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ABB S800 I/O Manual

Fieldbus communication interface for profibus dp/dpv1
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Fieldbus Communication Interface for PROFIBUS DP/DPV1
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Summary of Contents for ABB S800 I/O

  • Page 1 S800 I/O Fieldbus Communication Interface for PROFIBUS DP/DPV1 Power and productivity for a better world...
  • Page 3 S800 I/O Fieldbus Communication Interface for PROFIBUS DP/DPV1...
  • Page 4 In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hard- ware described in this document.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS About This Book General ..........................11 Document Conventions ....................11 Warning, Caution, Information, and Tip Icons..............11 Terminology........................12 Related Documentation ....................14 Section 1 - Introduction Product Overview ......................16 Product Scope.......................16 Section 2 - Installation Section 3 - Configuration CI801 FCI ........................29 Address Switches ....................29 PROFIBUS Connection ..................30 Power Supply Connections ..................32...
  • Page 6 Table of Contents Configuration and Performance ..................40 CI801 Configuration Rules .................. 40 CI830 Configuration Rules .................. 45 CI840 Configuration Rules .................. 49 Supported I/O Modules and Drives via PROFIBUS and CI801 ......54 Supported I/O Modules and Drives via PROFIBUS and CI830 ......55 Supported I/O Modules via PROFIBUS and CI840 ..........
  • Page 7 Table of Contents CI801 Fieldbus Communications Interface (FCI) ............93 Features ......................93 Description ......................93 Technical Data......................94 Dimensions......................96 Connections......................96 Block Diagram CI801 ..................98 CI830 Fieldbus Communications Interface (FCI) ............99 Features ......................99 Description ......................99 Technical Data....................100 Dimensions......................102 Connections......................102 Block Diagram CI830 ..................105 CI840 Fieldbus Communications Interface (FCI) ............106 Features ......................106 Description ......................106 Technical Data....................109...
  • Page 8 Table of Contents Dimensions ......................121 Connections ..................... 122 Block Diagram TU847..................124 INDEX 3BSE020926-600...
  • Page 9 Safety Summary Electrostatic Sensitive Device Devices labeled with this symbol require special handling precautions as described in the installation section. GENERAL Equipment Environment WARNINGS All components, whether in transportation, operation or storage, must be in a noncorrosive environment. Electrical Shock Hazard During Maintenance Disconnect power or take precautions to insure that contact with ener- gized parts is avoided when servicing.
  • Page 10 Safety Summary 3BSE020926-600...

  • Page 11: About This Book

    This book is not intended to be the sole source of instruction for the S800 I/O system. Document Conventions Microsoft Windows conventions are normally used for the standard presentation of material when entering text, key sequences, prompts, messages, menu items, screen elements, etc.

  • Page 12: Terminology

    Terminology About This Book 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 Although Warning hazards are related to personal injury, and Caution hazards are...
  • Page 13 About This Book Terminology Term Description I/O cluster An extension of the I/O Station’s ModuleBus connected to the FCI by fiber optic connections. Up to 12 I/O devices per cluster. I/O device A complete I/O device consists of one MTU and one I/O module.

  • Page 14: Related Documentation

    I/O system. S800 I/O Modules and Termination Describes the I/O modules and Units termination units in the S800 I/O system. S800 I/O Modules and Termination Describes the I/O modules and Units with Intrinsic Safety Interface termination units with I.S. interface in the S800 I/O system.

  • Page 15: Section 1 Introduction

    The S800 I/O is distributed modular I/O which communicates with numerous controllers over a Advant Fieldbus 100 (AF100), PROFIBUS-DP/DPV1 or directly. The S800 I/O provides easy installation of the I/O modules and process cabling. It is highly modularized and flexible so that I/O modules can be combined to suit many applications.

  • Page 16: Product Overview

    Section 1 Introduction Product Overview The S800 I/O provides easy installation of the I/O modules and process cabling. It is highly modularized and flexible so that the I/O modules can be combined to suit many applications. The S800 I/O modules and a Fieldbus Communication Interface (FCI) are combined to form an I/O Station.
  • Page 17 Section 1 Introduction Product Scope I/O Station modules are mounted on DIN rails and are connected by the ModuleBus. Figure 2 shows the FCI modules connected to the Optical ModuleBus Port TB842. LED Status Indicators ModuleBus Interface Connector Power Supply Address TB842 Switch #1...
  • Page 18 An I/O Station can consist of the FCI module, ModuleBus Modems and the I/O modules. The FCI is the bus-master on the S800 I/O ModuleBus and communicates with the S800 I/O modules. It is a pure “slave station” on PROFIBUS-DP which is controlled by a master station.
  • Page 19 Section 1 Introduction Product Scope I/O Station modules are mounted on DIN rails and are connected by the ModuleBus. This principle allows horizontal and vertical mounting on the wall. Figure 3 shows the FCI Module. LED Status Indicators ModuleBus PROFIBUS DIN Rail Interface Connector...
  • Page 20 Product Scope Section 1 Introduction The FCI communicates with the PROFIBUS Master, ModuleBus Modems and the I/O modules. The FCI handles the I/O-modules operations such as read and write data, read status and configuration of modules and channels. The FCI has a connector for the TB810/TB811 Optical ModuleBus Port.
  • Page 21 An I/O Station can consist of the FCI modules, ModuleBus Modems and the I/O modules. The FCI is the bus-master on the S800 I/O ModuleBus and communicates with the S800 I/O modules. It is a pure “slave station” on PROFIBUS-DPV1 which is controlled by a master station.
  • Page 22 Product Scope Section 1 Introduction LED Status Indicators Rx/Tx Rx/Tx PRIM PRIM DUAL DUAL ModuleBus Interface Connector Address Switch #1 (Address 66 shown) Address Switch #2 CI840 CI840 TB842 TB806 Power Supply Service Connections Ports PROFIBUS Connector Figure 5. CI840 FCI Module, TU847 Termination Unit and TB842 Optical ModuleBus Port 3BSE020926-600...
  • Page 23 Section 1 Introduction Product Scope Figure 6. CI840 FCI Module, TU846 Termination Unit and TB842 Optical ModuleBus Port 3BSE020926-600...
  • Page 24 Product Scope Section 1 Introduction The FCI communicates with the PROFIBUS Master, ModuleBus Modems and the I/O modules. The FCI handles the I/O-modules operations such as read and write data, read status and configuration of modules and channels. The FCI has a connection to the TB842 Optical ModuleBus Port.
  • Page 25 Section 1 Introduction Product Scope For CI840 FCI and TU846/TU847 dimensions, see Figure 7 Figure Figure 7. TU847 Dimensions (Same Dimensions for TU846) 3BSE020926-600...
  • Page 26 Product Scope Section 1 Introduction 128 mm (5.04”) 47 mm (1.85”) 124 mm (4.88”) 162,9 mm (6.41”) 186,5 mm (7.34”) Figure 8. CI840 FCI and TU847 Terminal Unit Dimensions (Same Dimensions for TU846) 3BSE020926-600...

  • Page 27: Section 2 Installation

    Section 2 Installation Refer S800 I/O Getting Started (3BSE020923*). For PROFIBUS, see PROFIBUS DP Wiring and Installation (3BDS009029*). 3BSE020926-600...
  • Page 28 Section 2 Installation 3BSE020926-600...

  • Page 29: Section 3 Configuration

    Section 3 Configuration CI801 FCI The FCI needs to be connected to the PROFIBUS-DPV1 and have an address selected. It is also connected to a 24 V d.c. power source to provide power to the I/O Station. Also refer to Configuration and Performance on page 40 for information on how to estimate the fieldbus and power loading of each I/O station configuration.

  • Page 30: Profibus Connection

    PROFIBUS Connection Section 3 Configuration PROFIBUS Connection The FCI connects to the PROFIBUS through the 9 pin D-way connector on the front. This allows the FCI (if not the last one at the PROFIBUS segment) to be removed from the PROFIBUS without disconnecting the other nodes of the fieldbus.
  • Page 31 Section 3 Configuration PROFIBUS Connection Table 2 shows the fieldbus connection assignments. Table 2. FCI PROFIBUS Connections Designation Description Shield Shield/protective ground Not used RxD/TxD-P Receive/Transmit data - plus Direction control (optional) DGND Data ground Supply voltage for the terminating resistors Not used RxD/TxD-N Receive/Transmit data -...

  • Page 32: Power Supply Connections

    Figure 11. CI801 FCI Power Supply Connections The incoming power can then be distributed to other FCIs or the I/O modules if desired. Refer to S800 I/O Getting Started (3BSE020923*) manual for power supply connection diagrams. Power connections can accept 0.25 - 2.5 mm (24 - 14 AWG) wire size.

  • Page 33: Ci830 Fci

    Section 3 Configuration CI830 FCI CI830 FCI The FCI needs to be connected to the PROFIBUS-DP and have an address selected. It is also connected to a 24 V d.c. power source to provide power to the I/O Station. Also refer to Configuration and Performance on page 40 for information on how to estimate the fieldbus and power loading of each I/O station configuration.
  • Page 34 PROFIBUS-DP Connections Section 3 Configuration Figure 13 for CI830 connection details. CI830 PROFIBUS Tx Rx Profibus Cable Figure 13. CI830 FCI PROFIBUS Terminal Connections Table 4 shows the fieldbus connection assignments. Table 4. FCI PROFIBUS Connections Designation Description Shield Shield/protective ground Not used RxD/TxD-P Receive/Transmit data - plus...

  • Page 35: Power Supply Connections

    Figure 14. FCI Power Supply Connections The incoming power can then be distributed to other FCIs or the I/O modules if desired. Refer to S800 I/O Getting Started (3BSE020923*) for power supply connection diagrams. Power connections can accept 0.25 - 2.5 mm (24 - 14 AWG) wire size.

  • Page 36: Ci840 Fci

    CI840 FCI Section 3 Configuration FCI power supply connections are presented in Table Table 5. FCI Power Connection Terminal Designation Description +24 V d.c. Supply 0 V d.c. Supply Redundant Power Supply Monitoring Input Redundant Power Supply Monitoring Input CI840 FCI The FCI needs to be connected to the PROFIBUS-DPV1 and have an address selected.

  • Page 37: Profibus Connections

    Section 3 Configuration PROFIBUS Connections CI840 CI840 Address Switch #1 Address Switch #2 Figure 15. TU846/TU847 Front Panel PROFIBUS Connections The FCI connects to the PROFIBUS via the 9 pin D-way connector on the front of TU846/TU847. This allows the FCI (if not the last one at the PROFIBUS segment) to be removed from the PROFIBUS without disconnecting the other nodes of the fieldbus.
  • Page 38 PROFIBUS Connections Section 3 Configuration Figure 16 for CI840 connection details. CI840 CI840 Profibus Cables Figure 16. CI840 FCI PROFIBUS Terminal Connections Table 6 shows the fieldbus connection assignments. Table 6. FCI PROFIBUS Connections Designation Description Shield Shield/protective ground Not used RxD/TxD-P Receive/Transmit data - plus Direction control (optional)

  • Page 39: Power Supply Connections

    Figure 17. FCI Power Supply Connections The incoming power can then be distributed to other FCIs or the I/O modules if desired. Refer to S800 I/O Getting Started (3BSE020923*) manual for power supply connection diagrams. Power connections can accept 0.25 - 2.5 mm (24 - 14 AWG) wire size.

  • Page 40: Configuration And Performance

    Due to the PROFIBUS-DPV1 specification, it is not possible to always connect 24 I/O modules to one FCI. The reason is that the S800 I/O system includes more data and user parameters than PROFIBUS-DPV1 can handle. Table 8 shows maximum number of I/O modules that can be connected to one CI801.
  • Page 41 Section 3 Configuration CI801 Configuration Rules Table 8. Maximum Number of Modules on CI801 Module Type Number of Modules AI801, AI810, AI830, AI830A, AI835, 14 (11) AI835A, AI890, AI893, AI895 AI820, AI825 24 (22) AI843 11 (9) AI815, AI845 14 (11) AO801, AO810, AO810V2, AO890, 7 (5) AO895...
  • Page 42 CI801 Configuration Rules Section 3 Configuration The values in brackets are in Extended HART mode and HCIR. In order to find out if a given configuration of analog and digital modules can be used the following method should be used: •...
  • Page 43 Section 3 Configuration CI801 Configuration Rules Table 9. Calculation of Number of Modules on CI801 (Continued) Number Module User Input Output User Para- Input Output Type Parameters Bytes Bytes Modules meters Bytes Bytes AI820 AI825 AI830/ AI830A AI835 AI835A AI843 AI815, AI845 AI890...
  • Page 44 CI801 Configuration Rules Section 3 Configuration Table 9. Calculation of Number of Modules on CI801 (Continued) Number Module User Input Output User Para- Input Output Type Parameters Bytes Bytes Modules meters Bytes Bytes DI803 DI810 DI811 DI814 DI818 DI820 DI821 DI828 DI840 DI890...

  • Page 45: Ci830 Configuration Rules

    Due to the PROFIBUS-DP specification it is not possible to always connect 24 I/O modules to one FCI. The reason is that the S800 I/O system includes more data and user parameters than PROFIBUS-DP can handle. Table 10 shows maximum number of I/O modules that can be connected to one CI830.
  • Page 46 AO801, AO810, AO810V2, AO890 AO820 DP820 DP840 All DI and DO modules ABB Standard Drive 17/24 (1) See Table In order to find out if a given configuration of analog and digital modules can be used the following method should be used: •...
  • Page 47 Section 3 Configuration CI830 Configuration Rules • Round up the values InSize, OutSize and the sum of ParamSize+15 to the nearest multiple of eight (8), for example, 233 is rounded to 240. • Finally calculate the memory size with the formula: MemSize =a + 2xRoundParamSize + 3x(RoundInSize +RoundOutSize).
  • Page 48 CI830 Configuration Rules Section 3 Configuration Table 11. Calculation of Number of Modules on CI830 (Continued) User Number Module Input Output User Paramete Input Output Type Bytes Bytes Para- Modules Bytes Bytes meters AO810/ AO810V2 AO820 AO890 DI801 DI802 DI803 DI810 DI811 DI814...

  • Page 49: Ci840 Configuration Rules

    Redundant CI840: 62 stations Single CI840: 99 stations Supported communication speeds: 93.75 kbit/s to 12 Mbit/s The maximum number of S800 I/O stations per bus segment is: Communication speed 12Mbit/s: 20 stations Communication speed <1.5Mbit/s or less: 32 stations The maximum number of I/O modules in a station is: 24 modules...
  • Page 50 MTUs in a redundant cluster. Due to the PROFIBUS-DPV1 specification it is not possible to always connect 24 I/O modules to one FCI. The reason is that the S800 I/O system includes more data and user parameters than PROFIBUS-DPV1 can handle.
  • Page 51 Section 3 Configuration CI840 Configuration Rules Table 12. Maximum Number of Modules on CI840 (Continued) Module Type Number of Modules DO801, DO810, DO814 22 (21) DO802, DO815, DO820, 24 (24) DO821 DO818 13 (13) DO828 22 (21) DO840 20 (19) DP820 8 (6) DP840...
  • Page 52 CI840 Configuration Rules Section 3 Configuration – InSize is less than or equal to 239 in normal mode, 199 in Extended HART mode. – OutSize is less than or equal to 112 in normal mode, 90 in Extended HART mode. If any of these three values is too high then the configuration can not be used.
  • Page 53 Section 3 Configuration CI840 Configuration Rules Table 13. Calculation of Number of Modules on CI840 (Continued) Number Module User Input Output User Para- Input Output Type Parameters Bytes Bytes Modules meters Bytes Bytes AO815/ AO845/ AO845A AO890 AO895 DI801 DI802 DI803 DI810 DI811...

  • Page 54: Supported I/O Modules And Drives Via Profibus And Ci801

    Supported I/O Modules and Drives via PROFIBUS and CI801 Section 3 Configuration Table 13. Calculation of Number of Modules on CI840 (Continued) Number Module User Input Output User Para- Input Output Type Parameters Bytes Bytes Modules meters Bytes Bytes DO802 DO810 DO814 DO815...

  • Page 55: Supported I/O Modules And Drives Via Profibus And Ci830

    • DO801, DO802, DO810, DO814, DO815, DO818, DO820, DO821, DO828, DO840, DO890. • DP820, DP840. • ABB Standard Drives. Have to be connected via TB820. – ACS400 with standard drive – ACS600 with standard application – ACS800 with standard application –...

  • Page 56: Supported I/O Modules Via Profibus And Ci840

    Supported I/O Modules via PROFIBUS and CI840 Section 3 Configuration • ABB Standard Drives – ACS400 with standard drive – ACS600 with standard application – ACS800 with standard application – ACS600 with crane application – ACS800 with crane application –...

  • Page 57: Data Scanning

    Section 3 Configuration Data Scanning Data Scanning ModuleBus data is scanned (read or written) cyclically, depending on the I/O module configuration. To calculate the I/O scan cycle time in the FCI do as follows: Totalize (number of module type x) * (used execution time for type x) (see Table 14) if the value is a multiple of 2 add 2 to the value.
  • Page 58 0.43 0.43 0.50 DP820 1.72 1.72 2.09 DP840 3.00 3.00 3.00 6.00 ABB Engineered drive 1.72 ABB Standard drive 0.71 0.86 FCI CI801 1.18 FCI CI830 firmware 1.0 to 1.2 1.40 FCI CI830 firmware 1.3 or later 2.24 FCI CI840 2.10...
  • Page 59 Section 3 Configuration Data Scanning For example, a station with CI830 with firmware 1.3, two AI810, one AO810/AO810V2, two DI810, two DO820 and one AI830/AI830A will give the following I/O scan cycle time: 2 AI810 => 2*3.00 ms = 6.00 ms 1 AO810/AO810V2 =>...
  • Page 60 Data Scanning Section 3 Configuration the AI810s and the AO810/AO810V2 every (4*12 ms) 48 ms and the AI830/AI830A every (10*12 ms) 120 ms. Minimum I/O scan cycle time = 4 ms For example, a station with CI840, single or redundant, two AI810, one AO810/AO810V2, two DI810, two redundant pairs of DO840 and one redundant pair of AI845 will give the following I/O scan cycle time: 2 AI810 =>...

  • Page 61: Section 4 Operation

    The FCI acts as a pure slave station on PROFIBUS-DP/DPV1. The FCI controls all operations of an S800 I/O station. It is the bus-master on the S800 I/O ModuleBus. It does this by handling all communications between the PROFIBUS Master and the S800 I/O modules.
  • Page 62 Functional Description Section 4 Operation The FCI is responsible for: • Module configuration and supervision. • Performing signal conditioning on input and output values. • Dynamic data transfer. Module Configuration and Supervision The FCI stores the configuration for all configured I/O Modules in the station. The FCI will continuously supervise all I/O modules being configured by the PROFIBUS Master.
  • Page 63 1 and 6 Input and output values are updated “as fast as possible” (depends on the S800 I/O module configuration). Process Figure 18. Dynamic Data Exchange for PROFIBUS-DP/DPV1 in Runtime The transportation of dynamic data between PROFIBUS-DP/DPV1 and the ModuleBus is the main task for the FCI.
  • Page 64 Functional Description Section 4 Operation Data Scanning Principles The data transfer between PROFIBUS-DP/DPV1 and the ModuleBus is not synchronized. Read and write operations are performed from and to a dual port memory in the FCI. The ModuleBus data is scanned (read or written) cyclically, depending on the I/O module configuration.

  • Page 65: I/O Module Functionality

    For information about Profibus DPV1 services see Memory Maps for CI801 (3BSE036959*) or Memory Maps for CI840 (3BSE025251*). I/O Module Functionality All S800 I/O modules have some common functionality. This section describes these common functions of the I/O modules. An S800 I/O module complies with the following framework: •...
  • Page 66 Section 4 Operation Module Identity All S800 I/O modules contains a module identity. The module identity is used to verify that an I/O module of the expected (user configured) type is mounted before taking it operational. It protects the system from performing unexpectedly.
  • Page 67 Section 4 Operation I/O Module Functionality The states are described in more detail below: Init State In the Init state the actual initialization of the module is performed, including a self- test. Inputs Not scanned Outputs Inactive: 0 V LEDs Fault Not Configured State In the Not Configured state the module waits to be configured.
  • Page 68 I/O Module Functionality Section 4 Operation OSP (Outputs Set as Predefined) State The OSP state is only used by modules with output channels. If OSP is activated it is entered from the Operational state in two cases: • The supervision time-out on PROFIBUS-DP/DPV1 has elapsed. •...
  • Page 69 Section 4 Operation I/O Module Functionality Loading Parameters At start-up, the configuration parameters are loaded by the FCI in the NotConfigured state. When valid configuration parameters are written to the module, it will change from the Not Configured state to the Ready state. After entering the Ready state the module may be set to Operational.
  • Page 70 I/O Module Functionality Section 4 Operation 3BSE020926-600...

  • Page 71: Section 5 Maintenance

    Section 5 Maintenance Preventive Maintenance Refer S800 I/O Getting Started (3BSE020923*). Hardware Indicators CI801 FCI Module LEDs The CI801 FCI has indicators for fault, operational state, power condition, and PROFIBUS communication traffic. Table 15 describes the LEDs, and Figure 20 shows the location of the LEDs on the module.

  • Page 72: Ci830 Fci Module Leds

    CI801 FCI Module LEDs Section 5 Maintenance LED Status Indicators Figure 20. CI801 FCI with Status LEDs Location 3BSE020926-600...
  • Page 73 Section 5 Maintenance CI830 FCI Module LEDs CI830 FCI Module LEDs The CI830 FCI has indicators for fault, operational state, power status, PROFIBUS communication status, and optical ModuleBus communication status. Table 16 describes the LEDs, and Figure 21 shows the location of LEDs on the module. Table 16.
  • Page 74 CI830 FCI Module LEDs Section 5 Maintenance PROFIBUS LED Status Indicators SERVICE STN. ADDR. x 10 CI830 TB810/TB811 SWX.X/Y PROFIBUS Tx Rx Figure 21. CI830 FCI with TB810/TB811 Status LEDs Location 3BSE020926-600...

  • Page 75: Ci840 Fci Module Leds

    Section 5 Maintenance CI840 FCI Module LEDs CI840 FCI Module LEDs The CI840 FCI has indicators for fault, operational state, power status, PROFIBUS communication state, and for the state in a redundant configuration. Table 17 describes the LEDs, and Figure 22 shows the location of the LEDs on the module.

  • Page 76: Error Messages

    Error Messages Section 5 Maintenance Rx/Tx Rx/Tx PRIM PRIM DUAL DUAL LED Status Indicators CI840 CI840 Figure 22. CI840 FCI with Status LEDs Location Error Messages Please see the relevant PROFIBUS Master documentation. 3BSE020926-600...

  • Page 77: Fault Finding And Repair

    Section 5 Maintenance Fault Finding and Repair Fault Finding and Repair Communication Module Replacement General Communication modules CI801, CI830, and TB820 cannot be replaced online. Communication modules CI840 and TB840 can be replaced online. The following notes are applicable to replacement of modules, and its effect on the process: •...
  • Page 78 Store extracted modules in protective envelopes. The modules are initialized automatically by the system, and it takes approximately 60 seconds for a CI801/CI830/CI840 to start up. Additional Information on Individual S800 Communications Modules Table 18 provides additional information for replacement of S800 I/O modules. 3BSE020926-600...
  • Page 79 Needs space to the left in order to be removed. In normal operation mode, before a CI801 is replaced, the supply to the S800 I/O is to be switched off. Power connections can be removed by pulling the header terminals out of the unit.
  • Page 80 Needs space to the left in order to be removed. In normal operation mode, before a CI830 is replaced, the supply to the S800 I/O is to be switched off. Power connections can be removed PROFIBUS by pulling the header terminals out of the unit.

  • Page 81: Application Memory Reset

    Section 5 Maintenance Application Memory Reset Application Memory Reset A CI830 can keep an application in memory for a long time, even with the power supply disconnected. To avoid a problem with an FCI that may have an old application, the application memory should be cleared. To clear the application memory in CI830: Set the address switches to 99.

  • Page 82: Ci840 Firmware Version

    CI840 Firmware version Section 5 Maintenance CI840 Firmware version From CI840 firmware version 3.0/0 and later, it is possible to read its firmware version from the service port, at startup. In a redundant pair, the firmware version can be read from the backup module. A change over from primary state to backup state can be done by the DTM or by disconnecting the PROFIBUS cable on the primary.
  • Page 83 Section 5 Maintenance Load the CI801 Software Upgrade Physical Connections Connect the PC to the CI801, using a TK212/TK212A cable and the service adapter (FS801+TK802) connected between the service port (PROFIBUS connection) on CI801 and the COM1 or COM2 on the PC. Set the station address on CI801 to 0. CI801 TK212/TK212A TK802...
  • Page 84 Load the CI801 Software Upgrade Section 5 Maintenance To load the firmware: Run the program, loader32_42-1.exe Click Next. Select the COM-Port to use, and enter the path to the image file. Click Download. When the download is finished, set the station address back to the used address. Switch off the power supply and then switch on the power supply, to restart CI801.

  • Page 85: Load The Ci830 Software Upgrade

    Section 5 Maintenance Load the CI830 Software Upgrade Troubleshooting Problem: The cable is disconnected during download, or the power went down. Solution: Restart CI801 by switching the power OFF and then switching the  power ON. Labelling Update the firmware version on the firmware label. Connection cable Figure 24.

  • Page 86: Troubleshooting

    Load the CI830 Software Upgrade Section 5 Maintenance Connection Connect the PC and the CI830, using a TK527 (3BSC950004R1) cable between the RS232 service port on the CI830 and the COM1 or COM2 on the PC. Loading the BASE Software Run the program, loader32.exe Click Next.

  • Page 87: Load The Ci840 Software Upgrade

    Section 5 Maintenance Load the CI840 Software Upgrade Labelling Put the largest label on the back of the CI830 and the smaller one on the front of CI830. See Figure PROFIBUS STN. ADDR. x 10 CI830 Label SW*1.1/0 PROFIBUS Figure 25. CI830 Software Label Location Load the CI840 Software Upgrade Hardware Requirements for CI840/CI840A rev.

  • Page 88: Bse020926

    Load the CI840 Software Upgrade Section 5 Maintenance Connection Connect the PC and the CI840 (TU846/TU847), using a TK212/TK212A cable between the RS232 service port A or B on the TU846/TU847 (CI840) and the COM1 or COM2 on the PC. Loading the Firmware There are two different upgrade instructions for the CI840A and CI840AZ, depending on its Product Revision (PR: x).
  • Page 89 Section 5 Maintenance Load the CI840 Software Upgrade Loading the Firmware in the Primary FCI when the Backup is Running Perform a switch-over to put the Primary FCI in backup state. It can be done by using the DTM or disconnecting the PROFIBUS cable on the primary FCI. Follow the same instructions as for Single FCI.
  • Page 90 Load the CI840 Software Upgrade Section 5 Maintenance 10. Disconnect power to CI840 and connect the power again, for start up of CI840. Loading the Firmware on Backup FCI when the Primary FCI is Running CI840 with firmware 3.0/2 or earlier 11.
  • Page 91 Section 5 Maintenance Load the CI840 Software Upgrade Troubleshooting Problem: Cable is disconnected during download or the power supply goes off. Solution: Restart the CI840 by switching the power OFF and switching the power ON again. Labelling Update the firmware version on the firmware label. Connection Cable Figure 26.
  • Page 92 Load the CI840 Software Upgrade Section 5 Maintenance Rx/Tx Rx/Tx PRIM PRIM DUAL DUAL Position A Position B CI840 CI840 Service port Figure 27. CI840 and TU847 3BSE020926-600...

  • Page 93: Ci801 Fieldbus Communications Interface (Fci)

    Interface (FCI) is an intelligent communication interface between a Controller via the PROFIBUS-DPV1 fieldbus and the S800 I/O modules via the ModuleBus. CI801 contains one PROFIBUS-DPV1 interface, electrical ModuleBus interfaces, LED indicators and a service port. The Profibus connector is also used for service.

  • Page 94: Technical Data

    Technical Data Appendix A Specifications CI801 has isolated power converters that generates internal power for CI801 and current limited +5 V supply for electrical ModuleBuses. Besides +5 V CI801 also distribute a fused 24 V for the ModuleBus. The module is DIN-rail mounted and grounded to the DIN-rail. The module detachable screw terminals for power supply D-way terminals for PROFIBUS, one connector for the Optical ModuleBus Port TB842, mounted on TB806, and one electrical ModuleBus.
  • Page 95 Appendix A Specifications Technical Data Table 19. CI801 FCI Specification (Continued) Item Description Safety classification Class I according to IEC 536; (earth protected) Protection rating IP20 according to IEC 529, (IEC 144) Rated insulation voltage 50 V Dielectric test voltage 500 V a.c.

  • Page 96: Dimensions

    Dimensions Appendix A Specifications Dimensions Figure 28. CI801 FCI Dimensions Connections Table 20. Power Supply Connections (XI) Designation Description +24 V d.c. Supply 0 V d.c. Supply 3BSE020926-600...
  • Page 97 Appendix A Specifications Connections Table 21. FCI PROFIBUS Connections (X2), Also Used as Service Port Designation Description Shield Shield/protective ground Not used RxD/TxD-P Receive data/transmit data positive Direction control (optional) DGND Data ground Supply of termination resistance (5V) Not used RxD/TxD-N Receive data/transmit data negative DGND...

  • Page 98: Block Diagram Ci801

    Block Diagram CI801 Appendix A Specifications Block Diagram CI801 TB806 CI801 Electrical TB842 ModuleBus Profibus Station address Power supply Figure 29. Block Diagram CI801 3BSE020926-600...

  • Page 99: Ci830 Fieldbus Communications Interface (Fci)

    The CI830 Fieldbus Communications x 10 Interface (FCI) is an intelligent communication interface between a CI830 Controller via the PROFIBUS-DP fieldbus and the S800 I/O modules via the PROFIBUS TxRx ModuleBus. CI830 has four basic parts: Module termination board, power supply board, processor board and the optical port (see block diagram).

  • Page 100: Technical Data

    Technical Data Appendix A Specifications D-way terminal for PROFIBUS, connector for the service port, connector for the Optical ModuleBus Port TB810/TB811 and the electrical ModuleBus. Technical Data Table 22. CI830 FCI Specification Item Description Microprocessor (CPU) Motorola MC68340 running at 8 bit mode with a speed of 16 MHz Flash PROM 512 kbyte...
  • Page 101 Appendix A Specifications Technical Data Table 22. CI830 FCI Specification (Continued) Item Description Protection rating IP20 according to IEC 529, (IEC 144) Rated insulation voltage 50 V Dielectric test voltage 500 V a.c. Acceptable wire sizes 0.25 - 2.5mm , 24 - 14 AWG Recommended torque: 0.5 - 0.6 Nm Stripping length: 6-7.5 mm, 0.24-0.30 in Width...

  • Page 102: Dimensions

    Dimensions Appendix A Specifications Dimensions Figure 30. CI830 FCI Dimensions Connections Table 23. Power Supply Connections (XI) Designation Description +24 V d.c. Supply 0 V d.c. Supply Redundant Power Supply “A” Monitoring Input Redundant Power Supply “B” Monitoring Input 3BSE020926-600...
  • Page 103 Appendix A Specifications Connections Table 24. Service Port (X3) Designation Description Transmit Data channel B Receive Data channel B Signal Ground Receive Data channel A (for debugging only) Transmit Data channel A (for debugging only) Table 25. FCI PROFIBUS Connections (X2) Designation Description Shield...
  • Page 104 Connections Appendix A Specifications Table 25. FCI PROFIBUS Connections (X2) (Continued) Designation Description RxD/TxD-N Receive/Transmit data - minus Not used 3BSE020926-600...

  • Page 105: Block Diagram Ci830

    Appendix A Specifications Block Diagram CI830 Block Diagram CI830 Fiber Optical ModuleBus Module SHIELD 1 PROFIBUS Connector DGND GLUE DSUB9 STN. RxD/TxD-P SPC4 RS-485 ADDR RxD/TxD-N MC68340 DDCC+ FLASH Reset logic, +5 V Supervision RS-485 +5 V +5 V P(owok) RS-485 DIN-rail R(un)

  • Page 106: Ci840 Fieldbus Communications Interface (Fci)

    Description The CI840 Fieldbus Communications Interface (FCI) is an intelligent communication interface between a Controller via the PROFIBUS- DPV1 fieldbus and the S800 I/O modules via the ModuleBus. CI840 is designed to be used in redundant applications. CI840 contains one PROFIBUS-DPV1...
  • Page 107 Appendix A Specifications Description The Module Termination unit is DIN-rail mounted and grounded to the DIN-rail. The Module Termination Unit TU847 carries screw terminals for power supply and redundant power supply monitoring, two D-way terminals for PROFIBUS, two connectors for the service ports, one connector for the Optical ModuleBus Port TB842, mounted on TB806, and one electrical ModuleBus.
  • Page 108 Description Appendix A Specifications Rx/Tx Rx/Tx PRIM PRIM DUAL DUAL CI840 CI840 Figure 31. CI840 and TU847 3BSE020926-600...

  • Page 109: Technical Data

    Appendix A Specifications Technical Data Technical Data Table 26. CI840 FCI Specification Item Description Microprocessor (CPU) Motorola MCF5307 with a speed of 64 MHz Flash PROM 1 Mbyte Fast RAM 8 Mbyte Power Input 24 V d.c. (19.2 - 30) Power Input Fuse 2 AF Power Consumption at 24 V d.c.

  • Page 110: Connections

    Connections Appendix A Specifications Table 26. CI840 FCI Specification (Continued) Item Description Switch over time at communication error Typical < Watchdog Time + 50ms + on Profibus used by primary CI840 (6 * Profibus cycle time) Time to OSP in case of communication Single FCI: Watchdog Time +...

  • Page 111: Block Diagram Ci840, Single Modulebus

    Appendix A Specifications Block Diagram CI840, single ModuleBus Block Diagram CI840, single ModuleBus Figure 32. Block Diagram CI840, single ModuleBus 3BSE020926-600...

  • Page 112: Block Diagram Ci840, Dual Modulebus

    Block Diagram CI840, dual ModuleBus Appendix A Specifications Block Diagram CI840, dual ModuleBus TB846 Optical TU846 CI840 module bus TB842 Electrical Modulebus A +5V_B POWOKA POWA +5V A +24V_A POS6-0 Electrical Modulebus B POWB POWOKB +5V B +24V_B Profibus A +5V P 0V_P Service A...

  • Page 113: Tu846 Redundant Mtu For Ci840, Dual Modulebus

    Appendix A Specifications TU846 Redundant MTU for CI840, dual ModuleBus TU846 Redundant MTU for CI840, dual ModuleBus Features • Power supply connection. • Two PROFIBUS connections. • Two service tool connections. • Two rotary switch for station address setting. • Connection for two ModuleBuses.

  • Page 114: Technical Data

    Technical Data Appendix A Specifications The MTU can be mounted on a standard DIN rail. It has a mechanical latch that locks the MTU to the DIN rail. The latch can be locked/unlocked with a screwdriver. The MTU has two BLOCK signals, one for each module position, that keeps the modules in its init state until it is locked in its position.

  • Page 115: Dimensions

    Appendix A Specifications Dimensions Table 27. TU846 Redundant MTU for CI840 (Continued) Item Value Height 186 mm (7.32”) including latch Weight 0.5 kg (1.1 lbs.) Dimensions Figure 34. Dimensions TU846 3BSE020926-600...

  • Page 116: Connections

    Connections Appendix A Specifications Connections Table 28. TU846 Power Supply Connections Designation Description +24 V d.c. Supply In 0 V d.c. Supply In Redundant Power Supply “A” Monitoring Input Redundant Power Supply “B” Monitoring Input Table 29. PROFIBUS Connector Pin-out Designation Description Shield...
  • Page 117 Appendix A Specifications Connections Table 30. Service Port Connector Pin-out (Continued) Designation Description Signal ground Signal ground Receive data Not used Not used 3BSE020926-600...

  • Page 118: Block Diagram Tu846

    Block Diagram TU846 Appendix A Specifications Block Diagram TU846 TB846 Optical TU846 CI840 module bus TB842 Electrical Modulebus A +5V_B POWOKA POWA +5V A +24V_A POS6-0 Electrical Modulebus B POWB POWOKB +5V B +24V_B Profibus A +5V P 0V_P Service A Stn.address Power supply...

  • Page 119: Tu847 Redundant Mtu For Ci840, Single Modulebus

    Appendix A Specifications TU847 Redundant MTU for CI840, single ModuleBus TU847 Redundant MTU for CI840, single ModuleBus Features • Power supply connection. • Two PROFIBUS connections. • Two service tool connections. • Two rotary switch for station address setting. • ModuleBus connections.

  • Page 120: Technical Data

    Technical Data Appendix A Specifications The MTU can be mounted on a standard DIN rail. It has a mechanical latch that locks the MTU to the DIN rail. The latch can be locked/unlocked with a screwdriver. The MTU has two BLOCK signals, one for each module position, that keeps the modules in its init state until it is locked in its position.
  • Page 121 Appendix A Specifications Dimensions Table 31. TB847 Redundant MTU for CI840 (Continued) Item Value Height 186 mm (7.32”) including latch Weight 0.5 kg (1.1 lbs.) Dimensions Figure 36. Dimensions TU847 3BSE020926-600...
  • Page 122 Connections Appendix A Specifications Connections Table 32. TU847 Power Supply Connections Designation Description +24 V d.c. Supply In 0 V d.c. Supply In Redundant Power Supply “A” Monitoring Input Redundant Power Supply “B” Monitoring Input Table 33. PROFIBUS Connector Pin-out Designation Description Shield...
  • Page 123 Appendix A Specifications Connections Table 34. Service Port Connector Pin-out (Continued) Designation Description Signal ground Signal ground Receive data Not used Not used 3BSE020926-600...

  • Page 124: Block Diagram Tu847

    Block Diagram TU847 Appendix A Specifications Block Diagram TU847 Figure 37. Block Diagram TU847 3BSE020926-600...
  • Page 125 INDEX CI830 16, 18, 21, 79 to 80, 82, 87 Parameters Connections Loading 69 Power supply 32, 35, 39 Loading invalid 69 PROFIBUS-DP 30, 33, 37 Non-volatile 69 PROFIBUS-DP 13, 16, 18, 21, 61 I/O module functionality 65 Data scanning principles 64 Ready state 67 Error state 68 State...
  • Page 126 Index Index 3BSE020926-600 3BSE020926-600...
  • Page 128 Contact us Copyright© 2003-2014 ABB. www.abb.com/800xA All rights reserved. www.abb.com/controlsystems Power and productivity for a better world...

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