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SattLine CPU80

The recent addition of the actively supported SattLine CPU80 controller and new communication modules secures Sattline installations for the future.

The CPU80 controller introduced in the SattLine 3.0 version and the classic Series 200 controllers can fully coexist in the SattLine environment. CPU80 supports both S800 I/O and Satt I/O.

An existing Sattline installation can easily be stepwise upgraded or extended on controller or I/O level when needed giving the possiblity to stay in full operation for several years to come.

The CPU80 controller with it's hardware communcation modules, is a high capacity next generation Satt DCS process controller for medium to large size applications, that mainly has the same functionality as the classic 200 series controllers.

The CPU80 controller supports S800 I/O via PROFIBUS DP, Satt I/O via ControlNet and various serial communications protocols via RS232:

  • CI854B for PROFIBUS DP
  • CI865 for ControlNet
  • CI853 for RS232 communication 

SattBus communication is supported on Ethernet. RS485 communication is possible to convert via RS232. NN-bus communication is not supported.

SattLine CPU80 life cycle status
SattLine CPU80 is in the Active life cycle phase, meaning it is being actively developed and supported.

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Overview
Application
SattLine looks the same, works the same, and has the same functionality no matter the application and system size. Thus, you can grow with the same system without replacing or reconfiguring anything which is already done. The system consists of both a software and a hardware part.

The software architecture is build up of configuration, programs, libraries and modules.

Modules
SattLine control programs are built by designing and assembling modules (objects). Lower level modules implement process objects like valves or basic functions like event detection.
The modules are stored in libraries containing graphics and program code. Basic objects can be used to form higher hierarchies like a mix tank, raw material intake, etc.

The software reuse enables fast program configuration, high quality development, and consistency, with kept flexibility.

The total application is called a program configuration which contains all programs for the plant. The configuration is split up into programs and libraries.

Program
A program is a hierarchical module collection of graphics, equations, variables, etc. The program can be distributed so that the station or controller can execute several programs.

A program can refer to libraries for module and data type definitions. The programs can also exchange information.

Library
A library is very similar to a program, but is only used to define modules and data types. Libraries may refer to other libraries and can be used by many programs.

Communication
The communication between the stations and the controller (within a program) is automatically set up by the system. There are integration functions like database communication via ODBC or program communication via OLE/OPC. Other Windows programs can be started from commands inside SattLine.

The hardware architecture is build up of the user interface, the control system and communication.

User interface
The user interface consists of four license types that run on Microsoft Windows and on PC/Intel systems or virtually on VMware 6.0

The Workstation can be used for supervision, programming, maintenance, data storing, etc. All users have the same interface and interaction principles. A sophisticated privilege system ensures a safe workplace. The Workstation is available in different licenses sizes. They have the same functionality but differ in application size.

The Viewer station is a low cost license limited for a few hours of operation after each start and without programming.

The Local station is a local operator station license for shop floor control. The license is limited in size and has no programming.

The Programming station is a license for programming and testing only.

Control system

The control system is based on DIN-rail mounted modules, consisting of freely combined CPU80, fieldbus and serial communication modules.
The CPU control system is compatible with the previous Series 200 CPUs having the same functionality, making upgrading easy.

Support of S800 I/O and S200 I/O 
Both I/O system is based on three module types: communication interface, terminal base and I/O module. The I/O modules are available as digital, analogue, pulse and combined input and output. Several terminal bases are offered. The small footprint facilitates a very compact installation.

The I/O can be installed distributed. Thereby, the need for field cabling and documentation is reduced. The I/O modules can be changed on-line and the I/O system can be set to fail-safe mode.

Communication
The communication between the different SattLine nodes is based on MMS and standard Ethernet (single or redundant). Co-operation and integration with foreign equipment and programs is enabled through special functions. There are various communication protocols available like Profibus, COMLI, etc.

SattLine Functions
SattLine contains a number of libraries. Modules in the libraries are used to solve general functions to provide process control as required from a DCS system.

The modules describe control solutions at different levels. Modules for physical objects like valves or motors, modules for analogue control algorithms or special function modules are natural parts of the SattLine libraries.

The modules include functions like alarm and event management, history logging and journal handling, control loop modules, report configuration modules, I/O configuration modules, etc.

Generally, a module can contain, besides control algorithms through sequences and equation blocks, variables and parameters for these algorithms and also graphics for presentation and interaction as well as other modules.

Alarm and Event Management
Changes in process status requires fast action by the system and the operator. This is handled by the event and alarm handling functions.
Alarms as well as events are not restricted to a change of a variable in the system, but also have further information as Tag, Event text, Severity, Class, Type of event, Time filters and Status text.
The time stamped events can be shown in different lists, printed on different printers or acknowledged/logged in different workstations.
For quick action, an event can initiate a process command or pop up a window containing more information or instructing the operator how to act.
Acknowledgement of events can be done under protection by user privileges.

History logging
Historical data can be logged on one or several workstations as a journal file on disk. 

The journal can contain history data as well as single snapshots of data or manually entered data. Operation as read, write, etc. on the journal can be performed from any workstation or process controller.

A journal contains data marked with time and tag. Integer, real, Boolean, string variables as well as user defined data types (records) can be stored. The storage is either done cyclically or event triggered or a combination. Different data can be stored in the same journal e.g. batch journal containing events, history trends and reports related to a specific batch. Journals can be presented as curve diagrams.

Control Loops
PID modules and supporting modules make it possible to create cascade-, feed forward- and split range control loops. 

The PID function has anti reset windup facility, bumpless transfer between manual and automatic modes, low pass filter for the derivative part of the PID, autotuning with gain scheduling and dead time control function. As special modules fuzzy control for the case of one to many inputs and outputs, stiction compensator - a control function for compensation of static friction in control valves and a control loop performance monitor for detection of oscillations are available. For the analogue signals, functions as scaling, filtering, linearization, limitation, integration and differentiation are possible.

Other modules for generation of set point ramps and other profiles, combining PID’s via multiplexes or max./min. selectors or three point controllers with feedback are part of the control loop library.

Interaction of the control loop function is done in pop-up windows. Standard windows are bargraphs, trend curves and parameter list presentations.

Time channel modules, automatic check of feedback signals, time controlled alarm activation and object runtime supervision

- Time channel modules are used for periodic starting and stopping of process objects according to the system clock, weekdays, holidays, etc.
- Automatic check of feedback signals (ACOF) from e.g. valves can be supervised by standard modules.
- Time controlled alarm activation according to different alternatives e.g. while opening or while closing are available.
- Object runtime supervision (RUTI) is a function supervising total runtime of process objects like motors. 

Validation is applied to many aspects of pharmaceutical manufacture. Examples include services, equipment, computers, processes and cleaning. In each case, the objective is to "Establish documented evidence which provides a high degree of assurance that a specific process will consistently produce a product meeting its pre-determined specifications and quality attributes."

SattLine looks the same, works the same, and has the same functionality no matter the application and system size. Thus, you can grow with the same system without replacing or reconfiguring anything which is already done.

Qualification documents for automated systems can only be produced satisfactorily when a complete specification of the System Integration Methodology exists. 

The SattLine DCS system are developed and maintained under a rigorous quality system and includes features to reinforce cGMP requirements and expectations. 

The companies approach in application projects is to use a System Integration Methodology following a Life-cycle model, the resulting Quality Report is an important document to be included in the Validation Report. These elements are necessary to produce a control system that fulfills the cGMP requirements.

Audited supplier
World-wide leading pharmaceutical manufacturers have audited ABB Automation's development, production, training, after sales and maintenance departments.

Audits have shown that the manufacturers are convinced that ABB can deliver validated automation systems and software. This has been proved by many installations and successfully executed FDA inspections of the facilities. Among the customers are companies like Novo Nordisk, Hoffmann-La Roche, Novartis, Astra and others.

System integration methodology
Project execution to develop SattLine applications to the pharmaceutical industry is defined in the Engineering Guidelines (EGL) with extensions of Pharmaceutical Guidelines (PGL).

For the different phases in the Life-cycle model, the purpose of the phase, acceptance criteria and review activities are defined and documented.

Test specifications are defined to prove that the system performs correctly as defined in the related specification. Tests are performed and reviewed to verify the functionality of the application system.

At the completion of the, project the project quality report is issued to the validation report as input. 

Support and maintain your system

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