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ABB AC 800M Hardware And Operation

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Version 2.1
Controller Hardware
Hardware and Operation

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Summary of Contents for ABB AC 800M

  • Page 1 Control AC 800M Version 2.1 Controller Hardware Hardware and Operation...
  • Page 3 Control AC 800M Version 2.1 Controller Hardware Hardware and Operation...
  • 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

    Section 1 – Introduction Product Overview......................AC 800M – General....................PM8xx/TP830 Processor Unit – General..............PM861/PM864/TP830 Processor Unit – Redundancy ..........Control Software......................Ethernet Address......................AC 800M Controller – Key Features ................3BSE 027 941 R301 3BSE 027 941 R301...
  • Page 6 Site Selection and Building Requirements ..............43 Cables .......................... Power Supply....................... Enclosures........................Mounting AC 800M Units onto DIN-Rail ................ 49 Installing the PM8xx/TP830 Processor Unit in Single Configuration......Installing the PM861/PM864/TP830 Processor Unit in Redundant Configuration..64 Installing the PROFIBUS DP Interface, CI851/TP851.............
  • Page 7 AC 800M Controller (PM8xx) ..................109 Start-up ..........................112 Start Modes........................112 Automatic Switch-Over to Backup CPU................114 Verification of Satisfactory AC 800M Operation............. 115 Verification of Single CPU ..................115 Verification of Redundant CPU .................. 117 Section 5 – Maintenance Preventive Maintenance Frequency Schedule..............
  • Page 8 Power Supply Units – Types SD821, SD822 and SD823 ..........181 SS822 Voting Unit – (for Redundant Power Supply) ............189 TC562 Modem Unit – (Westermo MD-12DC) ..............191 SB821 External Battery – AC 800M Memory Back-up ........... 193 DIN-Rail – TS 35/7.5 ......................194 Miscellaneous Equipment ....................195 TB850 Terminator for CEX-bus (Male)..............
  • Page 9 Appendix E – Standards Hazardous Location Approval..................213 Appendix F – Environmental Data Environmental Data for AC 800M Products ..............215 Climatic and Mechanical Environmental Conditions ..........216 CE Compliance ......................218 Electromagnetic Compatibility and Main Voltage Conditions ........219 Installation Requirements ...................
  • Page 10 7DEOH RI &RQWHQWV 3BSE 027 941 R301...

  • Page 11: About This Book

    General This book describes the hardware platform AC 800M, together with the controllers and associated units that are used in the AC 800M Controller. It also describes in detail how to install, configure, operate and perform the necessary maintenance on all equipment making up the AC 800M Controller.
  • Page 12 How to Use This Book About This Book Section 3, Configuration Provides information on the hardware configuration for the AC 800M Controller. Section 4, Operation Includes information on start-up and shut-down procedures together with verification procedures for the AC 800M Controller.

  • Page 13: Use Of Warning, Caution, Information, And Tip Icons

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

  • Page 14: Document Conventions

    Control Builder M, an engineering tool used to configure and program the AC 800M controller. Central I/O Input/Output units, mounted onto a DIN-rail, and directly connected to the AC 800M controller via ModuleBus. CEX-bus Communication Expansion Bus, (for communication units).
  • Page 15 About This Book Terminology Table 1. Terminology (Continued) Term/Acronym Description DIN-rail Industry standard ‘Top Hat’ type mounting rail. Electro-Magnetic Compatibility. Ethernet Network cabling system according to IEEE802.3. Ethernet Address The same as Media Access Control (Ex. MAC layer in IEE802.3 = transceiver + cable). Fieldbus Communication Interface.

  • Page 16: Applicable Specifications

    Applicable Specifications About This Book Table 1. Terminology (Continued) Term/Acronym Description Random Access Memory, normally a read/write memory of random access type is assumed. Redundancy Control Unit. RCU Link RCU Link Cable transfers data between Primary and Back-up CPU. The two CPUs are connected to the RCU Link Cable.

  • Page 17: Related Documentation

    Appendix E, Standards must be followed. Related Documentation Table 2 on page 17 details the documentation and media applicable to the AC 800M Controller. Table 3 on page 19 details the media associated with the AC 800M Controller.
  • Page 18 S200L I/O. User’s Guide Terminal Diagrams AC Gives information about the inputs/outputs 800M of the AC 800M units. The diagrams can be used as templates for a connection diagram. Terminal Diagrams S800 Gives information about the inputs/outputs of the S800 I/O units. The diagrams can be used as templates for an I/O connection diagram.
  • Page 19 Software AC 800M/C Application A handbook for technicians who intend to (contd.) Programming, Strategy program Control IT for AC 800M/C products and Design using the programming tool, Control Builder M. It gives strategic hints and directions in project design, different...
  • Page 20 Related Documentation About This Book 3BSE 027 941 R301...

  • Page 21: Safety Summary

    In order to minimize the risk of injury to personnel and/or damage to the equipment, always comply with the following Safety Instructions when installing and operating an AC 800M Controller system. Local, stricter statutory regulations must always take precedence over the Safety Instructions given here.

  • Page 22: Personnel And Process Safety

    – resetting or switching units to manual operation • The AC 800M Controller system must be shut down before carrying out the above. • Never connect the equipment to the mains power supply during installation work.
  • Page 23 Remember at all times, that the control system can be controlled from a remote engineering station, connected at another node via Control Network. • Remember, the AC 800M Controller will start automatically when voltage is applied. The level of safety can be improved considerably by taking steps to bring the process to a safe state should power supplies, communication links or parts of the control system fail.

  • Page 24: Machine Safety

    Machine Safety Safety Summary Machine Safety The following safety rules must be observed at all times: • To avoid discharging static electricity, ground both yourself and any tools before handling printed circuit boards and other sensitive pieces of the equipment •...

  • Page 25: Operating Environment

    Safety Summary Operating Environment Operating Environment Before the AC 800M Controller system is brought online, investigate which environmental conditions are applicable. Take note in particular of the following: • The controller must not be exposed to conditions that exceed the values given in the relevant technical specifications.
  • Page 26 Operating Environment Safety Summary 3BSE 027 941 R301...

  • Page 27: Section 1 Introduction Product Overview

    Product Overview AC 800M – General AC 800M can be defined as a hardware platform to which individual hardware units may be connected and which, depending on the specific unit configuration and operating system selected, can be programmed to perform multiple functions.
  • Page 28 AC 800M – General Section 1 Introduction The AC 800M Controller consists of a selection of units mounted on horizontal DIN-rails, which can be housed within an enclosure. The majority of units consist of a base mounting plate and removable cover attached with screws. The baseplate,...
  • Page 29 Section 1 Introduction AC 800M – General Status Indicators INIT Push button Tx/Rx RCU Link Optic Ports Connector (PM861/PM864) Tx/Rx External Battery Status Supply Socket Indicators Power Supply Supervision Signal Socket (SS822) CN1/CN2 Ports COM3/COM4 Ports DIN-rail Locking Device Figure 2. Processor Unit – General View (here shown with PM861)

  • Page 30: Pm8Xx/Tp830 Processor Unit - General

    PM8xx/TP830 Processor Unit – General Section 1 Introduction PM8xx/TP830 Processor Unit – General Physically the PM8xx/TP830 Processor Unit consists of two basic parts: • Processor Unit (PM856/PM860/PM861/PM864) with processor and Power Supply boards • Baseplate (TP830), housing the unit termination board Figure 4 on page 32 and Figure 5...
  • Page 31 Section 1 Introduction PM8xx/TP830 Processor Unit – General Processor Unit Cover Release Screw Cover Assembly CEX-bus Socket ModuleBus Socket Fuses CEX-bus/ModuleBus Baseplate TP830 Figure 3. Processor Unit Assembly – General View (here shown with PM860/TP830) 3BSE 027 941 R301...
  • Page 32 PM8xx/TP830 Processor Unit – General Section 1 Introduction +5V DC Power System and ModuleBus CEX-bus +3.3V DC user mem. controller controller Battery CompactFlash External battery (+3.3V) Communication INIT controllers Logic Ethernet Ethernet RS232 RS232 COM3 COM4 Figure 4. PM856/PM860 – Functional Block Diagram 3BSE 027 941 R301...
  • Page 33 Section 1 Introduction PM8xx/TP830 Processor Unit – General CEX-Bus System Shadow ModuleBus Interface Interface and user memory mem. FPGA +24V +5V DC +3.3V Battery RCU Link (+3.3V DC) Compact Flash Communication Controllers INIT Logic Ethernet Ethernet RS232 RS232 RS232 COM3 COM4 COM4 PRIM DUAL...
  • Page 34 ModuleBus of an AC 800M Controller. However, a further seven clusters (each comprising up to 12 units) can be added to the optical ModuleBus, thus achieving a total count of 96 units per AC 800M Controller when using only the ModuleBus.
  • Page 35 Note 2 – Central S800 I/O. Maximum 96 units. Note 3 – Remote S800 I/O. Maximum 24 units/station, 24 x 32 = 768 units per segment. Figure 6. Example of AC 800M/S800 I/O Interconnection in Single CPU Configuration 3BSE 027 941 R301...

  • Page 36: Pm861/Pm864/Tp830 Processor Unit - Redundancy

    PM861/PM864/TP830 Processor Unit – Redundancy Section 1 Introduction PM861/PM864/TP830 Processor Unit – Redundancy Processor unit redundancy is available. In this case, the controller contains two processor units, each including memory for system and application software. One unit is acting as primary, the other is backup (hot stand-by). The primary processor unit controls the process.
  • Page 37 Section 1 Introduction PM861/PM864/TP830 Processor Unit – Redundancy Fault Tolerance Principle The principle of fault tolerance in the redundant processor units is based on continuous updating of the backup unit to the same status as the primary unit. This enables the backup unit to assume control without affecting surrounding systems in a bumpless manner.

  • Page 38: Control Software

    Control Software The software used by the AC 800M Controller is named Control Software. This name does not stand for a specific software package; is merely a generic name for the scope of functions used in a controller. These functions are provided by: •...
  • Page 39 Section 1 Introduction Ethernet Address Related Documentation on page 17 for details on loading the software and using Ethernet address. SE00263650 3BSE018105R1 PR:A ETHERNET: 0000230A008E SE00263650 PM861K01 Figure 7. Identification Labels 3BSE 027 941 R301...

  • Page 40: Ac 800M Controller - Key Features

    AC 800M Controller – Key Features Section 1 Introduction AC 800M Controller – Key Features • Flexibility. The AC 800M Controller can be ordered housed in ABB cabinets, or as individual units that may be custom-mounted • Modularity, allowing for step-by-step expansion •...

  • Page 41: Product Release History

    This number is required to keep the configuration of all units and components on the AC 800M platform together, and to act as a reference in the future between different documents. As the AC 800M hardware platform configuration grows in future releases, so the version number will increase accordingly.
  • Page 42 Product Release History Section 1 Introduction 3BSE 027 941 R301...

  • Page 43: Section 2 Installation

    The AC 800M system is designed for use within demanding industrial environments. This section provides information on standard requirements regarding the location at which or the building(s) in which the AC 800M Controller system is to be stored or installed.
  • Page 44 – Should the AC 800M system be installed in a control room, adjacent to large machinery such as shakers or large presses where frequent major vibration is expected, then shock absorbers or an isolation pad may be required to protect system equipment.

  • Page 45: Cables

    10 cm (4 in) from other cables. • All cables connected to AC 800M should be routed at a distance of 30cm (12 in) from all power cables and 10 cm (4 in) from cables belonging to the relevant international immunity standard, class 4.

  • Page 46: Power Supply

    10 m [9.1 yds]) lightning protection equipment must be installed. Power Supply Under normal circumstances, the power supply required by AC 800M Controller and associated field equipment can be obtained from the plant’s standard 120/230 V AC mains supply.
  • Page 47 Always install a protective ground connection on equipment connected to a 230 V AC supply. Fusing the External Mains Supply Cable The recommended fuse rating for the external mains supply of a standard AC 800M Controller configuration, housed within a floor or wall-mounted cabinet, is given in Table 5 on page 47.

  • Page 48: Enclosures

    Enclosures Section 2 Installation The AC 800M controller will shut down safely in the event of a power failure. During down-time, the application memory and the system clock will be backed up by the internal battery. In systems subject to long non-operational periods, it is recommended that an external battery back-up unit be installed.

  • Page 49: Mounting Ac 800M Units Onto Din-Rail

    ABB Cabinets As a suitable enclosure, ABB recommends the following two cabinets, both specially adapted for mounting the AC 800M Controller and S800 I/O. Both are sealed to protection class IP54 and can support the Controller and S800 I/O units with no requirement for additional cooling equipment: •...
  • Page 50 DIN-rail. It is essential that the locking device be placed in the LOCKED position to avoid possible problems caused by vibration and/or intermittent grounding. For further visual information on mounting AC 800M Controller units, see Figure 9 on page 51.
  • Page 51 Mounting AC 800M Units onto DIN-Rail 1. OPEN 2. SLIDE 3. LOCKED Figure 8. Baseplate Locking Device Lugs for extra screws to provide secure mounting in locations subject to vibration Figure 9. DIN-rail Mounting of AC 800M Units 3BSE 027 941 R301...
  • Page 52 Figure 10. AC 800M Controller – Side View Removing Units Complete with Baseplates The AC 800M units must be disconnected from the power source before removing them from a DIN-rail! Use the procedure below to remove a unit, complete with baseplate: Isolate the power supply to the controller units.
  • Page 53 Section 2 Installation Mounting AC 800M Units onto DIN-Rail Turn the locking device anti-clockwise to the OPEN position (1) and ease the unit baseplate outward and upward at the base. Lift the unit to remove it from the DIN-rail. The unit baseplates are easily disconnected from each other by gently prying...
  • Page 54 Mounting AC 800M Units onto DIN-Rail Section 2 Installation Unit to Baseplate Alpha Code Lock Since the units are very similar in design, baseplates have been given a two-part, pre-set Alpha code locking device that prevents the installation of an incompatible type of unit onto the baseplate should the Alpha codes not agree.
  • Page 55 Section 2 Installation Mounting AC 800M Units onto DIN-Rail will occur. If difficulty is experienced with installing a unit onto a baseplate, this is a positive indication that the Alpha code lock/unit compatibility is incorrect. Figure 12 on page 55 for further details of the Alpha code lock arrangement.

  • Page 56: Installing The Pm8Xx/Tp830 Processor Unit In Single Configuration

    Installing the PM8xx/TP830 Processor Unit in Single Configuration Section 2 Installation Installing the PM8xx/TP830 Processor Unit in Single Configuration Use the procedure below to install the processor unit along the DIN-rail: If already mounted, remove the CEX-bus and ModuleBus terminations from the sides of the processor unit.
  • Page 57 85. Do not place the internal back-up battery in the battery holder until the AC 800M Controller has been powered-up normally and the memory back-up function has been activated. If no normal power supply is connected to the processor unit with the battery in place, then the CPU memory will immediately start to consume battery power.
  • Page 58 Installing the PM8xx/TP830 Processor Unit in Single Configuration Section 2 Installation Terminator TB850 Rx/Tx Rx/Tx CPU unit CI851 CI851 Figure 13. TB850 Terminator for CEX-bus (male) A TB850 male CEX-bus termination unit is supplied with each package (PM856K01, PM860K01, PM861K01 and PM864K01) of the PM8xx/TP830 processor unit.
  • Page 59 Section 2 Installation Installing the PM8xx/TP830 Processor Unit in Single Configuration Rx/Tx Rx/Tx CPU unit CI852 CI851 CI853 COM1 COM2 TK850 Cable Terminator TB851 Rx/Tx CI852 CI853 CI853 COM1 COM2 COM1 COM2 Figure 14. TB851 Terminator for CEX-bus (female) 3BSE 027 941 R301...
  • Page 60 Installing the PM8xx/TP830 Processor Unit in Single Configuration Section 2 Installation Figure 15. SA/SB Connectors for Supervision Signals 3BSE 027 941 R301...
  • Page 61 STP in a protected environment to connect to Commercial Off-The-Shelf (COTS) Ethernet components, (HUBS/Transceivers/and so forth), that convert to optical fiber. ABB recommends the use of optical fiber in an industrial environment, for example 62.5/125 100 Base-FX, max. distance 1500 m (1600 yd) Table 7.
  • Page 62 Installing the PM8xx/TP830 Processor Unit in Single Configuration Section 2 Installation COM3 Port The COM3 is an RS232-C port with modem signals. This port is used for serial protocols such as Modbus, Siemens 3964R, COMLI or custom-design. Table 8. TP830 COM3 Connections (RJ45 connector) Designation Direction Description...
  • Page 63 Section 2 Installation Installing the PM8xx/TP830 Processor Unit in Single Configuration COM4 Port The COM4 port is an RS232-C port, opto-isolated and without modem signals. Connect Control Builder to this port when connecting directly to the controller, or, when not required, without the need use the remote tool connection via the Control Network.

  • Page 64: Installing The Pm861/Pm864/Tp830 Processor Unit In Redundant Configuration

    Installing the PM861/PM864/TP830 Processor Unit in Redundant Configuration Section 2 Installing the PM861/PM864/TP830 Processor Unit in Redundant Configuration In redundant configuration two PM861/PM864 units are mounted onto two separate DIN-rails. If sufficient space is available, the units can be mounted onto the same DIN-rail Note that in redundant CPU configuration, COM3 and the electrical ModuleBus on the baseplate can not be used.
  • Page 65 Section 2 Installation Installing the PM861/PM864/TP830 Processor Unit in Redundant TP830 Baseplates cable connections: Connect the power leads to both CPUs and the power supervision signals from SS822 to screw terminals SA and SB (see Figure 15 on page 60). Both CPUs must be powered from the same supply (single or redundant).
  • Page 66 Installing the PM861/PM864/TP830 Processor Unit in Redundant Configuration Section 2 Communication Ports Same as for single configuration (see Table 7 on page 61, Table 8 on page 62 and Table 9 on page 63). CEX-bus ext. cable TK850 RCU Link cable TK851 Figure 16.

  • Page 67: Installing The Profibus Dp Interface, Ci851/Tp851

    The CI851 is powered from the processor unit via the CEX-bus and requires therefore no additional external power source. Use the following procedure to install the CI851/TP851: Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 49 and Installing the PM8xx/TP830 Processor Unit in Single Configuration on page 56.
  • Page 68 Installing the PROFIBUS DP Interface, CI851/TP851 Section 2 Installation Installation of PROFIBUS DP Table 10. CI851 - PROFIBUS DP Connector Designation Description Shield Shield/protective ground – Not Used B-line Receive/Transmit Data B-line RTS(TTL) Indicates direction RTS(TTL) Indicates direction GND Bus GND Bus +5 V Bus For terminating resistors...

  • Page 69: Installing The Foundation Fieldbus H1 Interface, Ci852/Tp852

    No field device on the FF H1 bus is powered from the CI852. An AC 800M Controller connected to a CI852 constitutes a FOUNDATION Fieldbus linking device. Use the following procedure to install the CI852/TP852:...
  • Page 70 Installing the FOUNDATION Fieldbus H1 Interface, CI852/TP852 Section 2 Installation For additional information on designing a fieldbus (connectors, cables and devices), Related Documentation on page 17. A catalog referencing suppliers, devices, services and other fieldbus-related items, is available for FIELDBUS ONLINE via the Internet web site. Powering Field Devices Field devices requiring power from the fieldbus need special power supplies connected to the data wires (in the same way as a field device).

  • Page 71: Installing The Rs232-C Interface, Ci853/Tp853

    CI853 is powered from the processor unit via the CEX bus and requires therefore no additional external power source. Use the following procedure to install the CI853/TP853: Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 49 and Installing the PM8xx/TP830 Processor Unit in Single Configuration on page 56.

  • Page 72: Installing The Profibus Dp-V1 Interface, Ci854/Tp854

    The CI854 is powered from the processor unit via the CEX-bus and requires therefore no additional external power source. Use the following procedure to install the CI854/TP854: Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 49 and Installing the PM8xx/TP830 Processor Unit in Single Configuration on page 56.
  • Page 73 Section 2 Installation Installing the PROFIBUS DP-V1 Interface, CI854/TP854 Installation of PROFIBUS DP-V1 Table 13. CI854 – PROFIBUS DP-V1 Connector Designation Description Shield Shield/protective ground – Not Used RxD/TxD-P Receive/Transmit Data P-line CNTR-P Indicates Direction to Repeater (TTL) DGND Digital Ground +5 V, for terminating resistors –...

  • Page 74: Installing The Ethernet Interface For Masterbus 300, Ci855/Tp853

    The baseplate, TP853, provides two Ethernet ports for connection of redundant Ethernet network for MasterBus 300. Use the following procedure to install the CI855/TP853: Mount the unit on the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 49 and Installing the PM8xx/TP830 Processor Unit in Single Configuration on page 56.

  • Page 75: Installing The S100 I/O Interface, Ci856/Tp856

    The CI856 is powered from the processor unit via the CEX-bus and requires therefore no additional external power source. Use the following procedure to install the CI856/TP856: Mount the unit on the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 49 and Installing the PM8xx/TP830 Processor Unit in Single Configuration on page 56.

  • Page 76: Installing The Insum Interface, Ci857/Tp853

    The CI857 is powered from the processor unit via the CEX-bus and requires therefore no additional external power source. Use the following procedure to install the CI857/TP853: Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 49 and Installing the PM8xx/TP830 Processor Unit in Single Configuration on page 56.

  • Page 77: Installing The Modulebus

    Section 2 Installation Installing the ModuleBus Installing the ModuleBus The ModuleBus has an electrical and a fiber optical interface that are logically the same buses. A maximum of 12 I/O units can be connected to the Electrical ModuleBus and up to seven clusters to the fiber optical ModuleBus. The fiber optical interface is intended for local distribution of I/O clusters and for connection of engineered and standard drives.

  • Page 78: Installing The Sd82X Power Supply

    Installing the SD82x Power Supply Section 2 Installation Installing the SD82x Power Supply Use the following procedure to install the SD821, SD822 and SD823 power supply units. Mount the selected unit onto the DIN-rail at the required position. Set the mains switch on the front of the power supply unit to the required voltage: 115 V for 110–120 V AC 230 V for 220–240 V AC (default position on delivery).

  • Page 79: Installing The Mains Breaker Unit

    Section 2 Installation Installing the Mains Breaker Unit Installing the Mains Breaker Unit The mains breaker unit is supplied in separate components that must be mounted onto a DIN-rail in order to form a complete assembly. Different distribution options are available, but for the sake of simplicity, the installation described covers the redundant power supplies/independent power supplies option.
  • Page 80 Installing the Mains Breaker Unit Section 2 Installation Removing the fuse holders or the jumper connections provides visual indication if the power supply has been disconnected. The fuse holders have built-in red LEDs to indicate a ruptured (defective) fuse. PE – Green/Yellow To Power PE –...

  • Page 81: Installing The Ss822 Voting Unit

    Section 2 Installation Installing the SS822 Voting Unit Installing the SS822 Voting Unit The SS822 voting unit is used to connect two redundant power supplies to a common load. Depending on the system configuration requirements, the two redundant power supplies may be connected to completely separate mains supplies or to the same mains supply, as shown in Figure 19 on page 81.

  • Page 82: Power Supply Supervision

    Power Supply Supervision Section 2 Installation L+ L+ L– L– L+ L+ L– L– F OK PM861 SD821 SD821 SS822 L– L PE L PE A+ B+ L+ L+ L– From Mains Breaker Protective Ground PM861 L– Figure 20. Redundant Power Supply Powering Redundant CPUs Power Supply Supervision The status of power supplies in redundant configuration can be supervised via the SS822 voting unit.
  • Page 83 81 and Figure 20 on page 82 show redundant power supplies powering AC 800M units. Here the SA/SB signals also indicate physical power supplies. Figure 22 on page 84 shows one redundant power supply powering the AC 800M units and one for powering field equipment.
  • Page 84 Power Supply Supervision Section 2 Installation Supervision signals to CPU unit via TP830 L+ L+ L– L– L+ L+ L– L– F OK SD821 SS822 SD821 L PE L PE A+ B+ L+ L+ L– +24 V From Mains Powering Breaker Units L–...

  • Page 85: Installing The Sb821 External Battery Unit

    PM8xx in order to avoid reducing available memory back-up time. Do not connect the TK821V020 cable until the AC 800M Controller has been powered-up normally and the memory back-up function has been activated. If...

  • Page 86: Installation In Cabinets

    Installation in Cabinets Section 2 Installation Installation in Cabinets The figures listed below are examples of how the AC 800M Controllers, Power Supply units, Voting units and S800 I/O units can be configured and mounted within cabinets: • Figure 23 on page 87: Wall Cabinet –...
  • Page 87 Section 2 Installation Installation in Cabinets ModuleBus Expansion Cable Aluminum Profile Cable Duct Mains Breaker SD821 24 V Distribution Unit Terminals Figure 23. Wall Cabinet – Single Power Supply Arrangement 3BSE 027 941 R301...
  • Page 88 Installation in Cabinets Section 2 Installation Mains Breaker SD821 SD821 Unit (Units) (Field) 24 V Distribution 24 V Distribution (Units in Cabinet) (Field Equipment) Figure 24. Wall Cabinet – Dual Power Supply (Local/Field) Arrangement 3BSE 027 941 R301...
  • Page 89 Section 2 Installation Installation in Cabinets SD822 Redundant Power Supply Units (Field Equipment) Mains Breakers SS822 Voting Units SD822 Redundant Power Supply Units Figure 25. Floor Mounted Cabinet (Horizontal Unit Arrangement) 3BSE 027 941 R301...

  • Page 90: Mounting Dimensions For Proper Ventilation

    Section 2 Installation Mounting Dimensions for proper Ventilation To maintain adequate cooling airflow through the AC 800M Controller units, there must be no obstruction within 50 mm (2 in) above and 25 mm (1 in) below the units, as shown in Figure 26 on page 90.

  • Page 91: Section 3 Configuration

    Alternatively the Control Builder may be connected via the COM4 port (RS232-C) on the AC 800M Controller. Use the tool cable TK212 and a serial port on the PC. In redundant configuration the Control Builder is connected to the Primary CPU COM4 port.

  • Page 92: Connection To A Control Network

    INDUSTRIAL ENVIRONMENT NON-INDUSTRIAL ENVIRONMENT Switch FO = Fiber Optic link STP = Shielded Twisted Pair Link USE STP GENERALLY Control Builder Operator Station Figure 27. Example of AC 800M Controllers Connected to a Control Network 3BSE 027 941 R301...

  • Page 93: Communication Possibilities

    Ethernet and PPP. It provides for full redundancy to achieve high network availability. The AC 800M controller is always connected to the Control Network via an STP (Shielded Twisted Pair) cable. Should the local environment be of an industrial nature, the AC 800M / Control network connection must be converted over to a Fiber Optic (FO) cable.
  • Page 94 Communication Possibilities Section 3 Configuration By adding communication interfaces to the CEX-bus, the number of protocols and processor unit ports can be expanded. The available CEX-bus interface quantities are shown in Table 14 on page 94. Table 14. Interfaces Available on the CEX-bus Number of Interfaces on CEX- Number of Interface...

  • Page 95: Controller Ip Addresses

    Section 3 Configuration Controller IP Addresses Controller IP Addresses Before a redundant hardware installation you have to concider the following. Remember that the Backup controller IP Addresses must be set in the primary Processor Unit. This can only be done though the IPConfig tool. There are three alternatives: •...

  • Page 96: I/O Systems

    For more information on supported I/O systems and units, see Related Documentation on page 17. ModuleBus The ModuleBus in the AC 800M controller consists of one electrical and one optical unit: • Electrical ModuleBus, (see Figure 28 on page 97) – 1 cluster (group), with a maximum of 12 S800 I/O units connected.
  • Page 97 Section 3 Configuration I/O Systems This provides a total of eight clusters (groups), with a maximum 8 x 12 = 96 S800 I/O units connected to an AC 800M Controller with single CPU configuration. Optical Electrical ModuleBus ModuleBus PM8xx Local...
  • Page 98 I/O Systems Section 3 Configuration In redundant CPU configuration, connection of S800 I/O is carried out through the optical ModuleBus. Each CPU is connected to one TB840 on each cluster (see Figure 29 on page 98). Redundant CPUs Electrical ModuleBus can not be used Termination is not necessary Local 2 x TB840...
  • Page 99 Section 3 Configuration I/O Systems PROFIBUS DP and PROFIBUS DP-V1 A PROFIBUS DP/DP-V1segment, capable of providing up to 32 nodes, can be directly connected to a PROFIBUS DP Interface unit type CI851/TP851, or a PROFIBUS DP-V1 Interface unit, type CI854/TP854. This segment can be further extended using repeater units.

  • Page 100: Drive System

    Drive System Section 3 Configuration Drive System ABB Standard (Std) and Engineered (Eng) Drives can be connected to AC 800M via the optical ModuleBus or via PROFIBUS DP and CI830. ModuleBus In single CPU configuration, ABB Drives can be connected to the processor unit via the optical ModuleBus.
  • Page 101 Max 12 units per cluster Optical TB820 DI810 AI810 AO820 ABB Std Drive Branching Unit Optical Optical ABB Std Drive ABB Std Drive ABB Std Drive Figure 30. Example of Connection of ABB Drives in Single CPU Configuration 3BSE 027 941 R301...

  • Page 102: Power Supply System

    SS822 voting devices – to the 24 V DC distribution terminals. The AC 800M Controller and its I/O system are normally located in one or several enclosures or cabinets. The cabinet housing the AC 800M Controller can also...

  • Page 103: Powering Units In The Cabinet

    Interference Powering field equipment from a power supply located in the AC 800M Controller cabinet often requires the use of long 24 V DC cables that can easily pick up local interference and direct it straight back to the power supply units. When installing the...
  • Page 104 Powering Field Equipment outside the Cabinet Section 3 Configuration To avoid the AC 800M Controller being influenced by field equipment, it is strongly recommended that separate power supplies be installed (see Figure 24 on page 88 Figure 25 on page 89).

  • Page 105: Powering From An External +24 V Dc Source

    107). Powering from an External +24 V DC Source The AC 800M Controller can be powered from an external +24 V DC source. This source is often common for many different types of plant equipment, resulting in long power cables to the AC 800M Controller. Furthermore, heavy load changes can cause variations in controller supply voltage making it necessary to take precautions against low voltage in order to prevent controller malfunction.
  • Page 106 Device Power Supplies Redundant Mains Power Supplies Mains 1 Supply to Units Mains Breaker 24 V DC Voting Distribution Mains 2 Device Terminals Mains Breaker Power Supplies Figure 31. Power Supply Options for AC 800M Units 3BSE 027 941 R301...
  • Page 107 Section 3 Configuration Powering from an External +24 V DC Source Supply to Units Mains 24 V DC Mains Breaker Distribution Terminals Independent Power Supplies Supply to Field Equipment 24 V DC Distribution Terminals Supply to Units Mains 24 V DC Mains Breaker Distribution Independent...
  • Page 108 Powering from an External +24 V DC Source Section 3 Configuration 3BSE 027 941 R301...

  • Page 109: Section 4 Operation

    Section 4 Operation AC 800M Controller (PM8xx) Section 4 Operation This section describes the operation of the AC 800M Controller, comprising a PM8xx (single or redundant configuration) processor unit, together with various optional units. For additional technical information on optional units, see...
  • Page 110 AC 800M Controller (PM8xx) Section 4 Operation Table 15. PM8xx – LED Indicators (Continued) Marking Color Function B(attery) Green Normal state – ON Lit when condition of internal or external battery is satisfactory. The LED is controlled by a software battery voltage test –...
  • Page 111 Section 4 Operation AC 800M Controller (PM8xx) Switches and Push buttons Table 16. PM8xx – Switches and Push buttons Marking Type Function INIT Manual Push Initiates button 1. Cold Restart if INIT is held less than 2.5 seconds. 2. Controller Reset if INIT is held more than 3 seconds.

  • Page 112: Start-Up

    Start-up Section 4 Operation Table 17. PM8xx/TP830 – Connectors (Continued) Marking Function MODULEBUS Provides expansion of I/O unit capability. CEX-BUS Provides extension of on-board communication ports. Valid for PM861/PM864 RCU Link Connector Provides information and data transfer between Primary and Backup CPU in redundant configuration. Start-up Refer to relevant document (see Related Documentation...
  • Page 113 Section 4 Operation Start Modes Cold Restart The application program restarts. Variable values are initialized unless marked Cold retain. To initiate a cold restart, the Controller must be restarted by briefly pressing the INIT push button (less than 2.5 seconds). Cold Restart in Redundant Configuration To restart CPUs running in redundant configuration: Perform a Controller Reset of the backup CPU (see below).

  • Page 114: Automatic Switch-Over To Backup Cpu

    Automatic Switch-Over to Backup CPU Section 4 Operation Automatic Switch-Over to Backup CPU In a redundant configuration an automatic switch-over from the Primary CPU to the Backup CPU occurs in the following situations, provided they are in synchronized state (DUAL LED is lit): •...

  • Page 115: Verification Of Satisfactory Ac 800M Operation

    Section 4 Operation Verification of Satisfactory AC 800M Operation Verification of Satisfactory AC 800M Operation To affirm, following start-up, that the AC 800M Controller and all associated units are operating correctly, see Table 18 on page 115. Verification of Single CPU Check the status of each LED indicator and compare it against the criteria listed in the table.
  • Page 116 Verification of Single CPU Section 4 Operation Table 18. AC 800M Controller – Verification of Satisfactory System Operation AC 800M LED Indicator Status Controller Status F(ault) Red LED must be OFF R(un) Green LED must be ON (steady) CI855 Ethernet Interface Unit for MasterBus 300...

  • Page 117: Verification Of Redundant Cpu

    Verification of Redundant CPU Check, in redundant configuration, the following LED indicators on PM861/PM864 (see Table 19 on page 117). Table 19. AC 800M Controller (PM861/PM864) – Verification of Satisfactory System Operation in Redundant configuration LED Indicator Status AC 800M Controller Status...
  • Page 118 Verification of Redundant CPU Section 4 Operation 3BSE 027 941 R301...

  • Page 119: Section 5 Maintenance

    Preventive Maintenance Frequency Schedule Section 5 Maintenance This section describes preventive and corrective maintenance measures for the AC 800M Controller together with troubleshooting procedures for both the system and individual units. :DUQLQJ Before attempting maintenance or troubleshooting, read the Safety Summary on page 21.

  • Page 120: Changing The Battery

    PM8xx B(attery) LED flashes or is extinguished. • multiple or extended power cuts have occurred. • extended periods of system downtime have occurred for maintenance or malfunctions. For reasons of safety, exchange the battery only when the AC 800M is powered up. 3BSE 027 941 R301...
  • Page 121 Section 5 Maintenance Internal Battery Captive screw Cover Internal battery holder Figure 33. Right-hand Cover Removal – here shown with PM860 To exchange the internal battery: Using a blade screwdriver, release the captive screw from the PM8xx and remove the right-hand cover. Identify and remove the internal battery.
  • Page 122 Internal Battery Section 5 Maintenance Replace the PM8xx right-hand cover and tighten the screw. Dispose of the run-down Lithium battery in an approved manner. INIT Internal battery – PM860 COM3 COM4 Figure 34. Internal Battery Location – here shown with PM860 3BSE 027 941 R301...

  • Page 123: Sb821 External Battery Unit

    Section 5 Maintenance SB821 External Battery Unit SB821 External Battery Unit The external battery is mounted inside the SB821 External Battery unit. Since the battery is not rechargeable, it is important to exchange it on a regular basis (refer to the Maintenance Frequency Schedule for further details).
  • Page 124 Carefully remove the battery. Insert a serviceable battery and check that battery polarity and orientation are correct. For further battery details see SB821 External Battery – AC 800M Memory Back-up on page 193. Replace the cover, mount the unit onto the DIN rail, and reconnect the cable.
  • Page 125 Section 5 Maintenance SB821 External Battery Unit SB821 3.6 V Lithium Battery Unit Note the warning text on the battery. B– B+ SH Figure 35. SB821 External Battery Unit – Cover Removed 3BSE 027 941 R301...

  • Page 126: Unit Change Online

    Unit Change Online Section 5 Maintenance Unit Change Online Change online entails adding or removing units in a controller without disturbing the execution of the running application program. Units are connected to the CEX- bus and the electrical ModuleBus (S800 I/O). CEX-bus Communication interfaces CI851/852/853/854/855/856 or CI857...

  • Page 127: Corrective Maintenance Procedures

    Section 5 Maintenance Corrective Maintenance Procedures Reconnect the Power Supply Socket to the new processor unit. Reconnect the optical ModuleBus and RCU Link Cable. Press the INIT push button on the replaced processor unit. Observe the startup procedure and make sure that Dual mode is reached, that the Dual LED is lit on both processor units.

  • Page 128: Fault-Finding Procedures

    Fault-Finding Procedures Section 5 Maintenance Check that the relevant LED lights up. Fault-Finding Procedures PM8xx Processor Unit Table 21. PM8xx – Fault-Finding Procedure Fault Possible Cause and Corrective Action F(ault) LED is ON Controller Re-start, (INIT), in progress. • Wait for Controller restart to finalize. If condition persists: •...

  • Page 129: Pm861/Pm864 Processor Unit In Redundant Configuration

    Section 5 Maintenance PM861/PM864 Processor Unit in Redundant Configuration PM861/PM864 Processor Unit in Redundant Configuration Table 22. PM861/PM864 Redundant Configuration – Fault-Finding Procedure Fault Possible Cause and Corrective Action DUAL LED is OFF on both The CPUs are in the process of being re-started CPUs or configured.

  • Page 130: Profibus Dp - Ci851

    PROFIBUS DP – CI851 Section 5 Maintenance PROFIBUS DP – CI851 Table 24. PROFIBUS DP CI851 – Fault-Finding Fault Possible Cause and Corrective Action Neither R(un) nor F(ault) LEDs The CI851 board is in the process of being re- are ON started or configured.

  • Page 131: Foundation Fieldbus - Ci852

    Section 5 Maintenance FOUNDATION Fieldbus – CI852 FOUNDATION Fieldbus – CI852 Table 25. FOUNDATION Fieldbus CI852 – Fault-Finding Fault Possible Cause and Corrective Action R(un) and F(ault) The CI852 board is in the process of being restarted or LEDs are not ON configured.
  • Page 132 FOUNDATION Fieldbus – CI852 Section 5 Maintenance Table 25. FOUNDATION Fieldbus CI852 – Fault-Finding (Continued) Fault Possible Cause and Corrective Action One or more field 1.A device may be: devices appear to • Incorrectly addressed. be slow to • Connected with incorrect polarity. respond or •...
  • Page 133 Section 5 Maintenance FOUNDATION Fieldbus – CI852 Table 25. FOUNDATION Fieldbus CI852 – Fault-Finding (Continued) Fault Possible Cause and Corrective Action The network Use an oscilloscope to check the communication signals for problem is abnormalities. proving very • The oscilloscope must be of differential or battery difficult to solve operated type.

  • Page 134: On-Board Rs232-C Channels - Ci853

    On-board RS232-C Channels – CI853 Section 5 Maintenance On-board RS232-C Channels – CI853 Table 26. On-board RS232-C Channels CI853 – Fault-Finding Fault Possible Cause and Corrective Action The PM8xx is transmitting and the • Check that the communication Tx1/Tx2 LEDs are flashing, but interface cable is connected.

  • Page 135: Profibus Dp-V1 - Ci854

    Section 5 Maintenance PROFIBUS DP-V1 – CI854 PROFIBUS DP-V1 – CI854 Table 27. PROFIBUS DP-V1 CI854 – Fault-Finding Indication Possible Cause and Corrective Action Neither R(un) nor F(ault) The CI854 board is in the process of being LED’s are ON restarted or configured.

  • Page 136: Masterbus 300 Interface - Ci855

    MasterBus 300 Interface – CI855 Section 5 Maintenance 0DVWHU%XV  ,QWHUIDFH ± &, 7DEOH  0DVWHU%XV  &, ± )DXOW )LQGLQJ )DXOW 3RVVLEOH &DXVH DQG &RUUHFWLYH $FWLRQ Neither R(un) nor F(ault) LEDs The CI855 board is in the process of being are ON restarted or configured.

  • Page 137: S100 I/O Interface - Ci856

    Section 5 Maintenance S100 I/O Interface – CI856 S100 I/O Interface – CI856 Table 29. S100 I/O CI856 – Fault Finding Fault Possible Cause and Corrective Action Neither R(un) nor F(ault) The CI856 unit is in the process of being LED’s are ON configured.

  • Page 138: Insum Interface - Ci857

    INSUM Interface – CI857 Section 5 Maintenance ,1680 ,QWHUIDFH ± &, 7DEOH  ,1680 &, ± )DXOW)LQGLQJ )DXOW 3RVVLEOH &DXVH DQG &RUUHFWLYH $FWLRQ Neither R(un) nor F(ault) LEDs The CI857 board is in the process of being are ON restarted or configured. Allow time for this to finalize If the condition persists, and no other unit LED on the CEX-bus is lit:...

  • Page 139: Appendix A Hardware Units Pm856/Pm860 And Tp830 - Processor Unit

    Appendix A Hardware Units PM856/PM860 and TP830 – Processor Unit Appendix A Hardware Units PM856/PM860 and TP830 – Processor Unit Key Features • MPC860 Microprocessor running at 48 MHz. • 8 MB RAM with internal or external battery back-up facility. •...

  • Page 140: Technical Data

    Technical Data Appendix A Hardware Units Technical Data Technical data for PM856/PM860 and TP830 is described in Table 31 on page 140. Table 31. PM856/PM860 and TP830 – Technical data Item Value Memory • 2 MB flash PROM (firmware storage). •...
  • Page 141 Appendix A Hardware Units Technical Data Table 31. PM856/PM860 and TP830 – Technical data (Continued) Item Value Weight • 1100 g (2.4 lb) (package PM856K01 with PM856, TP830 and bus terminations). • 1100 g (2.4 lb) (package PM860K01 with PM860, TP830 and bus terminations).
  • Page 142 Technical Data Appendix A Hardware Units Table 32. PM856/PM860 and TP830 Interfaces – Technical data (Continued) Item Value Modem support COM4 Serial Communication Communication speed 9600 baud Signal levels RS232-C Connector RJ45 Modem support Electrical ModuleBus I/O capacity 1 x S800 I/O base cluster with up to 12 x S800 I/O units. Supply current •...
  • Page 143 External battery Minimum 1 month Table 34 on page 143 shows Internal battery data. For external battery data, SB821 External Battery – AC 800M Memory Back-up on page 193. Table 34. PM856/PM860 and TP830 – Internal battery data Item Value...

  • Page 144: Performance Data

    Performance Data Appendix A Hardware Units Performance Data The PM856 and PM860 processor units have the same internal design. They differ only in performance when executing an application program. Using the same application program in PM856 and PM860, the difference in execution time can be expressed as: Execution time in PM856 = 2 *Execution time in PM860 Example: If a certain application program has an execution time of 100 ms in...

  • Page 145: Pm861 And Tp830 - Processor Unit

    Appendix A Hardware Units PM861 and TP830 – Processor Unit PM861 and TP830 – Processor Unit Key Features • MPC860 Microprocessor running at 48 MHz. • 16 MB RAM with internal or external battery back-up facility. • 12 x S800 I/O units can be connected to the electrical ModuleBus.

  • Page 146: Technical Data

    Technical Data Appendix A Hardware Units Technical Data For technical data on PM861 and TP830, see Table 35 on page 146. Table 35. PM861 and TP830 – Technical data Item Value Memory • 2 MB flash PROM (firmware storage). • 16 MB of SDRAM (11 MB available for application program and 5 MB used for executable firmware).
  • Page 147 Minimum 3 weeks (1) 3 weeks is valid for one PM861 processor unit. Table 34 on page 143 shows internal battery data. For external battery data, SB821 External Battery – AC 800M Memory Back-up on page 193. 3BSE 027 941 R301...

  • Page 148: Performance Data

    Performance Data Appendix A Hardware Units Electro-magnetic Compatibility and Electrical Safety PM861/TP830 meets the requirements specified in EMC Directive 89/336/EEC. For more information regarding electrical safety, see Appendix D, Directive Considerations. LED Indicators Table 15 on page 109. Performance Data The PM861 processor unit, in single configuration, has the same performance data as the PM860.

  • Page 149: Pm864 And Tp830 - Processor Unit

    Appendix A Hardware Units PM864 and TP830 – Processor Unit PM864 and TP830 – Processor Unit Key Features • MPC862 Microprocessor running at 96 MHz. • 32 MB RAM with internal or external battery back-up facility. • 12 x S800 I/O units can be connected to the electrical ModuleBus.

  • Page 150: Technical Data

    Technical Data Appendix A Hardware Units Technical Data For technical data on PM864 and TP830, see Table 37 on page 150. Table 37. PM864 and TP830 – Technical data Item Value Memory • 2 MB flash PROM (firmware storage). • 32 MB of SDRAM (27 MB available for application program and 5 MB used for executable firmware).
  • Page 151 Minimum 3 weeks (1) 3 weeks is valid for one PM864 processor unit. Table 34 on page 143 shows internal battery data. For external battery data, SB821 External Battery – AC 800M Memory Back-up on page 193. 3BSE 027 941 R301...

  • Page 152: Performance Data

    Performance Data Appendix A Hardware Units Electro-magnetic Compatibility and Electrical Safety PM864/TP830 meets the requirements specified in EMC Directive 89/336/EEC. For more information regarding electrical safety, see Appendix D, Directive Considerations. LED Indicators Table 15 on page 109. Performance Data The PM864 processor unit, in single configuration, has performance data which theoretically peaks at twice the performance compared to the PM860.

  • Page 153: Ci851 And Tp851 - Profibus Dp Interface

    DC/DC converter that supplies appropriate voltages from the +24V supply, via the CEX-bus. The PROFIBUS DP must always be terminated at the two outer nodes. ABB recommends the use of connectors with built-in termination since the fieldbus will always be terminated even if fully disconnected from the unit.
  • Page 154 CI851 and TP851 – PROFIBUS DP Interface Appendix A Hardware Units Functional Block Diagram Communication Communication Extension Bus Extension Bus +24 V DC/DC converter Bus interface +5 V Communication unit AnyBus -M PROFIBUS-DP Communication Extension Unit Communication Extension Baseplate Communication line Figure 36.
  • Page 155 Appendix A Hardware Units CI851 and TP851 – PROFIBUS DP Interface Indicators Table 39. CI851 – PROFIBUS DP LED Indicators Designation/Color Function F(ault) /Red Unit error detected. Controlled by Control Software. Set and cleared by the Hardware during controller Reset. R(un) /Green Operating.
  • Page 156 CI851 and TP851 – PROFIBUS DP Interface Appendix A Hardware Units Table 40. CI851 PROFIBUS DP Interface Specifications (Continued) Item Value Capacity Max 32 loads Protection Rating IP20 according to EN60529, IEC 529 Weight 700 g (1.5 lb) (package CI851K01 with CI851 and TP851).

  • Page 157: Ci852 And Tp852 - Foundation Fieldbus H1 Interface

    CI852 Description The CI852, connects the FOUNDATION Fieldbus H1 (FF H1) to the AC 800M. The FF H1 has a communication speed of 31.25 kbit/s and is intended for remote connection of field instruments. The CI852 is connected to the bus via a transformer, and as such neither supplies nor consumes bus electrical power.
  • Page 158 CI852 and TP852 – FOUNDATION Fieldbus H1 Interface Appendix A Hardware Units Functional Block Diagram Communication Communication Extension Bus Extension Bus +24 V DC/DC converter Bus interface +5 V Communication unit with FOUNDATION fieldbus interface Communication Extension Unit Communication Extension Baseplate Communication line Figure 37.
  • Page 159 Appendix A Hardware Units CI852 and TP852 – FOUNDATION Fieldbus H1 Interface Indicators The CI852 FOUNDATION Fieldbus H1 interface has the following LED indicators. Table 41. CI852 FOUNDATION Fieldbus H1 – LED Indications Indication/Color Function F(ault) /Red Unit error detected. Controlled by Control Software.
  • Page 160 CI852 and TP852 – FOUNDATION Fieldbus H1 Interface Appendix A Hardware Units Table 42. CI852 Foundation Fieldbus Interface Specifications (Continued) Item Description Status indicators Red LED for error Green LED for run Yellow LED for traffic Connector Male 9-pin D-type connector. Current consumption from 140 mA typical (200 mA max.).

  • Page 161: Ci853 And Tp853 - Rs232-C Interface

    Appendix A Hardware Units CI853 and TP853 – RS232-C Interface CI853 and TP853 – RS232-C Interface Key Features • Two RS232-C ports implemented with RJ45 connectors, located on the TP853 Baseplate, (act as an extension of the onboard RS232-C port on PM8xx should more RS232-C ports be required).
  • Page 162 CI853 and TP853 – RS232-C Interface Appendix A Hardware Units Functional Block Diagram Communication Communication Extension Bus Extension Bus +24 V DC/DC Bus interface converter Microprocessor with FPROM, SRAM, Dual Port RWM and two serial interfaces Communication Extension Unit Communication Extension Base plate Communication lines Figure 38.
  • Page 163 Appendix A Hardware Units CI853 and TP853 – RS232-C Interface Indicators Table 43. CI853 RS232-C – LED Indications Indication/ Color Function F(ault) /Red Error detected in the unit. Controlled by the Control Software. Set and cleared by the Hardware during Reset of the controller. R(un) /Green Operating.
  • Page 164 CI853 and TP853 – RS232-C Interface Appendix A Hardware Units Table 44. CI853 – RS232-C Communication Interface Specifications (Continued) Item Description Communication speed Selectable in steps from 75 to 115200 baud. 75, 110, 134.5, 150, 300, 600, 1200, 1800, 2000, 2400, 9600, 19200, 38400, 115200 baud.

  • Page 165: Ci854 And Tp854 - Profibus Dp-V1 Interface

    PROFIBUS interface with line redundancy unit and a DC/DC converter that supplies the appropriate voltages from the +24V supply, via the CEX- bus. The PROFIBUS DP must always be terminated at the two outer nodes. ABB recommends the use of connectors with built-in termination since the fieldbus will always be terminated, even if fully disconnected from the unit.
  • Page 166 CI854 and TP854 – PROFIBUS DP-V1 Interface Appendix A Hardware Units Functional Block Diagram Communication Extension Bus +24 V DC/DC CEX-Bus Interface Converter CPU-Kernel and Memory +5 V / +3.3 V PROFIBUS Master ASIC Line Redundancy Unit Communication Extension Unit RS485 Communication Extension Baseplate...
  • Page 167 Appendix A Hardware Units CI854 and TP854 – PROFIBUS DP-V1 Interface Indicators Table 45. CI854 – PROFIBUS DP-V1 LED Indicators Designation/Color Function F(ault) /Red Unit error detected. Controlled by Control Software. Set and cleared by the Hardware during controller Reset. R(un) /Green Operating.
  • Page 168 CI854 and TP854 – PROFIBUS DP-V1 Interface Appendix A Hardware Units Table 46. CI854 PROFIBUS DP-V1 Interface Specifications (Continued) Item Value Connectors Two DB9, female on TP854. Current consumption 190 mA typical (max. 240 mA). (from CEX-bus 24 V DC) Power dissipation 4.6W typical.

  • Page 169: Ci855 And Tp853 - Ethernet Interface For Masterbus 300

    Description CI855 The CI855/TP853 can be used to connect an AC 800M to single or redundant MB 300 Networks. This allows DataSet communication and transmission of time between AC 400 Master and AC 800M. The TP853 Baseplate has two RJ45 Ethernet connectors for connecting to MB300.
  • Page 170 CI855 and TP853 – Ethernet Interface for MasterBus 300 Appendix A Hardware Units Indicators 7DEOH  &, ± 0DVWHU%XV  /(' ,QGLFDWRUV 'HVLJQDWLRQ&RORU )XQFWLRQ F(ault) /Red Unit error detected. Controlled by Control Software. Set and cleared by the Hardware during controller Reset.
  • Page 171 Appendix A Hardware Units CI855 and TP853 – Ethernet Interface for MasterBus 300 Functional Block Diagram Communication Communication Extension Bus Extension Bus +24V DC/DC Converter Bus Interface 68360 QUICC Communication Processor Glue for Ethernet Communication Extension Module Communication Extension Baseplate Communication Ethernet Line Figure 40.
  • Page 172 CI855 and TP853 – Ethernet Interface for MasterBus 300 Appendix A Hardware Units Technical Data 7DEOH  &, 0DVWHU%XV  ,QWHUIDFH 6SHFLILFDWLRQV ,WHP 9DOXH Type Ethernet unit Protocol MasterBus 300 based on Ethernet Communication speed 10 Mbit/s (half duplex) Status indicators Run normally green, FAIL exceptionally red, the four traffic indicators RX/TX1, RX/TX 2, COLL1 and COLL2 are yellow...

  • Page 173: Ci856 And Tp856 - S100 I/O Interface

    CI856 incompatible components. Description The CI856/TP856 connects S100 I/O to AC 800M.The TP856 Baseplate has one 36-pin centerline miniature ribbon connector for connecting S100 I/O racks. The baseplate has a code lock, see...
  • Page 174 CI856 and TP856 – S100 I/O Interface Appendix A Hardware Units Indicators Table 49. CI856 – S100 I/O LED Indicators Designation/Color Function F(ault) /Red Unit error detected. Controlled by CI856 Software. Set by the Hardware during controller Reset. Cleared by the CI856 Software after successful startup.
  • Page 175 Appendix A Hardware Units CI856 and TP856 – S100 I/O Interface Functional Block Diagram Communication Communication Extension Bus Extension Bus +24 V DC/DC converter CEX-bus interface +2.5 V SDRAM 8 MB +3.3 V ColdFire µP MCF5307 Flash 2 MB S100 I/O-bus interface +5 V Communication Extension Unit Communication Extension Baseplate...
  • Page 176 CI856 and TP856 – S100 I/O Interface Appendix A Hardware Units Technical Data Table 50. CI856 S100 I/O Interface Specifications Item Value Type S100 I/O Communication Interface Galvanic isolation Status indicators Run normally green, FAIL exceptionally red, the indicator TO are yellow flashing at S100 I/O access time-outs.

  • Page 177: Ci857 And Tp853 - Insum Interface

    Description CI857 The CI857/TP853 can be used to connect an AC 800M controller to INSUM through TCP/IP over Ethernet and an INSUM TCP/IP Gateway that has a LON interface communicating with the underlying INSUM system.
  • Page 178 CI857 and TP853 – INSUM Interface Appendix A Hardware Units Indicators 7DEOH  &, ± ,1680 ,QWHUIDFH /(' ,QGLFDWRUV 'HVLJQDWLRQ&RORU )XQFWLRQ F(ault) /Red Unit error detected. Controlled by Control Software. Set and cleared by the Hardware during controller Reset. R(un) /Green Operating.
  • Page 179 Appendix A Hardware Units CI857 and TP853 – INSUM Interface Functional Block Diagram Communication Communication Extension Bus Extension Bus +24V DC/DC Converter Bus Interface 68360 QUICC Communication Processor Glue for Ethernet Communication Extension Module Communication Extension Baseplate Communication Ethernet Line Figure 42.
  • Page 180 CI857 and TP853 – INSUM Interface Appendix A Hardware Units Technical Data 7DEOH  &, ,1680 ,QWHUIDFH 6SHFLILFDWLRQV ,WHP 9DOXH Type Ethernet unit. Protocol TCP/IP Communication speed 10 Mbit/s (half duplex) Status indicators Running normally: Green. Exceptional fault: Red. Two traffic indictors - Tx1/Rx1 - controlled by traffic pace: Flashing yellow.

  • Page 181: Power Supply Units - Types Sd821, Sd822 And Sd823

    Appendix A Hardware Units Power Supply Units – Types SD821, SD822 and SD823 Power Supply Units – Types SD821, SD822 and SD823 Key Features • Simple DIN-rail mounting • Parallel connection permitted for load sharing • Class I Equipment (when connected to Protective Ground, (PE)) •...
  • Page 182 Power Supply Units – Types SD821, SD822 and SD823 Appendix A Hardware Units 110 mm (4.3 in) 50 mm (2.0 in) 103 mm (4.1 in) 97 mm (3.8 in) L+ L+ L– L– SD821 Mains Voltage Selection Switch (115 / 230) Figure 43.
  • Page 183 Appendix A Hardware Units Power Supply Units – Types SD821, SD822 and SD823 110 mm (4.3 in) 103 mm (4.1 in) 65 mm (2.6 in ) 97 mm (3.8 in) L+ L+ L– L– SD822 Mains Voltage Selection Switch (115 / 230) Figure 44.
  • Page 184 ABB recommends the use of these robust and reliable power supply units (PSUs) for providing power to the AC 800M Controller when connected to an industrial mains network of installation category III. All three PSUs can be used for both non- redundant and redundant applications, as well as load sharing functions.
  • Page 185 Appendix A Hardware Units Power Supply Units – Types SD821, SD822 and SD823 The output voltage of all three PSUs is a regulated, low noise, 24V DC. A green LED on the PSU front panel indicates that the output circuit is providing the correct output voltage level.
  • Page 186 Power Supply Units – Types SD821, SD822 and SD823 Appendix A Hardware Units Insulation of Power Supply Units (PSU) Basic with protective conductor; primary circuit separated from all other live circuits by reinforced insulation. Rated insulation voltage, Primary to Secondary 300V AC. Dielectric test voltage 3000V AC (EN 60950).
  • Page 187 Appendix A Hardware Units Power Supply Units – Types SD821, SD822 and SD823 Technical Data Table 54. PSU’s SD821, 822 and 823 – Technical Data SD821 SD822 SD823 Parameter Converter Converter Converter Rated output current (A) 2.5 A 10 A Rated output power 60 W 120 W...
  • Page 188 Power Supply Units – Types SD821, SD822 and SD823 Appendix A Hardware Units Table 55. PSU’s SD821, 822 and 823 – Mounting Dimensions SD821 SD822 SD823 Parameter Converter Converter Converter Dimensions, Width 50 mm (2.0 in) 65 mm (2.6 in) 120 mm (4.7 in) HxD = 125 x 110 mm (4.9”...

  • Page 189: Ss822 Voting Unit - (For Redundant Power Supply)

    Appendix A Hardware Units SS822 Voting Unit – (for Redundant Power Supply) SS822 Voting Unit – (for Redundant Power Supply) Redundant Power Supply Configurations The SS822 Voting Unit has been specifically designed for utilization as a control unit within a redundant power supply configuration. The output connections from two identical Power Supply Units (PSUs) are connected to the SS822, see Figure 31 on page 106 and...
  • Page 190 SS822 Voting Unit – (for Redundant Power Supply) Appendix A Hardware Units Table 56. SS822 Voting Unit – Supervision Data Supervision Data SS822 Voltage, low trip level (for decreasing voltage) Voltage, low trip hysteresis 0.7V Voltage, high trip level for rising voltage High trip hysteresis 0.7V...

  • Page 191: Tc562 Modem Unit - (Westermo Md-12Dc)

    The TC562 Short Distance Modem unit can be used both for point-to-point communication and for communication over a distance between pieces of equipment or units, for example a computer and printer or a robotic device. ABB recommends their use when the distance between units/equipment exceeds 15m.
  • Page 192 0.2mm with a capacitance of 40-80pF/m within an industrial environment. For an office environment, ABB recommends a minimum cable gauge of 0.14mm and a capacitance of 40-100pF/m. Use a shielded cable in a heavy industrial environment and an unshielded cable in an office environment. A shielded cable is often given a higher capacitance and will therefore provide a higher data transmission speed.

  • Page 193: Sb821 External Battery - Ac 800M Memory Back-Up

    SB821 External Battery – AC 800M Memory Back-up 'HVFULSWLRQ The SB821 battery unit is used as an external power supply to provide extended memory back-up for the AC 800M Controller. The unit is DIN-rail mounted and provided with a separate connecting cable (TK821V020), 2m (2.2yd.) in length.

  • Page 194: Din-Rail - Ts 35/7.5

    DIN-Rail – TS 35/7.5 Appendix A Hardware Units DIN-Rail – TS 35/7.5 The figure below shows the profile and dimensions in mm (in.) of the DIN-rail TS 35/7.5. Normal supplied length is 2m (6.6ft.) (to standard DIN 46 277, EN 50 022). (0.3”) (0.3”) (1.4”)

  • Page 195: Miscellaneous Equipment

    Appendix A Hardware Units Miscellaneous Equipment Miscellaneous Equipment TB850 Terminator for CEX-bus (Male) Terminator TB850 Rx/Tx Rx/Tx CPU unit CI851 CI851 Figure 50. TB850 Terminator for CEX (male) 3BSE 027 941 R301...

  • Page 196: Tb851 Terminator For Cex-Bus (Female)

    TB851 Terminator for CEX-bus (Female) Appendix A Hardware Units TB851 Terminator for CEX-bus (Female) A TB851 (female) Terminator for CEX-bus is required when a TK850 extension cable is used. Rx/Tx Rx/Tx CPU unit CI852 CI851 CI853 COM1 COM2 TK850 Cable Terminator TB851 Rx/Tx...

  • Page 197: Tb807 Modulebus Terminator Plug

    Appendix A Hardware Units TB807 ModuleBus Terminator Plug TB807 ModuleBus Terminator Plug The Terminator plug must always be mounted on the last I/O unit of the ModuleBus. If no units are used on the ModuleBus, no bus termination is required. No ModuleBus termination is required in redundant CPU configuration.

  • Page 198: Tk853

    One 9-pole male D-sub (DE9P) • One 8-pole RJ45 plug Weight 100 g (0.2 lb) (TK853V02) Length 2.0 m (6.56’) (TK853V02) 7 RTS 4 DTR AC 800M 3 TD Modem 5 0 V RJ45 plug Male 9-pole, 2 RD D-sub connector (DE9P) 1 DCD...

  • Page 199: Tk212 Tool Cable

    One 9-pole female D-type • One 8-pole RJ45 plug Weight 125 g (0.3 lb) Length 3.0 m (9.84’) 8 CTS 6 DSR AC 800M 2 RD 1 DCD 5 0 V RJ45 plug Female 9-pin, 3 TD D-type connector 4 DTR...

  • Page 200: Al-Profile Support For Din-Rail

    Appendix A Hardware Units Al-Profile Support For DIN-Rail Units comprising the AC 800M controller are mounted onto DIN-rails (type: TS 35/7.5). However, the DIN-rail itself is not rigid enough to support the units on its own. For this reason a support is recommended, such as an A1-profile, specifically...

  • Page 201: Appendix B Power Consumption

    General At an ambient temperature of 40°C (104°F) it is considered unnecessary to calculate the heat dissipation requirements for a standard AC 800M Controller with S800 I/O configuration, mounted within ABB floor-mounted or wall-mounted cabinets. For a standard AC 800M Controller configuration housed within a floor-mounted or wall-mounted cabinet, the recommended fuse rating for the external mains supply Table 63.

  • Page 202: Current Consumption And Power Dissipation

    Current Consumption and Power Dissipation Table 64 on page 202 for typical current consumption and power dissipation data for AC 800M units. Table 64. Current Consumption and Power Dissipation Data for AC 800M Units Current at 24 V Power Dissipation Unit...
  • Page 203 Appendix B Power Consumption Current Consumption and Power Dissipation Table 65. CPU Current Supply to CEX-bus and ModuleBus +5 V +24 V ModuleBus max. 1.5 A max. 1.0 A CEX-bus Not Applicable max. 2.4 A (1) Corresponds to additional 0.5 A on +24 V. Maximum current of the +24V supplied to the CPU (incl.
  • Page 204 Current Consumption and Power Dissipation Appendix B Power Consumption Calculations Calculate the current requirements for each bus (ModuleBus and CEX-bus). Be sure not to exceed the limits given in Table 65 on page 203. Data relating to TB820, TB840 and CI830 is accessible from the S800 I/O documentation. Related Documentation on page 17.

  • Page 205: Appendix C - Recommended Components

    Recommended Components Appendix C Recommended Components Recommended Components All recommended components listed below were successfully utilized during exhaustive tests made by ABB, prior to launching the AC 800M Controller. Table 67. Recommended Components – PROFIBUS DP Component Description PROFIBUS DP...
  • Page 206 Recommended Components Appendix C Recommended Components Table 68. Recommended Components – FOUNDATION Fieldbus Component Description FOUNDATION Due to the large selection of commercially available equipment Fieldbus manufactured to FOUNDATION Fieldbus Standard (IEC 1158- 2), there is no recommendation for specific FOUNDATION Fieldbus components.
  • Page 207 Appendix C Recommended Components Recommended Components Table 69. Recommended Components for Control Networks Component Description HUBS 3Com Hub, 8/TPO – (8 ports, RJ45) (For Non- Suitable for smaller systems Industrial No supervision required. Environments) No configuration required. Plug and play capability. BayStack, 350/24 –...
  • Page 208 Recommended Components Appendix C Recommended Components Table 69. Recommended Components for Control Networks (Continued) Component Description SWITCHES Hirschmann Rail Switch RS2 (8 ports, Ring, Bus or Star topology RJ45) (Industrial Environments Suitable for larger systems Supervision required. Fiber optic capabilities High Mean Time Between Failures (MTBF) Rugged Design for high temp use No plug and play capability.
  • Page 209 DIN-rail end support device Accessories Phoenix: UK 4-TG+ST-BE (Standard commercially available components) Cabinets ABB Automation Technology Products, LV systems Wall cabinet RE820 • for 3 DIN-rails • W 800 x H 1200 x D 330 mm (31.5 x 40.1 x 13.0 in) •...
  • Page 210 Recommended Components Appendix C Recommended Components Table 71. Recommended Components – Process Cables Component Description Mains Various Manufacturers, to Standard; • RKFK 3x1.5 mm RS232-C Unitronic • CY 3 x 0.25 mm • CY 7x 0.25 mm Belden • Belden 8723 2 pair (0.34 mm •...

  • Page 211: Appendix D Directive Considerations

    Modules mentioned in this manual, for which product or packing is CE marked, comply with the LVD where applicable. To fulfill the LVD for AC 800M and S800 I/O, the power supplies shall provide a secondary safety extra low voltage (SELV) or a protected extra low voltage (PELV).
  • Page 212 Low-Voltage Directive (LVD) Appendix D Directive Considerations 3BSE 027 941 R301...

  • Page 213: Appendix E Standards

    To comply with CSA and/or UL certification for use at hazardous locations, the following information becomes part of the product literature for CSA and/or UL-certified ABB industrial control products. • Equipment labeled with reference to Class I, Groups A, B, C and D, Division 2, hazardous locations is suitable for use in Class I, Division 2, Groups A, B, C, D or non-hazardous locations only.
  • Page 214 Hazardous Location Approval Appendix E Standards 3BSE 027 941 R301...

  • Page 215: Appendix F Environmental Data Environmental Data For Ac 800M Products

    Control products incl. I/O-systems are normally intended for Industrial environment. Products manufactured by ABB and other companies are normally type-tested or evaluated to ensure compliance with the environmental standards specified below. Environmental specifications applicable to peripheral equipment, for example printers, may differ.

  • Page 216: Climatic And Mechanical Environmental Conditions

    Climatic and Mechanical Environmental Conditions Appendix F Environmental Data Climatic and Mechanical Environmental Conditions Industrial Environment Table 72. Industrial Environment Environmental Specification Compliance Environment Transportation Operative with Standard Factor and Storage Range Temperature –25 to +70°C Cabinets EN 61131-2 +5 to +40°C –25 to +60°C Units +5 to +55°C...
  • Page 217 Appendix F Environmental Data Climatic and Mechanical Environmental Conditions Table 72. Industrial Environment (Continued) Environmental Specification Compliance Environment Transportation Operative with Standard Factor and Storage Range Vibration 10< f <50 Hz, Continuous: EN 61131-2 0.0375 mm amplitude (Occasional: 0.075 mm amplitude) 50<...

  • Page 218: Ce Compliance

    CE Compliance Appendix F Environmental Data CE Compliance All products comply with EMC Directive 89/336/EEC and Low Voltage Directive 73/23/EEC (relevant products also comply with the Teleterminal Directive). Products are CE-marked. Some products require enclosures, as specified in User Guides, to meet the EMC Directives. Compliance is verified through conformity with the following minimum standards: •...

  • Page 219: Electromagnetic Compatibility And Main Voltage Conditions

    Appendix F Environmental Data Electromagnetic Compatibility and Main Voltage Conditions Electromagnetic Compatibility and Main Voltage Conditions Table 73. Electromagnetic Compatibility and Main Voltage Conditions Environmental Specification Compliance with Industrial Standard Environment Factor Environment Emission Class A EN 55011 –Radiated –Conducted Immunity 10V/m EN 61000-4-3...
  • Page 220 Electromagnetic Compatibility and Main Voltage Conditions Appendix F Environmental Data Table 73. Electromagnetic Compatibility and Main Voltage Conditions (Continued) Environmental Specification Compliance with Industrial Standard Environment Factor Environment Main voltage a.c : –15% to +0% Main voltage DC –15% to 20% of rated value Main frequency a.c.

  • Page 221: Installation Requirements

    Appendix F Environmental Data Installation Requirements Installation Requirements Installation regulations for all products are included in relevant product documentation. Some general installation rules and applications are given below. Laying Field Cables There are no special requirements for laying field and communication cables connected to products.

  • Page 222: Lightning Protection

    Lightning Protection Appendix F Environmental Data Lightning Protection Industrial installations and power plants are normally provided with well-integrated grounding networks, installed as part of the power distribution system. Such installations do not require additional lightning protection. Additional lightning protection is always necessary when: •...

  • Page 223: Index

    Index CI853 Communication Interface 27 ABB Drives 100 Fault-Finding 134 AC 800M Indicators 163 Safety 21 Installation 71 Alpha Code Lock 54 Technical Data 163 Al-profile 200 CI854 Applicable Specifications 16 Communication Interface 27 Fault-Finding 135 Indicators 167 Battery Installation 72...
  • Page 224 ,QGH[ Communication Ports 61 Connection To Fault-Finding Control Network 92 to 93 External Battery 129 FOUNDATION Fieldbus H1 69 FOUNDATION Fieldbus CI852 131 INSUM 76 INSUM CI857 138 MasterBus 300 74 Internal Battery 129 PROFIBUS DP 67 MasterBus 300 CI855 136 PROFIBUS DP-V1 72 PM856 128 RS232C 71...
  • Page 225 ,QGH[ Indicators CI851 155 Mains Breaker Unit CI852 159 Installation 79 CI853 163 Mains Net Filter 46 CI854 167 MasterBus 300 CI855 170 Connection To 74 CI856 174 Installation 74 CI857 178 Module to Baseplate Alpha Code Lock 54 Installation Modulebus CEX-bus 76 Electrical 96...
  • Page 226 ,QGH[ PM860 PROFIBUS DP-V1 15, 27, 99 CPU Unit 27, 30, 139 Connection To 72 Fault-Finding 128 Installation 72 Installation 56 PROM 15 Performance Data 144 Protective Earth 47 Technical Data 140 Protective resistor 24 PM861 Push Buttons 111 CPU Unit 27, 30 Fault-Finding 128 Installation in Redundant Configuration 64 RCU 16...
  • Page 227 ,QGH[ SD823 181 Tool Cable 65 Power Supply Module 27 TK850 Technical Data 187 CEX-bus Extension Cable 64, 76, 197 Signal noise 25 TK851 SS822 81, 189 RCU Link Cable 64, 197 Technical Data 190 TK853 71 Switches 111 Technical Data 198 TP830 Baseplate 30 TP851 67, 153...
  • Page 228 ,QGH[ 3BSE 027 941 R301...
  • Page 230 3BSE 027 941 R301. Printed in Sweden March 2003 Copyright © 1999-2003 by ABB. All Rights Reserved ® Registered Trademark of ABB. ™ Trademark of ABB. http://www.abb.com/control Automation Technology Products Automation Technology Products Automation Technology Products Västerås, Sweden Mannheim, Germany Wickliffe, Ohio, USA www.abb.com/processautomation...

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