 02
Fax
+41 58 586 73 28
www.abb.com/cement
www.abb.com/minerals

Bad

en

Baden-Daettwil
LC Industrial Automation and
Minerals Applications
Building Part L/First Floor
(use main entrance at the fountain)

100 m

fstr.

elho

Seg

1
tr.

Baregg
Tunnel

Dttwil
Birmenstorf

storfers

Birmen

N1
Zrich

r.

erst

lling

Me

H
Hospital

Rtihof

ch

isba

Fisl

EXIT
Baden-West

N1
Bern Basel

More detailed maps will be submitted


together with training confirmation notice
or on request.
1
2
3

Entrance Learning Centre


Employees and visitors parking
Bus stop Segelhof
(Take RVBW bus no. 7 from Baden
in direction Birmenstorf)

ABB University Switzerland

January
Week
Mo
Tu
We
Th
Fr

Course Schedule 2006


No.
Industrial Automation and Minerals Applications
Basic Courses
Cement Process Technology Course
Minerals Processing
Metals Processing
Networks with Windows 2003 Basics
Windows 2003 Server / Networks Configuration for Industrial IT

CHCEM
CHMIN
CHMET
CH005
CH006

Product Courses
Expert Optimizer Developer Toolkit
CHEXLK
Expert Optimizer Advanced Kiln Control Strategy Tuning
CHEXLS
MES @ Metals Application Engineering
CHMESM
Knowledge Manager Application Engineering
CHKM
Knowledge Manager System Management
CHKMS
Knowledge Manager Personal Assistant Power User
CHKMPA
Knowledge Manager LIMS Application
CHKMLM
CHSPC
Knowledge Manager Statistical Production Analysis
Laboratory Information Management System
CHLIMS
Raw Mix Preparation
CHRMP
Gearless Mill Drive Basic Course
CHGMD1
Gearless Mill Drive On-site Operation and Maintenance
CHGMD2
ACS600 Maintenance and Operation
G300
ACS800 Maintenance and Operation
G152
Advant Controller 400 / MP 200 Configuration and Operation
A331
Industrial IT 800xA Applications for Minerals
Control Engineering with PDA tool and Control Builder
CH110
Industrial IT 800xA Applications for Minerals Configuration and Operation
CH112
Industrial IT 800xA Applications for Minerals Operation
CH113
Industrial IT 800xA System Maintenance and Troubleshooting
T302
Industrial IT 800xA System using Foundation Fieldbus
Field Device Integration with Asset Optimization
T303
Industrial IT 800xA System using PROFIBUS/HART
Field Device Integration with Asset Optimization
T304
Industrial IT 800xA System Administration and Installation
T305
Industrial IT 800xA System Configuration
T306
Industrial IT 800xA System Hardware and Troubleshooting
T308
Industrial IT 800xA System Safety AC800 M High Integrity Configuration and MaintenanceT309
Industrial IT 800xA System Basic Configuration
T314
Industrial IT 800xA System Engineering
T315
Industrial IT 800xA System for Advant/Master Configuration
T320

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February
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April
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June
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July
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28
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August
30
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October

September
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November
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December

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days remarks

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Mon-Thu
Mon-Tue
Wed-Fr
Thu-Fri
Mon-Fri

8
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Mon-Wed
Mon-Fri
on request
Mon-Fri
on request
on request
on request
on request
on request
on request
on request
on request
Tue-Wed
Thu-Fri
on request

5
Mon-Fri
10 Mon-Fri
2 on request
5 on request
5

on request

4
4
5
3
3
5
10
5

on request
on request
on request
on request
on request
on request
on request
on request

= public holiday

Organising Learning Centre (LC):

= LC Industrial Automation and Minerals Application, Baden-Dttwil

E
E

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E E

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E E

E E

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Week 1 2 3 4

Legend: E= English, G= German

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5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

The latest version of our course schedule can be found on Internet:


www.abb.com/abbuniversity (click on Switzerland)

Product Courses
Expert Optimizer - Developer Toolkit
5
Expert Optimizer - Advanced Kiln Control Strategy Tuning
6
MES @ Metals - Application Engineering
6
Knowledge Manager - Application Engineering
7
Knowledge Manager - System Management
7
Knowledge Manager - Personal Assistant Power User
8
Knowledge Manager - LIMS Application
8
Knowledge Manager - Statistical Production Analysis
9
Laboratory Information Management System
9
Raw Mix Preparation
10
Gearless Mill Drive - Basic Course
10
Gearless Mill Drive - On-site Operation and Maintenance
11
ACS600 - Maintenance and Operation
11
ACS800 - Maintenance and Operation
12
Advant Controller 400 / MP 200 - Configuration and Operation
12
Industrial IT 800xA applications for Minerals Control Engineering with PDA tool and Control Builder
13
Industrial IT 800xA applications for Minerals - Configuration and Operation
14
Industrial IT 800xA applications for Minerals - Operation
14
Industrial IT 800xA System - Maintenance and Troubleshooting
15
Industrial IT 800xA System using Foundation Fieldbus Field Device Integration with Asset Optimization
16
Industrial IT 800xA System using PROFIBUS/HART Field Device Integration with Asset Optimization
16
Industrial IT 800xA System - Administration and Installation
17
Industrial IT 800xA System - Configuration
18
Industrial IT 800xA System - Hardware and Troubleshooting
18
Industrial IT 800xA System Safety - AC800 M High Integrity Configuration and Maintenance19
Industrial IT 800xA System - Basic Configuration
19
Industrial IT 800xA System - Engineering
20
Industrial IT 800xA System for Advant/Master - Configuration
21

CHEXLK
CHEXLS
CHMESM
CHKM
CHKMS
CHKMPA
CHKMLM
CHSPC
CHLIMS
CHRMP
CHGMD1
CHGMD2
G300
G152
A331
CH110
CH112
CH113
T302
T303
T304
T305
T306
T308
T309
T314
T315
T320

Further Training (tailor-made seminars, special courses, project courses, ABB internal courses and lectures) on all above
and other topics, products and systems can be arranged on request.
The standard course language for scheduled sessions is English and the prices out of the price list are applicable.
Delivery in other languages (German, French, Spanish and Portuguese) is possible for most courses but must be quoted
individually.

focus on Process Technology and Industrial Automation Basics


focus on Process Control and ABB IndustrialIT Solutions
focus on Drives Applications

previous course
is recommended
previous course
is required

Commissioning
Personnel

ABB Local Office


Personnel

Testing Personnel

Engineering
Personnel

Project Managers

ABB personnel
Sales and Services
personnel

CHCEM
CHMIN
CHMET
CH005
CH006

Electrical /Control
Engineers and
System Integrators

3
3
4
4
5

Process and
Chemical Engineers

Couse No.

Laboratory
personnel

Basic Courses
Cement Process Technology
Minerals Processing
Metals Processing
Networks with Windows 2003 - Basics
Windows 2003 Server / Networks - Configuration for Industrial IT

see page

Metallurgists

Title

Plant, Production
and Planning
Personnel

Take the right train

System Engineers
and Users

Customers, consultants and others

Operators and
Maintenance Personnel

Course Selection Table

TECHNOLOGY AND SOLUTIONS

CHCEM

CHMIN

Industrial Automation and Minerals Applications

Industrial Automation and Minerals Applications

Cement Process Technology

Minerals Processing

Objectives
The course goal is to give ABB service, sales and
engineering staff as well as project managers a better
understanding of the cement plant language enabling
them to better and confidentially define and solve
cement plant and equipment problems. Participants will
also be educated to be better able to sell ABB products
to our customers within these industries.

Objectives
The course goal is to give ABB service, sales and
engineering staff as well as project managers a better
understanding of the Mining and Mineral Processing
and related industries enabling them to better and
confidentially define and solve plant and equipment
problems. Participants will also be educated to be
better able to sell ABB products to our customers
within these industries.

Contents
What is cement?
Raw material
Pyroprocessing
Mechanical aspects
Coolers
Thermodynamics
Cement grinding
Cement storage and handling
Material transport/conveying
Environmental impact
Health and safety
Plant organisation
Instrumentation
Main aspects according to geographical parameters
Guest speaker presentations regarding ABB products
available for the cement industries
Half day visit of a cement plant in Switzerland

Contents
Introduction to Mining and Mineral Processing
Ore extraction and handling
Metallurgical simulation
Metallic ore minerals
Crushers (comminution)
Grinding mills
Industrial screens
Classification
Gravity concentration
Dense medium separation
Froth flotation
Leaching
Solvent extraction
Electrowinning of Copper and Zinc
Magnetic separation
Ore sorting
Pyrometallurgy
Dewatering
Tailings disposal
ABB in Mining and Mineral Processing (guest
speaker presentations)
ABB products used within the Mining and Mineral
Processing industries (guest speaker presentations)
Selling of ABB products to customers (guest speaker
presentations)

Methods
Lectures, demonstrations, hand-outs, group work,
exercises and discussions. In addition to the theoretical
part a half day visit of a cement plant in Switzerland
gives the necessary knowledge of how such a plant
works.
Participants
ABB service, sales and engineering staff as well as
project managers or related customers.

Methods
Lectures, demonstrations, hand-outs, group work,
exercises, presentation of video material regarding the
various processes and ABB products used within the
Mining and Mineral Processing industries as well as
discussions.

Prerequisites
Fluent technical English.
Duration
4 days.

Participants
ABB service, sales and engineering staff as well as
project managers or related customers.
Prerequisites
Fluent technical English
Duration
2 days.

ABB University Switzerland

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CHMET

CH005

Industrial Automation and Minerals Applications

Metals Processing

Industrial Automation and Minerals Applications

Networks with Windows 2003


Basics

Objectives
The course goal was designed to give ABB service, sales
and engineering staff as well as project managers a
better understanding of the Metals Processing sector
enabling them to better and confidently define and
solve plant and equipment problems. The course
material will be integrated with pertinent ABB
literature to ensure optimal linkage of information.

Objectives
Participants learn the basic knowledge about MS Windows 2003 used in networks with Ethernet and TCP/IP.
Upon completion of this course, the students know the
relevant hardware components of a computer and are able
to check the correct configuration. They know the differences between Workgroups / Domains and understand
the structure of IP-addresses. They know the function of
the required components in IndustrialIT networks and can
describe a redundant topology. They understand the
concept of user rights with Groups and Users and they
are able to share files / printers. They know how to do
troubleshooting in a network.

Contents
General introduction to Metals Processing
Steelmaking Processes
Casting of Steel
Minimills
Hot Rolling of Steel
Pickling of Steel
Cold Rolling of Steel
Annealing
Temper Rolling
Tension Levelling
Cleaning Lines
Slitting
Tubing production
Galvanizing of Steel
Tin Plating
Rod and Bar Mills
Foundries
ABB and the Metals Sector
- ABB products available
- How can ABB products and services improve
existing processes
- How to best sell our products to customers
- Discussion with ABB experts

Contents
Overview Windows (2003) family
Hardware
bus types, hard drives
disk configurations (RAID, partitions)
Device Manager
Network models
Workgroups and Domains
Client / Server
Ethernet and TCP/IP
IP-addresses and subnets
components (cabling, hubs, switches and routers)
topology with redundancy
Users and Groups
Sharing of files and printers
Troubleshooting
Methods
Lectures, demonstrations and practical exercises

Methods
Lectures, demonstrations, hand-outs, group work,
exercises, presentation of video material regarding the
various processes and ABB products used within the
Metals Processing sector as well as discussions and a
plant tour.

Participants
Engineering, planning, commissioning, maintenance,
testing and service personnel, working with networks for
industrial automation
Sales personnel and project managers, who want to have
basic knowledge

Participants
ABB service, sales and engineering staff as well as
project managers or related customers.

Prerequisites
Basic knowledge about Windows 2003 user interface
Duration
2 days

Prerequisites
Fluent technical English plus attendance of the Minerals
Processing course.
Duration
3 days

ABB University Switzerland

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CH006

CHEXLK

Industrial Automation and Minerals Applications

Industrial Automation and Minerals Applications

Windows 2003 Server / Networks


Configuration for IndustrialIT

Expert Optimizer
Developer Toolkit

Objectives
Participants learn the basic knowledge about the configuration of MS Windows 2003 Server and the design of
networks for IndustrialIT.
Upon completion of this course, the students are able
setup a Domain Controller with Active Directory and
know the differences between Workgroups / Domains.
They are able to build up an IndustrialIT network and
know the required components. They understand the
structure of IP-addresses and know the tools for troubleshooting respectively monitoring of networks. They
are able to create new Groups / Users and understand the
concept of handling user rights. They know how to make
backups and Remote Access connections to a network.

Objectives
The course goal is to teach students how to configure and
modify the ABB Expert Optimizer system and to give an
overview of the control strategy.
Contents
Overview and use of Expert Optimizer tools
Expert Optimizer Personal Assistant
Expert Optimizer Developer Toolkit
Explanation and use of application server, data server
and data collector
System configuration
Expert Optimizer Builder
Control Application Modules
Strategy Objects
Fuzzy-Logic and Neuro-Fuzzy Technology
Control and Optimisation based on Modelling
Technology
Control structure (description, configuration and basic
tuning of control strategies)
Study of a kiln control strategy
Study of a cooler control strategy
Study of a mill control strategy
Building and configuring displays

Contents
Overview Windows XP / Server 2003 family
Hardware (Device Manager, file and systems)
Management Console (MMC)
Networks with Ethernet and TCP/IP
IP-addresses and subnets
components (cabling, hubs, switches and routers)
topology with redundancy
Domain with Active Directory
Access rights
local and global Groups
user rights / administer policies
Sharing of files and printers
DNS / DHCP
Monitoring and troubleshooting
Remote Access
Backup and restore / System administration
Redundancy with RNRP

Methods
Lectures, demonstrations, hands-on exercises, group
work and discussions
Participants
Process and chemical engineers.
Prerequisites
Participants should have process knowledge plus basic
control and instrumentation experience as well as a
good knowledge of MS Windows and fluent technical
English.

Methods
Lectures, demonstrations and practical exercises
Participants
Engineering, planning, commissioning and service
personnel

Duration
8 days.
The course duration can be reduced to the last 5 days
for participants already working with the system in case
of a new release or system upgrade.

Prerequisites
Basic knowledge about installation and configuration of
Windows 2003 Professional or Windows XP Professional,
as well as computer hardware basics
Duration
5 days

ABB University Switzerland

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CHEXLS

CHMESM Industrial Automation and Minerals Applications

Industrial Automation and Minerals Applications

Expert Optimizer Advanced Kiln


Control Strategy Tuning

MES @ Metals Application


Engineering

Objectives
The course goal is to teach students how to configure,
operate and tune the ABB Expert Optimizer system.

Objectives
The course goal is to teach students how to configure,
operate and maintain the MES con-figurable solution
for Metals applications. Upon completion, students
understand the func-tionality of their product suites
reporting on plant activities and can actively influence
optimization of production through effective system
configuration.

Contents
Principles of kiln and process control
Advanced understanding of ABB kiln control
strategies
How to design and control strategies
Ruleblocks
Kiln Cycles
Kiln Tuning
Kiln Simulator
BZT
Diagnostics
Optimisation
PC Intro and Strategy
Simple and Twin Line Strategy

Contents
Explanation and use of the standard product suites
Execution Manager
- Production Schedule and Orders
- Product Definitions and Preset Dispatcher
- Production Resource Management
Knowledge Manager
- Data Collection
- Data Storage and Data Manipulation
- Maintenance, Downtime and Trends
Developer Toolkit
- Production Performance Analysis (Displays and Reports)

Methods
Lectures, demonstrations, hand-outs, practical exercises
and discussions

Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.

Participants
Process and plant engineers
Prerequisites
Participants should have process knowledge plus basic
control and instrumentation experience as well as a
good knowledge of MS Windows and fluent technical
English. The participants should already have attended
the toolkit training course and be familiar with the
toolkit.
Options: This course can be carried out when using the
participants/customers own specific strategy or a similar
one. Simulation can only be part upon request and
notice in advance.
This course is only available in English.

Participants
Engineering, planning, operating, commissioning,
maintenance and service personnel, working in the field
of Metals applications.
Prerequisites
Basic knowledge of the underlying control system. A
good knowledge of MS Windows, data handling and
reporting requirements as well as fluent technical
English.
Duration
5 days

Duration
5 days.

ABB University Switzerland

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CHKM

CHKMS

Industrial Automation and Minerals Applications

Industrial Automation and Minerals Applications

Knowledge Manager
Application Engineering

Knowledge Manager
System Management

Objectives
The course goal is to teach students how to configure
and operate the Knowledge Manager system, using the
Developer Toolkit and Personal Assistant tools.

Objectives
The course goal is to teach students how to effectively
configure, operate and manage the Knowledge
Manager system on a day-to-day basis while ensuring
the security of the system.

Contents
Explanation and use of the standard features
Data collection and process data management
Production information management, monitoring
and accounting
Downtime Management and Maintenance support
Explaining interfaces (including SAP)
Configuring new signals
Defining Logs
Setting stop causes
Creating templates
Building reports
Modifying provided templates and reports
Introduction to Excel Add-In and Statistical
Production Analysis tools
Managing user access
On-line help

Contents
Shut down and restart of the Knowledge Manager
system
Monitoring plant events and alarms
Using the error list
PL/SQL module
Managing user system access
Backup requirements and settings
Methods
Lectures, demonstrations, hand-outs, group work,
exercises and discussions.
Participants
Plant, electrical and control engineers who are going to
maintain the system and authorise access.

Methods
Lectures, demonstrations, hand-outs, group work,
exercises and discussions.

Prerequisites
Basic knowledge of the underlying control system. A
good knowledge of MS Windows, data handling and
reporting requirements as well as fluent technical
English. Furthermore, participants should have
completed the Knowledge Manager or LIMS five days
standard training course before being allowed to attend
this advanced education.

Participants
Plant, electrical and control engineers who are going to
maintain the system and use its functions.
Prerequisites
Basic knowledge of the underlying control system. A
good knowledge of MS Windows, data handling and
reporting requirements as well as fluent technical
English.

Duration
2 days.

Duration
5 days.

ABB University Switzerland

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CHKMPA Industrial Automation and Minerals Applications

CHKMLM Industrial Automation and Minerals Applications

Knowledge Manager
Personal Assistant Power User

Knowledge Manager
LIMS Application

Objectives
The course goal is to teach students how to operate the
Knowledge Manager Personal Assistant user interface
effectively, and be aware of the functionality available.

Objectives
By the end of the course participants will be able to use
and manage, effectively, all of the elements provided in
the Laboratory Information Management System
(LIMS) module and will understand the principles of
effective module configuration.

Contents
Running reports
Specifying your own filters
Entering comments on Operation and Production
Reports
Manually correcting data on Operation and
Production Reports
Understanding the security settings
Selecting Stop Causes
Splitting, adding and deleting Stops
Viewing maintenance forecast reports and resetting
counters
Managing your own folders
Building and using URL reports
Configuring your own Operation Reports
Creating your own basic Trend reports

Contents
Managing addresses
Defining equipment
Defining sample locations
Designing analysis definitions
Specifying analysis plans
Sample management and registration
Sample scheduling and worklists
Using LIMS materials
Designing LIMS templates
Configuring LIMS reports and charts
Building test certificates
Managing user access
Methods
Lectures, demonstrations, hand-outs, group work,
exercises and discussions.

Methods
Lectures, demonstrations, hand-outs, exercises and
discussions.

Participants
Laboratory staff and managers who are going to
maintain the system and use its functions.

Participants
All users of Knowledge Manager Personal Assistant
especially those who wish to configure their own
operation reports and trends.

Prerequisites
Participants must already have the skills that are
specified in the contents list of the Knowledge
Manager Application Engineering course. Also a good
knowledge of MS Windows and should have fluent
technical English.

Prerequisites
A basic knowledge of MS Windows as well as fluent
technical English.
Duration
1 day.

ABB University Switzerland

Duration
2 days.

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CHSPC

CHLIMS

Industrial Automation and Minerals Applications

Industrial Automation and Minerals Applications

Knowledge Manager
Statistical Production Analysis

Laboratory Information
Management System

Objectives
The course goal is to teach students how to use the
Knowledge Manager SPC (Statistical Process Control)
tools efficiently. Practical exercises using various plant
data and required charts form an integral part of this
education.

Objectives
By the end of the course participants will be able to use
and manage the Laboratory Information Management
System (LIMS) effectively and will understand the
principles of effective system configuration.
Contents
Configuring new signals
Defining Logs
Managing addresses
Defining equipment
Defining sample locations
Designing analysis definitions
Specifying analysis plans
Sample management and registration
Sample scheduling / work list
Manual entry forms
Sample status list
Sample survey
Using LIMS materials
Designing LIMS templates
Configuring LIMS reports and charts
Building test certificates
Managing user access

Contents
Basics of Statistical Production Analysis including a
brief history
Statistical functions in Knowledge Manager
SPC configurator
Applying control charts for continuous processes
Opening SPC trends
SPC chart types
Selecting chart types
Histogram
Background statistics
Statistical techniques
Interpreting control charts
Configuring SPC trends
Configuring graphical elements
Methods
Lectures, demonstrations, hand-outs, group work,
exercises and discussions

Methods
Lectures, demonstrations, hand-outs, group work,
exercises and discussions.

Participants
Plant, electrical and control engineers as well as
laboratory staff who are going to use SPC functions in
their plant.

Participants
Laboratory staff and managers who are going to
maintain the system and use its functions.

Prerequisites
Participants must already have the skills that are
specified in the contents list of the Knowledge
Manager Application Engineering course. They should
have a good knowledge of MS Windows, fluent
technical English and basic knowledge of statistics.

Prerequisites
Participants must have a good knowledge of MS
Windows and should have fluent technical English.
Duration
5 days.

Duration
1 day.

ABB University Switzerland

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CHRMP

CHGMD1 Industrial Automation and Minerals Applications

Industrial Automation and Minerals Applications

Raw Meal Preparation

Gearless Mill Drive Basic Course

Objectives
The course goal is to teach students how to configure,
operate and maintain the Raw Mix Preparation system.

Objectives
Participants learn the theoretical background, operation
and maintenance aspects of gearless mill drives. Upon
completion of this course students know the hardware
components and the installation principles. They
understand the functionality of the main components
of the drive system.

Contents
System overview
Raw mix proportioning module
Pre-blending proportioning module
Raw mill optimization module
Raw meal design capabilities
Data acquisition
Reporting
User interface
Interfaces to laboratory
Integration to the installed control system
Tuning and troubleshooting

Contents
System overview
General description of individual components
Function description of main system components
MV switches and converter transformer
Cyclo-converter and excitation
Ringmotor
Drive control
System control (PLC) and auxiliaries
Operation and maintenance aspects

Methods
Lectures, demonstrations, hand-outs, group work,
exercises and discussions.

Methods
Lectures, handouts and discussions.

Participants
System managers and users of the raw mix preparation
process as well as laboratory staff.

Participants
Engineering, design and planning personnel as well as
commissioning, maintenance and service personnel

Prerequisites
Basic knowledge of the raw mix preparation process,
the underlying control system and reporting
requirements as well as fluent technical English.

Prerequisites
Basic knowledge of electrotechnics.
Duration
5 days.

Duration
2 days.

ABB University Switzerland

10

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CHGMD2 Industrial Automation and Minerals Applications

G300

Gearless Mill Drive On-site


Operation and Maintenance

ACS600
Maintenance and Operation

Objectives
Participants learn the operation and maintenance of
gearless mill drives. Upon completion of this course
students know the hardware components and the
installation principles. They are able to start-up,
operate, maintain and troubleshoot gearless mill drives.

Objectives
Participants learn the operation and maintenance of
ACS600 digital frequency converters.
Upon completion of this course, the students know the
hardware components and the installation principles.
They understand the DTC (Direct Torque Control)
functionality. They are able to start-up, operate, commission, maintain and troubleshoot a drive. They know how
to adjust and tune it by using the available programming
tools.

Contents
Operation & maintenance of main system
components
Converter transformer
Cyclo-converter and excitation
Ringmotor
Drive control
System control (PLC) and auxiliaries
Spare parts handling
Communication options (overview)
Fault tracing and troubleshooting

Industrial Automation and Minerals Applications

Contents
Control and operation principles of AC drives
Hardware and software overview
Direct Torque Control (DTC) principle
Hardware components
main circuit diagrams
locating and identifying electronic boards and terminals
Installation principles and initial inverter start-up
Control Panel functions
Application software
parameter settings
application macros
Operation, commissioning and fine-tuning
Communication options (overview)
Fault tracing and troubleshooting
Software tool DriveWindow
ACS611 Regenerative Drive

Methods
Lectures, demonstrations and practical exercises.
Participants
Engineering, design and planning personnel as well as
commissioning, maintenance and service personnel.
Prerequisites
Basic knowledge of electrotechnics.
Attendance of Gearless Mill Drive Basic Course.

Methods
Lectures, demonstrations and practical exercises

Duration
3 days.

Participants
Engineering, planning, commissioning, maintenance,
testing and service personnel

Remark
This course can only be delivered at customers sites
where equipment is available for demonstration and
exercise purposes.

Prerequisites
Basic knowledge of (power) electronics
Duration
2 days

ABB University Switzerland

11

Course Program 2006

TECHNOLOGY AND SOLUTIONS

G152

A331

Industrial Automation and Minerals Applications

Industrial Automation and Minerals Applications

ACS800 Maintenance and


Operation

Advant Controller 400 / MP 200


Configuration and Operation

Objectives
Participants learn the operation and maintenance of
ACS800 digital frequency converters.
Upon completion of this course, the students know the
hardware components and the installation principles.
They can describe the features and advantages of the
ACS800 drive in comparison to the ACS600 drive. They
are able to start-up, operate, commission, maintain and
troubleshoot a drive. They know how to adjust and
program it by using the available programming tools.

Objectives
Participants learn the configuration and operation of
Advant controller AC400 / MP200 using the Engineering
Station 100ES.
Upon completion of this course, the students know the
system components and the system architecture. They
are able to create, modify, test and troubleshoot
application programs. They understand the functionality
of the different engineering tools and are able to handle
projects with the respective programs.

Contents
Hardware and software overview
Comparison with ACS600
Component and board functions
main circuit diagrams
locating and identifying electronic boards and terminals
Installation principles and initial inverter start-up
Control Panel functions
Application software
parameter settings
application macros
Operation, commissioning and fine-tuning
Fault tracing and troubleshooting
Optional equipment overview
Software tools
DriveWindow for commissioning
DriveAP for adaptive programming

Contents
Overview about ABB Advant Master systems
System components and design
Programming by using ABB MasterPiece Language
AMPL
Project handling
Network and nodes
Programming tools and methods
Application Builder APB
Online Builder ONB
Function Chart Builder FCB
Source Code Editor
Definition, configuration and modification of the
database
Configuration and modification of PC-Programs
Documentation of the application software
Backup and restore
Test and diagnostic functions
Troubleshooting

Methods
Lectures, demonstrations and practical exercises

Methods
Lectures, demonstrations and practical exercises

Participants
Engineering, planning, commissioning maintenance, testing and service personnel

Participants
Engineering, planning, commissioning, maintenance,
testing and service personnel

Prerequisites
Basic knowledge of (power) electronics.

Prerequisites
Basic knowledge of automation and computer
technology

Duration
2 days

Duration
5 days

ABB University Switzerland

12

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CH110

Methods
The course flow is based on three main practical
exercises, where students will configure and program a
complete Cement Transport Group, Mill Lubrication
Group and Cement Mill Group. Lectures and
demonstrations are done before each main exercise.
The teacher is then guiding the students through the
exercises, step by step.

Industrial Automation and Minerals Applications

IndustrialIT 800xA Applications for


Minerals Control Engineering with
PDA tool and Control Builder
Objectives
Participants learn to use the configuration tool of PDA
(Plant Design & Allocation) to create Minerals control
applications. They learn to download the prepared
application from PDA to the Control Builder
programming tool, where they will finalize it by
programming the interlock (glue) logic for the
different consumer and group objects.
Upon completion of this course students know the
basic functionality of the PDA tool and know how to
set up a project in PDA. They are able to configure a
Minerals control appli-cation based on customer input
data by using PDA. They know how to download the
pre-pared application from PDA to Control Builder
and are able to program the interlock (glue) logic for
the different consumer and group objects based on real
process conditions. They know the detailed
functionality of the different objects in the Minerals
library with the required data types and understand the
program structure well.

Participants
Engineering and planning personnel that need to do
control programming and
commissioning for Minerals applications.
Prerequisites
Attendance of course CH112 or equivalent experience.
Duration
5 days

Contents
Engineering workflow
PDA basic functionality
setting up a project
general form functions
Application configuration with PDA:
import customer data
I/O allocation
configure basic objects
configure consumer objects
configure group objects
configure loop objects
configure start- and stop sequences for the different groups
Download to Control Builder l
Programming of interlock (glue) logic based on real
process conditions.

ABB University Switzerland

13

Course Program 2006

TECHNOLOGY AND SOLUTIONS

CH112

CH113

Industrial Automation and Minerals Applications

Industrial Automation and Minerals Applications

IndustrialIT 800xA Applications for


Minerals
Configuration and Operation

IndustrialIT 800xA Applications for


Minerals
Operation

Objectives
Participants learn the operation and configuration of the
IndustrialIT Extended Automation System 800xA by
using the Minerals application libraries.
Upon completion of this course, the students know the
system architecture of the automa-tion system and the
hardware components of the controller. They know how
to configure, modify and test controller application programs with the Control Builder programming tool. They
are able to operate the HSI (Human System Interface)
and can configure process graphics, trends and alarms.
They know the basic functionality of the different objects
in the Minerals library with the required data types and
understand the program structure.

Objectives
Participants learn to operate a plant that is controlled by
an IndustrialIT Extended Automation System 800xA,
based on Minerals application libraries.
Upon completion of this course, the students know the
basic system architecture and are able to log on into the
system. They understand the operator interface of the
HSI (Human System Interface) and know how to navigate through the system. They know the basic functionality of graphic displays and faceplates. They are able to
monitor and control all relevant objects of the plant.
They know how to acknowledge alarms and are able to
use event and alarm lists as well as trend displays.
Contents
Overview IndustrialIT 800xA System
Basic System architecture
Log on into the system
Operator interface
Navigation through the system
Graphic displays
Faceplates
Operation
basic objects
consumer objects
group objects
loop objects
Events and alarms
Historical data and trends

Contents
System architecture
Hardware AC800M
Plant explorer
Variables and Data types
Monitoring and testing applications
Programming according IEC 61131-3
Function Block Diagram (FBD)
Structured Text (ST)
Program configuration with control modules
Minerals libraries and Minerals applications; Program
structure
OPC communication / Operator interface
Configure Process graphics
Configure Events and alarms
Configure Data logging and Trend Displays
Backup / Restore
Workshop

Methods
Lectures, demonstrations and practical exercises
Participants
Operators that need to control and supervise the plant.

Methods
Lectures, demonstrations and practical exercises. At the
end of the course a workshop is done. This workshop
covers a larger exercise and is used to consolidate the
most impor-tant items from the training which the students will need for their future work.

Prerequisites
No special knowledge required
Duration
2 days

Participants
Engineering, planning, operating, commissioning, maintenance and service personnel, working in the field of
Minerals applications
Prerequisites
Basic knowledge of automation and computer
technology
Attendance of course CH005 or equivalent experience
Duration
10 days

ABB University Switzerland

14

Course Program 2006

TECHNOLOGY AND SOLUTIONS

T302

Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.

Industrial Automation and Minerals Applications

IndustrialIT 800xA System


Maintenance and Troubleshooting

Participants
This training is targeted to commissioning and
maintenance personnel, system administra-tors and
service & support engineers.

Objectives
The goal of this course is to learn how to maintain and
troubleshoot an Extended Automation System 800xA.
Upon completion of this course, students will be able
to:
Troubleshoot and exchange AC 800M hardware
Trace alarms from HSI down to control logic and
trace
Trace signals in Control Builder
Troubleshoot and diagnose the OPC communication
to AC 800M
Troubleshoot and diagnose communication between
controllers
Troubleshoot communication to S800
Troubleshoot redundant networks
Monitor system performance
Diagnose process graphics
Configure user accounts and describe how access
rights work
Configure time synchronization
Use diagnose tools for Windows
Describe how to create a maintenance plan and do
preventative system maintenance
Perform disaster recovery
Collect log files

Prerequisites
Students should have attended either the Basic
Configuration course T314 or the Engineering course
T315 or have knowledge and experience associated
with the content of these courses plus fluent technical
English
Duration
5 days

Contents
Hardware diagnostics
Hardware redundancy
Signal and alarm tracing
I/O communication
Communication between controllers
OPC communication
Network
Windows diagnostic
System 800xA performance
Time synchronization
Security
Preventative system maintenance
Disaster recovery

ABB University Switzerland

15

Course Program 2006

TECHNOLOGY AND SOLUTIONS

T303

Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.

Industrial Automation and Minerals Applications

IndustrialIT 800xA System using


Foundation Fieldbus Field
Device Integration with Asset
Optimization

Participants
This training is targeted to System 800xA users who
want to couple FF devices to 800xA controllers.
Prerequisites
Students should have attended either the Basic
Configuration course T314 or the Engineering course
T315 or have knowledge and experience associated
with the content of these courses.

Obectives
The goal of this course is to learn the configuration and
commissioning of Foundation Field-bus-applications
with Asset Optimization in the Extended Automation
System 800xA. Upon completion of this course,
students will be able to:
Explain the fundamentals of Foundation Fieldbus
Design and plan the topology of a System 800xA
with Foundation Fieldbus devices
Use the Fieldbus Builder FF
Configure, commission and maintain a Foundation
Fieldbus installation using the LD800HSE linking
device
Configure the data exchange between FF devices and
OPC server
Configure the data exchange between FF devices and
800xA controllers using CI860
Build an application using FF devices of the ABB
Device Integration Package
Set up messenger services
Use the integrated Asset Maintenance Workflow

Duration
5 days

T304

IndustrialIT 800xA System using


Profibus/HART Field Device
Integration with Asset
Optimization
Objectives
The goal of this course is to learn the configuration and
commissioning of Profibus/HART. Upon completion of
this course, students will be able to:
Explain the fundamentals of Profibus/HART
Design and plan the topology of a System 800xA
with Profibus/HART devices
Configure and commission HART devices on Modulebus and Profibus
Use FDT and Fieldbus Builder P/H
Configure, commission and maintain a Profibus
installation with several devices
Build an application using Profibus/HART devices of
the ABB Device Integration Package
Set up messenger services
Use the integrated Asset Maintenance Workflow

Contents
Foundation Fieldbus fundamentals
System 800xA topology with FF field devices
LD800HSE Linking device
Fieldbus Builder FF
HSE Subnet
Data exchange with OPC server
Upload FF configuration
Data exchange with CI860
SMS, E-mail messaging
Maintenance Workplace
CMMS Maximo, SAP/PM Connectivity
ABB device integration package with predefined
devices containing:
OPC connectivity, faceplates, Asset Monitors
Availability, Wiring, Safety

ABB University Switzerland

Industrial Automation and Minerals Applications

16

Course Program 2006

TECHNOLOGY AND SOLUTIONS


Contents
Profibus/HART fundamentals
System 800xA topology with Profibus/HART field
devices
Profibus Master Unit CI854
Profibus DP with S900, LD800P
HART devices on Modulebus and Profibus
FDT and Fieldbus Builder P/H
Basic HART DTM with Diagnostics of HART devices
SMS, E-mail messaging
Maintenance Workplace
CMMS Maximo, SAP/PM Connectivity
Device calibration using DMS
Using the ABB devices integration package with predefined devices containing Aspects for:
OPC connectivity, faceplates and Asset Monitoring
HART Multiplexer Integration
Availability, Wiring, Safety

T305

Industrial Automation and Minerals Applications

IndustrialIT 800xA System


Administration and Installation
Objectives
The goal of this course is to learn how to install and
administer an Extended Automation System 800xA. It
covers the Core System, but not the additional options
such as Batch etc. Upon completion of this course, students will be able to:
Describe the Aspect Integrator Framework
Plan a complete system architecture and state the
system limits
Describe remote access to an System 800xA
Design and setup a redundant automation network
Setup audit trail functionality
Configure and maintain redundant servers
Configure access rights on Windows and 800xA level
with user accounts, group policies, roles and
permissions
Set up clock synchronization to AC 800M
Configure SMS and e-mail notification
Configure IT assets
System backup / restore
Set up a distributed engineering environment
Configure Windows domains / workgroups
Install and license the System 800xA software

Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.
Participants
This training is targeted to System 800xA users who want
to couple Profibus/HART devices to 800xA controllers.
Prerequisites
Students should have attended either the Basic Configuration course T314 or the Engineering course T315 or
have knowledge and experience associated with the content of these courses.

Contents
Aspect Integrator Framework
System planning
Security
Network setup
Redundancy
Audit trail
Clock synchronization
Remote access
IT assets
Backup / restore
Distributed engineering
Domain / workgroups
Software installation

Duration
4 days

Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.
Participants
This training is targeted to system engineers,
administrators and system integrators.
Prerequisites
Students should have attended either the Basic Configuration course T314 or the Engineering course T315 or
have knowledge and experience associated with the content of these courses. In addition, they should have
attended the courses MS2151 / MS2152 or have equivalent experience plus fluent technical English.
Duration
4 days

ABB University Switzerland

17

Course Program 2006

TECHNOLOGY AND SOLUTIONS

T306

T308

Industrial Automation and Minerals Applications

IndustrialIT 800xA System


Information Management
Configuration

IndustrialIT 800xA System


Hardware and Troubleshooting
Objectives
The goal of this course is to learn how to troubleshoot
the AC 800M hardware in an Extended Automation
System 800xA. Upon completion of this course,
students will be able to:
Explain the System 800xA architecture and the
function of the different components
Operate objects through faceplates
Handle alarms
Navigate in the Project Explorer
Describe the structure of application programs i.e.
variables, libraries, programs, tasks
Configure the AC 800M hardware and corresponding
I/Os
Load the controller and work in online mode
Troubleshoot and exchange AC 800M hardware
Troubleshoot Profibus and Modulebus communication to the S800 I/Os
Troubleshoot the OPC communication to the AC
800M controller
Monitor control applications
Trace alarms from the Human System Interface (HIS)
down to control logic
Trace signals in Control Builder
Collect log files

Objectives
The goal of this course is to learn the configuration of
the Information Management provided by the
Extended Automation System 800xA. Upon
completion of this course, stu-dents will be able to:
Install Information Management
Configure historical data for collection, storage,
archiving and distribute data and events
Configure Soft Points
Configure Calculations
Connect OPC DA and OPC AE Servers
Configure OLE/DB and ODBC data access for local
and remote access
Configure and schedule reports
Configure Information Management to store plant
information
Configure client data retrieval
Troubleshoot the Information Management
Contents
Overview 800xA Information Management
Information Management installation
Soft Point Server
Calculations
Connectivity to OPC Servers for DA and AE
Data Logging
Message Logging
Archiving of Data
ODBC and OLE/DB access using the Open Data
Access
Scheduling Services
Report Services
PDL integration for Batch (optional)
Data Retrieval
Maintenance

Contents
System 800xA architecture
Operation
Project Explorer
AC 800M hardware
Hardware diagnostics
Hardware redundancy
Monitoring applications
Alarm tracing
Signal tracing
I/O communication
OPC communication

Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.

Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.

Participants
This training is targeted to commissioning and
maintenance personnel, system administrators,
application and service & support engineers.

Participants
This training is targeted to first level maintenance
personnel.

Prerequisites
Students should have attended either the Basic
Configuration course T314 or the Engineering course
T315 or have knowledge and experience associated
with the content of these courses.

Prerequisites
Students shall know the fundamentals of working with
Control Systems and have basic knowledge of
Windows 2000.
Duration
3 days

Duration
5 days

ABB University Switzerland

Industrial Automation and Minerals Applications

18

Course Program 2006

TECHNOLOGY AND SOLUTIONS

T309

T314

Industrial Automation and Minerals Applications

IndustrialIT 800xA System Safety


AC800 M High Integrity
Configuration and Maintenance

Industrial Automation and Minerals Applications

IndustrialIT 800xA System


Basic Configuration
Objectives
The goal of this course is to learn the basic
configuration of the Extended Automation System
800xA. Upon completion of this course, students will
be able to:
Explain the System 800xA architecture and the
function of the different components
Modify existing application programs by using
Function Block Diagrams, Sequential Func-tion
Charts, Structured Text and Control Modules
Navigate in the system and create new objects /
aspects
Describe the structure of application programs i.e.
variables, libraries, programs, tasks
Troubleshoot the OPC connectivity to AC800M
Configure the AC 800M hardware and corresponding
I/Os
Load the controller and work in online mode
Modify graphic displays
Manage and configure alarm and events
Monitor trends and configure historical data
collection
Describe the use of Function Designer
Import / export System 800xA data

Objectives
The goal of this course is to learn the configuration and
maintenance of the Extended Automation System
800xA with AC800M High Integrity. Upon completion
of this course, students will be able to:
Describe the AC800M High Integrity components
Specify requirements for a SIL certified AC800M HI
controller
Explain the SIL levels
Configure the AC800M HI controller with the
corresponding I/Os
Create ESD and F&G applications by using the necessary libraries
Configure Access Management
Create communications between SIL applications and
controllers
Use the Safety Manual
Maintain and troubleshoot an AC800M HI controller
Contents
Safety standards
SIL levels
AC800M HI hardware
Hardware configuration
S880I/O, Configuration & setup
Access Management
FireGasLib
SupervisionLib
ESD Applications
Maintenance and troubleshooting
Fire & Gas applications
Communication between SIL applications
Safety Manual
Redundancy

Contents
System 800xA architecture
Engineering Workplace
Application structures
AC 800M Hardware
OPC connectivity
Applications with FBD and ST
Control Modules
Sequential Function Chart (SFC)
Alarm and Events
Historian and Trends
Graphic Displays
Operator Workplace
Function Designer
Import / export

Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.
Participants
This training is targeted to system, process,
instrumentation, maintenance and application
engineers.

Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.

Prerequisites
Students should have attended the basic configuration
course T314 or have knowledge and experience
associated with the content of the course.
Duration
3 days

ABB University Switzerland

19

Course Program 2006

TECHNOLOGY AND SOLUTIONS


Participants
This training is targeted to System 800xA users who
need to learn the fundamentals in order to form a
foundation for maintenance and administration skills.
If more comprehensive engineering skills are needed, it
is recommended to consider T315 instead.

T315

Industrial Automation and Minerals Applications

IndustrialIT 800xA System


Engineering
Objectives
The goal of this course is to learn the engineering of
the Extended Automation System 800xA with AC
800M controllers. Upon completion of this course,
students will be able to:
Explain the System 800xA architecture and the
function of the different components
Navigate in the system and create new objects /
aspects
Create a new project and plan the structure of
application programs
Configure the AC 800M hardware and corresponding
I/Os
Design and configure application programs by using a
variety of IEC 61131-3 languages
Setup the OPC connectivity to AC800M
Develop project specific libraries
Configure graphic displays, faceplates and graphic
elements
Manage and configure alarm and events
Configure historical data and trends
Configure workplaces and user accounts
Backup / restore System 800xA data
Use the Function Designer and Signal objects
Use bulk data handling with templates

Prerequisites
Students shall know the fundamentals of working with
Control Systems and have basic knowledge of
Windows 2000.
Duration
5 days

Contents
System 800xA architecture
Engineering Workplace
Project and application structures
AC 800M Hardware
OPC connectivity
Applications with FBD and ST
Control Modules
Sequential Function Charts (SFC)
Alarm and Events
Historian and Trends
Graphic Displays
Faceplates and Graphic Elements
Operator Workplace
Function Designer
Backup / restore
Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.
Participants
This training is targeted to application engineers,
programmers and system integrators.
Prerequisites
Students shall know the fundamentals of working with
Control Systems and have basic knowledge of
Windows 2000.
Duration
10 days
ABB University Switzerland

20

Course Program 2006

TECHNOLOGY AND SOLUTIONS

T320

Prerequisites
Students should have attended the AC400
configuration course A331 (course A400 for AC100) or
have knowledge and experience associated with the
content of the courses plus need fluent technical
English.

Industrial Automation and Minerals Applications

IndustrialIT 800xA System for


Advant Master Configuration
Objectives

Duration
5 days

The goal of this course is to learn the installation,


configuration and maintenance of the Extended
Automation System 800xA for Advant Master AC400
and AC100.
Upon completion of this course, students will be able
to:
Plan an appropriate architecture for a system 800xA
with Advant Master
Install the AC400 Connect software
(AC100 Connect optional)
Navigate in the system and create new objects /
aspects
Configure and maintain the communication between
800xA and Advant controllers
Configure and modify graphic displays, faceplates and
graphic elements
Manage and configure alarm and events
Configure historical data collection and trends
Configure time synchronization
Create and customize a workplace
Configure user accounts and describe how access
rights work
Save and restore data
Contents
System 800x architecture for Advant Master
AC400 Connect installation
Plant Explorer introduction
Controller communication and Database integration
Graphic Displays
Faceplates
Alarm and Events
Historical data collection
Trends
Time synchronization
Workplace configuration
Security
Backup and restore
Methods
Lectures, demonstrations, hand-outs. practical exercises
and discussions.
Participants
This training is targeted to system and application
engineers, commissioning and maintenance personnel,
service engineers and system integrators.

ABB University Switzerland

21

Course Program 2006

ABB University Switzerland

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ABB University Switzerland

Course Program 2006

Generation

Transmission

Distribution

Industry

Power System Management


Protection and Substation Automation
Power Plant Automation

Network Control

Industrial Automation
Waste to Energy

Power Electronics and


Medium Voltage Drives

Power System Communications

Power Electronics and


Medium Voltage Drives
Minerals Applications

Technology and Solutions

Robotics
Printing
Motors and Machines

Switchgear Technology
Transformer Technology

Business Processes and Tools


Management and Leadership
Personal Competencies and Skills

To create, build up, find, select,


organize, present and exchange Knowledge;
To pass on Knowledge freely
to wherever our customers and employees
currently need it and can independently
utilise, convert, renew and extend it:
Knowledge management

ABB University Switzerland


Administration
Bruggerstrasse 72
CH-5400 Baden/Switzerland
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Web
E-mail
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+ 41 58 585 67 34
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ABB University Switzerland.