IndustrialIT AC 800M and S800 I/O Getting Started
IndustrialIT AC 800M and S800 I/O Getting Started
NOTICE This document contains information about one or more ABB products and may include a description of or a reference to one or more standards that may be generally relevant to the ABB products. ABB may have one or more patents or pending patent applications protecting the intellectual property in the ABB product(s) described in this publication.
TABLE OF CONTENTS About This Book General ..............................................................................................................................7 Document Conventions .....................................................................................................7 Warning, Caution, Information, and Tip Icons..................................................................7 Related Documentation ....................................................................................
Table of Contents Section 4 - Operation Hardware Indicators ........................................................................................................ 43 AC 800M Controller (PM8xx) ............................................................................ 43 LED Indicators..................................................................................................... 43 Switches and Push Buttons ..................................................................................
About This Book General This manual is intended to give the reader a general knowledge about AC 800M, S800 I/O and S800L hardware. It includes a general product overview, guidance for installation, configuration examples, information valuable during operation and maintenance considerations. Several other manuals forms the complete documentation of AC 800M, S800 I/O and S800L hardware which are listed in the subsection Related Documentation.
Related Documentation 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.
Section 1 Product Overview 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 a removable module attached with screws. The hardware units that form the AC 800 M controller are: • Central Processor unit (CPU) • Communication interface modules for different protocols • S800 I/O modules • Power supply modules Figure 1.
Central Processing Unit (CPU) Section 1 Product Overview Central Processing Unit (CPU) The CPU consist of a base plate TP830 (Terminal Plate) and a processor module PM8XX with various speed and memory combinations. The base plate TP830 carries the majority of the connections to processor, the power supplies and communication interfaces, as well as to external buses.
Section 1 Product Overview LED Status Indicators Central Processing Unit (CPU) Compact Flash slot INIT Push button CF Connector RCU Link Connector (PM861/PM864/ PM865) Tx/Rx Optical ModuleBus Electrical ModuleBus CEX-Bus Tx/Rx Status Indicators External Battery Supply Socket Power Supply and Supervision Signal Socket (SS822/SS823) CN1/CN2 Ports DIN-rail Locking Device COM3/COM4 Ports Lugs for extra screws to provide secure mounting in locations subject to vibration Figure 2.
Communication Interface Section 1 Product Overview Communication Interface A number of communication modules can be connected to the controller. See Appendix A, IndustrialIT System 800xA AC 800M Controller - Data Sheet for more information on the various modules. Communication Interface connected with CEX bus: Up to 12 communication units can be placed on Communication Expansion Bus (CEX) bus. The CEX bus must be terminated if a communication unit is connected.
Section 1 Product Overview S800 I/O S800 I/O connected with Modulebus: • Connection via Electrical Modulebus (single controller only) – • Up to 12 I/O modules Connection via Optical Modulebus – 1-7 I/O clusters with up to 12 I/O modules per cluster (connected using Modulebus Modem TB820 or TB840A) PM851 is restricted to one optical Modulebus cluster.
S800 I/O 14 Section 1 Product Overview 3BSE056248
Section 2 Installation Mounting AC 800M and S800 I/O Units onto DIN-Rail AC 800M and S800 I/O units are DIN-rail mountable. Each unit has a DIN rail locking mechanism that achieve mechanical locking and effective grounding. The additional screw lugs, located in the lower part of the units are used to provide extra fastening in environments subject to excessive vibrations. AC 800M units (CPU and communication interfaces) must be mounted on horizontal DIN rails.
Mechanical Installation - Metal Sheet Section 2 Installation The metal sheet shall at least be 2.5 mm thick and at least 180 mm high with preferably one side bend 90 degrees to increase the stability. The metal sheet shall be mechanically fastened at least every 500 mm to the cabinet or rack with a minimum of four screws. The fastening to the cabinet frame shall be performed with self-tapping screws to get a good grounding connection. DIN-rail type with height 7.5 mm shall be used. Refer to type NS 35/7.
Section 2 Installation Mechanical Installation - Prefabricated Aluminum Profile Figure 4. Cabinet with Controller and I/O on metal sheet Mechanical Installation - Prefabricated Aluminum Profile There are aluminum profiles for horizontal and vertical mounting. The aluminum profile gives an excellent grounding and rigid mounting of products concerned. The aluminum profile shall be fastened to the cabinet with at least 4 self-tapping screws.
Mounting and Removing PM8xx, CI8xx and S800L Units Section 2 Installation The aluminum profiles are available in different sizes. For horizontal mounting use 3BSE022255R1 (465 mm, 19") or 3BSE022256R1 (592 mm, 24") or 3BSE022257R1 719 mm, 28.31"). For vertical mounting use 3BSE049768R1 (1800 mm, 71"). Figure 5.
Section 2 Installation 1 . OPEN Mounting and Removing PM8xx, CI8xx and S800L Units 2. SLIDE 3. LOCKED Figure 6. Base plate Locking Device It is not allowed to manipulate CEX bus base plates in a powered and running system. Before changing or removing a base plate, all CEX modules on that segment must be removed. To prevent damage to the pins, be sure the base plate plugs and sockets are fully aligned as the units interconnect. Under no circumstances use excessive force.
Mounting and Removing S800 I/O Units Section 2 Installation When disconnecting units from each other, use a screw driver according to Figure 7 F R Rx1 F R Rx/Tx Tx1 RTS F R P B Rx2 Tx2 INIT CI851 CI853 COM1 COM2 PM860 CN1 CN2 COM3 COM4 Figure 7. Separating the Base Plates Mounting and Removing S800 I/O Units The S800 I/O is mounted on a standard DIN-rail according to EN 50022 NS35/7,5.
Section 2 Installation Mounting and Removing S800 I/O Units To mount the FCI, ModuleBus Modem or MTU, place it on the top edge of the DIN rail, release the rail latch with a flat blade screw driver and snap the bottom mechanism into place. When the unit is in place on the DIN rail and in position, take away the screw driver and the rail latch will fix the unit in position on the DIN rail. Release the unit from the DIN rail in a similar way.
Mounting and Removing S800 I/O Units Section 2 Installation Snapping the FCI, ModuleBus Modem or MTU to the DIN-rail makes contact by a grounding spring with the chassis. Connection of the MTU, or S800L module, ModuleBus connector to the FCI, ModuleBus Modem, next MTU or S800L module is made by sliding the MTU or the S800L module along the mounting rail and then locking it in place (Figure 9). F R T1 T2 D D E F E F D A B C D AF100 1 A B C SWX.X/Y L+ L+ SA L- L- SB A B C STN. ADDR.
Section 2 Installation Mounting and Removing S800 I/O Units The MTU and S800L module (locking screw in position) can be disconnected from the FCI, ModuleBus Modem, another MTU or S800L module by using a screw driver and pressing it between the two items. F R T1 T2 E F P D D AF100 1 A B C SWX.X/Y L+ L+ SA L- L- SB DO801 E F STN. ADDR.
Mounting and Removing S800 I/O Units Section 2 Installation I/O Module Installation on Module Termination Unit Connection of the I/O module to the MTU is made by setting the I/O Module Keys #1 and #2 to the correct setting, place the I/O Module Lock/Switch to the unlock position and then push the I/O module straight onto the MTU. The I/O module is locked and electrically connected to the MTU by the I/O Module Lock/Switch.
Section 2 Installation Mounting and Removing S800 I/O Units Figure 12. Mounting of I/O module on MTU At the mounting of a S800 I/O Box on a Termination Unit the following should be observed: Press the Box straight and right on to stop into the Termination Unit. Above shown angle shall be 0°. Turn the Locking Device clockwise to its end position. Above shown state with the Locking Device in a position before end position shall not exist for an active module.
Power Supply Section 2 Installation Power Supply It is recommended to feed the system components and field equipment from different power supplies. Example of system components are Controllers, Communication Modules, Fieldbus Communication Interfaces and Modulebus Modems, (for instance PM864A, CI854A, CI840A and TB840A). Example of field equipment is transmitters, actuator as well as the field side of the S800 I/O modules (terminals on MTU and S800L marked L+ and L-).
Section 3 Configuration Controller Configuration - Basic Rules and Examples Information regarding limitations for the different controllers can be found in IndustrialIT 800xA - Control and I/O, AC 800M Controller Hardware, Hardware and Operation (3BSE036351Rxxxx).
Controller Configuration - Basic Rules and Examples Section 3 Configuration Single CPU Configuration 28 3BSE056248
Section 3 Configuration Controller Configuration - Basic Rules and Examples Single CPU with Redundant CI Configuration 3BSE056248 29
Controller Configuration - Basic Rules and Examples Section 3 Configuration Redundant CPU with Non-Redundant CI Configuration 30 3BSE056248
Section 3 Configuration Controller Configuration - Basic Rules and Examples Redundant CPU with Redundant CI Configuration 3BSE056248 31
S800 I/O Configuration - Basic Rules and Examples Section 3 Configuration S800 I/O Configuration - Basic Rules and Examples Information regarding limitations for the different I/O modules can be found in IndustrialIT, Control and I/O, S800 I/O, General Information and Installation (3BSE020923Rxxxx).
Section 3 Configuration S800 I/O Configuration - Basic Rules and Examples Non-redundant PROFIBUS Node In total max 24 modules per CI801 but limited by: • PROFIBUS data capability. • CI801/TB820 Power supply capability. • Required scan cycle time. Modules not supported: DI825, DO880, AI880A, DI830, DI831, DI880, DI885. 5 Mbit/s ABB Drives and SOE on DI840 are not supported.
S800 I/O Configuration - Basic Rules and Examples Section 3 Configuration Line/Master-redundant PROFIBUS Node In total max 24 modules per CI840A but limited by: • PROFIBUS data capability. • CI840A/TB820 Power supply capability. • Required scan cycle time. Modules not supported: DI825, DO880, AI880A, DI830, DI831, DI880, DI885. ABB Drives and SOE on DI840 are not supported.
Section 3 Configuration S800 I/O Configuration - Basic Rules and Examples Line/Master-redundant PROFIBUS Node with Redundant I/O In total max 24 modules per CI840A (a redundant pair is 2 modules) but limited by: • PROFIBUS data capability. • CI840A/TB820 Power supply capability. • Required scan cycle time. Modules not supported: DI825, DO880, AI880A, DI830, DI831, DI880, DI885. ABB Drives and SOE on DI840 are not supported.
S800 I/O Configuration - Basic Rules and Examples Section 3 Configuration Direct I/O to non-redundant AC 800M Controller In total max 96 modules but limited by: • PM8xx and TB820 Power supply capability. • Required scan cycle time. • Required CPU load. Supported modules: DI880, DO880, AI880A are supported if PM865 and TB840A (instead of TB820).
Section 3 Configuration S800 I/O Configuration - Basic Rules and Examples Direct I/O to redundant AC 800M Controllers In total max 84 modules but limited by: • TB840A Power supply capability. • Required scan cycle time. • Required CPU load. Supported modules: AI880A, DI880, DO880 are supported if PM865. The optical ModuleBus can be configured for long distances and in star configurations using TB825 see Long distance distribution in star as Direct I/O to AC 800M on page 42.
S800 I/O Configuration - Basic Rules and Examples Section 3 Configuration Direct redundant I/O to redundant AC 800M Controllers In total max 42 pairs of modules but limited by: • TB840A Power supply capability. • Required scan cycle time. • Required CPU load. Supported redundant modules: DI840, DO840, AI843, AO845, DP840, AI845. AI880A, DI880, DI880 are supported if PM865.
Section 3 Configuration S800 I/O Configuration - Basic Rules and Examples High Integrity I/O to non-redundant High Integrity Controller In total max 96 modules but limited by: • PM8XX and TB840A Power supply capability. • Required scan cycle time. • Required CPU load. The optical ModuleBus can be configured for long distances and in star configurations using TB825 see Long distance distribution in star as Direct I/O to AC 800M on page 42.
S800 I/O Configuration - Basic Rules and Examples Section 3 Configuration High Integrity I/O to redundant High Integrity Controllers In total max 84 modules but limited by: • TB840A Power supply capability. • Required scan cycle time. • Required CPU load. The optical ModuleBus can be configured for long distances and in star configurations using TB825 see Long distance distribution in star as Direct I/O to AC 800M on page 42.
Section 3 Configuration S800 I/O Configuration - Basic Rules and Examples HI redundant or hot replacement I/O to redundant PM865 In total max 42 pairs of modules but limited by: • TB840A Power supply capability. • Required scan cycle time. • Required CPU load. Supported modules: DI840, DO840, AI843, AO845, DP840, DI880, DO880, AI845, AI880A.
S800 I/O Configuration - Basic Rules and Examples Section 3 Configuration Long distance distribution in star as Direct I/O to AC 800M Calculation of the ModuleBus delay for the configuration in the figure above: ModuleBus delay = (total delay in optical fiber) + 5 x (opto-to-opto delay in TB820) + 2 x (delay in TB825) + (opto-to electrical delay in TB820) = (4 x 15 + 3 x 1.5 + 1000) x 0.01 + 5 x 4 + 2 x 2.4 + 6.5 = 42 s.
Section 4 Operation Hardware Indicators AC 800M Controller (PM8xx) Equipped with Control Software, the basic PM8xx/TP830 hardware units mounted on the AC 800M hardware platform constitute an AC 800M Controller. LED Indicators See Figure 2, for description of placement. Table 1. PM8xx - LED Indicators Marking Color Function F(ault) Red Normal state - OFF Re-start (INIT) temporarily lit F(ault).
LED Indicators Section 4 Operation Table 1. PM8xx - LED Indicators (Continued) Marking Color Function B(attery) Green Normal state - ON Lit when internal or external battery voltage is above 3.1 V. The LED is controlled by a software battery voltage test(1).
Section 4 Operation Switches and Push Buttons Switches and Push Buttons Table 2. PM8xx - Switches and Push Buttons Marking INIT Color Function Manual Push Button Initiates 1. Cold Restart if INIT is held less than 2.5 seconds. 2. Controller Reset if INIT is held more than 3 seconds. If INIT is pushed on the Primary CPU in redundant configuration a switch over to the backup CPU will be initiated.
S800 I/O Module LEDs Section 4 Operation Table 4. Common LEDs for Communication Interfaces in Redundant operation Marking Color Description PRIM(Primary) Yellow Indicates the primary unit in redundant configuration. (LED is on in both single and redundant configuration). DUAL Yellow Indicates when unit is running in redundant configuration. Table 5. Special LEDs Module Marking Color Description CI858 Tools Yellow Indicates reception / transmission of data frames on the PC Tool buss.
Section 4 Operation S800 I/O Module LEDs • W - The WARNING LED shall indicate when a non-fatal error is detected and the module continues to run. • O - The OSP LED shall indicate when the I/O module is in OSP state, that is, when the module is commanded to OSP or when automatically set to OSP state due to communication error. • PRIM - The PRIMARY LED shall indicate when the I/O module is primary (in a redundant pair).
S800 I/O Module LEDs Marking Section 4 Operation Color Description F (Fault) Red Internal fault in the module affecting all channels(1) R (Run) Green Operational state W (Warning) Yellow External fault or internal channel error O (OSP) Yellow OSP state (Outputs Set as Predetermined) P (Primary Yellow LED indicating that the module is operating as primary in a redundant pair Channel status Yellow (+red) This LED shows both value (Yellow ON/OFF) and error (red) (1) Modules without self
Section 4 Operation S800L I/O Module LED S800L I/O Module LED Figure 15 shows examples of front panels for different types of I/O modules. On the front of each I/O module there is one LED indicating the module status. See the tables below for information on the meaning and indications for these modules. For modules with special LED indications see respectively module in Appendix A, IndustrialIT System 800xA AC 800M Controller - Data Sheet.
S800L I/O Module LED Section 4 Operation S 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 STATUS STATUS S AI801 0(4)...20 mA DO801 24 V 0.5 A L+ L- 24 V L+ L- 24 V + 1 I + 2 I 3 + 4 I + I + 5 I + 6 I + 7 I + 8 I 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Figure 15.
Section 4 Operation Marking S(Status) S800L I/O Module LED Color Description Red Fault in the module(1) Green Operational state (1) Modules without self test function, for example, DI/DO modules: The S-LED will switch on to red at power up or restart of the module and switch off after the first successful access to the module. Modules with self test function for example, AI/AO modules: The S-LED will switch on to red at power up, restart of the module or when the module goes to Error state.
Start Modes Section 4 Operation Start Modes The controller may be started with the following start modes: Warm init • Power Off / On with a battery backed up CPU. • Applications restart with retain values. Cold init • Press init <2.5 s. • Applications restart with cold retain values. Reset 52 • Press init >3 s or until RUN lead flashes. • Applications are deleted in controller.
Section 5 Maintenance/Replacement of Faulty Units Online Replacement of Unit Replacement 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 () Can be removed or replaced online Restrictions apply; refer to the installation section for each interface.
Online Replacement of Unit 54 Section 5 Maintenance/Replacement of Faulty Units 3BSE056248
PM851 PM856 PM860 PM861A PM864A PM865 PM866 CPUs/Features Appendix A IndustrialIT System 800xA AC 800M Controller - Data Sheet PM851K01 incl: 1 PM851 CPU and required optional items PM856K01 incl: 1 PM856 CPU and required optional items PM860K01 incl: 1 PM860 CPU and required optional items PM861AK0 1 incl: 1 PM861A CPU and required optional items PM861AK0 2 incl: 2 PM861A CPUs and required optional items PM864AK0 1 incl: 1 PM864A CPU and required optional items PM864AK0 2 incl: 2 PM864A CPUs a
PM864A PM865 PM866 8 Mb 8 Mb 16 Mb 32 Mb 32 Mb 64 Mb CPU redundancy support No No No Yes Yes Yes Yes Performance Relation 1.0 ms 1.0 ms 2.0 ms 2.0 ms 3.1 ms 3.1 ms 4.3 ms 12 12 12 PM860 8 Mb PM856 Memory (RAM) PM851 PM861A CPUs/Features Appendix A IndustrialIT System 800xA AC 800M Controller - Data Sheet Down to 1 ms Cycle time per application programs Comm.
Module Protocol Master or slave CI854A CI860 DP-V1 HSE (PA via Linking Device) (H1 via Linking Device) CI853 1 CI855 2 CI858 CI856 CI862 CI865 CI867 Drivebus S100 I/O Trio I/O Satt I/O Modbus TCP IEC 61850 Modbus TCP Satt I/O TRIO I/O S100 I/O interface Drivebus INSUM CI857 Modbus MB300 IEEE 802.
Module redundancy Dimensions 58 yes yes no no no no no no no yes IEC 61850 Modbus TCP Satt I/O TRIO I/O S100 I/O interface Drivebus INSUM MB300 RS-232 C Foundation Fieldbus PROFIBUS Supported Communication modules Appendix A IndustrialIT System 800xA AC 800M Controller - Data Sheet no W 58 x H 186 x D 135 mm (2.3 x 7.3 x 5.3 in.
Appendix B System 800xA S800 I/O System Data Sheet General specifications Power supply 24V d.c. (19.2 - 30V) Temperature range 0...55°C (non-condensing)(1) Protection class IP20 Standards complied with: - Electrical safety EN 3810, EN 50178, IEC 61131-2, UL508, CSA 22.2 No. 142-M1987 - Hazardous locations (Class1 Zone 2 and Class 1 Division 2) No. 213-M1987, FM 3600, FM 3611, UL 60079-15, CSA 22.2 No.213-M1987 CAN/CSA-E60079-15:02 - Corrosive gases ISA Class G2 or G3 (ISA-71.
Appendix B System 800xA S800 I/O System - Data Sheet TB820/825/842 Optical cluster modem/ports for ModuleBus/drives integration. CI840A For redundant PROFIBUS-DP/V1. Hot Configuration in Run & HART® pass through. GSD file provided. TB840A Optical cluster modem for redundant or single ModuleBus. Installed on TU807/TU840/TU841/TU848/TU849. Used with AC 800M. Module Termination Units (MTU:s) Compact, 50V applications TU810 With screw terminals. TU812 With 25 pin D-sub connector.
Appendix B System 800xA S800 I/O System - Data Sheet S800 I/O modules Digital input modules DI810 16 channels, 2 groups of 8 ch., 24V d.c., current sink. DI811 16 channels, 2 groups of 8 ch., 48V d.c., current sink. DI814 16 channels, 2 groups of 8 ch., 48V d.c., current source. DI820 8 channels, separate returns, 110V d.c., 120V a.c. DI821 8 channels, separate returns, 220V d.c., 230V a.c. DI825 With time tagging. 8 channels, sep. returns, 125V d.c. DI830 With time tagging.
Appendix B System 800xA S800 I/O System - Data Sheet DO821 8 channels, separate returns, 5-250V, max 3A a.c./d.c., relay (N.C.). Analog input modules AI810 8 channels, single-ended, 0(4)-20mA, 0(2)-10V, 12bits. AI815 8 channels, common return, 0(4)-20mA, 0(1)-5V, HART AI820 Differential inputs, 4 channels, 0(1)-5V, ±0(2)-10V, ±0(4)-20mA, 14 bits+sign. AI825 Galvanically isolated, 4channels, ±0(2)-10V, ±0(4)20mA, 14 bits+sign.
Appendix B System 800xA S800 I/O System - Data Sheet DO840 16 channels, common return, 24V d.c., max 0,5A, current source, short-circuit-proof, extended diagnostics. DO880 16 channels, 24V d.c., max. 0.5A, current source, SIL3, short-circuit-proof, extended diagnostics. AI843 TC input, 8 channels + ref. junction, TC types: B, C, E, J, K, L, N,R, S, T, U, -30...75mV, 16 bits, extended diagnostics. AI845 8 channels, common return, 0(4)-20mA 0(1)-5V, extended diagnostics, HART support.
Appendix B System 800xA S800 I/O System - Data Sheet AI890 8 channels, single-ended, 0(4)-20mA, 12 bits, transmitter power supply. AI893 8 channels, TV 7 + ref. junction, separate returns, TC types B, C, E, J, K, L, N, R, S, T, U, -10...80mV, RTD: Pt50-1000, Ni100-500, Cu10-100, resistor 04000Ω, 3-wire, 15 bits + sign., TC/RTD inputs. AI895 8 channels, single-ended, 4-20mA, 12 bits, transmitter power supply, HART interface.
Appendix C Dimensions Redundant Comm.
Appendix C Dimensions 66 3BSE056248
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