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PAC8000 Hybrid Controller8000 Process I/O hardwareOverview8000 is a completely modular I/Osolution for both general purpose andhazardous area applications. It is basedon a carrier system that supports arange of modules and offers a widevariety of I/O functions, including ACmains and intrinsic safety signals, evenwithin the same node.I/O ModulesI/O modules transfer signals to andfrom field instruments. Input modulesreceive signals fromtransmittersandsensors and convertthem into a digitalformforpresentation to theController.Outputmodulesreceive commands from the Controllerand transfer them to actuators. A widerange of modules is available, includingtypes for low-level instrumentation, ACmains and intrinsically safe signals, I/Omodules typically have 4, 8 or 16 fieldchannels.Field terminalsField terminals provide the interfacebetween the I/O modules and the fieldwiring. They include fusing and loopdisconnectas options.Amechanicalkeyingsystempreventsan I/O module from being connected tothe wrong type of field terminal. Fieldterminals mount onto the modulecarrier, one to each I/O module. Theyare clamped firmly by the I/O module toform an electrical and mechanicalassembly of high integrity. They may bereplaced in service without removingcarriers or disturbing the operation ofother modules.CarriersCarriers form 8000's physical andelectrical backbone by providing amounting to support and interconnectthe controller, power supplies, I/Omodules and field terminals, and carrythe address, data and power lines of theinternal Railbus. They provide terminationpoints for the LAN and to the I/Omodules. I/O module carriers areavailable to support four or eight I/Omodules.System power suppliesSystem power supplies are available forthe node to convert local AC or DCsupplies to power the node or pro-videfield power for I/O modules. 8000'sinnovative BussedField Power schemefor distributing fieldpoweravoidscomplex wiring atthe field terminaland minimizes thecarrier wiring.'HART-ability'The use of 'smart' instruments on processplants is growing but this investment isnot always fully exploited. Whether it isfor a new installation, or the upgrade ofan existing one, GE Intelligent Platformshassolutions thatprovidetheconnections between the HART fieldinstruments, the control systems and theprocessautomationmaintenancesoftware. Specifically, the 8000 ProcessI/O system has been designed to betransparent to HART signals, thusallowing the host control software andanyHARTfieldinstrumentstocommunicate directly with each other. Inaddition, 8000's HART connection systemprovides on-line access from a PC to theHART field devices for monitoring deviceperformance.8521-HC-MTHART devices may be selected for regularstatus monitoring and alerts can be issued ifthe status changes.The benefits from this approach are: reduced commissioning time and cost reduced process downtime throughstatus monitoring power loop maintenance costs by usingfield device diagnostics.8000 in your systemEach PAC8000 node can address up to 64 I/Omodules which, depending upon the numberof channels per module, can pro-vide up to1024 I/O points at a single node! A node canconsist of a mixture of analog and discretemodules and this gives maximum flexibilityto the system designer. Full HART passthrough is provided - the 8000 appears"transparent", allowing the inquiring "agent"to access the HART capabilities of fieldinstruments. GE Intelligent Platformsrecommends placing no more than 25 nodeson the subnet of a network.Redundancy options8000 has been designed to increaseavailabilityandminimizedowntime.Redundant controllers, LAN Channels andpower supplies can be specified as options toincrease system availability. Possible downtime is further reduced by ensuring that thesystem components using active circuitrycan be removed and replaced quickly andeasily. Even the field terminals can bereplaced without interrupting the operationof adjacent I/O modules. Carriers have noactive circuitry and are unlikely to needreplacement.Hazardous area applicationsThe 8000 is a truly field mountable systemeven in areas where flammable gases arepresent. It is available in versions to suitdifferent area classification schemes:a) Equipment and field wiring located ingeneral purpose areas, Class 1, Division2 hazardous locations or Zone 2hazardous areas.b) Equipment mounted in general purposeareas, Class 1, Division 2 hazardouslocations or Zone 2 hazardous areas,with field wiring located in Division 1hazardous locations or Zone 0hazardous areas.

PAC8000 Hybrid Controller8521-HC-MT8000 with general purpose field wiringMany industry applications do not present an explosionrisk from gas or dust hazards. In others, the environmentmay be classified as a Zone 2 or Division 2 hazardousarea, where flammable material is expected to occuronly in abnormal conditions. For both of these the 2/2system provides effective distributed I/O for processcontrol. 8000 supports a full range of I/O module typescovering inputs and outputs for both analog anddiscrete circuits. The node can be mounted out on theplant in a suit-able enclosure providing protectionagainst the environment. Figure 1 shows a nodecontaining all the key components: a PAC8000Controller, I/O modules on their carriers and a pair ofcarrier-extenders linked with an extension cable.8000 with intrinsic safety field wiringThe 8000 Process I/O System is capable of supportingI/O modules with intrinsic safety (IS) field wiring, forconnection to certified or 'simple apparatus' field devicesin Division 1 or Zone 0 hazardous areas (see Figure 2). Arange of I/O module types with IS field circuits forindustry-standard DI, DO, AI and AO applications issupported.I/O modules with built-in protectionAll voltage and current-limiting components required forIS protection are incorporated within the I/O modulehousings, so no external, add-on Zener barriers orgalvanic isolators are necessary. IS field terminals aredistinguished from other types by blue coloring of theterminal housing. A unique and sophisticatedmechanical keying mechanism prevents modules withdifferent protection techniques from being interchanged, so that potentially explosive or damagingconditions cannot occur.Integrated power suppliesPower for IS I/O modules is derived from integrated,modular power supply units. Each power unit is capableof supplying between eight and twenty I/O modules,depending on the I/O type and mix. Optional powersupply redundancy is supported by means of an additional, redundant supply unit connected in an 'n 1' arrangement. In applications withmixed IS and non-IS field wiring, the full facilities of the 'Bussed Field Power' regime are retained for the non-IS part of the system. In nodespopulated only with IS I/O modules, a separate system power supplymodule provides power for the Bus Interface Module and 'node services'. Redundancy of this supply is also supported.Mixed I/O types within a single nodeIS and non-IS field wiring types can also be incorporated within one 8000 node. In this arrangement, the two parts of the node areseparated by a 'Railbus Isolator' module. The Railbus Isolator provides a section of internal communications bus ('Railbus') for the IS I/Omodules which is protected from invasion by damaging fault voltages Uniquely, a single 8000 node (under the command of one BusInterface Module) can then support a mixture of certified IS field devices, certified Division 2 or Zone 2 field devices and general purpose I/O,including AC mains circuits. Only one Railbus Isolator is used per 8000 node.

PAC8000 Hybrid Controller 8521-HC-MTpowerful, robust controller for advanced control strategiesPAC8000 Strategy Builder for process control applicationsIEC 61131-3 software for logic control applicationsprocess & logic control strategies execute concurrentlyredundant controllers with bumpless transferdual redundant high speed Ethernet connectionsfield mountable in harsh process environmentspeer to peer communications between controllerson-line configuration and reconfigurationHART pass-through of process and status variablesOpen control platformThe PAC8000 Hybrid Controller is a powerful process controllerthat can receive, store and execute process strategies andsequential or discrete logic applications concurrently. Thecontroller provides a tight control loop response, providing acontrol output in response to input data within 100ms. Thecontroller communicates at 10/100MB/sec-ond, providing veryefficient communications and assuring the system has thecapacity for advanced control strategies.Controller redundancytake up user-defined failsafe attitudes. In the event of power lossthe PAC8000 Controller will perform a cold restart which restoresthe program(s) and assume a predefined status.Peer-to-peer communicationsPAC8000 Controllers can communicate with each other on a peerto-peer basis, enabling controllers to share data with each other.This capability assures that critical information can be efficientlyshared between controllers instead of requiring data to be passedto each controller from the control room.Redundant controllers can be used for critical control applications.The redundant controller pair operates in parallel, checking statusmultiple times through the processing loop enabling the backupcontroller to continuously monitor the health of the mastercontroller, assuring a rapid and bumpless transfer to the standbycontroller.I/O module configurationNetwork redundancyFirmware updatesIn addition to controller redundancy, the PAC8000 Controller hastwo high-speed Ethernet ports to provide security ofcommunication. Each port can be connected to an independentLAN which is continuously monitored for its integrity. If the primaryport detects a network failure, traffic is immediately switched tothe other LAN to maintain full communication.In keeping with its ability to maintain operations on a continuousbasis, a redundant PAC8000 Controller is also capable of receivinga firmware upgrade. In a manner similar to that used for strategyupdates, a controller can receive an update to its firmware whilein the field. When the upgrade has been confirmed as successfulthe controller can be returned to full operation as a master or as aprotective standby.Executable control programsControl programs are downloaded to the PAC8000 Controller topro-vide process control with PAC8000 Strategy Builder and logiccontrol with IEC 61131-3 compatible programming languages. Thecontrol programs are held in non-volatile memory to enable themto be restored automatically after power cycling of the controller.The use of a redundant controller also enables a new controlprogram to be downloaded to the standby unit while the processcontinues. When the download has been completed and verified,the standby can be switched to master status to employ the newprogram.Remote Modbus DevicesThe PAC8000 Logic Controller communicates via Modbus TCP overEthernet and can operate in either Modbus Master or ModbusSlave mode to communicate with remote Modbus devices. Eachcontroller also has 2 serial ports that can be configured as aModbus Master to control and obtain information from ModbusSlaves and other serial devices, such as weighscales, barcodereaders, etc. The serial ports can also be configured as a ModbusSlave, accepting write commands from Modbus Master devicesand providing information on its data registers.Failsafe and automatic cold startIn the event of complete loss of communication the controller willadopt a user-defined failsafe mode and similarly instruct the I/O toThe PAC8000 Controller receives full details of all the I/O modulesunder its control and stores the information in non-volatilememory. At startup the controller downloads to the modules theirconfiguration details, which also include the failsafe states theyshould adopt in the event of communication failure.HART pass-throughThe PAC8000 controller has the ability to pass smart HARTinformation from field devices to a separate PC workstation, whichallows you to readily interface to asset management softwareapplications, to remotely manage the HART information containedin your HART based, field instruments. It works with a variety ofasset management packages, including Applied SystemTechnologies' Cornerstone Software or Emerson's AssetManagement Solutions. HART pass-through is supported via aserial port and will soon be available over the Ethernet ControlNetwork. Consult the factory for availability of the Ethernetsolution.Environmental stabilityLike all of the 8000 series equipment, the PAC8000 Controller isdesigned for use in harsh environments. It operates over atemperature range of –40 C to 70 C and is resistant to shock,vibration and corrosive environments.Hazardous area operationThe PAC8000 Controller is designed also to operate in Class I,Division 2 and Zone 2 hazardous areas and can control I/Omodules that have field wiring extending into the more hazardousDivision 1 and Zone 1 and Zone 0 areas.

PAC8000 Hybrid ControllerGrows as your needs growThe PAC8000 Hybrid Control System is scaleable to your needs.You can add modular I/O to your system as your needs increase.Redundant controllers can be added without the need to poweroff your system -the backup controller powers up automaticallyand is seamlessly brought online. Don't worry about expandingyour system software; your original PAC8000 Hybrid Workbenchcan address all of your software needs.Maximum number of nodesMutliple PAC8000 controller nodes can reside on the samenetwork allowing peer-to-peer communications, as explainedabove. However, too many nodes can degrade performance, soGE Intelligent Platforms recommends placing no more than 25nodes on the same subnet of a network.The PAC8000 Hybrid Controller 8521-HC-MT contains twopowerful embedded software environments that will runexecutable files downloaded to it from the Workbench.PAC8000 Process allows the controller to perform the functions ofprocess automation while PAC8000 Logic is intended for logicautomation applications.PAC8000 PROCESS OVERVIEWPAC8000 Process is a process control engineering andmanagement software solution with full distributed processcontrol system functionality. The system is a fully integratedadvanced process control and instrument engineering systemoffering configuration tools, modeling, simulation, troubleshootingutilities, project drawing management and self-documentation.PAC8000 Process is an open, easy-to-use, robust system providingthe flexibility to configure control systems ranging from a fewloops to thousands of points. The user can also scale their designallowing cost effective system expansion. In addition, the system'sextensive use of industry standards simplifies integration withother application.Note: For users interested in process applications only, the 8521PC-MT PAC8000 Process Controller is available. This is the samephysical controller but containing only the PAC8000 Processapplication. This controller can be programmed with the PAC8000Process Workbench or the PAC8000 Hybrid Workbench.PAC8000 Process WorkbenchPAC8000 Workbench consists of modular software building blocksthat are integrated into a process control solution. The systemcomprises two integrated components; the Instrument Index andthe PAC8000 Strategy Builder.Instrument IndexThe Instrument Index is used to model the process systemsinput/out-put by assigning controller, module and pointdestinations. Using a predetermined template, this task isaccomplished as a simple "fill in the blanks" procedure. TheInstrument Index uses this information to build the I/Oconfiguration data file. This data file will subsequently be used tocross-link the point attributes to the algorithms on the processcontrol diagrams.PAC8000 Strategy BuilderProcess control logic diagrams are developed using the PAC8000Strategy Builder. The control strategy is built by selecting theappropriate blocks, assigning symbolic tags, and then connectingthe blocks with analog or digital lines, using standard drawing8521-HC-MTforms and commands. SAMA style drawings define all thefunctions and parameters that form a process loop. Functionblock choices include; manual/auto station, function generators,pulse controllers, sequencers, bumpless transfers, PID and otherstandard function blocks. To further reduce development timetemplate diagrams can be created and reused within the currentproject or another future project. For example, a cascade loop canbe created and saved for repetitive use to generate additionalcontrol loops. When the drawing model is completed, the projectdiagrams are cross-linked with the I/O database to create: Comprehensive control system engineering documentation. Advanced control strategies. Operator interface database, alarms and faceplates. System maintenance tools.There is no need to review function block codes, re-enter tags,generate spare parts listings, or match control logic to theoperator interface. This allows the user to concentrate ondesigning control strategies and eliminate the repetitive tasks.Project ComponentsIn addition to these key design features, PAC8000 Hybrid Controlhas a wealth of tools and features that simplify the managementof the project and provide easy to use interfaces for the user.Comprehensive Self-DocumentationPAC8000 automatically generates as-built system documentationincluding I/O configuration reports, cross reference analysis, bill ofmaterials, instrument index, system start-up, maintenanceinformation, and wiring diagrams. The instrument index providesinstrument details such as manufacturer, model number, groupnumber, shift and day log, panel wiring information includingpanel in/out terminal block and panel in/out position, and fieldwiring information including cable color, size and type.Database and Tag Import utilityThe system generates the appropriate database, tag attributesand alarm parameters. The Tag Import Utility can be used toimport a tag list that is already defined in a spreadsheet format.The utility imports a .csv, tab or space separated file directly intothe Workbench, saving the need to manually recreate thisinformation if it already exists.Advanced Control StrategiesThe system automatically configures control solutions fromstraight-forward single loops to advanced control strategies. Withover sixty process control algorithms, PAC8000 has the solution;whether for regulatory, logic or sequential control. The algorithmsprovide the logic and analytic functions for complex controlstrategies such as feed forward, cascade, and multi-variablecontrol. Functions are provided for easily configuring biased multioutput loops as found in steam and water header pressurecontrol. The system automatically accounts for different devicecapacities, devices in service, and devices in automatic mode.Adaptive tuning functions for PID control is supported. Two andthree state device drivers provide the functionality for motor andvalve operations with failure alarms, local and remote operation,and interlocks. Sequential step functions with interlocks and firstout functionality are easily configured. The system automaticallyassigns controller addresses, optimizes controller communicationsand provides I/O card and point alarm status. By supportingportability between alternative open controller platforms,PAC8000 provides considerable flexibility in specifying systemhardware.

PAC8000 Hybrid ControllerOn-line Maintenance, Tuning and TroubleshootingSavings in time and system costs are not limited to initialdevelopment and start-up. The system provides suggestive tuningcapabilities, on-line and off-line control configuration, andintelligent control schematics from which the system can bemodified and tuned.PAC8000 SimulatorThe PAC8000 Simulator allows the animation of logic diagramswith either simulated data or live, real-time process data. TheSimulator is also used for tuning and operator control purposes.I/O diagnostic tags are provided for the operator interface fortroubleshooting assistance. Verification of control loop integrityand troubleshooting loop problems can be accomplished quicklyand efficiently.PAC8000 LOGIC OVERVIEWPAC8000 Logic is a 32-bit software application for distributedcontrol applications. It supports all five IEC 61131-3 languages:Ladder Diagram (LD), Structured Text (ST), Instruction List (IL),Sequential Function Chart (SFC) and Function Block Diagram (FBD),plus the Flow Chart (FC) languageThe PAC8000 Hybrid Workbench is used for creating and editingthe control code, for simulation, debugging, and on-linemonitoring. The code generated by the Workbench is thendownloaded to the PAC8000 Controller.Note: For users interested in logic applications only, the 8521-LCMT PAC8000 Logic Controller is available. This is the same physicalcontroller but containing only the PAC8000 Logic application. Thiscontroller can be programmed with the PAC8000 LogicWorkbench or the PAC8000 Hybrid Workbench.PAC8000 Logic WorkbenchThe Workbench contains a powerful project management toolthat graphically represents and organizes programs, resources,configurations, and networks within a project.The Workbench provides powerful and intuitive graphical andtextual editors. Docking toolbars and resizable split windows,drag-and-drop and cut-and-paste are all implemented toenhance ease-of-use.The Ladder Diagram (LD) is one of the PAC8000 familiar methodsof representing logical equations and simple actions. Contactsrepresent input arguments and coils represent output results.Each block in the selection list has a description text.The Structured Text (ST), is a high level structured language witha syntax similar to Pascal but more intuitive to the automationengineer. This language is mainly used to implement com

GE Intelligent Platforms PAC8000 Hybrid Controller 8521-HC-MT Overview PAC8000 Hybrid Control provides a fully integrated solution for process control, logic automation and strategy development. PAC8000 Hybrid Control . On-line changes PAC8000 Hybrid allows on-line configuration changes during testing, start-up, and maintenance phases. .