Is it possible to move controller from one Aspect system to another without production interuption?

We want to move AC800M controller from one aspect system to another aspect system without production interuption. Is there a documented way how to do that? On both, new and old Aspect systems will be the same version of 800xA with the same Control Structure and controller application.

Thanks.


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CZMALIT   

asked 1 month ago
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2

I have moved PM866 from standalone 800xA to the new 800xA of the same version during production shutdown. However AC800M was not restarted during movement and it kept values of all variables. So it should be possible even during production.

I am afraid I cannot reproduce that procedure in very detail. I exported application and PLC from Control structure and imported into the new 800xA.

At old Engineering PC I copied files from CompilerOutput directories at C:\ABB Industrial IT Data\Engineer IT Data\Control Builder M Professional\Projects\[your project]\PLC and App to the same CompilerOutput directories at new system Engineering PC. (or even copied the whole CompilerOutput directories)

The Control Builder complained several times while going online for the first time, but from that moment PLC was working in the new 800xA system without any problem.

kamil.herman   

answered 1 month ago


 


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Answers

2

I have moved PM866 from standalone 800xA to the new 800xA of the same version during production shutdown. However AC800M was not restarted during movement and it kept values of all variables. So it should be possible even during production.

I am afraid I cannot reproduce that procedure in very detail. I exported application and PLC from Control structure and imported into the new 800xA.

At old Engineering PC I copied files from CompilerOutput directories at C:\ABB Industrial IT Data\Engineer IT Data\Control Builder M Professional\Projects\[your project]\PLC and App to the same CompilerOutput directories at new system Engineering PC. (or even copied the whole CompilerOutput directories)

The Control Builder complained several times while going online for the first time, but from that moment PLC was working in the new 800xA system without any problem.

kamil.herman   

answered 1 month ago


 


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2

> "We want to move AC800M controller from one aspect system to another aspect system without production interuption"

In theory it is possible

> "Is there a documented way how to do that?"

Not that I know Of

You should test this carefully. There are many things that could go wrong and no chances to get away with making a mistake. If you are using Batch Manager on the controller, then I think this probably will not work because of the way the BM connects to the controller.

Disclaimer : The following is totally untested and comes without any warranty !

- Ensure that both Control Systems have **exactly** the same versions of 800xA Software and Libraries. If the versions are not exactly the same, then you will need to decide if they are "close enough" for you to proceed. Any differences in OPC Variable configurations would prevent the procedure from working.

1. Copy the Application

- Export the Controller Hardware and Applications from System A. The Export should have "NO Dependecies" and "EXCLUDE Extentions". Export related graphic displays and other information to a seprate file. Again with no dependencies or extensions".Also export any custom libraries and object types required by this application

- Import the Operator Graphics, Controller Hardware and Applications into System B

- Verify the system has been imported correctly and that you are 100% confident that everything is correct.

2. Copy the Cold and Warm Start Data

- Go to "C:\ABB Industrial IT Data\Control IT Data\OPC Server for AC 800M\Files" and copy the files for this controller and applications from the System A Connectivity Servers to safe Media.

- On System B Check the same files on the connectivity servers have been restored. If not, Copy them from the safe media to the Connectivity Servers

3. Connect the OPC Servers on system B to the controllers

This is where things may go wrong and you should test this before trying it on a live system.

- Disconect One Server on System A

- Connect One Server on System B

With luck, everything will start working.

Personally, I would also make a backup plan with Production so you know what to do if the controller stops, trips or has to be restarted.

Rob Lyon   

answered 1 month ago


 


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