ac800m

IndustrialITCompact Control Builder AC 800M

Version 5.0.2/0

Release Notes

NOTICEThis document contains information about one or more ABB products and may include adescription of or a reference to one or more standards that may be generally relevant tothe ABB products. The presence of any such description of a standard or reference to astandard is not a representation that all of the ABB products referenced in this documentsupport all of the features of the described or referenced standard. In order to determinethe specific features supported by a particular ABB product, the reader should consult theproduct specifications for the particular ABB product.

The information in this document is subject to change without notice and should not beconstrued as a commitment by ABB. ABB assumes no responsibility for any errors thatmay appear in this document.

In no event shall ABB be liable for direct, indirect, special, incidental or consequentialdamages of any nature or kind arising from the use of this document, nor shall ABB beliable for incidental or consequential damages arising from use of any software or hard-ware described in this document.

This document and parts thereof must not be reproduced or copied without written per-mission from ABB, and the contents thereof must not be imparted to a third party nor usedfor any unauthorized purpose.

The software or hardware described in this document is furnished under a license andmay be used, copied, or disclosed only in accordance with the terms of such license.

This product meets the requirements specified in EMC Directive 89/336/EEC and in LowVoltage Directive 72/23/EEC.

TRADEMARKSAll rights to copyrights, registered trademarks, and trademarks reside with their respec-tive owners.

Copyright © 2003-2008 by ABB. All rights reserved.

Release: September 2008Document number: 3BSE033044D5020

Table of Contents

TABLE OF CONTENTS

About This BookGeneral ..............................................................................................................................9

Document Conventions ...................................................................................................10

Use of Warning, Caution, Information, and Tip Icons ....................................................11

Applicable Specifications ................................................................................................12

Section 1 - IntroductionExecutive Summary.........................................................................................................13

Revision Record ..............................................................................................................14

Version Designation.........................................................................................................14

Software .............................................................................................................14

Libraries .............................................................................................................15

Hardware .............................................................................................................19

Product Support ...............................................................................................................19

Section 2 - Functionality ChangesIntroduction .....................................................................................................................21

New Functions .................................................................................................................21

Support for IEC 61850 using CI868 ....................................................................21

Improved Execution Performance........................................................................22

Engineering Environments ...................................................................................22

Control and I/O ....................................................................................................27

Compact Flash......................................................................................................27

Standard Libraries ................................................................................................27

New Hardware Units ............................................................................................31

MMS Communication..........................................................................................32

Legacy Protocols ..................................................................................................32

Maintenance .........................................................................................................33

3BSE033044D5020 53BSE033044D5020 5

Table of Contents

PROFIBUS-DP .................................................................................................... 34

Discontinued and Replaced Functions and Units............................................................ 34

Engineering Environments................................................................................... 34

Maintenance......................................................................................................... 38

Communication.................................................................................................... 38

Control Network .................................................................................................. 39

S800 I/O ............................................................................................................ 39

Installation ........................................................................................................... 40

Section 3 - CompatibilitySupported Versions.......................................................................................................... 41

Supported Versions for Coexistence of Controller Versions................................ 42

Compatible Hardware Modules ...................................................................................... 42

Compatible Firmware...................................................................................................... 45

Section 4 - Fixed ProblemsVersion 5.0.2/0 ................................................................................................................ 47

Administration Version 5.0.2/0 ............................................................................ 47

Operational Version 5.0.2/0 ................................................................................. 49

Configuration Version 5.0.2/0.............................................................................. 63

Version 5.0.1/2 ................................................................................................................ 73



Version 5.0.1/1 ................................................................................................................ 78

Administration Version 5.0.1/1 ............................................................................ 78



Section 5 - Known ProblemsAdministration................................................................................................................. 93

Control Builder .................................................................................................... 94

Controller ............................................................................................................ 95

Communication.................................................................................................... 97

6 3BSE033044D5020

Table of Contents

I/O Handling.........................................................................................................99

Operational ....................................................................................................................100

OPC Server.........................................................................................................100

Controller ...........................................................................................................101

Communication ..................................................................................................103

I/O Handling.......................................................................................................106

PROFIBUS-DP ..................................................................................................109

Configuration.................................................................................................................110

Control Builder...................................................................................................110

Controller ...........................................................................................................113

I/O Handling.......................................................................................................114

PROFIBUS-DP ..................................................................................................115

IEC 61850 ..........................................................................................................116

Instruction Manual Changes..........................................................................................119

3BSE033044D5020 73BSE033044D5020 7

Table of Contents

8 3BSE033044D5020

About This Book

GeneralThis document provides a brief overview on functionality. It lists the problems that existed in the previous version or service pack that were fixed and corrected in this release. It also enumerates known problems encountered in the final testing of this product release. Where possible the document identifies workarounds that help overcome the problem. The document contains additional notes that may be valuable to customers and service personnel working with the product. This document replaces the existing release notes for the prior release and is included on the product media.

This document provides important information and information not contained in the ordinary manuals, sales information, or other types of product information.

Refer to Compact Control Builder AC 800M when Control Builder is mentioned in this manual.

Refer to OPC Server for AC 800M when OPC Server is mentioned in this manual.

The term Modem refers to modems that are configured and controlled by a controller. It does not refer to modems that are transparent for the controller.

3BSE033044D5020 9

Document Conventions About This Book

Document ConventionsThe following conventions are used for the presentation of material:

• The words in names of screen elements (for example, the title in the title bar of a window, the label for a field of a dialog box) are initially capitalized.

• Capital letters are used for the name of a keyboard key if it is labeled on the keyboard. For example, press the ENTER key.

• Lowercase letters are used for the name of a keyboard key that is not labeled on the keyboard. For example, the space bar, comma key, and so on.

• Press CTRL+C indicates that you must hold down the CTRL key while pressing the C key (to copy a selected object in this case).

• Press ESC E C indicates that you press and release each key in sequence (to copy a selected object in this case).

• The names of push and toggle buttons are boldfaced. For example, click OK.

• The names of menus and menu items are boldfaced. For example, the File menu.

– The following convention is used for menu operations: MenuName > MenuItem > CascadedMenuItem. For example: select File > New > Type.

– The Start menu name always refers to the Start menu on the Windows Task Bar.

• System prompts/messages are shown in the Courier font, and user responses/input are in the boldfaced Courier font. For example, if you enter a value out of range, the following message is displayed:

Entered value is not valid. The value must be 0 to 30.

You may be told to enter the string TIC132 in a field. The string is shown as follows in the procedure:

TIC132

Variables are shown using lowercase letters.

sequence name

10 3BSE033044D5020

About This Book Use of Warning, Caution, Information, and Tip Icons

Use of Warning, Caution, Information, and Tip IconsThis publication includes Warning, Caution, and Information where appropriate to point out safety related or other important information. It also includes Tip to point out useful hints to the reader. The corresponding symbols should be interpreted as follows:

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices.

Electrical warning icon indicates the presence of a hazard which could result in electrical shock.

Warning icon indicates the presence of a hazard which could result in personal injury.

Caution icon indicates important information or warning related to the concept discussed in the text. It might indicate the presence of a hazard which could result in corruption of software or damage to equipment/property.

Information icon alerts the reader to pertinent facts and conditions.

Tip icon indicates advice on, for example, how to design your project or how to use a certain function

3BSE033044D5020 11

Applicable Specifications About This Book

Applicable SpecificationsThis product meets the requirements specified in EMC Directive 89/336/EEC and in Low Voltage Directive 72/23/EEC.

The libraries described in this document conform to the IEC 61131-3 Programming Languages standard, except for control modules, which are not supported by this standard.

12 3BSE033044D5020

Section 1 Introduction

This document represents the release notes for Compact Control Builder AC 800M, Version 5.0.2/0.

This document provides a brief overview on functionality. It lists the problems that existed in the previous version or service pack that were fixed and corrected in this release. It also enumerates known problems encountered in the final testing of this product release.Where possible the document identifies workarounds that help overcome the problem. The document contains additional notes that may be valuable to customers and service personnel working with the product. This document replaces the existing release notes for the prior release and is included on the product media.

Executive SummaryThis document covers the products listed in Version Designation on page 14.

The manual Compact Control Builder AC 800M, Getting Started, Introduction and Installation (3BSE041584Rxxx) describes how to install the product. It also describes how to perform an upgrade.

This release of Compact Control Builder AC 800M (Version 5.0.2/0) is compatible with Compact Control Builder version 5.0.x/x, 4.1.0/x and 4.0.0/0 with some reservations. See section 3, Compatibility, for further information.

3BSE033044D5020 13

Revision Record Section 1 Introduction

Revision Record

Version Designation

Software

Compact Control Builder AC 800M Version 5.0.2/0 contains software support for the following products:

Released Software Version

• Compact Control Builder AC 800M 5.0.2/0

• Firmware for PM851/PM856/PM860 5.0.2/0

• Firmware for PM861(A)/PM864(A)/PM866 5.0.2/0

• OPC Server for AC 800M 5.0.2/0

• MMS Server for AC 800M 5.0.2/0

• Base Software for SoftControl 5.0.2/0

• IP Config 1.5.3

• Serial Firmware Upgrade 2.2.3

• RNRP 2.25

Table 1. Revisions

Revision Release Date Remarks

Version 5.0.0/0 October, 2006 5.0

Version 5.0.0/1 March, 2007 5.0 RU1

Version 5.0.1/0 July, 2007 5.0 SP1

Version 5.0.1/1 December, 2007 5.0 SP1 RU1

Version 5.0.1/2 March, 2008 5.0 SP1 RU2

Version 5.0.2/0 September, 2008 5.0 SP2

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Section 1 Introduction Libraries

Libraries

There are three categories of libraries, see Libraries for new Applications on page 15, Classic Libraries on page 18 and Coexistence 5.0.1 on page 18.

Libraries for new Applications

These libraries should be used for new applications.

Library Version

• AlarmEventLib 1.4-6

• BasicGraphicLib 1.1-1

• BasicLib 1.5-7

• BatchLib 1.1-3

• COMLICommLib 1.2-1

• ControlAdvancedLib 1.3-3

• ControlBasicLib 1.1-4

• ControlExtendedLib 1.2-3

• ControlFuzzyLib 1.2-3

• ControlObjectLib 1.1-5

• ControlSimpleLib 1.1-2

• ControlSolutionLib 1.1-4

• ControlStandardLib 1.3-5

• ControlSupportLib 1.2-2

• FFH1CommLib 1.1-1

• GroupStartLib 1.3-3

• IconLib 1.2-1

• INSUMCommLib 1.1-2

• MB300CommLib 1.1-1

3BSE033044D5020 15

Libraries Section 1 Introduction

• MMSCommLib 1.2-8

• ModBusCommLib 1.2-1

• ModBusTCPCommLib 1.1-1

• ModemCommLib 1.1-1

• ProcessObjBasicLib 2.3-5

• ProcessObjDriveLib 1.3-6

• ProcessObjExtLib 2.3-6

• ProcessObjInsumLib 1.3-6

• S3964CommLib 1.2-1

• SattBusCommLib 1.2-1

• SerialCommLib 2.0-6

• SignalLib 1.5-6

• SignalBasicLib 1.0-4

• SignalSupportLib 1.0-4

• SupervisionBasiclLib 1.0-7

• SupportLib 1.2-4

• ABBDrvNpbaCI851HwLib 1.0-0

• ABBDrvNpbaCI854HwLib 1.0-2

• ABBDrvRpbaCI851HwLib 1.0-0

• ABBDrvRpbaCI854HwLib 1.0-2

• ABBPnl800CI851HwLib 1.0-0

• ABBPnl800CI854HwLib 1.1-0

• ABBProcPnlCI851HwLib 1.0-0

• ABBProcPnlCI854HwLib 1.0-1

• BasicHwLib 5.0-2

16 3BSE033044D5020

Section 1 Introduction Libraries

• CI851PROFIBUSHwLib 1.0-1

• CI852FFh1HwLib 1.0-0

• CI853SerialComHwLib 1.0-0

• CI854PROFIBUSHwLib 1.0-32

• CI855MB300HwLib 1.1-14

• CI856S100HwLib 1.1-10

• CI857InsumHwLib 1.2-25

• CI858DriveBusHwLib 1.0-6

• CI865SattIOHwLib 1.0-18

• CI867ModbusTcpHwLib 1.0-43

• CI868IEC61850HwLib 1.1-17

• COMLIHwLib 1.1-21

• ModbusHwLib 1.0-14

• ModemHwLib 1.0-0

• PrinterHwLib 1.0-0

• S200IoCI851HwLib 1.0-0


• S800CI801CI854HwLib 1.1-3

• S800CI830CI851HwLib 1.0-8

• S800CI830CI854HwLib 1.0-10

• S800CI840CI854HwLib 1.1-3

• S800IoModulebusHwLib 1.1-6



• S3964HwLib 1.0-10

• SerialHwLib 1.0-8

3BSE033044D5020 17

Libraries Section 1 Introduction

Classic Libraries

These are Classic (i.e., older) versions of libraries that exist in more than one major version. These library versions are supported, but they should not be used for new applications..

Library Version

• CommunicationLib 1.0-0

• ProcessObjBasicLib 1.0-5

• ProcessObjExtLib 1.0-10

• SerialLib 1.0-0

• SerialCommLib 1.2-2

Coexistence 5.0.1

This library contains the version 5.0.1 firmware, it is needed in case the controller should be kept running with that firmware version. This library version is supported, but it should not be used for new applications.

Library Version

• BasicHwLib 5.0-1

These libraries are not available for loading unless enabled via the Custom installation option during the Control Builder installation. If they are needed but were not enabled, then the Control Builder installation must be modified via Add/Remove Programs in Windows Control Panel.

Supplied manuals and online help do not describe these versions.

This library is not available for loading unless enabled via the Custom installation option during the Control Builder installation. If it is needed but was not enabled, then the Control Builder installation must be modified via Add/Remove Programs in Windows Control Panel.

18 3BSE033044D5020

Section 1 Introduction Hardware

Hardware

This release supports:

• AC 800M (PM851, PM856, PM860, PM861(A), PM864(A) and PM866)

Product SupportContact ABB technical support for assistance in problem reporting.

3BSE033044D5020 19

Product Support Section 1 Introduction

20 3BSE033044D5020

3BSE033044D5020 21

Section 2 Functionality Changes

IntroductionThis section summarizes functionality changes related to Compact Control Builder AC 800M, Version 5.0.2/0. The section contains the following:

• New Functions.• Discontinued and Replaced Functions and Units.

New FunctionsThe following information characterizes new functions for Compact Control Builder AC 800M, Version 5.0.2/0.

Support for IEC 61850 using CI868

The IEC 61850 for Substation Automation System (SAS) standard defines communication between intelligent Electronic Devices (IED) in the substation and other related equipment.

The CI868 Communication Interface makes it possible for the AC 800M Controller to be modeled as an IED receiving data from other IEDs to the 1131 variables, and to send data from its own 1131 variables to other IEDs per IEC 61850 data modeling. This is achieved using the IEC 61850 hardware library (CI868IEC61850HwLib).

The CI868 Communication Interface in SV 5.0 SP2 supports the GOOSE communication mechanism but not the MMS communication defined in the IEC 61850 standard.

Improved Execution Performance Section 2 Functionality Changes

22 3BSE033044D5020

Improved Execution Performance

Optimizations in the Application Compiler and the controller execution engine have reduced execution times for 1131 code (as seen in the Task Dialog, etc.) by eight to 25 percent compared to previous versions. This leads to a corresponding reduction of Cyclic Load for an upgraded, unchanged project.

The actual improvement is dependent on programming style, use of library blocks, etc. Other hints to improve controller performance are:

• Cyclic load can be reduced significantly if the new SignalBasicLib function blocks are used instead of SignalLib function blocks.

• Proper adjustment of the ModuleBus Scan Cycle Time can significantly improve performance.

Engineering Environments

Convert a Control Module Instance to a Single Control Module. Right-clicking on a Control Module instance in the Project Explorer and selecting the Convert to Single Control Module makes it is possible to convert a Control Module instance to a Single Control Module. The Control Module instance may contain other Control Modules.

Editors

Filter in Editors. Selecting Tools-> Filter from the editor of an Application, Function Block Type, Control Module Type, Single Control Module, or Program makes it possible to filter the content of a column in the variable grid of the editor. From the Filter dialog one can decide which rows to display or hide by selecting or deselecting criteria items. The Criteria items can also be text filtered. A button in the toolbar of the editors can also be used instead of the menu options. The filter functionality is available both in offline and online mode.

Sorting in Editors. Selecting Tools-> Sort A to Z or Tools-> Sort Z to A from the editor of an Application, Function Block Type, Control Module Type, Single Control Module, or Program makes it possible to sort the content in the variable grid in alphabetic order. Sorting will be per column. If no column is selected the sorting

Section 2 Functionality Changes Engineering Environments

3BSE033044D5020 23

will be based on the name column. Buttons in the toolbar of the editors can also be used instead of the menu options. The sorting functionality is available both in offline and online mode.

New Function Block Parameter Attribute: By_Ref

The attribute gives the Control Builder information about how to handle the parameter, if the value should be retained, cold retain etc. For in and out parameters the value of the parameter is copied into the called instance at the call of the Function Block. For structured data types and strings this can be quite time consuming. To improve performance a new attribute called by_ref is introduced. By using the by_ref attribute the data will be passed in the Function Block call instead of copied. The following limitations applies for by_ref:

• It is not allowed to connect expressions or literals to a reference parameter. Example: fb.par_in := 2;

• It is not allowed to read or write the parameter from outside the function block (except in the function block call). Example: k := fb.par_out;

Hidden Attribute on In_out Parameter. It is now possible to set the attribute hidden on in_out parameters. This was not previously supported.

Width of Columns in Hardware Editor Decided by Content

When a Hardware editor is opened the width of the columns is decided by the content of the columns. The user used to have to adjust the column width by using the menu command Tool->Adjust Column Widths or the short command Ctrl+Q.

Device Import Wizard

This version includes an improved version of the Device Import Wizard. It is recommended to use the new Device Import Wizard version, instead of the older one. A number of improvements and error corrections have been made.

• Improved check and substitution for illegal characters "." and "," inside device names, module names, and parameter names.

• Added check to guarantee unique names for devices and modules.

Engineering Environments Section 2 Functionality Changes

24 3BSE033044D5020

• Advanced status configuration for boolean channels is now working.

• Mapping of diagnostics from device to module level is now working for first import and re-import.

• Removed advanced status configuration for conversions 1 Byte to DInt and 1 Word to DInt since they were not supported by copy routines 301/401.

Search and Navigation

General.

• The amount of memory needed for the search data base is significantly lower compared to previous versions.

• Less time needed to build the search data base, for some applications it is a significant improvement.

• Assignment of a structured data type is now also found when searching for one of its components.

• It is now possible to search for a specific extensible parameter in online mode.

Search and Navigation in Function Block Diagram and Ladder Diagram Editor. When search and navigation is used in the Function Block Diagram editor the object will be highlighted. In previous versions only the FBD pane, where the object was located, was selected.

Search and Navigation in Online and Test Mode. Online searches are now modified to be so called deep searches and report all input/output of a certain signal as a result of a single search, irrespective of name changes at parameter connections. This means all information concerning reading and writing from the whole Application/Controllers about a signal is found through one click of the Search button. Previously the user had to contend with the time consuming task of making repetitive queries to follow a signal across projects the were potentially very large.


3BSE033044D5020 25

New Menu Options

Compiler Statistics Tool. Selecting Tools-> Compiler Statistics in the Project Explorer launches the Compiler Statistics Tool. This tool is available offline and can be used to, for example, list the number of POU instances in a Project or Application, how many times a certain instance is used, the size of the application, or an instance, number of parameters, etc.

View Different Versions of the Difference Report. Selecting Tools-> View Accepted Difference Reports in the Project Explorer makes it possible to open a previously approved difference report.

Library Usage. Right-clicking on a library and selecting Library Usage makes it possible to see if the Library is connected to an Application, Controller, or another Library. This new functionality will help the Engineer remove old versions of a Library that are no longer used in the project.

Presentation of Number of Instances in an Application. Right-clicking on an application and selecting Statistics makes it possible to see how many instances the selected application contains. The origin of the instances is also listed, i.e. which library or application the type is defined in.

Compile and Download

Additional Consistency Checks at Download to Controller. Additional consistency checks have been implemented in the Control Builder, to ensure that inconsistent or corrupt configuration and application data can never be downloaded to the Controller.

If any of the data (domain) files used at download are missing, or there is a mismatch of the timestamps etc, the download will be blocked with an error message.

The events leading to such a situation can be that a previous download was disrupted in an uncontrolled way, e.g., due to a network failure or memory full, or that data files could not be saved properly on disk.


26 3BSE033044D5020

Depending on what data is missing or causing the mismatch, the situation will have to be resolved by a ColdRestart of the concerned Application(s), or, sometimes, by a controller reset.

The most common reason for missing files are: communication is lost during setup of controller configurations, backup/restore has failed, and that the controller is running with an outdated backup media download.

Additional Warnings During Download to Controller. Additional warning messages are implemented to avoid the Controller being reconfigured in the wrong mode after a download e.g. if warm restart is selected but the changes in the application require a cold restart, the system previously made a cold restart. Now the warning Are you sure.. will be displayed and the user has the option to cancel the download.

Possible to Add Previously Deselected Applications During Online Without Download. It is now possible to add previously deselected downloaded applications during Online Without Download. Previously the workaround was to select Online With Download (no download was performed if the Applications was not changed).

New Compiler Switches. The following compiler switches are added.

• SFC Language: Checks that no SFC language is used.

• Force I/O from Code: Checks that there is no forcing of I/O signals from application code, i.e. writing to the forced component of an IO data type is not allowed.

• Multiple Calls to the Same Function Block: Checks that there is only one call to the same Function Block instance in a POU-type.

• None or Multiple Calls to ExecuteControlModules: Checks that Control Modules exist in a Function Block Type. There must be one, and only one, call to the firmware function ExecuteControlModules on the top level without conditions.

Difference Report

The following functionality has been added to the difference report.

Section 2 Functionality Changes Control and I/O

3BSE033044D5020 27

Line Comparison. Two lines in the Difference Report can be compared to each other. Select a line in the Difference Report and open the context menu and select 'Compare lines'.

Control and I/O

Filter Out System Alarms from Hardware Units

Filter out system alarms is a function that is used to reduce the number of alarms generated from hardware units. A typical example of when this functionality can be used is during commissioning of the system or when adding a new part to an existing system. The function is configured from the Hardware object editor on the controller. Select the Settings tab and there is a parameter called Filter out system alarms from hardware units. The different filter options are Off, Underflow, Over- and underflow, Channel error, and All.

Compact Flash

Warning Message when Compact Flash Card is Empty

If a Compact Flash card is inserted to the Controller and the card is empty a warning with the description No image will be generated.

Standard Libraries

The following objects have been added to the libraries delivered with the Control Builder.

New firmware functions

InhibitDownload. The firmware function InhibitDownload makes it possible to block a download to the Controller from Application code.

The errors and warnings will still be visible in the hardware tree and the Unit Status tab in the hardware online editors when the setting is set to filter out alarms. The filter prevents generation of system alarms and events that otherwise will end up in Alarm and Event Lists.

Standard Libraries Section 2 Functionality Changes

28 3BSE033044D5020

ReservedByTool. The firmware function ReservedByTool checks whether or not the controller is reserved by any Control Builder.

Serial_string_append_ASCII. The firmware function serial_string_append_ASCII appends a character to a string.

Serial_string_append_Hex. The firmware function serial_string_append_Hex appends the hexadecimal representation of a DWord to a string.

Serial_string_find_ASCII. The firmware function serial_string_find_ASCII returns the position of a specified character within a string.

Serial_string_get_ASCII. The firmware function serial_string_get_ASCII returns the ASCII code of a character in a string.

Serial_string_Hex_to_DWORD. The firmware function serial_string_Hex_to_DWORD converts a hexadecimal string to a DWord.

Serial_string_left. The firmware function serial_string_left function extracts the leftmost characters from a string.

Serial_string_mid. The firmware function serial_string_mid extracts a substring from a string.

Serial_string_put_ASCII. The firmware function serial_string_put_ASCII function replaces a character in a string.

Serial_string_replace_Hex. The firmware function serial_string_replace_Hex replaces a substring in a string with the hexadecimal representation of a DWord.

Serial_string_right. The firmware function serial_string_right extracts the rightmost characters from a string.

Section 2 Functionality Changes Standard Libraries

3BSE033044D5020 29

Signal Objects

SignalLib. The SignalLib library has been extended with the following objects. Object names that start with SD (Shut Down) are intended to be used together with the SD objects in the SupervisionBasicLib library for shutdown logic.

• SDLevelAnd4: The Control Module Type SDLevelAnd4 makes an AND function between four signals of SDLevelMConnection.

• SDLevelOr4: The Control Module Type SDLevelOr4 makes an OR function between four signals of SDLevelMConnection.

• SDLevelBranch4:The Control Module Type SDLevelBranch4 splits a signal of SDLevelMConnection into four new signals.

• SDLevelM: The Control Module Type SDLevelM provides an easy way to structure the Emergency or Process shutdown logic in the commonly used level hierarchy. There is an activation input parameter from surrounding objects as well as from superior levels, and output parameters to affect process objects as well as subordinate levels. These four input and output possibilities may be inhibited individually.

SignalBasicLib. The SignalBasicLib library is new and contains simple signal objects. The signal objects in this library are also suitable to use in non-SIL applications, since they consume less memory and execute faster than the ones in SignalLib.

• SignalBasicBool: The Function Block type SignalBasicBool is used for overview and maneuvering of boolean signals of data type bool.

• SignalBasicInBool: The Function Block type SignalBasicInBool is used for overview and forcing of boolean input signals of data type BoolIO.

• SignalBasicOutBool: The Function Block type SignalBasicOutBool is used for overview and forcing of boolean output signals of data type BoolIO.

• SignalBasicReal: The Function Block type SignalBasicReal is used for overview and maneuvering of analog signals of data type real.

• SignalBasicInReal: The Function Block type SignalBasicInReal is used for overview and forcing of analog input signals of data type RealIO.

Standard Libraries Section 2 Functionality Changes

30 3BSE033044D5020

• SignalBasicOutReal: The Function Block type SignalBasicOutReal is used for overview and forcing of analog output signals of data type RealIO.

SupervisionBasicLib. The SupervisionBasicLib library is new and contains Function Block types intended for shutdown logic. Basically, they have one normal condition and one safe condition. Some of the Function Block types in the library are not protected, i.e. it means that they can be copied to a user defined library/application and then modified according to user requests. The Function Block types that can be copied are: SDBool, SDReal, SDInBool, SDInReal, SDOutBool, and SDValve.

• SDBool: The Function Block type SDBool is a variant of SDInBool. The In parameter is of Bool data type, alarm/event handling when input value is different from Normal value.

• SDLevel: The Function Block type SDLevel provides an easy way to structure the Emergency or Process shutdown logic in the commonly used level hierarchy. There are activation input parameters for input signals (Cause) and superior levels (In), and output parameters for output signals (Effect) and subordinate levels (Out). These four signals can be inhibited by input parameters and by Faceplate commands.

• SDInBool: The Function Block type SDInBool extends the functionality of a Digital Input signal of data type BoolIO with alarm/event handling when input value is different from Normal value. The activation output (DiffNormalAct) is inhibitable and is intended for safety activation logic.

• SDInReal: The Function Block type SDInReal extends the functionality of an Analog Input signal of data type RealIO with alarm/event handling for up to two high levels, up to two low levels, and errors. Filtering is also provided. The activation outputs (GTHHAct, GTHAct, LTLAct, and LTLLAct) are inhibitable and are intended for safety activation logic.

• SDOutBool: The Function Block type SDOutBool extends the functionality of a digital output signal of data type BoolIO with alarm/event handling when output value is different than Normal value.

• SDReal: The Function Block type SDReal is a variant of SDInReal. The In parameter is of Real data type, alarm/event handling for up to two high levels, up to two low levels, and error.

Section 2 Functionality Changes New Hardware Units

3BSE033044D5020 31

• StatusRead: The Function Block type StatusRead is used, in application code, to retrieve the signals from the Status output from the Function Block types SDInBool, SDInReal, SDLevel, SDOutBool, and SDValve. When several status output signals are or-ed, the result can be connected to a StatusRead Function Block type to achieve overview indication.

• SDValve: The Function Block type SDValve is suitable for control and supervision of a shutdown valve with one position defined as 'fail', i.e. Fail Open (FO) or Fail Close (FC).

New Hardware Units

New Controller

PM866. The PM866 processor unit has the same characteristics has PM864, but it has 64-Mbyte memory and performance data which is approximately 1.4 times the performance of PM864.

New Communication Module

CI868 - Communication Interface for IEC 61850. The CI868 Communication Interface in SV 5.0 SP2 supports the GOOSE communication mechanism but not the MMS communication defined in the IEC 61850 standard.

New I/O Units

AI835A. Analog input module with improved CJT distribution support. It is fully backward compatible with AI835.

AI815. Analog HART enabled input module for single operation.

AO815. Analog HART enabled output module for single operation.

DI920. Digital input module with channel-by-channel isolation for connecting NAMUR sensors.

MMS Communication Section 2 Functionality Changes

32 3BSE033044D5020

New Terminal Unit

TU850. The TU850 is a terminal unit with channel wise disconnection support and current limitation.

New Power Supplies

• SD831 3 A @ 24 V.• SD832 5 A @ 24 V.• SD833 10 A @ 24 V.• SD834 20 A @ 24 V.• SS832 voting unit.

MMS Communication

Synchronized Write for MMS Internal Communication

It is now possible to get a synchronized write on MMS telegrams between applications running in the same Controller. MMS messages up to 800 bytes in length (corresponding to 100 to 250 simple variables) are sent synchronously by MMSWrite to an Access Variable in the same controller. No other 1131 tasks or communication subsystems can interrupt the transmission.

Legacy Protocols

INSUM

New INSUM MCU Type - MCU v2. There is a new INSUM MCU type called MCU v2 in the CI857InsumHwLib library. The new HWUnit works like the existing MCU HWUnit except that when process related Alarm bits are set, the Warning indication is not set.

The Alarm bits are still indicated as status bits but without indicating a Warning.

Section 2 Functionality Changes Maintenance

3BSE033044D5020 33

MODBUS TCP

Support for Real Data Type in MODBUS TCP. The data type real is now supported in MODBUS TCP Master communication.

Serial Communication

Read Messages Longer than 140 Characters Using SerialListen. It is now possible to listen for messages longer than 140 characters using the Function Block type SerialListen. A new status code, +400, has been added indicating that the receive buffer holds more characters to be read. The Function Block can then be called multiple times in the same scan.

Receive Buffer now not Always Emptied when Enabling the SerialListen Function Block. The SerialListen function block was changed in Version 5.0 so it automatically emptied the receive buffer when being enabled; however, this is not always the desired behavior.

In Version 5.0 SP2 the SerialListen function block has a new parameter called "ClearBuffer". The default value is True, and the block behaves like in Versions 5.0 and 5.0 SP1.

Setting the parameter to False means that the buffer handling works as in versions prior to 5.0; the receive buffer is then not emptied when the listen block is enabled.

Maintenance

Controller Analysis for Service Engineers

By selecting the button Show Controller Analysis in the Remote System dialog the Controller Analysis dialog will be opened. From this dialog it is possible to receive maintenance information from the Controller like reset Module Bus Fail Counters or get Module Bus I/O Revisions.

Firmware Upgrade from Compact Flash Card. Upgrading controller firmware using the compact flash card is now supported.

PROFIBUS-DP Section 2 Functionality Changes

34 3BSE033044D5020

PROFIBUS-DP

Support for Real Data Type on CI854 to Panel 800

Using the data type real when using CI854 together with Panel 800 is now supported.

Discontinued and Replaced Functions and UnitsThe following information characterizes discontinued and replaced functions and units for Compact Control Builder AC 800M, Version 5.0.2/0.

Engineering Environments

Project Constants Shall not be used as Initial Values in Objects

Initial values on parameters in Control Module types and Function Block types may NOT be originated from project constants. The reason is that if the value of the project constant is changed by a user this may result in different instances of the same type behaving differently if some instances are downloaded after the change with a cold restart and some are not downloaded at all. To solve this issue the project constants are replaced with a literal value with the same value as the project constants. This change has been done in the following libraries:

• SignalLib.

If Projects Constants in the "cInit" group are changed, then all unconnected parameters that use these Project Constants must be individually assigned.

Project Explorer

Editors

Retain Attributes on Parameter. When a parameter is created the retain attribute is no longer added automatically. This change is valid for both Control Module types and Function Block types.


3BSE033044D5020 35

Composite Data Types in Hardware editors. In the hardware editors the simple data types are replaced with composite data types, i.e. Bool is replaced with BoolIO. It is still possible to connect a simple data type to a channel, e.g. Real can be connected to an I/O channel of the type RealIO. The data type for UnitStatus is changed from Dint to HwStatus.

Menu Commands

Move Up/Down Commands Removed. The menu commands Move Up and Move Down are removed from the context menus of Control Modules and Single Control Modules. The objects are now always listed in alphabetic order.

Hardware

Not Possible to add CI851 or CI852 units in Hardware Tree. It is no longer possible to add CI851 or CI852 units to a Controller in the hardware configuration. The reason is that CI851 and CI852 are in classic mode. Projects that already contain CI851 or CI852 units are not affected by this change.

Compile and Download

New Error Messages at Download of I/O Connections.

• It is no longer possible to move the connection to an I/O channel from one application to another without first removing the existing connection. An attempt to move the connection will be prevented by the compiler error:

Error 9164 : The I/O-channel was used by another application at last download.

The workaround is:

1. Disconnect the channel from the variable in the first application,

2. Perform a download.

3. Connect the channel to a variable in the other application.

4. Perform a second download.


36 3BSE033044D5020

• If the controller configuration is successfully downloaded, but the following download of the applications is disturbed, the Control Builder might come to a situation where it is not able to analyze which I/O connections are configured and running in the controller. The disturbances that might have an influence on the application download can be:

– Memory full in the Control Builder or the controller.

– Communication interruption.

– Fatal error in the Control Builder during the download.

If the Control Builder can not analyze the I/O connections the download will be prevented by the compiler error:

9166 : The I/O-connections for the application are not possible to analyze. Cold restart of application is required.

Not Possible to Go Online to Controller After Downloading to Compact Flash.

In SV5.0 SP2, restrictions on Controller Configuration download have been implemented in order to reduce the risk for crashes and shutdowns at reconfiguration. This affects the supported workflows for loading a Compact Flash card.

In SV 5.0 SP2, to be able to download to a running controller, the Control Builder must have access to the domain file that was created at the previous download. If not, the controller must be Reset before a download can be made. This is not a restriction at normal use cases for downloading changes from the Control Builder. However, when a Control Builder makes a download to a Compact Flash card (attached to the Control Builder), it overwrites the file from the previous download. Consequently, after a download to a Compact Flash card, it is no longer possible to download from a Control Builder to the controller whose content was just loaded into the Compact Flash card. Also, if an attempt is made to download to the controller in this situation, there will be an incorrect error message saying that the system is inconsistent.

• Workaround, Clarifications and Helpful Hints

Do not load controllers alternately from a Control Builder, and from a Compact Flash card.


3BSE033044D5020 37

Never load a Compact Flash card from a Control Builder that is connected to the same 800xA System that is also used to download to the actual controller.

• Background

The Compact Flash card is primarily intended for use with the Compact products, and for use in controllers that are not connected to a network. It can; however, also be used in an 800xA System, and in a controller connected to a Control Network. However, since the Compact Flash card can only be loaded when attached to the Control Builder workstation, and its content is loaded into a controller at startup, there has never been general support for a workflow where a controller is loaded alternately from a Control Builder and from a Compact Flash Card. The user will easily end up in situations where warm download from the Control Builder is not possible. The intended work flow has always been to load the Compact Flash card in the workstation, then insert it in the controller, and then reset the controller.

Simulate Hardware is Default Turned Off. The possibility to use Simulate Hardware is default turned off in the control Builder. Select Tools-> Setup-> Station-> Application Download and then set the system variable HWSimulationAllowed to true to activate the hardware simulation. The system variable did not exist before, Simulate Hardware was always enabled.

Restrictions Against Downloading to Hardware Simulation Controllers. If Hardware Simulation controllers are connected on the same Control Network as the corresponding real controllers, the real controllers may receive unintentional downloads or be blocked from subsequent downloads to real controllers.

Never load a Hardware Simulation controller from a Control Builder that is connected to the same 800xA System that is also used to download to the actual controller. Always connect Hardware Simulated controllers to a separate System and network.

After a download to a Hardware Simulation controller, it is no longer possible to download from the same System to the corresponding real controller. Also, if an attempt is made to download to the controller in this situation, there will be an incorrect error message saying that the system is inconsistent.

Maintenance Section 2 Functionality Changes

38 3BSE033044D5020

Unchanged Applications not Stopped During Reconfiguration. When changes are downloaded to an Application the other running Applications in the Controller will not be affected. Previously all running Applications were stopped in the Controllers during the reconfiguration even if there were no changes downloaded to them.

Firmware Integrity Check at Upgrade via Ethernet. The integrity of the downloaded firmware is now checked by the AC 800M controller when upgrading the firmware via Ethernet. Additional integrity data has been added to the downloaded file; a corrupted firmware file will be discarded by the controller. This also means that a controller running Version 5.0 SP2 firmware will reject an Ethernet based downgrade of the firmware to an older version. Downgrade must be made using the Serial Firmware Upgrade tool.

Maintenance

System Variables

Change System Variables in Controller. Previously the Setup - System Variable dialog launched when the Change System Variables button in the Remote System dialog was used. System variables are now changed by selecting More in the Controller Analysis dialog that is launched from the Show Controller Analysis button in the Remote System dialog.

Communication

Increased Number of Connections to a CI855 Unit

There is a limitation to the number of connections that can be established to a CI855 unit. The limit has been increased from 30 to 100.

Section 2 Functionality Changes Control Network

3BSE033044D5020 39

Control Network

Removed No Time Sync Warning for Clock Master

If the parameter CS Protocol was set to CNCP and the parameter Clock Master OrderNo was set to 1 the warning No Time sync was given. The combination described will no longer result in a warning.

S800 I/O

AI835

• Over and under range limits have been changed so that over and under range indication works properly.

• Default value for parameter Fix Junction Temperature (FJT) is set to 25 °C.

AI843

• Over range limits have been changed for sensor type D °C at direct connection so that over and under range indication works properly.

AI893

• Over and under range limits have been changed so that over and under range indication works properly.

• Default value for parameter Fix Junction Temperature (FJT) is set to 25 °C.

• The ranges shown in Table 2 are adjusted. This will influence the scaling.

Table 2. AI893 Ranges (Old and New)

Sensor Type Unit Old Range New Range

B °C 0 to 1,820 44 to 1,8201

B °F 32 to 3,308 111.2 to 3,3081

L °F -212 to 1,652 -148 to 1,6521

Installation Section 2 Functionality Changes

40 3BSE033044D5020

Installation

The BasicHwLib 5.0-1, ProcessObjBasicLib 1.0, ProcessObjExtLib 1.0 and SerialCommLib 1.x libraries are removed from the typical installation. These libraries are not available for loading unless enabled via the Custom installation option during the Control Builder installation. If they are needed but were not enabled, then the Control Builder installation must be modified via Add/Remove Programs in Windows Control Panel.

N °C -248.8 to 1,300 270 to 1,3002

U °F -392 to 1,112 -328 to 1,1121

NOTES:1. Both the range visible during configuring of the module and the internal value

used for the range calculation has been changed.2. Only the internal value used for the range calculation has been changed.

Table 2. AI893 Ranges (Old and New) (Continued)

Sensor Type Unit Old Range New Range

3BSE033044D5020 41

Section 3 Compatibility

Controller peer to peer communication is possible with other controllers running Version 2.x/x, 3.x/x, 4.x.x/x or 5.x.x/x by means of Access Variables.

See Appendix C Upgrade in the manual Compact Control Builder AC 800M, Getting Started, Introduction and Installation (3BSE041584Rxxx) for further information.

Supported VersionsCoexistence of controller versions is supported, see Supported Versions for Coexistence of Controller Versions on page 42.

This release of Compact Control Builder AC 800M (Version 5.0.2/0) is compatible with the previous Versions 5.0.x/x, 4.1.0/x and 4.0.0/0.

Some Hardware Modules may have to be exchanged to new hardware revisions. See Compatible Hardware Modules on page 42, for further information. Listed Hardware Modules must be of stated version/revision or higher.

Control Builder and OPC Server must be upgraded to the new version in order to work together.

When upgrading, consideration should be given to memory usage in the controller. The firmware size has grown, resulting in less free memory, compared to previous versions (4.x), for user applications. The reduction primarily concerns processor modules with small amounts of free memory (PM851, PM856, and PM860) and to controllers including several types of CEX-modules. Please see section 3 in Compact Control Builder AC 800M, Product Guide (3BSE041586Rxxx) for information on memory requirements.

Supported Versions for Coexistence of Controller Versions Section 3 Compatibility

42 3BSE033044D5020

Supported Versions for Coexistence of Controller Versions

Starting from Version 5 and installing newer versions of Control Builder and OPC Server does not require a controller upgrade. Controllers with different firmware versions can coexist in the same network, and newer versions of Control Builder and OPC Server can connect to controllers of older versions (not older than Version 5). All Control Builders and OPC Servers must be of the same version in a running plant.

Coexistence is supported between the controller versions listed in Table 3.

Compatible Hardware ModulesThe Hardware Modules listed in must be of the stated version/revision or higher.

Listed I/O Modules are included due to compatibility issues only. For some other I/O Modules there is a recommendation about firmware and hardware versions for other reasons. See other relevant documentation regarding such reasons.

Table 3. Supported Versions for Coexistence of Controllers

Revision Release Date Build No. Remarks

Version 5.0.0/0 October, 2006 5.0.11.61 5.0

Version 5.0.0/1 March, 2007 5.0.12.5 5.0 RU1

Version 5.0.1/0 July, 2007 5.0.1001.755.0.1001.76

5.0 SP1

Version 5.0.1/1 December, 2007 5.0.1004.14 5.0 SP1 RU1

Version 5.0.1/2 March, 2008 5.0.1005.4 5.0 SP1 RU2

Version 5.0.2/0 September, 2008 5.0.2004.52 5.0 SP2

Firmware in all Hardware Modules must be upgraded to the delivered version. See Compatible Firmware on page 45 and Libraries on page 15.

Section 3 Compatibility Compatible Hardware Modules

3BSE033044D5020 43

Table 4. Compatible Hardware Modules

Module Required Version Recommended Version

PM851 PR:A

PM856 PR:A PR:F

PM860 PR:B PR:H

PM861(Singular)

PR:B PR:L

PM861(Redundant)

PR:B(1) PR:L

PM861A(Singular)

PR:B PR:C

PM861A(Redundant)

PR:B with FPGA 1.2/1-or-

PR:C

PR:C(2)

PM864 PR:B with FPGA 1.2/5-or-

PR:C

PR:H

PM864A(Singular)

PR:B PR:C

PM864A(Redundant)

PR:B with FPGA 1.2/1-or-

PR:C

PR:C(2)

PM866 PR:B

CI851 PR:A PR:H

CI852 PR:A PR:B

CI853 PR:C(3)

CI854 PR:BIndex 01.00

PR:GIndex 01.03(4)

Compatible Hardware Modules Section 3 Compatibility

44 3BSE033044D5020

CI854A PR:DIndex 02.05

CI855 PR:B PR:C(5)

CI856 PR:A PR:B(6)(7)

CI857 PR:B PR:C

CI858 PR:A

CI865 PR:B

CI867 PR:A

CI868 PR:A

TB840 PR:J(8) PR:M

TB840A PR:A

DI830 PR: H(9) PR: K

DI831 PR: H(10) PR: K

DI885 PR:C

AI845 PR:F

AO845 PR:F PR:J

AO845A PR:C

BC810 PR:C PR:E

200-APB12 1.6

200-IE8 B

200-OE4 B

(1) No empty base plates are allowed on the CEX-bus when using less than PR:D.(2) PR:D or later supports online replacement of a defect RCU-cable in configurations with BC810.(3) Firmware Version 1.0.6.0 or later (2002-01-17) must be used.

Hardware revision PR:A and PR:B can not be upgraded. Revision PR:C or newer must be used.

Table 4. Compatible Hardware Modules (Continued)

Module Required Version Recommended Version

Section 3 Compatibility Compatible Firmware

3BSE033044D5020 45

Compatible FirmwareThe firmware in the Hardware Modules listed in must be of stated label or version.

(4) When using less than Index 01.01:AC 800M may in some configurations not resume execution after a power fail.

(5) Less than PR:C does not support firmware upgrade.(6) PR:B is required when using DSBC173A or TK575V112 I/O Connection Cable.

PR:A sometimes fails to start up.(7) CI856 must be upgraded to PR:D or later in order to support online upgrade.(8) PR:B1, D, and E can also be used.

When using PR:B1, D and E: The optical Modulebus on PM861(A) or PM864(A) must be disconnected from the backup CPU before it is powered up, in case the primary CPU is already running.When using PR:B1, D, E and J: SA supervision will report error on SB, and vice versa.

(9) PR:F can also be used.(10) PR:F can also be used.

Table 5. Compatible Firmware

Module Label or Version

CI858(1)

(1) Not possible to upgrade from Control Builder.

FWCI858 1.0.0.2

CI801 1.2/3(2) (or later)

(2) CI801 Version 1.2/3 or later is required when using the added set of RTD sensors in AI830A. CI801 Version 1.3//0 or later is required when using AI815, AO815 and enhanced CJT functions in AI835A.

CI830 1.3/2(3)(4) (or later)

(3) CI830 versions less than 1.3/2 fails to set I/O to OSP in some situations.(4) CI830 Version 1.4/0 or later is required when using AI893 or DP840.

CI840 3.0/2(5) (or later)

(5) CI840 Version 3.3/8 or later is required when using the added set of RTD sensors in AI830A. CI840 Version 4.0/1 or later is required when using AI815, AO815 and enhanced CJT functions in AI835A.

CI920 1.4.1 (or later)

Compatible Firmware Section 3 Compatibility

46 3BSE033044D5020

3BSE033044D5020 47

Section 4 Fixed Problems

See Compact Control Builder, Version 5.0.1/0, Release Notes (3BSE033044D5010) regarding issues corrected in version 5.0.1/0.

Version 5.0.2/0Issues and problems are divided into functional categories:

• Administration Version 5.0.2/0• Operational Version 5.0.2/0• Configuration Version 5.0.2/0

Administration Version 5.0.2/0

Table 6 lists the major system or product administration issues that have been corrected since Version 5.0.1/2. A brief description of the correction has also been given.

Table 6. Corrected Administration Issues

Issue Correction or Fix

OPC Server Missing Files after Restore of Project

The domain files was not automatically included when a backup of a Control Builder project was done. This resulted in that the OPC Server couldn't connect to the controller when the project was restored.

800xACON-AD-5000-025

This problem has been corrected in Control Builder. The domain files (.cdo, cdoxml, ctd and ctdxml) are now included in the backup.

Administration Version 5.0.2/0 Section 4 Fixed Problems

48 3BSE033044D5020

All Serial Communication Stops after Hot Remove of CI853

All serial communication in a controller could have stopped if a CI853 was hot removed. This problem happened if PPP or COMLI via modem was configured on the CI853 that was removed.

800xACON-AD-5000-032

This problem has been corrected in the AC 800M firmware.

Potential Controller Shut Down After Upgrade

An AC 800M controller could have shut down during download after an upgrade. This could have happened regardless of whether or not the upgrade procedure was performed manually or by using the Online Upgrade wizard. The problem only occurred if one or more of the following functions were used in the controller:

• PROFIBUS (CI854).

• MODBUS TCP (CI867).

800xACON-AD-5011-001

This problem has been corrected in the Control Builder.

Product Bulletin: 3BSE047421D0042

S100: Initialization of CI856 Sometimes Fails

At start-up CI856 did not always start as it should.

800xACON-AD-5000-004

The problem has been corrected in revision; PR:D of the CI856.

Table 6. Corrected Administration Issues (Continued)


Section 4 Fixed Problems Operational Version 5.0.2/0

3BSE033044D5020 49

Operational Version 5.0.2/0

Table 7 lists the major system or product operational issues that have been corrected since Version 5.0.1/2. A brief description of the correction has also been given.

Table 7. Corrected Operational Issues


Online Display of CMD Editor May Cause Memory Full

During specific conditions the CMD Editor could leak memory in Online Mode or Test Mode which eventually led to memory full in Control Builder.

Some conditions for this problem were the CMD editor was left untouched on screen for a long time and the CMD Editor contained dynamic graphics but no status changes occurred.

800xACON-OL-5000-074

This problem has been corrected in Control Builder.

Compact CB without Network Connection Temporarily Hangs

When the Compact Control Builder lost network contact it could sometimes hang for about 20 seconds. This problem occurred repeatedly as long as the network connection was broken.

800xACON-OL-5000-073


Operational Version 5.0.2/0 Section 4 Fixed Problems

50 3BSE033044D5020

Corrupt Flash Card was not Indicated Properly

An error message appeared the first time a corrupt flash card was detected by the controller. However, if the corrupt flash card was removed and then reinserted, there was no indication that the card was reinserted. It took 28 hours until it was indicated that the card was still corrupted.

800xACON-OL-5000-002

The problem has been corrected in the AC 800M firmware.

The Status Information From Output I/O was not updated during the First Execution Scan

The status information in I/O data types connected to output I/O units was not updated during the first execution scan.

800xACON-OL-5000-046

The problem has been corrected in the AC 800M firmware.

Not Possible to Acknowledge Alarm

If the time difference between two "on" event notifications or one "on" and one "off" event notifications, concerning the same alarm, was too short (difference less than 1 ms) was it not possible to acknowledge the Alarm.

800xACON-OL-4100-038

This problem has been corrected in the OPC server.


Table 7. Corrected Operational Issues (Continued)



3BSE033044D5020 51

Strings Longer than Specified Caused Shut Down of OPC Server

If a string had a value longer than specified, i.e. a string declared as string[40] and the actual length of the string was 44 the OPC Server shut down and the error message "Buffer overrun! Invalid index used while connecting to controller." was printed in the session log of the OPC Server.

800xACON-OL-5000-063

This problem has been corrected in the OPC server and Control Builder.

Wrong Version when Browsing for OPC Server Files

An error message about wrong version number of the files was displayed if the browse functionality in the OPC Server was used to load the files needed by the OPC Server.

800xACON-OL-5000-064


The OPC Server was not Able to Perform MMS Rebuild when Required

Need for rebuild of the MMS telegrams was not detected when a 3:rd party OPC client was connected to the OPC server. This error caused unnecessary communication load between the OPC server and Controller

800xACON-OL-3100-001

This problem has been corrected in the SetState function in the OPC server.




52 3BSE033044D5020

Offset Included in Save Cold Retain Value in OPC Server

If the OPC server was configured for automatically save of cold retain values was the offset included in the save cold retain value interval, i.e. if the Save cold retain value was set to 1000 and the offset was set to 250 was the Save cold retain value changed to 1250.

800xACON-OL-5010-019


INSUMReceive Function Block may Report Wrong Value after Warm Download

The INSUMReceive Function Block could have reported the wrong value for subscribed Motor State after a warm download.

The problem could have occurred when performing a warm download i.e. going offline, performing an application change, and then going back online causing an application warm restart in the controller at the same time as the state of an MCU was changed by a process condition.

800xACON-OL-5011-002

This problem has been corrected both in the AC 800M firmware and in the INSUMReceive function block included in INSUMCommLib.

Product Alert: 3BSE047421D0047




3BSE033044D5020 53

'OR' Function Miscalculated when 32-bit Literal is Used as Operand

This error led to a faulty calculation result when the OR function was used with a literal value with more than 16 bits and the right-hand variable was used later in the same code block. The OR function was only malfunctioning if the literal used in the OR expression could not fit in16 bits, and both the upper half word (16-bit) and lower half word was not zero (0). Refer to Product Alert: 3BSE047421D0048 for details.

800xACON-OL-5020-005


Product Alert: 3BSE047421D0048

Redundant Mode Enabled Status Missing in Redundant Controller

If a power fail or short reset was conducted on a redundant Controller was the information about "Redundant mode enabled" missing in the unit status.

800xACON-OL-4100-039





54 3BSE033044D5020

SNTP Client Caused Unnecessary Load in AC800M

An SNTP Server returns a time packet with Li=3 (alarm) if the server is unsynchronized. If the SNTP client received this and there was no better server the SNTP client made 4 quick retries against the server without any delays. If many controllers did this at the same time excessive network load was generated that disturbed other communication.

800xACON-OL-4000-004

This problem has been corrected in the AC 800M firmware. A delay is added after each retry.

Lock Up Risk in DecoupleFilterCC

The DecoupleFilterCC Control Module in the library ControlAdvancedLib could lock up in extreme cases where the control signal were pushed to its limits. The reason for the lock up was when the module send a max and min-reached signal at the same time for the same channel to the precedent Control Module, if this Control Module happen to be a PID, the PID was locked up.

800xACON-OL-5020-002

This problem has been corrected in ControlAdvancedLib. The DecoupleFilterCC have been modified to only allow either maxreached or minreached signals.

Backtracking in AnalogOutCC

If the out rate per unit was lower in the AnalogOutCC module than in the previous Control Module in the loop did the backtracking not work.

800xACON-OL-5010-021

This problem has been corrected in ControlStandardLib.





3BSE033044D5020 55

Predetermined in SignalOutRealM and SignalSimpleOutRealM

The value of predetermined was not correct initiated in SignalOutRealM and SignalSimpleOutRealM when they were connected to objects that allowed backtracking.

800xACON-OL-5010-022

This problem has been corrected in SignalLib


Wrong Freeze Handling in SignalInBoolM and SignalBoolCalcInM

This is related to the control module types SignalInBoolM and SignalBoolCalcInM configured with the Freeze error handling option enabled.

If the parameter AckReqAtErr was set to true, then the object should have frozen the output until the operator acknowledged the error. However, the output followed the input instead.

800xACON-OL-5020-007

This problem has been corrected in SignalLib.

The objects now take AckReqAtErr into consideration and freeze the output until the error is acknowledged.

Possible to Set Nesting Level to More Than 10 for DataToSimpleEvent

According to the documentation was the maximum value of nesting levels in the Function Block type DataToSimpleEvent 10, but it was possible to configure a higher value in the Control Builder.

800xACON-OL-5000-066

This problem has been corrected in AlarmEventLib.




56 3BSE033044D5020

Max function returned wrong value

In some situations did the max function return the wrong value if the abs, atan, cos or sin functions were used inside it. This error was applicable for the SoftController, i.e. the error didn't exist in an AC 800M Controller.

800xACON-OL-3100-002

This problem has been corrected in the Base Software for SoftControl.

CPU Switchover Failed

If the primary CPU lost connection on CN1 and CN2 did the switchover to the backup CPU sometimes failed. This happened if the backup CPU had been restarted using the init button and then been synchronized again.

800xACON-OL-4100-040


MODBUS RTU Communication not Resumed after Hot Insert of CI853

If the MODBUS RTU communication protocol was used in combination with other serial protocols connected via the CI853 the communication did not start again after a hot insert of the CI853.

800xACON-OL-5000-080

This problem has been corrected in the MODBUSHwLib.




3BSE033044D5020 57

Hot Insert on CI856 or CI865 Disturbs Other CEX Units

If a CI856 (S100) or a CI865 (Satt I/O) was hot inserted it could disturb other CEX-units in the controller, causing them to hang.

800xACON-OL-4100-046


Not Possible to Write to Compact Flash Card

In some situations the controller could not access the Compact Flash card and error code -42 or -47 was received.

800xACON-OL-4100-041800xACON-OL-5000-006


Information About Application Version Mismatch Lost After Switchover

If the Application version stored on the compact flash card is different from the version running in the Controller will the warning Application version mismatch be displayed. If the warning was given in a redundant Controller did it disappear after a switchover.

800xACON-OL-4100-042


Only the First Value in MMSRead4RealIO was Read

When the Function Block type MMSRead4RealIO was used was only the first value (of four possible) read.

800xACON-OL-4100-043

This problem has been corrected in MMSCommLib





58 3BSE033044D5020

COMLI Slave Stopped After a Download

If the COMLI communication protocol was used and configured as a slave, the communication could have stopped after a download to the controller.

800xACON-OL-5010-031

This problem has been corrected in the COMLIHWLib.

COMLI Controller Shutdown when Receiving Incomplete Messages

If the COMLI communication protocol was receiving incomplete or distorted messages the controller could have shut down.

800xACON-OL-5010-032

This problem has been corrected in the COMLIHWLib.

Controller Not Responding when Using COMLI Communication

When the Request parameter on instance of the Function Block type ModemDialUp was set to true did the Controller stop the communication to other systems.

800xACON-OL-5010-023



SerialWrite Function Block Could Hang with Status -6829

If a SerialWrite instance was called twice in the same 1131 task scan could it hang with status -6829.

800xACON-OL-5000-067

This problem has been corrected in SerialHwLib.




3BSE033044D5020 59

SerialListen Function Block Could Hang

The Function Block type SerialListen could not always be interrupted by a new read request from the 1131 Application when it not quit had finished the last one. The new request would then be silently rejected, and the SerialListen would hang itself.

The problem occurred when running a big application with high load and with several tasks and when the task running the SerialListen ran with short cycle time.

800xACON-OL-5000-068


Controller Shutdown When Using SerialWrite in SerialCommLib

Enabling the Req parameter in the SerialSetup Function Block and then the En_C parameter in the SerialConnect Function Block did not cause any issues. However, if the Req parameter in the SerialSetup Function Block was then disabled and the parameter Req in the SerialWrite Function Block was enabled, this resulted in a Controller shutdown.

800xACON-OL-5000-071





60 3BSE033044D5020

SerialWriteWait Stops after Download

After a warm download the SerialWritewait Function Block in SerialCommLib sometimes stopped sending data. This error was typically indicated by the fact that the Ndr and Error parameter in the SerialWriteWrite Function Block was not set.

800xACON-OL-5000-072

This problem has been corrected in SerialCommLib.

Hang in Serial Communication when Connect and Listen Function Blocks were Toggled Rapidly

Rapidly enabling and disabling the parameters En_C and Enable in the Connect and Listen Function Block types in the COMLICommLib, MB300CommLib, and InsumCommLib libraries could have caused the SerialConnect Function Block to hang.

800xACON-OL-5010-027


Controller Shutdown When Running Serial Communication

Running several different serial protocols in combination with COMLI in the same Controller could, in some rare situations result in a Controller shutdown.

800xACON-OL-5010-028

This problem has been corrected in COMLIHwLib.




3BSE033044D5020 61

Controller Shutdown after Power Failure when Using Modem

If modem communication was running in a Controller and a power failure occurred, then the Controller would shut down and a short while later it would restart.

800xACON-OL-5020-004


Redundant Controller Generates CRC Errors on Control Network

A redundant controller could, under some circumstances generate an unusually high amount of CRC errors on the Control Network. This problem typically happened if the controller had a large outbound data flow on the Control Network via the CN1 port. The CRC errors are registered by external Ethernet switches and sometimes are also observed as frame alignment errors.

800xACON-OL-4100-045


CI867 MODBUS TCP Shutdown when Communicating with Serial Slaves via a Gateway

If MODBUS TCP communication was set up to communicate with two serial slaves connected via a gateway, then the CI867 MODBUS TCP could have shut down.

800xACON-OL-5010-033

This problem has been corrected in the CI867ModbusTcpHwLib.




62 3BSE033044D5020

CI867 MODBUS TCP Shutdown when changing IP addresses

The CI867 MODBUS TCP communication interface could have shut down if the IP addresses were changed or configured in the wrong way. This happened if the IP address was changed to an IP address previous used by the other port or if the same address was set on both ports.

800xACON-OL-5000-079


Error Marking at Normal Start-up of CI865

A subunit to a CI865 could be error marked in the Control Builder after a download, even if it was properly connected.

800xACON-OL-5000-078

This problem has been corrected in CI865SattIOHwLib. After download, subunits that are properly connected will not be error marked. Subunits that are not connected are error marked after a number of retries to establish communication.

Frozen diagnostics after Power Down/Up with SIMOCODE pro V

After power down/up of SIMOCODE pro V devices diagnostics such as Trip - External Fault 5 and Trip - External Fault 6 may still be indicated although they are no longer present.

800xACON-OL-4100-047

This problem has been corrected in the CI854/CI854A firmware Version 5.56 in CI854PROFIBUSHwLib



Section 4 Fixed Problems Configuration Version 5.0.2/0

3BSE033044D5020 63

Configuration Version 5.0.2/0

Table 8 lists the major system or product configuration issues that have been corrected since Version 5.0.1/2. A brief description of the correction has also been given.

Table 8. Corrected Configuration Issues


The Tool-Tip Functionality in the FBD/LD Panes No Longer Functions

If a pin of a Function Block Type or Function in a pane of the FBD or LD editors was selected the tool-tip with the description of the parameter was no longer shown.

800xACON-CN-5000-070


RNRP Settings Lost after Firmware Upgrade

The controller could lose the RNRP settings in the controller during a firmware upgrade. If the controller was located in another network area it was not possible to communicate with the controller from the Control Builder anymore.

800xACON-CN-5000-017


Reconfiguration of IP Addresses may put CI867 in fault mode

If the IP address on Ch2 was changed to a new address and then the IP address on Ch1 was changed to the previous address of Ch2 then the CI867 entered fault mode at download.

800xACON-CN-5000-083

This problem has been corrected in CI867ModbusTcpHwLib.

Configuration Version 5.0.2/0 Section 4 Fixed Problems

64 3BSE033044D5020

Wrong Indication of Cable Break on CI867 Backup Unit

If a cable break was detected on Ch2 on a CI867 backup unit then both Ch1 and Ch2 indicated cable break in the hardware tree.

800xACON-OL-5000-054


CI865 PR:A sometimes does not start correctly

CI865 may fail to start after power on, controller restart and at Online Upgrade. The probability for this is fairly low but not negligible.

800xACON-OL-5000-055

The problem has been corrected in CI865 PR:B.

CI854 Baudrate Change with Many Disturbed Slaves did not Work

Baudrate change with use of RLM01 and many slaves could have stopped the PROFIBUS.

800xACON-CN-5000-010

This problem has been corrected in the CI854/CI854A firmware Version 5.54 in CI854PROFIBUSHwLib.

Literal Value Connected to Anytype Parameter results in Control Builder Shutdown

If a literal value was connected to a parameter of the data type anytype did the Control Builder make a shutdown when a download was started.

800xACON-CN-4100-033


Table 8. Corrected Configuration Issues (Continued)


3BSE033044D5020 65

Too Large Floating Point Literals was Accepted in Assignment Statement

The expression Value2:= 8.0e+239; was accepted by the compiler and no error or warnings was generated during check or download.

800xACON-CN-3100-001

This problem has been corrected in Control Builder. If the value is to large will an error be launched during check or compilation.

Implicit Cast Warning when Literal Used for Parameter Connection

The restrictions for implicit cast was too tight for passing literal values on parameter connections.

800xACON-CN-4000-001


Control Builder Enter Not Responding When Open Project

In some rare situations did the Control Builder enter non responding mode when a project was opened. This happened if the project contained a single jump in a branch in the Sequence Function Chart Editor that was included in a subsequence.

800xACON-CN-5010-008


Change of Inverted Property on Unconnected Channels was not Saved

A change to the inverted property of an unconnected digital I/O channel was not saved. The next time the editor was open was the original value still present.

800xACON-CN-4100-035




66 3BSE033044D5020

Online Analysis Dialog Indicated Warm Restart of Application for Only Hardware Changes

If a hardware change was done in the project and a download was started was the download dialog displayed. If an Application was selected and the restart mode was changed to Init and then back to warm again did the Online analysis show warm restart.

800xACON-CN-4100-036

This problem has been corrected in Control Builder. Instead of warm restart the Application is labeled with "-".

Not Possible to Go Online After Interrupted Download

If a download to several Controllers was started and the download for some reason failed to one or several of the Controllers was it after that not possible to go online or make a new download to the controllers were the download was successful. The only way to make a download was to download with cold restart.

800xACON-CN-5000-087


Entry Assistance in CMD Connections Using Dot Notation was not Working

If the name of a variable/project constant was typed in the connection editor of a Control Module type did the user not get a suggestion of the components (if such existed) when a dot was typed after the name of the variable/project constant.

800xACON-CN-4100-037

This problem has been corrected in the Control Builder. The user will now get a list of the components when the dot is pressed.



3BSE033044D5020 67

Online Changes in Editor Caused Shutdown of Control Builder

If changes like adding a variable was done in an online editor in Control Builder and then a rebuild was done from the search and navigation interface was it possible to save the online changes by answer Yes in a dialog. Reopen of the editor that was changed online did in some situations result in a shutdown of the Control Builder.

800xACON-CN-5010-009

This problem has been corrected in Control Builder. The dialog with the save changes option is not displayed anymore.

Comments in Function Block Call Removed Parameter Connections

If comment like (* comment text *) was added after a parameter in a Function Block call in Structure Text, was the parameters below the comment removed the next time the connection editor was opened.

800xACON-CN-4100-039


Step Out of Subsequence Only worked The First Time in Online Mode

When using the SFC Editor, the "Step Out of Subsequence" button in the toolbar was not working properly in the case of stepping out of several levels of nested subsequences. It only worked the first time; to the level above.

800xACON-CN-4100-040




68 3BSE033044D5020

No Name on Step or Transition in SFC Caused Errors when Reopen Project

If a Step was renamed to no name, i.e. "" or blank " " was an error message displayed to the user when the code was checked. When the project was opened again was the step without the name removed. If a Transition was renamed to no name, i.e. "" or blank " " was an error message displayed to the user when the code was checked. The project was not possible to open again due to the invalid SFC code according to DTD schema.

800xACON-CN-4100-041

These problems has been corrected in the Control Builder. It is not be possible to rename a step or transition to an empty or blank name any longer.

SFC Code not Displayed after Save in SFC Editor

When Save was clicked in an editor with SFC code block, the display of code in the right-hand code pane (transition condition/step action code) became blank.

800xACON-CN-5020-009


Maximum Number of Extensible Parameters in DataToSimpleEvent

The maximum number of extensible parameters in the Function Block type DataToSimpleEvent in the AlarmeventLib library has always been 30 according to the documentation, but there was no check for this.

800xACON-CN-3100-002

This problem has been corrected in AlarmEventLib.



3BSE033044D5020 69

Code Sorting Loops when Using BatchLib and SeqStartLib

There was unintentional code sorting loops when some control module types from the BatchLib and SeqStartLib libraries were used.

800xACON-CN-4100-050

This problem has been corrected in BatchLib and SeqStartLib.

Closing Online Control Builder Caused Shutdown

Closing an Online Control Builder could in some situations result in a shutdown of it.

800xACON-CN-4100-043


Missing Components when Search And Navigation was Used in Access Variable Editor

If the path to an access variable contained a structured data type was the component of the data type not included when the Search and Navigation tool was launched, e.g. Motor1 was selected instead of Motor1.Status.

800xACON-CN-4100-044




70 3BSE033044D5020

I/O Reference Not Found by Online Search & Navigation

This problem was related to Search & Navigation in the Online/Test Mode.

If a structured variable was connected to an I/O channel and an online search for a subcomponent (for example MyVariable.Component1) was done, then the I/O reference was not found by Search & Navigation.

800xACON-CN-4100-049


Search and Navigation in Library did not Work

Searching for symbols in a library did not work (nothing was found) if the path in the Search In field ended with the library name.

800xACON-CN-5010-014


Control Builder Shutdown During Online Documentation

Usage of the menu option Online Documentation could result in a shut down of the Control Builder if it was selected for unconnected Applications or Applications that wasn't online.

800xACON-CN-4100-045

This problem has been corrected in Control Builder. It not possible to select the menu option Documentation Online any more for Applications that are unconnected or not online.



3BSE033044D5020 71

Project Documentation Failed When Using Own Defined Template in Word 2007

In Word 2007 is it possible to create templates with the extension ".dotx". From the Documentation dialog in the Control Builder was it only possible to browse fore templates with the extension ".dot".

800xACON-CN-5010-010

This problem has been corrected in Control Builder. If Word 2007 is installed is it also possible to browse for templates with the extension ".dotx".

Project Explorer Window opens behind the Windows Taskbar

If the Windows Taskbar was configured to be displayed at the left of the screen or at the top of the screen, the Project Explorer window displayed partly behind the Taskbar when Control Builder started.

800xACON-CN-5000-093


Bad Quality When Downloading Large Applications

During application downloading to the controller, the OPC Server could, in rare cases report bad item quality for a short period of time (about 10 seconds).

This could have happened for large applications with considerable stop/start times.

800xACON-CN-5010-013

This problem has been corrected in OPC Server for AC 800M.



72 3BSE033044D5020

Cold Restart Needed to Remove No Time Sync Warning

A change of the parameter CS protocol Type to No synch required a download with cold restart, otherwise was the message "No time sync" displayed.

800xACON-CN-5000-089

This problem has been corrected in the AC 800M firmware. A warm download is enough to download the changes.

Controller Firmware Upgrade from Versions 5.0.1/1 or 5.0.1/2

The firmware upgrade of AC 800M controller models PM851, PM856, or PM860 did not work automatically when done via Ethernet Network when upgrading from AC 800M Version 5.0.1/1 (5.0 SP1 RU1) or 5.0.1/2 (5.0 SP1 RU2).

800xACON-IN-5012-001



PPP not Working after First Download

The first time a download to the controller was done from a newly opened Control Builder or newly open project did the PPP stop working (status 0).

800xACON-CN-4100-047



Section 4 Fixed Problems Version 5.0.1/2

3BSE033044D5020 73


• Operational Version 5.0.1/2• Configuration Version 5.0.1/2


74 3BSE033044D5020





Excessive Toggling of Communication En_C Parameter Could Cause Controller Hang

An AC 800M controller could suddenly hang during normal execution.

The Application execution would stop, all communication would be stopped, and all connected I/O would freeze at the last value (i.e. not going to OSP).

The problem could however only occur if the value of the En_C parameter on any of these Function Blocks was frequently toggled by surrounding Application code during runtime:

• COMLIConnect

• MBConnect

• MBTCPConnect

• S3964RConnect

• SerialConnect

• INSUMConnect

It could only occur if a disconnect (En_C set to false) was made between a communication Read/Write command and the corresponding respond (or timeout).

800xACON-OL-5010-018


Safety Report: 3BSE047421D0038


3BSE033044D5020 75

Controller Shutdown due to Detection of False Heap Error

The AC 800M controller could in rare cases unnecessarily initiate a shutdown.

This was due to detection of a false heap error. The heap check mechanism could detect a de-allocation of a memory element as a faulty heap element and consequently make a shut down. For this to occur there had to be a high frequency of heap de-allocations.

This problem was introduced in Version 5.0.1/1.

800xACON-OL-5010-017






76 3BSE033044D5020

Controller Shutdown after Power fail in Redundant Controller

A controller shutdown due to memory corruption could occur after a power-fail restart of both PM86xx in a redundant configuration.

Normally the problem would occur after a power-fail restart followed by several downloads to the controller. In some cases the problem has been observed directly after the backup PM86xx has been synchronized but in other cases the corruption could exist in the controller for a longer time period without symptoms before the shutdown occurred.

The problem would normally manifest itself as a backup controller shut down with the following error code in the controller log

NOERROR != SendResult

but in some cases a controller shutdown has been observed.

800xACON-OL-5010-016






3BSE033044D5020 77





Hanging Communication Blocks after Warm Download

There was a problem occurring in non-address non-subscription communication function blocks (e.g. MB300Send and InsumWrite). Such blocks would hang with an error status code (typically -15) after each warm download.

This problem was introduced in Version 5.0.1/1 while correcting800xACON-CN-4100-031.

800xACON-CN-5010-007


Version 5.0.1/1 Section 4 Fixed Problems

78 3BSE033044D5020


• Administration Version 5.0.1/1• Operational Version 5.0.1/1• Configuration Version 5.0.1/1

Administration Version 5.0.1/1

Table 11 lists the major system or product administration issues that have been corrected since Version 5.0.1/0. A brief description of the correction has also been given.

Table 11. Corrected Administration Issues


Change of CI854 Web Server Password Failed

There was a problem when attempting to empty the CI854 Web server password.

When the 'New password' and 'Confirm new password' were empty, there was an alert that the password was illegal.

Despite this warning, the password was changed. After the Web page was reloaded, log-in was neither possible with an empty password nor with the old one.

The controller had to be powered down, in order to reset the password.

800xACON-AD-5010-003


Section 4 Fixed Problems Administration Version 5.0.1/1

3BSE033044D5020 79

SFC SB2 Upgrade Issue

There was a case when it was not possible to upgrade a project from SB2. Control Builder hanged during the upgrading process.

The problem occurred if a SFC code block contained simultaneous sequences branches, and if any of these branches consisted of a subsequence only.

800xACON-AD-5000-023


Table 11. Corrected Administration Issues (Continued)



80 3BSE033044D5020





Frozen Time at Power Fail

The time was frozen for about 10 seconds at every power fail. This would accumulate for each restart.

The problem did not exist in PM861A, PM864A and PM865.

800xACON-OL-4100-036



3BSE033044D5020 81

Erroneous Compilation of Integer Literal having the Value Zero

Control Builder could compile and download an erroneous (non functional) application. The problem occurred in certain complex code structures including the use of literals having the value zero.

The problem could only occur if the value zero was used directly in the code block; variables having the value zero were not affected.

This was more or less a theoretical problem, never reported by any end user.

800xACON-OL-5020-001


Control Builder will be shut down during compilation in case it detects one of the affected code structures. The session-log will include any of three messages:

• E 2007-11-19 10:48:32.583 Assertion: Unpredicted result when adding a zero literal, remove the zero literal.

• E 2007-11-19 10:54:08.011 Assertion: Unpredicted result when subtracting a zero literal, remove the zero literal.

• E 2007-11-19 11:00:37.628 Assertion: Unpredicted result when a zero literal is used as shift count, remove the shift expression.

Remove the literal value zero from the code, and perform the download once more.





82 3BSE033044D5020

Write Protection of SPI PROM

Serial SPI PROMs are used in the controller products for storage of product specific parameters such as capability information, MAC and IP addresses etc.

Inadvertent writes due to data disturbance has in some rare occasions caused permanent loss of one or more of these parameters. Affected CPU devices need to be restored at ABB factory.

800xACON-OL-5000-062


Drive Stop with Deceleration Ramp not Working

It was not possible to stop a Drive with deceleration ramp, it was always stopped without ramp.

The problem was in the Function Block DriveCmdSend in ProcessObjBasicLib. It sent the command 1143 (stop without deceleration ramp) before 1142 (stop with deceleration ramp).

All process objects in ProcessObjDriveLib were affected by this problem.

800xACON-OL-4100-037

This problem has been corrected in ProcessObjBasicLib 2.2-9.




3BSE033044D5020 83

No Feedback Alarm in UniCore

There was an error in the UniCore Function Block in ProcessObjBasicLib. The block did not generate any feedback alarms in case the parameter FBConfig was set to the value 3. All other values on the parameter worked as expected.

UniCore is used in the following objects, and they were consequently also affected by this problem:

ProcessObjExtLib:

• ValveUniM

• MotorUniM

• UniM

• MotorUni

• Uni

• ValveUni

ProcessObjBasicLib:

• UniSimpleM

• UniSimple

800xACON-OL-5010-013

This problem has been corrected in ProcessObjBasicLib 2.2-9.




84 3BSE033044D5020

Drifting Update of OPC Clients

The OPC Server keeps track of the time it last updated the OPC clients with subscriptions.

The time was however taken after the clients were updated, which lead to a small offset being added each time.

This could cause irregular logging of values in the client, because an update was skipped whenever the added offset had reached one interval time.

800xACON-OL-4100-035


OPC Quick Initial Update not always working

There is a mechanism in the OPC Server that should make sure added Items do not get Bad quality in the first call-back. This is achieved by starting the communication (or speeding it up if another Item for that variable already exist in a slower group), and then wait until the value is received from the controller. If no value have been received within a certain time limit a call-back is issued to the client with the quality Bad, but normally the value should be available before this time limit expires and a call-back with Good quality is issued.

The time limit has in some cases been seen to be too short, resulting in that an OPC client occasionally would initially get Bad data when adding new OPC Items.

800xACON-OL-5010-011


Quality is not set to Bad when the client is setting items to active if they already are active.

The timeout when waiting for initial update of newly added items is extended.




3BSE033044D5020 85

Device Specific CI854 PROFIBUS Diagnostics not Set/Reset

Diagnostics located only in the last diagnostic byte was not displayed in the HW-editor. The bits only appeared when a diagnostic change in another byte occurred at the same time.

Similarly it could happen that a bit was never reset, because it was set together with another one but was reset alone. In this case the CI854 had to be reset to delete the diagnostic.

800xACON-OL-5010-012

This problem has been corrected in the CI854/CI854A firmware Version 5.55 in CI854PROFIBUSHwLib 1.0-27.

CI867 MODBUS TCP Read/Write Timeout in Runtime

MODBUS TCP Read/Write blocks could in runtime sporadically return the status code-7006 (time out). This happened even if there was no problem with the communication.

The problem was caused by a too short internal timeout that would cause some requests to be dropped; these messages would not have any reply/response thus yielding the time out status.

800xACON-OL-5010-014

This problem has been corrected in the CI867 firmware Version 5.0.1016.1 in CI867ModbusTcpHwLib 1.0-26.

The timeout has been increased.




86 3BSE033044D5020

Controller Crash at Misconstructed CI867 MODBUS TCP

Function Blocks like MBTCPReadCyc, MBTCPRead and MBTCPWrite does not support more than 123(write) or 125(read) integer variables in one Function Block.

The controller would shut down in case this range was exceeded.

800xACON-OL-5010-015

This problem has been corrected in CI867ModbusTcpHwLib 1.0-26.

The status code -4925 is given if the range is exceeded.




3BSE033044D5020 87





Frozen I/O after Download of Application(s) Changes

There was a problem if Control Builder M crashed or lost communication connection to the Controller during download of Application(s) changes to the Controller.

The next successful download could lead to lost control over the I/O connected to the previously modified Application(s); all of the connected I/O in the modified Application(s) would get frozen.

The Application(s) facing the problem would still execute. Input I/O variables in such Application(s) would no longer be updated, nor would output I/O variables be feed into the outputs. I/O status would be frozen at the last received status. OPC communication to the Application(s) would be unaffected.

Affected I/O channels would not show any values at all in the online hardware editor in Control Builder

800xACON-CN-5010-003

This problem has been corrected in Control Builder and in the AC 800M High Integrity firmware.


Safety Report: 3BSE047421D0027


88 3BSE033044D5020

Interrupted Download of Controller Configuration Causing Controller Shut Down

An interrupted download of Controller Configuration changes could in rare cases lead to a controller shut down at the next download of Controller Configuration changes.

The problem could only occur if either of these two things happened during the first download.

• A Control Builder crash during the download of the Controller Configuration.

• The message Error in communication link to system 172.16.xx.xx. Do you want to continue with the transition to online? was showed during the download of the Controller Configuration.

The controller could then make a shut down at the next download of a changed Controller Configuration.

800xACON-OL-5000-061

This problem has been corrected in the AC 800M and AC 800M High Integrity firmware.



3BSE033044D5020 89

Controller Version Mismatch in Flash Image Causing Controller to Shut Down

Control Builder could in a rare case be unable to make a correct compilation of the controller configuration to an AC 800M. Erroneous data would be downloaded to the controller, which would cause the AC 800M to make a shut down.

The problem occurred when all of these three circumstances applied:

• The AC 800M controller last started up from a Compact Flash image.

• This image did not reflect the result from the last controller configuration download.

• Control Builder downloaded a changed controller configuration to an AC 800M controller.

800xACON-CN-4100-032





90 3BSE033044D5020

Receive Communication Blocks not Valid after Warm Download

There was a problem in case the variables used for the communication blocks did not have the retain attribute set.

If a change was made in the application and a warm download was performed, then the Valid parameter of the Receive blocks would never be set. To get a working state again the En_C parameter of the Connect block had to be toggled.

This problem concerned the receive communication blocks for INSUM and MB300.

800xACON-CN-4100-031


INSUM Communication Error Re-Triggered After Each Download

If there was a communication error to an INSUM device, the INSUM Process Object would re-trigger its object error for each new download. This was regardless if the alarm had been acknowledged or not prior to the download.

The object error was reset when downloading and was disappearing from the alarm list. After approximately one minute the object error alarm would be re-generated.

All objects in ProcessObjInsumLib had this problem.

800xACON-CN-5010-005

This problem has been corrected in ProcessObjInsumLib 1.2-13.



3BSE033044D5020 91

Download of new IP-Address Causing Controller Shut Down

If the IP-address for a controller was changed in the hardware editor in Control Builder (the Ethernet channel) and downloaded to the controller, then the controller could make a shut down during the download.

The controller made a shut down if the application was downloaded to an empty controller or if the application was downloaded with cold restart.

The controller was not shut down if the application was downloaded with warm restart.

800xACON-CN-5010-002



Toggling Communication Connection Causing Problem Further On

There was a problem in case the application toggled the communication connection by setting the En_C parameter to True -> False -> True on a Connect Function Block.

The problem occurred at the next download. A Soft Controller would crash, but in an AC 800M controller would the problem lead to memory leaks.

The problem did not affect MMS communication.

800xACON-CN-5010-006

This problem has been corrected in Soft Controller and in the AC 800M firmware.



92 3BSE033044D5020

Control Builder Hanging when Navigating from Search & Navigation

Control Builder could hang for ever when navigating from the Search & Navigation dialog.

The problem occurred when searching for project constants. When trying to open up the project constant editor from the Search And Navigation dialog the entire Control Builder hanged.

800xACON-CN-5010-004


Replace and Replace all in Control Module Diagram Editor did not Replace

Replace and Replace All in the Control Module Diagram Editor did not work. Nothing was changed even if the dialog said that substitutions had been made.

800xACON-CN-4100-027


Improved Device Import Wizard

This version includes an improved version of the Device Import Wizard.

• A few minor parsing errors have been corrected

• Support for empty strings (e.g. "")

It is recommended to use the new Device Import Wizard Version 1.2.1, instead of the older one.


3BSE033044D5020 93

Section 5 Known Problems

Issues and problems are divided into functional categories:

• Administration.• Operational.• Configuration.• Instruction Manual Changes.

AdministrationTable 14 lists the issues that may exist and affect system or product administration at time of release including user, node and service structure related issues and

Control Builder Section 5 Known Problems

94 3BSE033044D5020

problems.Workarounds, clarifications, or helpful hints have been provided for each issue wherever possible.

Table 14. Administration Issues

Issue Workarounds, Clarifications, and Helpful Hints

Control Builder

Coexistence with Different Project Name not Possible

When upgrading a project, the user is given the option of not overwriting the original project. This can be done by creating a new directory and either save the project with the same name, or changing the project name.

If a new name is selected, it is not possible to do a coexistence download. It is not possible to download a project to a controller where a project with a different name is already running.

If the user does not have the intention to perform a co-existence download, changing the name will not lead to any problems.

800xACON-AD-5020-005

Because the project was stored with a new name, the original project still exists. Simply delete the upgraded project, load the original again, and save in a different directory with the same name. Now Coexistence download will work.

Controller and Control Builder Problems after Decimal Symbol Changed From “Period” to “Comma”

If the Windows setting for the decimal symbol (under Regional and Language Options) is changed, this will cause inconsistencies in existing AC 800M applications. This can lead to Controller or Control Builder shutdowns immediately after the change.

800xACON-AD-5010-008

Do not change the Windows decimal symbol, or make any other changes to regional settings that change the decimal symbol. Keep it to ".".

Section 5 Known Problems Controller

3BSE033044D5020 95

Re-Import of PROFIBUS Devices will Fail if GSD File Name is Changed

Import of an already existing GSD file to the Control Builder will fail if the name of the updated GSD file is different compared with the original file.

800xACON-AD-5020-002

Change the name of the modified GSD file to be the same as original file.

Controller

Backup CPU will Experience Difficulties to Synchronize if BC810 is Hot-swapped During Synchronization

If BC810 is hot removed during the time when the backup CPU is synchronizing (DUAL LED on primary is flashing) and hot inserted before the end of the synchronization (the DUAL LED stops flashing), the backup CPU will stop and enter a state where restart attempts, by use of the INIT push button, will fail.

800xACON-AD-5000-001

Note: Any removal of BC810, at any time, will by design stop the backup CPU. The problem recognized and described here is the state where restart by the INIT button will fail.

Workarounds (any of these will help):

1. Do not perform hot swap of BC810 during synchronization. Synchronizing is an extremely volatile state.

2. If BC810 already has been removed during synchronization, then wait to insert it until the synchronization has ended and the backup CPU has stopped. Finally push the INIT button on the backup CPU.

3. If hot swap already has been performed during the synchronization then either redo the hot swap after end of synchronization and push the button or have the backup CPU powered off and then on again.

Table 14. Administration Issues (Continued)


Controller Section 5 Known Problems

96 3BSE033044D5020

INSUM GroupStart Stop During Switch in Online Upgrade

Group Start objects controlling INSUM objects from ProcessObjInsumLib may stop at an online upgrade. The groupstart objects may stop with the following alarm: Too few available objects.

800xACON-AD-5000-031

Resynchronize the INSUM GroupStart objects manually after the Online Upgrade.

Formatted Compact Flash Card Is Not Empty According to Controller

If a Compact Flash card has been used to upgrade firmware in the Controller there will still be some information left on the Compact Flash card after it has been reformatted. This can cause problems if the same Compact Flash card is later used to load a Controller Application. When the Controller starts up, it will try to load firmware (and fail), instead of loading the Controller Application from the Compact Flash card.

800xACON-AD-5020-003

Use a separate Compact Flash card for the firmware upgrade, and Compact Flash cards for storing Controller Applications.



Section 5 Known Problems Communication

3BSE033044D5020 97

Communication

Delayed Restart of SattBus on TCP/IP at Cold Restart Download

If using SattBus over TCP/IP and downloading the applications with the cold restart option, it may take several minutes before the SattBus communication is up and running.

There is no problem when making a normal (warm restart) download.

800xACON-AD-4100-003

No workaround exists.



Communication Section 5 Known Problems

98 3BSE033044D5020

Communication Interrupt for CI855, CI858, and CI865 at First Download to SP1 Controller from SP2 Control Builder

This problem occurs if the Control Builder and other system components have been upgraded to SV5.0 SP2, while a controller is still executing firmware Version SV 5.0 or SV 5.0 SP1, and the controller contains any CI855 (MB300), CI858 (DriveBus), or CI865 (SattIO) modules.

At the first download to the controller from the upgraded Control Builder, the CI855, CI858, and CI865 modules will be marked to be reconfigured, with the communication temporarily interrupted, even if there are no configuration changes. At the download the communication is interrupted the same way as at a real reconfiguration of the CI modules.

CI855 and the CI858 are restarted. CI865 is not restarted but the communication with the ACN and RACN nodes is restarted.

The communication restart will take:

15 to 20 sec for MB300 (CI855), about 10 sec for DriveBus(CI858), and about 20 sec to 1 min for SattIO (CI865).

The communication break will not be reported in the controller log file.

Subsequent downloads will be as expected, without unnecessary restarts.

800xACON-AD-5000-030




Section 5 Known Problems I/O Handling

3BSE033044D5020 99

I/O Handling

S100: Scanning of DSDI 110 may not Start after Adding a CI856 to a Running Controller

When adding a CI856 unit to an empty base plate (no unit has been configured previously) on a running controller, the scanning of the input channels of DSDI 110 may not start and no indication will be shown. This only happens if the channels of DSDI110 are configured to update on interrupt.

800xACON-AD-5000-002

• Use scanning instead of interrupt based updating.

• Interrupt based updating may be used with caution. If it is used and it does not work the updating can be started by hot remove/hot insert of the CI856 unit.

S100: Error for I/O Conflict on Physical Hardware not Cleared

If two S100 I/O boards are strapped to the same address, the CI856 will detect it and set Unit status to “I/O module ID conflict”, on the module which is configured to have that address.

Removing the boards with the conflicting addresses and inserting the board with the correct address does not clear the error.

800xACON-AD-5000-003

Hot remove/insert of CI856 corrects the problem, but stops all I/O communication from CI856 for a while.

Another way, that does not disturb the I/O communication for the working boards, is to change the address of the board to an unused address in the hardware configuration and download it. Then either change the address on the physical board to match the new one or change the address in the hardware configuration to the original address and download the configuration again.



Operational Section 5 Known Problems

100 3BSE033044D5020

OperationalTable 15 lists the issues that may exist and affect operation of the system or product at time of release. Workarounds, clarifications, or helpful hints have been provided for each issue wherever possible.

Table 15. Operational Issues


OPC Server

Query Condition Names does not Work Properly

The OPC AE Server for AC 800M gives the wrong answer to the query condition names call. AC 800M has two event categories that define condition names, “Process Condition Event” and “System Condition Event”. If asked for the condition names for one of the categories through the method IOPCEventServer::QueryConditionNames, condition names from both categories will be returned. This will entail that the same set of condition names are returned for both categories.

800xACON-OL-5000-007

No solution/workaround exists; however, this problem may only be encountered by a 3rd party OPC/AE Client.


3BSE033044D5020 101

Controller

Latency Caused by Alarm Burst

When an alarm changes state (gets activated, deactivated, or acknowledged), a small increment to the Task Execution time for a single scan (approximately 350 µs per changed alarm) will be added. If an alarm burst occurs, when many alarms are activated simultaneously, this could noticeably increase the Task Execution time. If latency supervision is enabled on the tasks that are executing the Alarm Condition Function Blocks or Control Modules, this could lead to a latency shutdown, if the Task settings are too tight.

NOTE: Latency supervision is always enabled for SIL tasks.

800xACON-OL-4100-044

Consider the extra time for an alarm burst when tuning the task settings in the Controller, especially the Interval, Offset, and Latency settings. An alarm burst of 100 alarms (in one scan) adds about 35 ms to the execution time, 200 alarms adds 70ms etc.

Using GetIntervalTime in Start_Code Might Hang the Soft Controller

The function GetIntervalTime has unpredictable behavior when used in Start_Code in a Soft Controller. This might hang the Soft Controller. There are no problems using this function in a real controller.

800xACON-OL-4100-008

A Start_Code code block does not have any interval time since it only executes once, before the tasks are started (the function will in this case return 0).

If the function shall be used upon application start, put it in an ordinary code block inside an IF-statement triggered with FirstScanAfterApplicationStart. The function will return the requested interval time of the task in which the program/module is executing.

Table 15. Operational Issues (Continued)


Controller Section 5 Known Problems

102 3BSE033044D5020

Controller Can Hang if Tool Port Cable is not Connected in the Other End

A cable connected to the tool port on the CPU (COM4), may cause the controller to hang during startup, if the cable is unconnected in the other end, or if the PC it's connected to is unpowered.

800xACON-OL-4100-009

Do not have an unconnected cable attached to COM4.

Error Printout in Controller Log from CI853

When using CI853, logging severity low errors (done by changing Error handler settings under "Controller settings menu") might result in error logs:

E 2004-10-12 11:09:35.336 ErrorHandler PM: CON 4119 Spur CEX IRQ 9 (1,1) spur IRQ since start

800xACON-OL-4100-010

The errors are harmless, but to avoid the printout, turn off logging of Severity low errors in the Control Builder in the "Controller Settings menu".

Power failure when SerialListenReply is treating a message result in pending operation If a Controller gets a power failure when the function block type SerialListenReply is treating a message the function block will enter the state pending operation (Status code -5331).

800xACON-OL-5000-050

Set the Enable parameter on the SerialListenReply function block to false and then to true again will solve the problem.




3BSE033044D5020 103

Communication

MMS Takes a Long Time to Start after Application Download

It takes about 10 to 13 seconds to restart MMS communication between controllers after an application download.

800xACON-OL-3100-003

A workaround is to have a parallel application containing an MMSConnect to the same partner. The parallel application is unchanged and keeps the connection to the partner during stop and restart of the original application. The time for bringing the MMS communication up after download is decreased to 5 seconds.

Long Time for MMSConnect to Become Valid When Restarting From Compact Flash

If a power failure occurs and the controller is restarted and loads the Application from the Compact Flash card, it will take about 90 sec before the MMSConnect is valid again.

800xACON-OL-4100-049




Communication Section 5 Known Problems

104 3BSE033044D5020

Settings for RNRP and for PPP Lost in a Redundant CPU

Settings for RNRP and for PPP may be lost after a power fail, if the battery is removed or low during the power fail.

In such a case the application is always lost, but additionally it may not be possible to communicate with the Controller from the Control Builder.

The problem happens if one CPU is primary when the configuration is downloaded and the other CPU is primary after the startup.

This should normally only be a problem in these cases:

• If the Control Builder uses PPP to communicate with the Controller

• If explicit RNRP configuration is used and the Controller and the Control Builder are connected to different network areas.

800xACON-OL-4100-011

To get the correct settings into the controller, connect a PC with the Control Builder to the same network area as the controller and download a project with the correct RNRP and/or PPP settings.

Shutdown of Active PPP Node can Cause other Node to Shut Down

The controller acting as a passive PPP node may shut down if the controller acting as the active PPP node is shut down.

800xACON-OL-4100-012

Make sure the active controller doesn't stop. Use UPS (Uninterruptedly Power Supply) if necessary. Or try to use other communication protocols, if possible.




3BSE033044D5020 105

Redundant MODBUS TCP Switchover Time Very Long

It may take from several tenths of a second to minutes to re-establish the connection to the MODBUS partner after a failover from one CI867 to its backup. The switchover may be caused by a cable disconnect, a CI867 removal, or a unit failure. The local switchover is done in a sub-second, but the partner does not recognize the new active CI module. The connection must time out, and a new connection must be established. This will take at least several seconds. A timeout of 15 minutes has been observed for a Melsec controller.

800xACON-OL-5010-029


3rd Party Modbus TCP Slaves must have Default Slave ID : FF

The slaves used in Modbus TCP are assumed to have the ID FF. If this is not the case the communication will not work.

800xACON-OL-5010-006

Configure the 3rd party slaves to have the address FF using the suppliers own tool and then connect them one by one to the Controller.

Disturbance on INSUM Communication Result in Incorrect Indication in GroupStartStandby

If there is a communication error (cable break) to the MCU the indication in the GroupStartStandby is sometimes wrong. The indication shows that the MCU's are running, but they aren't.

800xACON-OL-5000-045




I/O Handling Section 5 Known Problems

106 3BSE033044D5020

COMLI Communication Problem via GSM Modem, Start-Up Delay

On a COMLI connection via a dial-up GSM modem, a timeout message on the first COMLI may occur after the connection is established. There is a retransmission and then the behavior is correct.

800xACON-OL-5010-030

When configuring the COMLI Client logic (the Read/Write Function Blocks), make sure an initial failed message does not stop the continued communication.

I/O Handling

Modulebus I/O Started too Late

Warning!

Start of Applications and Modulebus I/O are not synchronized at startup. The controller applications may start before all Modulebus I/O has been started.

800xACON-OL-4100-013

Use the IO.Status value to interlock start-up actions.

I/O Running on CI865 Started too Late

Warning!

Start of Applications and I/O running on CI865 are not synchronized at startup. The controller applications may start before all CI865 I/O has been started.

800xACON-OL-5000-010

Use the IO.Status value to interlock start-up actions.



Section 5 Known Problems I/O Handling

3BSE033044D5020 107

OSP Values are Reset During Startup

Warning!The following issue occurs after the application(s) in the controller for some reason are erased (for example after a power fail with no attached battery or after making a long press on INIT). The I/O channels will in this state have entered their pre-configured OSP values. In order to restart the controller, the application(s) must be re-downloaded from Control Builder.

When the download of the application(s) is performed, just before the applications are restarted, I/O channels with pre-configured OSP values will be de-energized for a couple of seconds. After that, the I/O will be set by the now running application(s).

800xACON-OL-4100-014

Prior to the download; make sure the process is set into a state were it can accept the temporarily de-energized outputs.

S800 I/O Linearization

An S800 I/O analog input signal set to 4-20 mA will, if it is set to Linearization and connected via direct Modulebus, warn for underflow at 3.74 mA instead of normally 2 mA.

800xACON-OL-4100-015

For AI845 single range 4-20 mA sqrt can be used.




108 3BSE033044D5020

S900: I/O OSP Cleared

Warning! OSP on S900 I/O will be cleared in the following two occasions:

• During a short period of time after resuming after a controller power fail.

• Controller task abort, due to that a task has executed too long.

800xAIO9-OL-4100-001

No solution/workaround exists.

Unable to Acknowledge Warning for CI920

If a redundant pair of CI920 are configured, the hardware status displayed in the Control Builder is "redundant switch over"; this warning is not possible to acknowledge.

800xACON-OL-4100-018

The functionality of the S900 I/O does not affect this case.

No Channel Error from S900 I/O if Wire Break or Short Circuit

Digital inputs, digital outputs and analog outputs on S900 I/O does not report data quality 'bad' in the RealIO.Status component in case of wire break or short circuit. This is because S900 I/O sends this information via PROFIBUS diagnostics.A line fault on such channels results in:

• No system alarm with plain text

• A PID controller may go into windup

• The OPC status will not show bad

800xACON-OL-5000-004




Section 5 Known Problems PROFIBUS-DP

3BSE033044D5020 109

Problem to Use Long I/O Scan Cycle Time in Redundant AC 800M Using DP820

Scan cycle time more than 90ms results in that DP820 will go to OSP state for some seconds.

800xACON-OL-5000-008

Set Modulebus scan cycle time to max 90ms.

PROFIBUS-DP

PROFIBUS Slave CI840 does not Report which I/O Module Acting as Primary/Backup

Information about redundant I/O-modules is missing in the status component of the IEC61131-3 data types BoolIO or RealIO, if the redundant I/O-module is connected via the PROFIBUS slave CI840.

This means that the function block RedundantIn will not ramp as expected for I/O connected on PROFIBUS at switch-over.

800xACON-OL-4100-019


CI854 Stays in Fail Mode after Shortcut of PROFIBUS Line

Under some very special circumstances it a shortcut of both PROFIBUS lines can cause the CI854 to stay in STOP mode, as the cyclic communication is disturbed.

800xACON-OL-5010-025

Reset the CI854 after the shortcut is resolved.



Configuration Section 5 Known Problems

110 3BSE033044D5020

ConfigurationTable 16 lists the issues that may exist and affect configuration of the system or product at time of release. Workarounds, clarifications, or helpful hints have been provided for each issue wherever possible.

Table 16. Configuration Issues


Control Builder

Undo in Sort A-Z and Z-A Fails

If the sort A-Z or Z-A functionality has been used and then the undo button is used, the result will not be as expected.

800xACON-CN-5020-008

Close the editor without saving.

Using Recursive Relations between Objects or Between Libraries Not Allowed

It is not allowed to use recursive relations between objects or between libraries. If used the Control Builder may hang.

For example, if there exists two function block types A and B, you can declare a sub object of type A in type B, but if later on trying to declare a sub object of type B in type A the Control Builder might hang when the editor content is saved.

800xACON-CN-4100-002

If the Control Builder is not responding it has to be killed using Task Manager and then restarted.

Section 5 Known Problems Control Builder

3BSE033044D5020 111

String Length of 140 Characters Not Supported for String Constants

The maximum length of a string constant is 137 characters even if the length of the string is set to 140 characters.

800xACON-CN-5020-006


Changing CPU Type from PM851

All I/O-modules on Modulebus will be removed if the CPU type PM851 is changed to any other CPU-type e.g. PM860. All parameter settings and I/O-connections related to these I/O-modules will be removed.

800xACON-CN-4100-008

The hardware configuration related to the currently used PM851 CPU type e.g. hardware topology, parameter settings and I/O-connections has to be manually stored before the CPU type is changed. This could be done by manually copying relevant information unit by unit to an excel sheet. After the CPU type has been changed, the stored information has to be manually copied back.

Using Templates from SeqStartLib Generates the Warning Message: Multiple Calls to Same Function Block

The Multiple Calls to the Same Function Block compiler switch (introduced in SV5.0 SP2) generates warnings for the code that is copied when using the SFC2DSeqChainExample from SeqStartLib.

800xACON-CN-5020-010

The warnings can be ignored, or the Multiple Calls to the Same Function Block compiler switch can be set to None.

Table 16. Configuration Issues (Continued)


Control Builder Section 5 Known Problems

112 3BSE033044D5020

Power-fail During Download Might Fail

If power fails during download the controller may end up in a state where further reconfigurations are not possible. This will be indicated on the next attempt.

800xACON-CN-4100-010

To reconfigure the controller a Controller reset is necessary.

Firmware Upgrade After Remove of Applications in Controller Fails

If application(s) are removed from a running controller from the "Application Information" dialog and then a firmware upgrade is started from the "Firmware Information" dialog the controller will restart and the "Firmware Information" dialog is closed when the controller is up and running again, but the firmware isn't upgraded.

800xACON-CN-5000-003

Start a new firmware upgrade and verify that the firmware has been updated in the controller by using the "Firmware Information" button in the "Remote system dialog" or check the controller log.

Control Builder May Shut Down when Reconnect Hardware Libraries on Simulated Controller

The Control Builder may shut down if hardware libraries are replaced in a simulate marked controller.

800xACON-CN-5000-004

Remove the simulation mark on the Controller before reconnect of the hardware libraries and restore it.




3BSE033044D5020 113

Project Documentation from Control Builder

When using the menu entries “Documentation…” and “Documentation Online…” in the Control Builder it is important to not generate too many pages.

The time needed to generate the documentation in word increases dramatically when the number of pages increases. Sometimes it will take long time before the “Cancel” command is accepted by the system; if the document that is to be generated is very large.

800xACON-CN-5000-006

Instead of one big documentation of for example a large library, divide it into several smaller pieces like data types, function blocks and control modules.

Error Message When Aborting Print to File in Difference Report

If the menu option File -> Print in the Difference Report is selected and then "Print to file" checkbox is ticked and then if "Cancel" is selected in the "Print to File" dialog you will get an error message.

800xACON-CN-5010-001


Not possible to open projectText that is copied into a POU in the Control Builder may result in that the project is not possible to open again. This only happen if the text contains ASCII characters that are not supported by the Control Builder like ASCII 27 (ESCAPE).800xACON-CN-5000-082

Make sure that the text that is to be copied into the Control Builder doesn't contain any illegal characters.

Controller




114 3BSE033044D5020

SattBus on TCP/IP is not enabled in hardware simulated controller In a hardware simulated controller the SattBus TCP/IP communication is disabled.

800xACON-CN-5000-081

Make a warm restart (power fail with battery) of the Controller and then the SattBus TCP/IP communication will be enabled.

I/O Handling

DP840 Scaling Frequency Input

The frequency input range for DP840 connected to CI801 or CI840 is fixed at 0...20 000 Hz, even though Min and Max scaling properties has been altered.

800xACON-CN-4100-015


DP840 Variable Connections for Pulse Count and Frequency

DP840 can be configured for either pulse count or frequency measurement where frequency is the default. If the application variable is not connected to the input channel that corresponds to the configuration, the values are interpreted wrongly, which may lead for example to faulty alarms. Furthermore, pulse count values are not visible in the Hardware editor when no variable is connected to this channel.

800xACON-CN-4100-016

Ensure that the variable connection matches the channel configuration of the DP840. Connect an application variable to the pulse count channel of the DP840 to get the values in the hardware editor.



Section 5 Known Problems PROFIBUS-DP

3BSE033044D5020 115

Single I/O Modules Configured But Redundant IO Units in Project Explorer

If a redundant I/O module is configured and downloaded, unit A will be the primary and the hardware tree in Control Builder is displayed correctly. If the I/O module is later configured to be single (nonredundant) while unit A (primary, left) is physically removed, the Control Builder Project Explorer hardware tree may end up in a state indicating that the I/O module is redundant and that unit B is primary.

800xACON-CN-5020-004

This is a presentation problem. No Workaround exists.

PROFIBUS-DP

Deactivating of S900 I/O Channels, in Control Builder, is not Working Properly

Deactivating S900 I/O-channels via the hardware configuration in Control Builder is not working correctly. The I/O-channel status supervision could be indicated wrong.

800xACON-CN-4100-017

Remove and reinsert the S900 I/O-module.

Diagnostics on PROFIBUS Does Not Work Correct After Reconfiguration

In some situations are the diagnostics for PROFIBUS units not correctly displayed in the Control Builder when hardware devices with diagnostics have been removed from the configuration.

800xACON-CN-4100-029

Restart the Control Builder.



IEC 61850 Section 5 Known Problems

116 3BSE033044D5020

IEC 61850

Problem Encountered while Creating CCF File for REF Series IED

There is a problem in the SCL component whenever the REF series of IEDs are used for configuring the SCD File. The REF54x (x=1,3,5) inherently does not have an IEC 61850 interface and hence must use the SPAZC-40x SPA/IEC61850 adapter to attain IEC 61850 connectivity. Hence LD0 and LD1 are designated for SPAZC-40x and REF54x devices respectively.

800xACON-CN-5020-013

The SPAZC-40x IEC 61850 parser implementation requires the Access Point 'LD1' and hence it has to be retained in the CID file that is downloaded into SPA-ZC40x. However, this is not supported by the SCL Component being used by the IEC 61850 Wizard (and also CCT System Eng. tool) and hence has to be removed manually.

Similar is the case for REF542plus IED.

The above information is only applicable for the mentioned series of IEDs. Ideally, it is recommended that the user does not make hand made changes in the SCD file.

Import Wizard Progress Bar Showing Wrong Information

While importing SCD files using the IEC 61850 Import Wizard, the progress bar is not synchronized with the actual work progress and indicates work completed while the import is still underway.

800xACON-CN-5020-001

Wait until the IEC 61850 Import Wizard pops up a message indicating the completion of import of SCD.



Section 5 Known Problems IEC 61850

3BSE033044D5020 117

Tracing the IEC 61850 Partner from Control Builder

It may be difficult to trace the IEC 61850 partner from Control Builder since the partner IP address is not shown.

800xACON-CN-5020-003

The IP Address of the Partner IED is viewable through the CCF view section of the Import Wizard.

1. For all configured Hardware Trees, open the Import Wizard by right-clicking on the Controllers.

2. In the Import Wizard, select the CCF View tab.

3. The controllers participating in IEC 61850 communication and its associated CI868 will be displayed in the All CCF Files window.

4. When any of the CI868 are selected, the Tree structure of that particular CI868 will be displayed in the Selected CCF File window.

5. Select the partner IED and click on the Access point.

6. The properties are displayed in the Misc window.

7. The IP address will be displayed.



IEC 61850 Section 5 Known Problems

118 3BSE033044D5020

Problem with IEC 61850 Import using Import Wizard if Import is Aborted

If an import of IEC 61850 SCD data to the Control Builder and Aspect Directory is cancelled or interrupted in an uncontrolled way, it may leave an inconsistent hardware tree for the concerned AC 800M Controller. The hardware tree must then be deleted and recreated.

800xACON-CN-5020-011

No workaround exists. Always make sure a current backup of the system is available before making an Import.

Slow Performance of IEC 61850 Import Wizard

It may take a long time (several minutes) to do an import and create the hardware structure in the Control Builder for large SCD configurations.

800xACON-CN-5020-002

No workaround exists. Wait until the import is completed and the hardware structure is created in Control Builder.



Section 5 Known Problems Instruction Manual Changes

3BSE033044D5020 119

Instruction Manual ChangesTable 17 list the problems or issues in the instruction manuals that exist at product release. The corrections to the instruction have been indicated.

Table 17. Instruction Manual Changes

Instruction Error (Page) Change or Correction

Control Builder online help

800xACON-OL-4100-016

n/a S100 I/O Status Indication

A disconnected or broken S100 cable between the CI856 module and an I/O rack gives no error indication in the hardware tree on the S100 rack level or for the bus extender module. The same indication problem also arises at a power down of aS100 rack.

Note that all I/O modules in the rack are correctly error marked if this happens.

The problem concerns only the hardware units representing the rack itself and the bus extender module.

Instruction Manual Changes Section 5 Known Problems

120 3BSE033044D5020

Basic Control Software, Introduction and Configuration

800xACON-MC-5000-013

161 Missing information:

Information icon

If a controller is configured with redundant CEX units is it not possible to create an image for a Compact Flash card if the project hasn't been downloaded to the controller and the Control Builder hasn't been closed since that download. The project must have been downloaded to a PM861A or PM864A controller if the controller in the configuration is a PM861 or PM864.




3BSE033044D5020 121

Communication, Protocols and Design

800xACON-MC-5000-012

n/a Maximum limits of the data can be transferred on a Modbus TCP Read/Write function block call.

The maximum limits of the data to be transferred via Modbus TCP depend on the data type and the operation type as described below.

Limit bool:

MBTCP Read 2000

MBTCP Write 1967

Limit Dint/uint/int:

MBTCP Read 125

MBTCP Write 123




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Communication, Protocols and Design (cont.)

800xACON-MC-5000-012

n/a Maximum limits of the data can be transferred on a Modbus TCP Read/Write function block call.

(cont.)

MBTCPReadFileRecord: A maximum number of data that can be transferred is 124. If the data length requested is larger than this, the error (-7007) is active.

MBTCPWriteFileRecord: A maximum number of records that can be transferred on one function block call should not exceed maximum Modbus telegram size of 253 bytes. This gives a maximum of 122 records. If the data length is larger than this, the error (-7007) is active.

MBTCPWriteFileRecord and MBTCPReadFileRecord do not support Bool.

Limit Dint/uint/int:

MBTCPWriteFileRecord 124

MBTCPReadFileRecord 122




3BSE033044D5020 123

Communication, Protocols and Design (cont.)

800xACON-MC-5000-012

n/a Maximum limits of the data can be transferred on a Modbus TCP Read/Write function block call. (cont.)

Since the read/write multiple parameters of the function blocks accept connections from/to variables with structured data type, it is very important to build the variables in the correct set, especially for the structured bool data type. The client communication framework in the controller has limitation of 844 components of the structured data configured in each multiple parameter. Exceeding this limit, the communication will return error code -6824 cGCHardLimitExceeded. In other words, to achieve Modbus TCP communication to transfer a variable data with structured data type of 2000 bool components is not acceptable. As workaround, the variable data should be constructed as a structured data type of 4 structured data types of 500 bool components.




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Controller HW

Instruction: AC 800M Controller Hardware, Hardware and Operation

n/a Documentation Missing for New Power Supply Devices

Documentation regarding the new power supply devices SD831 – SD834 and SS832 is missing in the manual. Refer to Technical Descriptions 3BSE053111 and 3BSE054059 respectively for data on the products.



3BSE033044D5020. Printed in Sweden September 2008Copyright © 2003-2008 by ABB. All Rights Reserved® Registered Trademark of ABB.™ Trademark of ABB.

Automation Technology Products Wickliffe, Ohio, USAwww.abb.com/controlsystems

Automation Technology ProductsVästerås, Swedenwww.abb.com/controlsystems

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