AC 800M Controller Hardware System Version 5.
AC 800M Controller Hardware System Version 5.
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. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document support all of the features of the described or referenced standard.
Table of Contents About This User Manual General ............................................................................................................................23 User Manual Conventions ...............................................................................................23 Warning, Caution, Information, and Tip Icons................................................................24 Terminology............................................................................................
Table of Contents Site Selection and Building Requirements .......................................................... 59 Cables ............................................................................................................ 62 Power Supply ....................................................................................................... 63 Enclosures ............................................................................................................
Table of Contents Installing the PROFINET IO Interface CI871...............................................................129 Installing the MOD5 Interface CI872............................................................................129 Installing the EtherNet/IP Interface CI873....................................................................130 Installing the ModuleBus for PM8xx ............................................................................131 Installing the ModuleBus for PM891 .....
Table of Contents Verification of Satisfactory AC 800M Operation.......................................................... 185 Verification of Single CPU ................................................................................ 185 Verification of Redundant CPU ......................................................................... 188 Section 5 - Maintenance Preventive Maintenance Frequency Schedule............................................................... 191 Replacing the Battery ........
Table of Contents Satt I/O Interface – CI865 ..................................................................................224 Modbus TCP Interface – CI867 .........................................................................225 IEC 61850 Interface – CI868 .............................................................................227 AF 100 Interface - CI869 ...................................................................................228 PROFINET IO Interface - CI871 .......................
Table of Contents CI851 and TP851 – PROFIBUS DP Interface .............................................................. 284 CI852 and TP852 – FOUNDATION Fieldbus H1 Interface ......................................... 288 CI853 and TP853 – RS-232C Interface ........................................................................ 292 CI854/CI854A and TP854 – PROFIBUS DP Interface ................................................ 296 CI855 and TP853 – Ethernet Interface for MasterBus 300......................
Table of Contents TK853 ...........................................................................................................401 TK855 RCU Data Link Cable............................................................................401 TK856 RCU Control Link Cable .......................................................................402 TK212A Tool Cable ...........................................................................................402 Al-Profile Support For DIN-Rail ....................
Table of Contents Revision History Introduction ................................................................................................................... 449 Revision History............................................................................................................ 449 Updates in Revision Index A.........................................................................................
Safety Summary General 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. The Safety Instructions are classified as mandatory reading for all suitably qualified personnel intending to operate the AC 800M Controller.
Safety Summary Personnel and Process Safety TAKE CARE AT ALL TIMES – This will prevent accidents from occurring and help protect valuable equipment. A control system is a tool used to control various processes. Responsibility for attaining and maintaining a satisfactory level of safety rests with the personnel who engineer, operate and maintain the equipment.
Safety Summary (continued) • Process technicians are to be present when testing and operating process objects. • Never activate any System Initialization push-button if any uncertainty exists regarding exactly what occurs within the system during initialization. ALWAYS CHECK FIRST. • Remember at all times, that the control system can be controlled from a remote engineering station, connected at another node via Control Network.
Safety Summary Before replacing Units All procedures for replacing units can be located by referring to the relevant documentation. Removing or replacing units with system power connected can cause injury to personnel and damage to equipment. It is, therefore, of the utmost importance that the power supply be fully disconnected, on the process side, before removal or insertion of units takes place. See Online Replacement of Unit on page 198 and I/O documentation.
Safety Summary (continued) 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. The controller must not be used in an environment exposed to strong electrical interference.
Safety Summary Electrostatic Sensitive Device Devices labeled with this symbol require special handling precautions as described in the installation section. GENERAL WARNINGS Equipment Environment All components, whether in transportation, operation or storage, must be in a noncorrosive environment. Electrical Shock Hazard During Maintenance Disconnect power or take precautions to insure that contact with energized parts is avoided when servicing.
Safety Summary (continued) SPECIFIC WARNINGS (continued) Page 124: The CI862 baseplate has no locking device. Insert only the CI862 unit into this baseplate. Insertion of other unit types may cause damage to the equipment. Page 191: Before attempting maintenance or troubleshooting, read the Safety Summary on page 13. Failure to do so could lead to personal injury or damage to equipment. Page 198: It is not allowed to manipulate CEX bus baseplates in a powered and running system.
Safety Summary SPECIFIC CAUTIONS (continued) Page 76: Do not manipulate the locking device. ABB will take no responsibility for errors caused by manipulating locking devices. -79 and Page 92: 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, that is, the B(attery) LED flashes.
Safety Summary (continued) SPECIFIC CAUTIONS (continued) Page 114: It is not possible to change the CI852 unit via hot swap and it is not allowed to perform an online upgrade of firmware in a system containing CI852. Page 118: Hot swap is supported for CI854A (not CI854). Page 133: – 115 V for 110 – 120 V AC (default position on delivery).
Safety Summary SPECIFIC CAUTIONS (continued Page 195: Due to the batteries being connected in parallel, it is necessary, when using the SB821 external battery, to remove the internal battery from the processor unit in order to avoid reducing available memory back-up time. -200 and Page 201: Reuse of CPU modules replaced from redundant configurations within the same control network, might cause control network problems due to the MAC and IP address handling.
About This User Manual General Any security measures described in this User Manual, for example, for user access, password security, network security, firewalls, virus protection, etc., represent possible steps that a user of an 800xA System may want to consider based on a risk assessment for a particular application and installation.
Warning, Caution, Information, and Tip Icons About This User Manual 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. The corresponding symbols should be interpreted as follows: Electrical warning icon indicates the presence of a hazard which could result in electrical shock.
About This User Manual Terminology Terms that uniquely apply to this User Manual are listed in the following table. Table 1. Terminology Term/Acronym Description ABB Drives ABB Oy, Drives Group AC 800M A hardware platform, comprising Processor Units, communication interfaces and other supporting devices, that can be configured to provide a controller. AC 800M Controller A controller configured from the AC 800M hardware platform and Controller FW for AC 800M.
Terminology About This User Manual Table 1. Terminology (Continued) Term/Acronym FF Description FOUNDATION Fieldbus - Standard based on IEC 1158-2. 26 FF HSE FOUNDATION Fieldbus - High Speed Ethernet, a fieldbus system based on Ethernet and FOUNDATION Fieldbus specification. Hot removal Units with hot removal support can be removed online, without any disturbance to other units connected to the CEX-Bus. This includes that the unit can be removed online if it becomes faulty.
About This User Manual Applicable Specifications Table 1. Terminology (Continued) Term/Acronym Description RCU Link RCU Link Cable transfers data between Primary and Back-up CPU. The two CPUs are connected to the RCU Link Cable. An RCU Link Terminator is used on the RCU Link Connector in single CPU configuration. Remote I/O Input/Output units connected to a controller via a fieldbus. SELV Safety Extra Low Voltage (power supply).
TÜV Approval About This User Manual UL requirements for hazardous locations, the instructions in Appendix E, Standards must be followed. TÜV Approval Units mentioned in this document are TÜV qualified for IEC 61508 SIL2 or SIL3 if the product is marked with the TÜV logo. Released User Manuals and Release Notes A complete list of all User Manuals and Release Notes applicable to System 800xA is provided in System 800xA Released User Manuals and Release Notes (3BUA000263*).
Section 1 Introduction Product Overview AC 800M – General AC 800M is a hardware platform comprising individual hardware units, which can be configured and programmed to perform multiple functions. Once configured and programmed, the AC 800M effectively becomes the AC 800M or AC 800M HI controller.
AC 800M – General Section 1 Introduction PM851 is equivalent with PM856 unless stated otherwise. PM851A is equivalent with PM851 unless stated otherwise. PM856A is equivalent with PM856 unless stated otherwise. PM860A is equivalent with PM860 unless stated otherwise PM861A is equivalent to PM861 unless stated otherwise. PM864A is equivalent to PM864 unless stated otherwise.
Section 1 Introduction AC 800M – General classified applications. If the application is not SIL classified, standard S800 I/O units can be used with AC 800M HI controller. Figure 1 shows the physical appearance of an AC 800M Controller with an S800 I/O Unit. This physical appearance does not apply to PM891. AC 800M Communication interface I/O System Processor unit S800 I/O unit Figure 1.
AC 800M – General Section 1 Introduction LED Status Indicators Compact Flash slot INIT Push button CF Connector RCU Link Connector (PM861/PM864/ PM865/PM866) Tx/Rx Optical ModuleBus Electrical ModuleBus CEX-Bus Tx/Rx Status Indicators External Battery Supply Socket Power Supply and Supervision Signal Socket CN1/CN2 Ports DIN-rail Locking Device COM3/COM4 Ports Figure 2.
Section 1 Introduction PM8xx/TP830 Processor Unit – General PM8xx/TP830 Processor Unit – General The topic does not apply to PM891. See PM891 Processor Unit – General on page 40. Physically the PM8xx/TP830 Processor Unit consists of two basic parts: • Processor Unit (PM851/PM851A/PM856/PM856A/PM860/PM860A/PM861/PM861A/ PM864/PM864A/PM865/PM866) with processor and Power Supply boards. • Baseplate (TP830), housing the unit termination board.
PM8xx/TP830 Processor Unit – General Section 1 Introduction Processor Unit Cover Release Screw Cover Assembly CEX-Bus Electrical ModuleBus Fuses CEX-Bus/ModuleBus Baseplate TP830 Figure 3.
Power DC +3.3V DC System and user mem. +BV CPU Optical +5V DC 4 Electrical PM8xx/TP830 Processor Unit – General CEX-bus Section 1 Introduction ModuleBus controller CEX-bus controller Battery External battery 3 (+3.3V) RTC Compact Flash Communication controllers INIT Logic Ethernet Ethernet RS232 RS232 B R CN1 4 CN2 COM3 COM4 4 8 4 P F Figure 4. PM851/PM856/PM860 – Functional Block Diagram PM851/PM851A is restricted to one Ethernet (CN1) port.
Section 1 Introduction System and user mem. 1 2 3 4 L+ CEX-Bus Interface Shadow memory Optical CEX-Bus Electrical PM8xx/TP830 Processor Unit – General ModuleBus FPGA +24V RCU +5V DC LSA +3.3V SB Battery 2 1 3 RCU Link +BV B+ BS RTC CPU (+3.3V DC) Compact Flash SA SB Communication Controllers INIT Logic Ethernet CN1 Ethernet CN2 RS232 RS232 COM4 COM3 RS232 COM4 F R P B PRIM DUAL Figure 5.
Section 1 Introduction PM8xx/TP830 Processor Unit – General PROFIBUS DP, FOUNDATION Fieldbus H1, FOUNDATION Fieldbus High Speed Ethernet and dual RS-232C ports are some examples of unit types available for connection to the CEX-Bus. It is possible to use redundant communication interfaces, for example PROFIBUS DP. Figure 6 on page 38 provides examples of various ways to connect the S800 I/O units.
PM8xx/TP830 Processor Unit – General Section 1 Introduction See Note 3 CI854A Optical 1 Segment of PROFIBUS DP See Note 1 TB820 Optical To 6 Additional Optical Modulebus Clusters (not PM851) CI801 Optical R See Note 2 Additional stations up to maximum of 32 stations per TB820 Segment Repeater Unit Note1 - Maximum 7 clusters x 12 = 84 modules. Max 200 m between clusters. (1 cluster only for PM851)Restrictions apply, see I/O documentation. Note 2 - Remote S800 I/O.
Section 1 Introduction PM8xx/TP830 Processor Unit – General Max 12 units Max 12 units per Cluster CI860 CI854A FOUNDATION PROFIBUS DP Fieldbus HSE PM860 CPU DI810 AI810 See Note 4 DO810 Electrical Modulebus Cluster High Speed Ethernet Max 12 Modules per Cluster See Note 2 Optical TB820 DI810 AI810 AO820 See Note 1 To 6 Additional Optical Modulebus Clusters Optical FOUNDATION Fieldbus H1 Link LD 800HSE 1...
PM891 Processor Unit – General Section 1 Introduction PM891 Processor Unit – General PM891 is a high performance controller, which is capable of handling applications with high requirements. PM891 connects to the S800 I/O system through the optical Modulebus. It can act as a stand-alone Process Controller, or as a controller performing local control tasks in a control network.
Section 1 Introduction PM891 Processor Unit – General Figure 8 shows the front view, Figure 9 shows the top view, and Figure 10 shows the bottom view of PM891. LED Status Indicators CEX Bus Com Port External Battery Supply Socket Power supply and Supervision Signal Socket CN1 and CN2 ports Tx/Rx Optical ModuleBus port DIN-Rail locking device Figure 8.
PM891 Processor Unit – General Section 1 Introduction Screw terminals are provided for connections to the power supply and the external battery. The 24 V DC power supply powers all the units on the CEX-Bus. The optical module clusters are powered independently. RCU Data Link RCU Control Link INIT button Secure Digital (SD) slot Figure 9.
Section 1 Introduction PM891 Processor Unit – General Figure 10. PM891 - Bottom view with Tx1/Rx1 and CN1/CN2 ports. The Redundancy Link consists of two cables; RCU Data Link Cable and RCU Control Link Cable (see Figure 9). Figure 11 shows the block diagram of PM891.
PM891 Processor Unit – General Section 1 Introduction Figure 11.
Section 1 Introduction PM891 Processor Unit – General PM891 See Note 3 CI854A Optical 1 Segment of PROFIBUS DP See Note 1 TB820 Optical To 6 Additional Optical Modulebus Clusters (not PM851) CI801 Optical R See Note 2 Additional stations up to maximum of 32 stations per TB820 Segment Repeater Unit Note1 - Maximum 7 clusters x 12 = 84 modules. Max 200 m between clusters. (1 cluster only for PM851)Restrictions apply, see I/O documentation. Note 2 - Remote S800 I/O.
PM891 Processor Unit – General Section 1 Introduction Max 12 units CI860 CI854A FOUNDATION PROFIBUS DP Fieldbus HSE PM891 CPU High Speed Ethernet Max 12 Modules per Cluster See Note 2 Optical TB820 DI810 AI810 AO820 See Note 1 To 6 Additional Optical Modulebus Clusters Optical FOUNDATION Fieldbus H1 Link LD 800HSE 1...4 Links see Note 3 LD 800HSE see Note 3 HSE Device FF Field Device FF Field Device FF Field Device ...
Section 1 Introduction PM891/PM86x/TP830 Processor Unit – Redundancy PM891/PM86x/TP830 Processor Unit – Redundancy Processor unit redundancy is available for PM861, PM864, PM865, PM866, and PM891. 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. The backup stands by, ready to take over in case of a fault in the primary.
PM891/PM86x/TP830 Processor Unit – Redundancy Section 1 Introduction PM891 Redundancy The Redundancy Link in PM891 consists of two physical links. These are the RCU Data Link and the RCU Control Link. The RCU Data Link is a fast communication channel used to transfer the data required to keep the backup CPU synchronized with the primary CPU. TK855 RCU Data Link Cable is used for the data link. The RCU Control Link is used for role selection and CPU identity assignment (UPPER/LOWER).
Section 1 Introduction PM891/PM86x/TP830 Processor Unit – Redundancy If the primary unit fails because of an error, the backup unit resumes execution from the last rollback point, which means the last execution unit is partially re-executed by the backup unit. In order to re-execute a portion of the execution unit without affecting the peripheral units (communication units on the CEX-Bus), the peripheral units' references are also logged between rollback points.
AC 800M High Integrity Section 1 Introduction The following characteristics of the MAC and IP address handling should be considered in order to avoid network problems while reusing previously used CPU modules within the same plant: • The stored swap addresses will be remembered until erased by an IP-config session (Restore factory settings) or until started up as a backup CPU in new context (in this case a new swap will take place).
Section 1 Introduction • Oscillator supervision • CRC on firmware and data storage Control Software An SM811 operates like an SM810 for SIL2 but can also together with the PM865 form a controller compliant with SIL3 according to IEC61508, certified by TÜV. The ModuleBus telegrams used in a High Integrity system with the S800 High Integrity modules use the concept of long frames.
Ethernet Address for PM8xx (Except PM891) Section 1 Introduction Ethernet Address for PM8xx (Except PM891) Each TP830 Baseplate is provided with a unique Ethernet address that provides every CPU with a hardware identity. This functionality takes the form of two identification addresses residing in the non-volatile memory of the TP830 Baseplate. The lowest address (a 12 character Hex code) is located on an adhesive label attached to the TP830 Baseplate. The remaining address is the lowest +1.
Section 1 Introduction Ethernet Address for PM8xx (Except PM891) Figure 14.
Ethernet Address for PM891 Section 1 Introduction Ethernet Address for PM891 Each PM891 unit is provided with a unique Ethernet address that provides hardware identity to the unit. This functionality takes the form of two identification addresses residing in the non-volatile memory of PM891. The lowest address (a 12 character Hex code) is located on an adhesive label attached to the cover of PM891 unit. The remaining address is the lowest +1. See Figure 15 on page 55 for label location details of PM891.
Section 1 Introduction Ethernet Address for PM891 Figure 15.
AC 800M Controller – Key Features Section 1 Introduction AC 800M Controller – Key Features 56 • Modularity, allowing for step-by-step expansion. • Simple DIN-rail attachment/detachment procedures, using a unique slide and lock mechanism. • Fast, simple troubleshooting procedures available via unit/channel LEDs. • IP20 Class protection with no requirement for enclosures.
Section 1 Introduction Product Release History • Built-in battery backup of memory (except for PM891 that uses external battery backup only). • External battery backup. • CPU Redundancy (PM861/PM864/PM865/PM866/PM891). • Redundant/sectioned CEX-Bus using a pair of BC810. • Safety Integrity Level 2 certified controller using PM865/SM810/SM811. • Safety Integrity Level 3 certified controller using PM865/SM811 • Support for hot swap of CEX-Bus units.
Product Release History Section 1 Introduction Table 2. AC 800M Release History Version 58 Description User Doc 4.1 New information about SS823 is added. SM810 and Compact Flash have been added. 3BSE036351R4101 4.0 CI862 is added. 3BSE036351R4001 3.1 PM851 is added 3BSE 036 351 R101 3.0 PM865, PM861A, PM864A, BC810, SM810, CI854A, CI858, CI860 and SS823 are added. 3BSE 030 827 R201 2.1 PM864 is added. 3BSE 027 941 R301 2.1 CI855 and CI856 are added. 3BSE 027 941 R101 2.
Section 2 Installation This section contains guidelines for planning the installation of an AC 800M controller system (see Site Selection and Building Requirements on page 59). A complete list of measures to be taken with respect to the environment and other on-site conditions is not given here. The equipment should be adapted to the actual application by means of a thorough and correctly scoped system definition, ordering procedures and design requirements.
Site Selection and Building Requirements Section 2 Installation When planning a control system installation, the following points must be considered: • • • 60 Temperature: – It is important to note the ambient air temperature as well as that within enclosures. Lower temperatures increase system reliability and availability. – If maximum permitted temperatures are exceeded, the anticipated lifetime of wet, electrolytic capacitors and most semiconductors will be greatly reduced.
Section 2 Installation • Grounding: – • Site Selection and Building Requirements Grounding, cable selection and cable routing must be considered for electromagnetic interference-free operation. Planning considerations are discussed in the subsequent sections. Other requirements: – Room lighting independent of the equipment power source. A batterypowered emergency lighting system is recommended. – A well-developed process connection, with or without marshalling facilities.
Cables Section 2 Installation Cables Laying Field Cables There are no special requirements for laying field and communication cables connected to AC 800M. However: • Cables for short-distance communication without modems should always be routed at a distance of 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.
Section 2 Installation Power Supply 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. Mains Net Filter It is not necessary to use mains net filters when using the SD831/832/833/834 power supply units.
Enclosures Section 2 Installation 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 3 on page 64. Table 3. External Mains Supply – Fuse Rating Fuse Rating Fuse Type 10 A Delayed action fuse Should the configuration be other than that stated, instructions for calculating current consumptions can be found in the relevant I/O manual.
Section 2 Installation Mounting AC 800M Units onto DIN-Rail Normally the use of an additional enclosure will not influence the EMC characteristics of the controller. Enclosure Mounting When mounting the controller enclosure, it is important to provide certain minimum distances between the enclosure, the walls and the ceiling, in order to provide satisfactory ventilation.
Mounting on metal sheet Section 2 Installation There are two ways of mounting the product in cabinets, open rack or other types of installations; aluminum profile with mounted DIN-rail or DIN-rail mounted on a metal sheet of proper size. The aluminum profile or metal sheet shall be properly connected to protective earth. DIN-rail type with height 7.5 mm shall be used. Refer to type NS 35/7.5 according to standard EN50022.
Section 2 Installation Prefabricated aluminum profile Prefabricated aluminum profile There are aluminum profiles for horizontal 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. Pre-formed channels Al-profile DIN-rail Cable Duct Figure 16.
Prefabricated aluminum profile Section 2 Installation Mounting Procedure for PM8xx and CI8xx Units, Complete with Baseplates This topic does not apply to PM891. See Mounting Procedure for PM891 Unit on page 70. Before mounting any processor unit or communication interface onto the DIN-rail, read carefully the installation instructions provided with the equipment. Since the electronic unit and baseplate are supplied as a single unit, there is no requirement to separate them during the mounting procedure.
Section 2 Installation Prefabricated aluminum profile 1. OPEN 2. SLIDE 3. LOCKED Figure 17. Baseplate Locking Device Lugs for extra screws to provide secure mounting in locations subject to vibration Figure 18.
Prefabricated aluminum profile Section 2 Installation Figure 19. AC 800M Controller (except PM891) – Side View Mounting Procedure for PM891 Unit Before mounting any processor unit or communication interface on the DIN-rail, read carefully the installation instructions provided with the equipment. To mount the PM891 unit on the DIN-rail, a blade screwdriver that fits securely into the unit locking screw (1 mm slot) is required. For details about the unit locking screw, see Figure 20 on page 71.
Section 2 Installation 3. Prefabricated aluminum profile When the interconnection is complete, rotate the locking device clockwise to the LOCKED position (3). The PM891 unit is now fully locked into the position and has a good ground connection to the 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. 1. OPEN 2. SLIDE 3. LOCKED Figure 20. Unit locking for PM891 Figure 21.
Prefabricated aluminum profile Section 2 Installation Figure 22. PM891 - Side view Removing Processor Units Complete with Baseplates AC 800M units must be disconnected from the power source before removing them from a DIN-rail! It is not allowed to manipulate CEX bus baseplates in a powered and running system. Before changing or removing a baseplate, all CEX modules on that segment must be removed. Use the following procedure to remove a unit, complete with baseplate: 72 1.
Section 2 Installation 3. Prefabricated aluminum profile Rotate the locking device to the SLIDE position (2) on the unit baseplate, see Figure 17 on page 69. In order to provide adequate access and removal space, note that the SLIDE sequence must be carried out on the unit baseplates adjacent to the unit that is to be removed. 4. Gently ease the unit/baseplates sideways in order to release the contacts of the unit baseplate being removed. 5.
Prefabricated aluminum profile Section 2 Installation 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 23.
Section 2 Installation Prefabricated aluminum profile Unit to Baseplate Alpha Code Lock Baseplates have a pre-set Alpha code locking device. This locking device prevents the installation of an incompatible type of unit onto the base plate if the Alpha codes do not match. All identical unit types have the same factory pre-set, two-letter Alpha code installed prior to delivery. The following unit types have two-part, pre-set Alpha code locking devices installed (see Table 4 on page 75). Table 4.
Prefabricated aluminum profile Section 2 Installation Table 4.
Section 2 Installation Prefabricated aluminum profile Pre-Set Alpha Code Keys Figure 24.
Installing the PM86x/TP830 Processor Unit in Single Configuration Section 2 Installation Installing the PM86x/TP830 Processor Unit in Single Configuration This topic does not apply to the PM891 processor unit. See Installing PM891 in Single Configuration on page 87. Use the procedure below to install the processor unit along the DIN-rail: 1. If already mounted, remove the CEX-Bus and ModuleBus terminations from the sides of the processor unit.
Section 2 Installation 5. Installing the PM86x/TP830 Processor Unit in Single Configuration Baseplate cable connections: 6. a. Connect the power leads and, if applicable, power supervision signals from SS82x to screw terminals SA and SB (see Figure 28 on page 83). b. Connect the Control Network cables to CN1 (single connection) or CN1 + CN2 (redundant connection). c. Connect the serial protocol to COM3. d.
Installing the PM86x/TP830 Processor Unit in Single Configuration Section 2 Installation Always install a fresh internal or external battery at the end of the installation phase. The original battery is heavily utilized due to frequent blackouts during system installation. Terminator TB850 Figure 25.
Section 2 Installation Installing the PM86x/TP830 Processor Unit in Single Configuration TK850 Cable Terminator TB851 Figure 26.
Installing the PM86x/TP830 Processor Unit in Single Configuration BC810 Section 2 Installation PM861A/PM864A/PM865 Terminator TB850 RCU Link Cable Terminator TB850 BC810 Figure 27.
Section 2 Installation Installing the PM86x/TP830 Processor Unit in Single Configuration Figure 28.
Installing the PM86x/TP830 Processor Unit in Single Configuration Section 2 Installation Communication Ports CN1 and CN2 The control network connects to one or two RJ45 connectors (CN1 and CN2) depending on network option (single or redundant). Use an RJ45 connector for IEEE802.3 (Ethernet) for connecting to a category 5 Shielded Twisted Pair cable (STP class 5). Class 5, or higher, cable 10/100BaseT/TX max 100 m (110 yd).
Section 2 Installation Installing the PM86x/TP830 Processor Unit in Single Configuration COM3 Port The COM3 is an RS-232C port with modem signals. This port is used for serial protocols such as Modbus, Siemens 3964R, COMLI or custom-design. Table 6.
Installing the PM86x/TP830 Processor Unit in Single Configuration Section 2 Installation COM4 Port The COM4 port is an RS-232C 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. Table 7.
Section 2 Installation Installing PM891 in Single Configuration Installing PM891 in Single Configuration Use the procedure below to install the PM891 processor unit in single configuration: 1. If already connected, remove the CEX-Bus termination from the side of the PM891 processor unit. 2. Mount the PM891 processor unit, the communication interfaces, and the S800 I/O units on the DIN-rail. The communication interfaces for PM891 is connected to the CEX-Bus to the left of the processor unit.
Installing PM891 in Single Configuration 6. Section 2 Installation Connect the optical ModuleBus to the optical contacts (Tx1/Rx1) at the bottom of the processor unit (see Figure 10 on page 43). For information regarding optical cable selection and cable length, refer to the S800 I/O documentation. The connection to the optical ModuleBus is identical to that for the processor unit and for the FCI in S800 I/O (see Figure 54 on page 160.) 7.
Section 2 Installation Installing PM891 in Single Configuration COM4 Port The COM4 port is an RS-232C port, opto-isolated and without modem signals. Connect the Control Builder to this port when connecting directly to the controller, or, when not required, without the need use the remote tool connection through the Control Network. Table 9.
Installing the PM86x/TP830 Processor Unit in Redundant Configuration Section 2 Installation Installing the PM86x/TP830 Processor Unit in Redundant Configuration This topic does not apply to the installation of PM891 unit in redundant configuration. See Installing the PM891 Processor Unit in Redundant Configuration on page 94. In redundant configuration two PM861/PM864/PM865/PM866 units are mounted onto two separate DIN-rails.
Section 2 Installation 5. Installing the PM86x/TP830 Processor Unit in Redundant Configuration Connect the RCU Link Cable TK851 to both CPUs. Note that in redundant CPU configuration, COM3 and the electrical ModuleBus on the baseplate can not be used. Note that the RCU Link Cable TK851 must be used and can not be replaced by a similar cable. Using another cable will disable the identification of the CPUs in the CB and Operator Station.
Installing the PM86x/TP830 Processor Unit in Redundant Configuration 8. Section 2 Installation The CPUs are supplied with internal back-up batteries. When the batteries are to be used, place them in the Internal Battery Holder (Figure 63 on page 193). When the external SB821/SB822 battery units are to be used, install them according to the instructions in Installing the SB821 External Battery Unit on page 143/Installing the SB822 Rechargeable External Battery Unit on page 144.
Section 2 Installation Installing the PM86x/TP830 Processor Unit in Redundant Configuration Communication Ports Same as for single configuration (see Table 5 on page 84, Table 6 on page 85 and Table 7 on page 86). CEX-Bus ext. cable TK850 RCU Link cable TK851 Figure 29.
Installing the PM891 Processor Unit in Redundant Configuration Section 2 Installation Installing the PM891 Processor Unit in Redundant Configuration In redundant configuration, two PM891 units are mounted on two separate DIN-rails. If sufficient space is available, the units can be mounted on the same DIN-rail. Use the following procedure to install the processor units along the DIN-rail: 1. Mount the processor units. 2.
Section 2 Installation 6. Installing the PM891 Processor Unit in Redundant Configuration Provide connections for power supply and network: a. Connect the power leads to screw terminals L+ and L- of both CPUs, and the power supervision signals from SS8xx to screw terminals SA and SB. Both CPUs should be powered from the same supply (single or redundant). For redundant power supply, see Figure 46 on page 140. 7. b.
Installing the PM891 Processor Unit in Redundant Configuration Section 2 Installation Figure 30. Example of PM891-Redundant configuration Communication Ports Same as for single configuration (see Table 8 on page 88and Table 9 on page 89).
Section 2 Installation Installing the CEX-Bus without BC810 Installing the CEX-Bus without BC810 The CEX-Bus, used for connection of communication interfaces to the processor unit, is located on the left-hand side of the processor unit baseplate (TP830). A bus termination unit must always be fitted to the last unit on the CEX-Bus, as shown in Figure 25 on page 80. A TB850 male CEX-Bus termination unit is supplied with each PM8xx/TP830 processor unit.
Installing the CEX-Bus Interconnection Unit BC810/TP857 Section 2 Installation See Figure 31 on page 100 and Figure 32 on page 101 for configuration examples. Use the configuration which coincides with the requirements for availability, redundancy and safety of your AC 800M controller system. Do not connect the two CEX-Bus segments, separated with BC810, to each other with CEX-Bus extension cable TK850.
Section 2 Installation Installing the CEX-Bus Interconnection Unit BC810/TP857 Hot swap of the BC810 located next to a primary or single controller CPU, otherwise called “direct BC810”, might jeopardize the whole controller and should not be performed unless every module on the CEX-Bus are in a nonoperating state. Note: In an AC 800M HI controller this is unconditionally and intentionally leading to a shutdown of the controller.
Installing the CEX-Bus Interconnection Unit BC810/TP857 Section 2 Installation SM810/SM811(1) BC810 PM861A/PM864A/PM865/PM866 TK851 Cables SM810/SM811(1) BC810 PM861A/PM864A/PM865/PM866 (1) Only for High Integrity Systems and only together with PM865 Figure 31.
Section 2 Installation Installing the CEX-Bus Interconnection Unit BC810/TP857 CI854A SM810/SM811(1) BC810 PM861A/PM864A/PM865/PM866 RCU Link Cable CI854A SM810(1) BC810 (1) Only for High Integrity Systems and only together with PM865 Figure 32.
Installing the CEX-Bus Interconnection Unit BC810/TP857 CEX-Bus Units BC810 Section 2 Installation CPU SD8xx/SS8xx CEX-Bus Units BC810 CPU Figure 33. The Power Source Connected to the Same PM864/BC810 Segment, see Installing the CEX-Bus Interconnection Unit BC810/TP857 on page 97 and Power Supply System on page 173.
Section 2 Installation Installing the CEX-Bus Interconnection Unit BC810/TP857 CEX-Bus Units SM810/SM811 BC810 CPU SD8xx/SS8xx SM810/ CEX-Bus Units SM811 SD8xx/SS8xx BC810 CPU Figure 34. The Power Source Connected to a Different PM865/BC810 Segment, see Installing the CEX-Bus Interconnection Unit BC810/TP857 on page 97 and Power Supply System on page 173.
Installing SM810/TP855 Section 2 Installation Installing SM810/TP855 The SM810 is mounted directly to the CEX-Bus on the processor unit base plate or to the CEX-Bus interconnection unit BC810. The communication interfaces are then mounted to the CEX-Bus on the SM810. See Figure 31 on page 100 and Figure 32 on page 101 for configuration examples.
Section 2 Installation Installing SM810/TP855 Connection of Input Signals to SM810 0V B 0V A I1: Reset all forces I2: Access enable 24V A 24V B Figure 35. Connection of input signals to redundant SM810.
Installing SM810/TP855 Section 2 Installation Connection of Output Signals to SM810 24V B 24V A O1: Any force active O2: System alarm 0V Figure 36. Connection of output signals from redundant SM810.
Section 2 Installation Installing SM811/TP868 Installing SM811/TP868 The SM811 is mounted directly to the CEX-Bus on the processor unit base plate or to the CEX-Bus interconnection unit BC810. The communication interfaces are then mounted to the CEX-Bus on the SM811. See Figure 31 on page 100 and Figure 32 on page 101 for configuration examples. Use the enclosed cable TK852V010 to connect the SM Link of the two SM811s in case of redundant configuration.
Installing SM811/TP868 Section 2 Installation Table 11.
Section 2 Installation Installing SM811/TP868 Connection of Input Signals to SM811 0V B 0V A I1: Reset all forces I2: Access enable I3: Hot-insert of SM 24V A 24V B Figure 37.
Installing SM811/TP868 Section 2 Installation Connection of Output Signals to SM811 24V B 24V A O1: Any force active O2: System alarm 0V Figure 38.
Section 2 Installation Installing the PROFIBUS DP Interface, CI851/TP851 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: 1. Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 65 and Installing the PM86x/TP830 Processor Unit in Single Configuration on page 78. 2.
Installing the PROFIBUS DP Interface, CI851/TP851 Section 2 Installation Installation of PROFIBUS DP Table 12.
Section 2 Installation Installing the FOUNDATION Fieldbus H1 Interface, CI852/TP852 Installing the FOUNDATION Fieldbus H1 Interface, CI852/TP852 CI852 is powered from the processor unit via the CEX-Bus and requires therefore no additional external power source. 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: 1.
Installing the FOUNDATION Fieldbus H1 Interface, CI852/TP852 Section 2 Installation For additional information on designing a fieldbus (connectors, cables and devices), see fieldbus documentation. 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).
Section 2 Installation Installing the RS-232C Interface, CI853/TP853 Installing the RS-232C 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: 1. Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 65 and Installing the PM86x/TP830 Processor Unit in Single Configuration on page 78. 2. Connect the cable (maximum 15 m (16.
Installing the PROFIBUS DP Interface, CI854/CI854A/TP854 Section 2 Installation Installing the PROFIBUS DP Interface, CI854/CI854A/TP854 The CI854/CI854A 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/CI854A/TP854: 1. Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 65 and Installing the PM86x/TP830 Processor Unit in Single Configuration on page 78. 2.
Installing the PROFIBUS DP Interface, CI854/CI854A/TP854 F F R R RxA RxA RxB RxB PRIM PRIM DUAL DUAL Line A ON PROFIBUS A CI854A PROFIBUS B PROFIBUS A CI854A ON PROFIBUS B Section 2 Installation Line B Figure 39. Connection of Redundant PROFIBUS DP (CI854A) PROFIBUS DP Connection The PROFIBUS DP cable is connected via the 9-pin female D-type connector located on TP854.
Installing the PROFIBUS DP Interface, CI854/CI854A/TP854 Section 2 Installation Installation of PROFIBUS DP Table 15.
Section 2 Installation Installing the MasterBus 300 Interface, CI855/TP853 Installing the MasterBus 300 Interface, CI855/TP853 The CI855 is powered from the processor unit via the CEX-Bus and requires therefore no additional external power source. 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: 1.
Installing the S100 I/O Interface, CI856/TP856 Section 2 Installation 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: 1. Mount the unit on the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 65 and Installing the PM86x/TP830 Processor Unit in Single Configuration on page 78. 2.
Section 2 Installation Installing the INSUM Interface, CI857/TP853 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: 1. Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 65 and Installing the PM86x/TP830 Processor Unit in Single Configuration on page 78. 2.
Installing the DriveBus Interface, CI858/TP858 Section 2 Installation Installing the DriveBus Interface, CI858/TP858 The CI858 is powered from the processor unit via the CEX bus and requires therefore no additional external power source. The unit is mounted onto a horizontal DIN rail. Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DIN-Rail on page 65, Installing the PM86x/TP830 Processor Unit in Single Configuration on page 78 and CI858 and TP858 – DriveBus Interface on page 313.
Section 2 Installation Installing the FOUNDATION Fieldbus High Speed Ethernet Interface, Installing the FOUNDATION Fieldbus High Speed Ethernet Interface, CI860/TP860 The CI860 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 CI860/TP860: 1.
Installing the TRIO Fieldbus Interface CI862 Section 2 Installation Installing the TRIO Fieldbus Interface CI862 The CI862 is powered from the processor unit via the CEX-Bus and requires no additional external power source. No field device is powered from the CI862. Use the following procedure to install the CI862: 1. Mount the unit onto the DIN-rail. 2. Connect the field bus cable to the LAN connector (right most connector).
Section 2 Installation Bus Termination Table 17. Field Bus Termination Switch Settings of the CI862 (Continued) Dip Switch(1) Setting 3 150 ohms 4 Not Used (1) The dip switch must be closed to make the termination connection. The default is open, (no internal termination). (2) The 110 ohm option may be used to terminate cables with an impedance in the range of 100 to 120 ohms. As shown in Figure 78, the dip switch is located on the bottom of the housing when looking from the front.
Installing the Satt I/O Units and CI865 Module Section 2 Installation Installing the Satt I/O Units and CI865 Module The CI865 is powered from the processor unit via the CEX-Bus and requires no additional external power source. No field device is powered from the CI865. Use the following procedure to connect the ControlNet to the BNC connector of the I/O systems and the CI865 module. For more information see Satt I/O Interface for AC 800M (3BSE042821*).
Section 2 Installation Installing the Modbus TCP Interface CI867/TP867 Installing the Modbus TCP Interface CI867/TP867 The CI867 is powered from the processor unit via the CEX-Bus and no additional external power source is required. Use the following procedure to install the CI867/TP867: 1. Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DINRailon page 65 and Installing the PM86x/TP830 Processor Unit in Single Configurationon page 78. 2.
Installing the IEC 61850 Interface CI868 Section 2 Installation Installing the IEC 61850 Interface CI868 The CI868 is powered from the processor unit via the CEX-Bus with no additional external power source required. To install CI868: 1. Mount the unit onto the DIN-rail, see Mounting AC 800M Units onto DINRailon page 65. 2. Connect the 100Mbps Ethernet twisted pair cable to the CH1 connector on the baseplate. 3.
Section 2 Installation Installing the PROFINET IO Interface CI871 Installing the PROFINET IO Interface CI871 The CI871 unit is powered from the processor unit through the CEX-Bus, which requires no additional external power source. To install CI871: 1. Mount the CI871 unit on the DIN-rail. 2. Connect the 100 Mbps Ethernet cable to the CH1 connector on the baseplate. 3. Connect the other end of the Ethernet cable to the PROFINET IO network.
Installing the EtherNet/IP Interface CI873 Section 2 Installation Installing the EtherNet/IP Interface CI873 The CI873 is powered from the processor unit through the CEX-Bus, which requires no additional external power source. Follow the steps below to install CI873: 130 1. Mount the unit onto the DIN-rail. 2. Connect the 100 Mbps Ethernet twisted pair cable to the CH1 connector on the baseplate. 3.
Section 2 Installation Installing the ModuleBus for PM8xx Installing the ModuleBus for PM8xx This topic does not apply to PM891. See Installing the ModuleBus for PM891 on page 132. 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.
Installing the ModuleBus for PM891 Section 2 Installation Installing the ModuleBus for PM891 The ModuleBus for PM891 has a fiber optical interface. The interface is designed for a maximum of seven clusters, of twelve non-redundant or six redundant modules (that is, 7x12 = 84 modules). Redundant and non-redundant modules can be mixed. The fiber-optical interface is intended for local distribution of I/O clusters. .
Section 2 Installation Installing the SD83x Power Supply Installing the SD83x Power Supply The SD83x power supply units (SD831 / SD832 / SD833 / SD834) should be mounted horizontally at a DIN rail. The units have to be used in non-hazardous locations only. The four PSUs have data as follows: – SD831 = Input a.c. 100-240 V or d.c. 110-300 V. Output d.c. 24 Volts regulated @ 3 A. – SD832 = Input a.c. 100-120 or 200-240 V. Output d.c. 24 Volts regulated @ 5 A – SD833 = Input a.c. 100-120 or 200-240 V.
Installing the Mains Breaker Unit Section 2 Installation 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, see Figure 61 on page 177 and Figure 62 on page 178. For the sake of simplicity, the installation described covers the redundant power supplies/independent power supplies option.
Section 2 Installation Installing the Mains Breaker Unit 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. 3 PE – Green/Yellow 4 2 5 6 7 1 8 9 1 To Power supply for Field Equipment PE – Green/Yellow MAINS PE – Green/Yellow To Power supply for units PE = Protective Ground PE – Green/Yellow Figure 42.
Installing the SS823/SS832 Voting Unit Section 2 Installation Installing the SS823/SS832 Voting Unit The SS8xx 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 43 on page 137 for SS823, Figure 44 on page 138, and Figure 45 on page 139 for SS832.
Section 2 Installation Installing the SS823/SS832 Voting Unit Figure 43.
Installing the SS823/SS832 Voting Unit Section 2 Installation Figure 44.
Section 2 Installation Installing the SS823/SS832 Voting Unit Figure 45. SS832 Redundant Configuration up to 20 A 3. 3BSE036351-510 A Connect the SS82x voting unit to the processor unit. Figure 46 on page 140 shows the connection to PM861/PM864/PM865 in redundant configuration.
Installing the SS823/SS832 Voting Unit Section 2 Installation From Mains Breaker Protective Ground Figure 46.
Section 2 Installation Installing the SS823/SS832 Voting Unit Power Supply Supervision The status of power supplies in redundant configuration can be supervised via the SS8xx voting unit. The supervision signals SA and SB from the SS8xx are connected to the corresponding terminals of the CPU. + 24 V on the SA/SB indicates working power supplies. 0 V on SA/SB indicates an error in the corresponding power supply and lack of redundancy.
Installing the SS823/SS832 Voting Unit Section 2 Installation SA SB L+ L+ L– L– OK L+ L+ L– L– OK SD821 N L PE OK + F OK + F A L PE B SS822 SD821 N A+ B+ L+ L+ L– L+ From Mains Breaker L– Protective Ground L+ L+ L– L– OK L+ L+ L– L– OK SD821 N L PE SD821 N L PE +24 V Powering Units 0V OK+ F OK + F A B SS822 A+ B+ L+ L+ L– L+ +24 V L– 0V From Mains Breaker Protective Ground Supervision signals to CPU unit via TP830 Powering Field Equipment Figure 48.
Section 2 Installation Installing the SB821 External Battery Unit Installing the SB821 External Battery Unit Use the following procedure to connect the external battery unit: 1. Mount the SB821 external battery unit at a suitable position on the DIN-rail. 2. For connecting the SB821 external battery unit, use the 2 m (2.2 yd) cable TK821V020. Plug one end into the battery unit and the other into the external battery supply socket of the PM8xx processor unit (see Figure 2 on page 32). 3.
Installing the SB822 Rechargeable External Battery Unit Section 2 Installation Installing the SB822 Rechargeable External Battery Unit Use the following procedure to connect the rechargeable external battery unit: 1. At delivery the Li-Ion battery package is not connected internally. Follow the steps in the Data and installation sheet, which is enclosed in the packing box, to connect the battery package properly. 2.
Section 2 Installation Installation of I/O Units Installation of I/O Units For further information regarding mounting, removing and releasing procedures for I/O Units, refer to the appropriate I/O system documentation.
Installation in Cabinets Section 2 Installation ModuleBus Expansion Cable Aluminum Profile Cable Duct Mains Breaker Unit SD831 24 V Distribution Terminals Figure 49.
Section 2 Installation Mains Breaker Unit Installation in Cabinets SD831 (Units) SD831 (Field) 24 V Distribution (Units in Cabinet) 24 V Distribution (Field Equipment) Figure 50.
Installation in Cabinets Section 2 Installation SD832 Redundant Power Supply Units (Field Equipment) Mains Breakers SS832 Voting Units SD832 Redundant Power Supply Units Figure 51.
Section 2 Installation Mounting Dimensions for Proper Ventilation 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 52 on page 149. Note that the CPU and Communication Interfaces must be mounted on a horizontal DIN-rail. >50 mm (2.0 in) Unobstructed areas >261 mm (10.3 in) >25 mm (1.0 in) >50 mm (2.
Mounting Dimensions for Proper Ventilation 150 Section 2 Installation 3BSE036351-510 A
Section 3 Configuration General Information Using the engineering tool Control Builder, it is possible to configure hardware (I/O and communication units) and make application programs with control languages according to IEC 61131-3. Programs can be compiled and run off-line as an aid to process simulation before finally downloading an application to the controller. The Control Builder offers a set of options, each with its own set of properties.
Connecting Control Builder Section 3 Configuration Connecting Control Builder The Control Builder is installed in a PC that is normally connected to the AC 800M Controller via the Control Network and the CN1 or CN2 ports on the controller (see Figure 53 on page 153). Alternatively, the Control Builder may be connected via the COM4 port (RS-232C) on the AC 800M Controller. Use the tool cable TK212 and a serial port on the PC.
Section 3 Configuration Connection to a Control Network Connection to a Control Network Control Network is a private IP network domain for both real time data and general system communication between industrial computers. It is scalable, from a very small network with a few nodes, to a large network containing a number of “Network Areas” and many hundreds of nodes.
Communication Possibilities Section 3 Configuration The network can utilize different and mixed link implementations such as Fast Ethernet and PPP. It provides for full redundancy, in order 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.
Section 3 Configuration • Communication Possibilities COM3 is an RJ45 port for RS-232C with modem signals. Examples of protocols are Modbus, Siemens 3964R, COMLI or custom-design. For more details, see protocol-specific documentation. COM3 port is not available for PM891. • COM4 is an RJ45 port for connection of service tools (see Connecting Control Builder on page 152). The port has no modem signals.
Communication Possibilities Section 3 Configuration Table 19.
Section 3 Configuration Controller IP Addresses (2) The maximum total limit on CEX-Bus is the electrical one, there might be further limitations due to performance for a particular unit. (3) Only one port (CH1) is used in the interfaces CI868, CI871 and CI873. For information on available serial protocols for the CI853 interface, see COM3 above. If redundant controllers (PM8XX) are used along with redundant communication interfaces, it ensures full redundancy and supports the online upgrade of firmware.
I/O Systems Section 3 Configuration If network redundancy is used, the IP address of the CN2 port of the primary processor cannot be set using IPConfig. This address must be set in Control Builder 3. Set the IP address of the CN1 port on the backup CPU. Use default settings (0.0.2.0 is added to the address of the primary CPU), unless your network administrator requires otherwise. See IPConfig online help.
Section 3 Configuration I/O Systems • S800 I/O units via CI854/CI854A and CI801, PROFIBUS DP. Support for HART routing, and hot configuration during run. • S900 I/O units can be connected to PROFIBUS DP. • ABB Drives can be connected to the ModuleBus, via CI801 and also via Modulebus on the PM8xx. Some Drives equipment can be connected directly to PROFIBUS or PROFINET IO. Please refer to Drives-specific documentation for more information.
I/O Systems Section 3 Configuration 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 ModuleBus Electrical ModuleBus PM8xx Local TB820 Optical ModuleBus Central/Remote TB820 Maximum of 7 clusters (groups) (Maximum of 1 cluster for PM851) TB820 Maximum of 12 x I/O units Figure 54.
Section 3 Configuration I/O Systems In redundant CPU configuration, S800 I/O is connected through the optical ModuleBus. Each CPU is connected to one TB840 on each cluster (see Figure 55 on page 161). Redundant CPUs Electrical ModuleBus cannot be used Local 2 x TB840 Optical ModuleBuses Central/Remote 2 x TB840 Maximum of 7 clusters (groups) 2 x TB840 Maximum of 12 x I/O units Figure 55.
I/O Systems Section 3 Configuration PROFIBUS DP A PROFIBUS DP segment, capable of providing up to 32 nodes, can be directly connected to a PROFIBUS DP Interface unit type CI854A/TP854. This segment can be further extended using repeater units. PROFIBUS PA can be connected to PROFIBUS DP via the PROFIBUS linking device LD 800P, see Appendix C, Recommended Components. For further details refer to PROFIBUS documentation, available at the PROFIBUS Internet site.
Section 3 Configuration I/O Systems Figure 56. Example of System Structure for PROFIBUS PROFINET IO PROFINET IO describes a device model oriented to the PROFIBUS framework. It consists of places of insertion (slots) and groups of I/O channels (subslots). The PROFINET IO engineering is performed in a way familiar to PROFIBUS. The distributed field devices are assigned to the controllers during configuration.
I/O Systems Section 3 Configuration The PROFINET IO is interfaced to the AC 800M controller , using the PROFINET IO commmunication interface, CI871. Figure 57.
Section 3 Configuration I/O Systems FOUNDATION Fieldbus High Speed Ethernet (FF HSE) FOUNDATION Fieldbus (FF) is a fieldbus protocol based on international standards and designed for applications in the manufacturing industry, process automation and buildings automation. The guidelines for this fieldbus standard are published by the Fieldbus Foundation. FF defines two communication profiles, H1 and HSE. The H1 profile allows a transmission rate of 31.25 kbit/s.
I/O Systems Section 3 Configuration FF linking devices operate as gateways between the AC 800M and the field devices on the H1segments both for the configuration data of the field devices and for the process data which is exchanged cyclically between AC 800M and the field devices. Figure 58.
Section 3 Configuration I/O Systems TRIO/Genius Remote I/O TRIO is a Genius remote I/O product that provides discrete, analog and high-speed counter blocks for connection to the AC 800M. Configuration of the I/O block units and the CI862 is done using Control Builder M.
Drive System Section 3 Configuration Drive System ABB Standard (Std) and Engineered (Eng) Drives can be connected to AC 800M through any of the following: • • • • • The optical ModuleBus CI801 and PROFIBUS DP NPBA-12, RPBA-01, or FPBA-01 PROFIBUS DP Adaptor modules along with CI854 RETA-02 or FENA-01/-11 Ethernet Adapter modules along with CI871 (PROFINET IO) CI858 DriveBus Interface. ModuleBus In single CPU configuration, ABB Drives can be connected to the processor unit via the optical ModuleBus.
Section 3 Configuration Drive System PROFINET IO and CI871 The RETA-02 Ethernet Adapter module and FENA-01/-11 Ethernet Adapter module are optional devices for ABB drives, which enables the connection of the drive to a PROFINET IO (PNIO) network. The drive is considered as a PNIO device on the PROFINET IO network, and it is compatible with all PNIO controller stations that support PROFINET IO and sub-slots.
Drive System Section 3 Configuration • ACS 1000 product family See also CI858 and TP858 – DriveBus Interface on page 313 170 3BSE036351-510 A
Section 3 Configuration Drive System CI854 CI858 Max 12 Modules per Cluster Optical Optical See DriveBus topology ABB Std Drive TB820 ABB Std Drive Optical Branching Unit ABB Std Drive ABB Std Drive Max 12 Modules per Cluster 1 Segment of PROFIBUS DP CI801 Max 12 Modules per Cluster Optical Optical ABB Std Drive TB820 ABB Std Drive Branching Unit ABB Std Drive ABB Std Drive Optical Figure 59.
Drive System Section 3 Configuration DRIVEBUS CI858 MSTR Branching Units CH0 NDBU CH1 CH0 Drive CH2 CH0 Drive MSTR CH1 CH3 CH0 CH0 Drive ... NDBU CH2 CH0 ... Drive Drive CH3 CH0 Drive ... Up to 24 Drives Figure 60.
Section 3 Configuration Power Supply System Power Supply System The configuration of a power supply system for an AC 800M controller is very straightforward. Configurations Figure 61 on page 177 and Figure 62 on page 178 gives a series of simple circuit diagrams showing various possibilities for connecting the incoming mains power – via the mains breaker, the power supply units and the SS83X voting devices – to the 24 V DC distribution terminals.
Powering Units in the Cabinet Section 3 Configuration Powering Units in the Cabinet This power supply is only connected to units within the cabinet such as: • PM8XX, which also powers all communication interfaces (via the CEX-Bus) and all S800 I/O units connected to its electrical ModuleBus. • BC810 powers all communication interfaces connected to its own segment. • TB820V2/TB840 (optical modem for S800 I/O) which also powers all S800 I/O units connected to its electrical ModuleBus.
Section 3 Configuration Powering Field Equipment outside the Cabinet To avoid the AC 800M Controller being influenced by field equipment, it is strongly recommended that separate power supplies be installed (see Figure 50 on page 147 and Figure 51 on page 148).
Powering from an External Source Section 3 Configuration Powering from an External 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.
Section 3 Configuration Powering from an External Source Single Power Supply Supply to Units SD 8xx Mains Mains Breaker Power Supply 24 V DC Distribution Terminals SD 8xx Supply to Redundant Power Supplies Mains Units Mains Breaker SS 8xx SD 8xx Voting Device 24 V DC Distribution Terminals Power Supplies Redundant Mains Power Supplies SD 8xx Mains 1 Supply to Units Mains Breaker SS 8xx SD 8xx Mains 2 Voting Device 24 V DC Distribution Terminals Mains Breaker Power Supplies Figure 61
Powering from an External Source Section 3 Configuration Powering Field Equipment Mains Supply to Units SD 8xx 24 V DC Distribution Terminals Mains Breaker Independent Power Supplies Supply to Field Equipment SD 8xx 24 V DC Distribution Terminals Supply to Units SD 8xx Mains Mains Breaker Independent Power Supplies 24 V DC Distribution Terminals Supply to Field Equipment SD 8xx Mains Breaker Independent Mains Breaker Units 24 V DC Distribution Terminals Figure 62.
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 Appendix A, Hardware Units. AC 800M Controller (PM8xx) Equipped with Control Software, the basic PM8xx/TP830 or PM891 hardware units mounted on the AC 800M hardware platform constitute an AC 800M Controller.
AC 800M Controller (PM8xx) Section 4 Operation Table 20. PM8xx – LED Indicators (Continued) Marking P(ower) Color Green Function Normal state – ON When lit, indicates that the CPU DC/DC converter is generating valid +5 V and +3.3 V DC supply voltages. No software control. 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 AC 800M Controller (PM8xx) Switches and Push buttons Table 21. PM8xx – Switches and Push buttons Marking Type INIT Manual Push button Function 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 switchover to the backup CPU will be initiated. Connectors Table 22.
Start-up Section 4 Operation Table 22. PM8xx/TP830 and PM891 – Connectors (Continued) Marking CEX-BUS Function Provides extension of on-board communication ports. Valid for PM861/PM864/PM865 RCU Link Connector Provides information and data transfer between Primary and Backup CPU in redundant configuration. Valid for PM891 RCU Data Link Connector Provides transfer of data required to keep the backup CPU synchronized with the primary CPU.
Section 4 Operation Start Modes – After having rebuilt the hardware on the CEX bus, that is, after removing or adding a number of base plates (equipped with CEX modules or not) the upper CPU (the CPU connected to the part of the RCU Link cable that is marked “UPPER”) must be started as the primary CPU the first time. Start Modes Warm Start Application-controlling tasks are initiated. Variable values are initialized unless marked Retain or Cold retain.
Automatic Switch-Over to Backup CPU Section 4 Operation Controller Reset The system stops. The application program and variables are erased. To initiate Controller Reset, press and hold the Controller INIT push button (more than three seconds) until the Run LED begins to flash. A Controller Reset must be performed if the system is in an undefined position and consequently unavailable to the user.
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 23 on page 185. Verification of Single CPU Check the status of each LED indicator and compare it against the criteria listed in the table. If the status is other than that listed, see Fault-Finding Procedures on page 204. Table 23.
Verification of Single CPU Section 4 Operation Table 23.
Section 4 Operation Verification of Single CPU Table 23.
Verification of Redundant CPU Section 4 Operation Table 23.
Section 4 Operation Verification of Redundant CPU To check that the redundancy, is working correctly, perform a manual switch-over from the Primary CPU to the Backup CPU. This should be performed with caution, and consideration to possible impact on the process. A manual switch-over is initiated by: • Resetting the Primary CPU • Powering off the Primary CPU The RCU Link Cable must NEVER be removed from the primary Processor Unit during redundant operation.
Verification of Redundant CPU Section 4 Operation 190 3BSE036351-510 A
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. Before attempting maintenance or troubleshooting, read the Safety Summary on page 13. Failure to do so could lead to personal injury or damage to equipment. Preventive Maintenance Frequency Schedule Table 25.
Replacing the Battery Section 5 Maintenance Table 25.
Section 5 Maintenance Internal Battery The battery must be exchanged whenever: • The 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. Captive screw Cover Internal battery holder Figure 63.
Internal Battery Section 5 Maintenance To exchange the internal battery: 1. Using a blade screwdriver, release the captive screw from the PM8xx and remove the right-hand cover. 2. Identify and remove the internal battery. Insert a serviceable battery and check that battery polarity and orientation are correct, according to the marking on the housing. 3. When power is re-established, ensure that the B(attery) LED is illuminated 4. Replace the PM8xx right-hand cover and tighten the screw. 5.
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). For access to the battery and housing, remove the cover (see Figure 65 on page 196). When replacing the battery, be sure to check that polarity and orientation are correct.
SB821 External Battery Unit Section 5 Maintenance 7. Replace the cover, mount the unit onto the DIN rail, and reconnect the cable. 8. When power is re-established, check that the B(attery) LED lights up. 9. Dispose of the run-down Lithium battery in an approved manner. SB821 3.6 V Lithium Battery Unit Note the warning text on the battery. ! X1 B– B+ SH Figure 65.
Section 5 Maintenance SB822 Rechargeable External Battery Unit SB822 Rechargeable External Battery Unit The Li-Ion battery package is mounted inside the SB822 unit. To prevent problems you need to charge it on a regular basis. Specification for the battery package: • Type: Rechargeable Lithium-Ion, 3.75V 2.3 Ah • Size: Prismatic 14.5x43x50 mm • Lithium equivalent content: 0.8 g Replacing the Battery in an SB822 Rechargable External Battery Unit To replace the Li-Ion battery: 1.
Online Replacement of Unit Section 5 Maintenance 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 (CI8xx) Can be removed or replaced online. Restrictions apply, refer to the installation section for each interface and to Appendix A, Hardware Units.
Section 5 Maintenance Exchange of CPU in Redundant Configuration without BC810 Exchange of CPU in Redundant Configuration without BC810 For PM86x, only the CPU unit can be exchanged during operation, and not the associated baseplate. Removing the baseplate jeopardizes the functioning of CEX-bus interfaces, if any.
Exchange of CPU in Redundant Configuration with BC810 8. Section 5 Maintenance Observe the startup procedure and make sure that Dual mode is reached, that is, the Dual LED is lit on both processor units. During synchronization, the new processor unit inherits the IP address from the running processor unit. Reuse of CPU modules replaced from redundant configurations within the same control network, might cause control network problems due to the MAC and IP address handling.
Section 5 Maintenance Exchange of CPU in Redundant Configuration with BC810 5. Gently ease the unit/baseplate sideways in order to release the contacts of the unit. 6. 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 them apart with a blade screwdriver (see Figure 23 on page 74). 7.
Exchanging a Defect RCU Link Cables Online Section 5 Maintenance Exchanging a Defect RCU Link Cables Online In Configuration with BC810 Do not replace the RCU link cable online in a previous version than 5.0. The support for online replacement also depends on hardware Product Revision levels. Please consult Release Notes (3BSE021377*) for detailed information.
Section 5 Maintenance Corrective Maintenance Procedures Corrective Maintenance Procedures Changing Fuses – ModuleBus and CEX-Bus This topic does not apply to PM891, which does not contain internal fuses. To change the TP830 internal ModuleBus and CEX-Bus fuses: 1. Using a blade screwdriver, release the two spring-loaded captive screws on the PM8xx cover. 2. Carefully remove the processor unit. 3. Identify both the ModuleBus and CEX-Bus fuse-holders to the right on the TP830 Baseplate.
Fault-Finding Procedures Section 5 Maintenance Fault-Finding Procedures The following sections describe elementary fault-finding procedures. For complete instructions contact ABB Support. PM8xx Processor Unit in Single CPU Configuration Table 26. PM8xx – Fault-Finding Procedure Fault 204 Possible Cause and Corrective Action F(ault) LED is ON Controller Re-start, (INIT), in progress. • Wait for Controller restart to finalize. Missing firmware. • Upgrade firmware. Firmware upgrade in progress.
Section 5 Maintenance PM861/PM864/PM865/PM866/PM891 Unit in Redundant Configuration Table 26. PM8xx – Fault-Finding Procedure (Continued) Fault B(attery) LED is flashing Possible Cause and Corrective Action Battery voltage (Internal or External) is below 3.1 V or non-existent. • Install new battery. External battery cable disconnected. • Connect external battery cable. See Fault-Finding Table 30 on page 208. PM861/PM864/PM865/PM866/PM891 Unit in Redundant Configuration Table 27.
CEX-Bus Interconnection Unit - BC810 Section 5 Maintenance CEX-Bus Interconnection Unit - BC810 Table 28. BC810 – Fault-Finding Procedure Fault Fault LED is ON Run LED is OFF Possible Cause and Corrective Action No 3.3 V caused by internal short circuit or overvoltage from power supply • Check external 24 V voltage with voltmeter. • Send unit for repair. Hardware error. • Send unit for repair.
Section 5 Maintenance SM810/SM811 SM810/SM811 Table 29. SM810/SM811 – Fault-Finding Fault Possible Cause and Corrective Action Neither R(un) nor F(ault) LEDs The SM810/SM811 board is in the process of are ON being restarted or configured. Allow time for this to finalize. If the condition persists, and no other unit LED on the CEX-Bus is lit: • Check the Log File • Check the CEX-Bus fuse inside the CPU unit. • Initiate a reset signal (INIT) from the CPU unit. • Replace the SM810/SM811 unit.
Internal Battery / SB821 External Battery/SB822 Rechargeable External Battery Section 5 Internal Battery / SB821 External Battery/SB822 Rechargeable External Battery The PM891 unit does not contain internal battery. Table 30. Internal / SB821/SB822 External Battery/– Fault-Finding Fault B(attery) LED indicator on PM8xx processor unit is flashing Possible Cause and Corrective Action Internal battery • Renew the PM8xx internal battery SB821: • Check external battery connections.
Section 5 Maintenance PROFIBUS DP – CI851 PROFIBUS DP – CI851 Table 31. 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 reare ON started or configured. Allow time for this to finalize. If the condition persists, and all other units on the CEX-Bus have non-illuminated LEDs: F(ault) LED is ON • Check that a valid HW configuration including the CI851 is downloaded to the controller.
FOUNDATION Fieldbus H1 – CI852 Section 5 Maintenance FOUNDATION Fieldbus H1 – CI852 Table 32. FOUNDATION Fieldbus H1 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. Allow time for this to finalize. If the condition persists, and all units on the CEX-Bus have non-illuminated LEDs: • Check that a valid HW configuration including the CI852 is downloaded to the controller.
Section 5 Maintenance FOUNDATION Fieldbus H1 – CI852 Table 32. FOUNDATION Fieldbus H1 CI852 – Fault-Finding (Continued) Fault One or more field devices appear to be slow to respond or completely dead Possible Cause and Corrective Action 1.A device may be: • Incorrectly addressed. • Connected with incorrect polarity. • Faulty and causing breakdown or heavy loading of the network. 2.
FOUNDATION Fieldbus H1 – CI852 Section 5 Maintenance Table 32. FOUNDATION Fieldbus H1 CI852 – Fault-Finding (Continued) Fault The network problem is proving very difficult to solve (continued). Possible Cause and Corrective Action Use an oscilloscope to check the communication signals for abnormalities. • The oscilloscope must be of differential or battery operated type. • Probes must have a minimum of 1 MOhm input resistance, and less than 1000 pF input capacitance.
Section 5 Maintenance On-board RS-232C Channels – CI853 On-board RS-232C Channels – CI853 Table 33. On-board RS-232C Channels CI853 – Fault-Finding Fault Possible Cause and Corrective Action The PM8xx is transmitting and the • Tx1/Tx2 LEDs are flashing, but the connected device is not • receiving data. Check that the communication interface cable is connected. Check the hand-shake signals. OR The connected device is transmitting, but the Rx1/Rx2 LEDs are not flashing.
PROFIBUS DP – CI854/CI854A Section 5 Maintenance PROFIBUS DP – CI854/CI854A Table 34. PROFIBUS DP CI854/CI854A – Fault-Finding Indication Neither R(un) nor F(ault) LED’s are ON Possible Cause and Corrective Action The CI854/CI854A board is in the process of being restarted or configured. Allow time for this to finalize.
Section 5 Maintenance PROFIBUS DP – CI854/CI854A Table 34. PROFIBUS DP CI854/CI854A – Fault-Finding (Continued) Indication RxB LED is OFF DUAL LED is OFF on both modules (CI854A only) Possible Cause and Corrective Action No communication on Line B. • Check that slaves are configured and connected to this line. • If redundant slaves are used check that the redundancy is working properly. The backup slave has to answer to the life list requests sent by the master.
MasterBus 300 Interface – CI855 Section 5 Maintenance MasterBus 300 Interface – CI855 Table 35. MasterBus 300 CI855 – Fault Finding Fault Possible Cause and Corrective Action Neither R(un) nor F(ault) LEDs The CI855 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: Check that a valid HW configuration including the CI855 is downloaded to the controller.
Section 5 Maintenance S100 I/O Interface – CI856 S100 I/O Interface – CI856 Table 36. S100 I/O CI856 – Fault Finding Fault Neither R(un) nor F(ault) LED’s are ON Possible Cause and Corrective Action The CI856 unit is in the process of being configured. Allow time for this to finalize. If the condition persists, and no other unit LED on the CEX-Bus is lit: F(ault) LED is ON • Check that a valid HW configuration including the CI856 is downloaded to the controller.
INSUM Interface – CI857 Section 5 Maintenance INSUM Interface – CI857 Table 37. INSUM CI857 – Fault-Finding Fault Possible Cause and Corrective Action 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: • Check that a valid HW configuration including the CI857 is downloaded to the controller. • Check the CEX-Bus fuse inside the processor unit.
Section 5 Maintenance DriveBus Interface - CI858 DriveBus Interface - CI858 Table 38. DriveBus CI858 – Fault-Finding Fault Possible Cause and Corrective Action Neither R(un) nor F(ault) LEDs The CI858 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: F(ault) LED is ON • Check that a valid HW configuration including the CI858 is downloaded to the controller.
DriveBus Interface - CI858 Section 5 Maintenance Table 38. DriveBus CI858 – Fault-Finding (Continued) Fault Dbus;Tx1 LED is OFF I/O;Rx1 LED is ON (not flashing) I/O;Rx1 LED is OFF I/O;Tx1 LED is ON (not flashing) I/O;Tx1 LED is OFF Possible Cause and Corrective Action The unit is not properly configured or unit error. • Check the CB for a failure message. • If there is no failure message replace the CI858 unit. The unit is not receiving data. • Check all cables and connections.
Section 5 Maintenance FOUNDATION Fieldbus High Speed Ethernet - CI860 FOUNDATION Fieldbus High Speed Ethernet - CI860 Table 39. FOUNDATION Fieldbus High Speed Ethernet CI860 – Fault-Finding Fault Possible Cause and Corrective Action Neither R(un) nor F(ault) LEDs The CI860 board is in the process of being are ON restarted or configured. Allow time for this to finalize.
FOUNDATION Fieldbus High Speed Ethernet - CI860 Section 5 Maintenance Table 39. FOUNDATION Fieldbus High Speed Ethernet CI860 – Fault-Finding (Continued) Fault 100Mbit/s is OFF Possible Cause and Corrective Action If RxTx LED is flashing: A valid connection with10 MBit/s is established. RxTx LED is ON A link to the corresponding ethernet device is established. No Ethernet packages are sent/received. RxTx LED is flashing A link to the corresponding ethernet device is established.
Section 5 Maintenance TRIO Interface - CI862 TRIO Interface - CI862 Table 40. TRIO Interface CI862 - Fault Finding Indication Neither R(un) nor F(ault) LED’s are ON Possible Cause and Corrective Action The CI862 is in the process of being restarted or configured. Allow time for this to finalize. If the condition persists, and all other units on the CEXbus have non-illuminated LEDs: F(ault) LED is ON • Check that a valid HW configuration including the CI862 is downloaded to the controller.
Satt I/O Interface – CI865 Section 5 Maintenance Satt I/O Interface – CI865 Table 41. Satt I/O CI865 – Fault Finding Possible Cause and Corrective Action Fault Neither R(un) nor F(ault) LED’s are ON The CI865 unit is in the process of being configured. Allow time for this to finalize. If the condition persists, and no other unit LED on the CEX-Bus is lit: • Check that a valid HW configuration including the CI865 is downloaded to the controller.
Section 5 Maintenance Modbus TCP Interface – CI867 Modbus TCP Interface – CI867 Table 42. Modbus TCP Interface CI867 - Fault Finding Fault Neither R(un) nor F(ault) LED's are ON F(ault) LED is ON Possible Cause and Corrective Action The CI867 unit is in the process of being configured. Allow time for this to finalize. If the condition persist, and no other unit LED on the CEX-Bus is lit: • Check that a valid HW configuration including the CI867 is downloaded to the controller.
Modbus TCP Interface – CI867 Section 5 Maintenance Table 42. Modbus TCP Interface CI867 - Fault Finding Fault PRIM is ON Possible Cause and Corrective Action In non-redundant mode: • This module is started by the application. In redundant mode: • DUAL is OFF This module is started by the application and this module act as the primary interface. In non-redundant mode: • This is always OFF in non-redundant mode.
Section 5 Maintenance IEC 61850 Interface – CI868 IEC 61850 Interface – CI868 Table 43. IEC 61850 Interface CI868 - Fault Finding Fault Neither R(un) nor F(ault) LED's are ON F(ault) LED is ON Possible Cause and Corrective Action The CI868 unit is in the process of being configured. Allow time for this to finalize. If the condition persist, and no other unit LED on the CEX-Bus is ON: • Check that a valid HW configuration including the CI868 is downloaded to the controller.
AF 100 Interface - CI869 Section 5 Maintenance AF 100 Interface - CI869 The Mast LED in the CI869 module is not used. Table 44 lists the other indications. Table 44. AF 100 Interface, CI869 - Indications and Fault Finding Indication Both R(un) and F(ault) LED's are OFF Possible Cause and Corrective Action (for faults) Possible Cause 1: The CI869 module is connected to the controller, but the configuration is not downloaded to the controller for that position.
Section 5 Maintenance AF 100 Interface - CI869 Table 44. AF 100 Interface, CI869 - Indications and Fault Finding Indication F(ault) LED is ON Possible Cause and Corrective Action (for faults) Possible Cause 1: The CI869 module is in the process of upgrading the firmware (if the upgrade is in progress). Corrective Action 1: Wait for the firmware to be upgraded. Possible Cause 2: Fault in the CI869 module. Corrective Action 2: Hot remove and hot insert the CI869 module.
AF 100 Interface - CI869 Section 5 Maintenance Table 44. AF 100 Interface, CI869 - Indications and Fault Finding Indication Possible Cause and Corrective Action (for faults) Dual LED is ON The CI869 module is run in redundant configuration. Prim(ary) LED is ON The CI869 module is run in redundant configuration, and it functions as the primary module.
Section 5 Maintenance PROFINET IO Interface - CI871 PROFINET IO Interface - CI871 Table 45. PROFINET IO Interface, CI871 - Indications and Fault Finding Fault Neither R(un) nor F(ault) LEDs are ON F(ault) LED is ON Possible Cause and Corrective Action The CI871 unit is in the process of configuration. If the condition persist, and no other unit LED on the CEX-Bus is ON: • Check that a valid hardware configuration including the CI871 is downloaded to the controller.
MOD5 Interface - CI872 Section 5 Maintenance MOD5 Interface - CI872 Table 46 provides the indications and possible causes, and the corrective actions for the faults, appearing in the MOD5 communication interface, type - CI872. Table 46.
Section 5 Maintenance MOD5 Interface - CI872 Table 46. MOD5 Communication Interface, Type CI872 - Indications and Fault Finding (Continued) Indication F(ault) LED is ON Possible Causes, and Corrective Actions (for faults) Possible Cause 1: The CI872 module is in the process of upgrading the firmware (if the upgrade is in progress). Corrective Action 1: Wait for the firmware to be upgraded. Possible Cause 2: Fault in the CI872 module. Corrective Action 2: Hot remove and hot insert the CI872 module.
MOD5 Interface - CI872 Section 5 Maintenance Table 46. MOD5 Communication Interface, Type CI872 - Indications and Fault Finding (Continued) Indication DUAL LED is ON Possible Causes, and Corrective Actions (for faults) The yellow DUAL LED is illuminated when the CI872 module is run in redundant configuration. The module that has the DUAL LED illuminated is the primary [active] module in a redundant configuration.
Section 5 Maintenance MOD5 Interface - CI872 Table 46. MOD5 Communication Interface, Type CI872 - Indications and Fault Finding (Continued) Indication Rx/Tx LED's are flashing, but there is no communication Possible Causes, and Corrective Actions (for faults) Possible Cause 1: MTMConnect and/or MTMReadCyc and/or MTMDefCyc are disabled. Corrective Action 1: Enable MTMConnect, MTMReadCyc, and MTMDefCyc function blocks.
EtherNet/IP Interface - CI873 Section 5 Maintenance EtherNet/IP Interface - CI873 Table 47. EtherNet/IP Communication Interface CI873 - Indications and Fault Finding Possible Cause and Corrective Action Fault Neither R(un) nor F(ault) LEDs are ON The CI873 unit is in the process of being configured. Wait until the configuration is complete. If the condition persist, and no other unit LED on the CEX-Bus is ON: F(ault) LED is ON • Check the CEX-Bus fuse inside the PM8xx processor unit.
Section 5 Maintenance EtherNet/IP Interface - CI873 Table 47. EtherNet/IP Communication Interface CI873 - Indications and Fault Finding Possible Cause and Corrective Action Fault Dual LED is ON The CI873 module is run in redundant configuration. Prim(ary) LED is ON The CI873 module is run in redundant configuration, and it functions as the primary module.
EtherNet/IP Interface - CI873 238 Section 5 Maintenance 3BSE036351-510 A
Appendix A Hardware Units PM851/PM856/PM860 and TP830 – Processor Unit This section does not apply to the Feature Pack release of System 800xA 5.1. See PM851A/PM856A/PM860A and TP830 – Processor Unit on page 245. Key Features • MPC860 Microprocessor running at 48 MHz. • 8 MB RAM with internal or external battery back-up facility. • 12 x S800 I/O units can be connected to the electrical ModuleBus. • Four on-board communication ports: • – CN1 + CN2, Ethernet ports (IEEE 802.
Technical Data Appendix A Hardware Units • Compact Flash interface which supports loading of application and cold retain data storage. Technical Data Technical data for PM851/PM856/PM860 and TP830 is described in Table 48 on page 240. Table 48. PM851/PM856/PM860 and TP830 – Technical data Item Memory Power Dissipation Value • 2 MB flash PROM (firmware storage). • 8 MB of SDRAM. 5 W typical 10 W typical (incl. full supply to ModuleBus and CEXBus, see Appendix B, Power Consumption).
Appendix A Hardware Units Technical Data Table 48. PM851/PM856/PM860 and TP830 – Technical data (Continued) Item Weight Dimensions Value • 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). W 119 x H 186 x D 135 mm (4.7 x 7.3 x 5.3 in.) Width is measured along the DIN-rail, depth from the wall, and height vertically, including lock mechanism.
Technical Data Appendix A Hardware Units Table 49. PM851/PM856/PM860 and TP830 Interfaces – Technical data Item Value COM4 Serial Communication Communication speed 9600 baud Signal levels RS-232C Connector RJ45 Modem support No Electrical ModuleBus I/O capacity 1 x S800 I/O base cluster with up to 12 x S800 I/O units. Supply current • Max 24 V – 1.0 A (short circuit proof, fuse 2 A fast) • Max 5 V – 1.
Appendix A Hardware Units Technical Data Battery The memory content is backed up with either an internal or external battery unit (SB821). For back-up time see Table 50 on page 243. The figures given in Table 50 on page 243 are valid if the batteries are installed after a normal CPU power-up, allowing for the memory back-up function to be activated. Table 50.
Performance Data Appendix A Hardware Units For more information regarding EMC and safety, see Appendix D, Directive Considerations. LED Indicators See Table 20 on page 179. Performance Data The PM851/PM856/PM860 differ in performance when executing an application program.
Appendix A Hardware Units PM851A/PM856A/PM860A and TP830 – Processor Unit PM851A/PM856A/PM860A and TP830 – Processor Unit Key Features • MPC860 Microprocessor running at 48 MHz. • For PM851A, 12 MB RAM with internal or external battery back-up facility. • For PM856A, 16 MB RAM with internal or external battery back-up facility. • For PM860A, 16 MB RAM with internal or external battery back-up facility. • 12 x S800 I/O units can be connected to the electrical ModuleBus.
Technical Data Appendix A Hardware Units Technical Data Technical data for PM851A/PM856A/PM860A and TP830 is described in Table 52. Table 52. PM851A/PM856A/PM860A and TP830 – Technical data Item Memory Power Dissipation Value • 2 MB flash PROM (firmware storage). • 12 MB of SDRAM for PM851A. • 16 MB of SDRAM for PM856A and PM860A. 5 W typical 10 W typical (incl. full supply to ModuleBus and CEXBus, see Appendix B, Power Consumption). Current Consumption 180 mA typical (300 mA max.) (excl.
Appendix A Hardware Units Technical Data Table 52. PM851A/PM856A/PM860A and TP830 – Technical data (Continued) Item Weight Dimensions Value • 1100 g (2.4 lb) (package PM851AK01 with PM851A, TP830 and bus terminations). • 1100 g (2.4 lb) (package PM856AK01 with PM856A, TP830 and bus terminations). • 1100 g (2.4 lb) (package PM860AK01 with PM860A, TP830 and bus terminations). W 119 x H 186 x D 135 mm (4.7 x 7.3 x 5.3 in.
Technical Data Appendix A Hardware Units Table 53. PM851A/PM856A/PM860A and TP830 Interfaces – Technical data Item Value COM4 Serial Communication Communication speed 9600 baud Signal levels RS-232C Connector RJ45 Modem support No Electrical ModuleBus I/O capacity 1 x S800 I/O base cluster with up to 12 x S800 I/O units. Supply current • Max 24 V – 1.0 A (short circuit proof, fuse 2 A fast) • Max 5 V – 1.
Appendix A Hardware Units Technical Data Table 54. Back-up times for PM851A/PM856A/PM860A Source Back-up time Internal battery Minimum 2 weeks External battery SB821 Minimum 8 months External battery SB822 Minimum 4 weeks when fully charged Note: Recharge time for an empty battery is approximately 7 hours. Table 55 shows Internal battery data.
Performance Data Appendix A Hardware Units Performance Data The PM851A/PM856A/PM860A differ in performance when executing an application program. Using the same application program in PM851A/PM856A and PM860A, the difference in execution time can be expressed as: Execution time in PM851A/PM856A = 2 *Execution time in PM860A Example: If a certain application program has an execution time of 100 ms in PM860A, the same application program will have an execution time of 200 ms in PM851A/PM856A.
Appendix A Hardware Units PM861/PM861A and TP830 – Processor Unit PM861/PM861A 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. • Four on-board communication ports: – CN1 + CN2, Ethernet ports (IEEE 802.
Technical Data Appendix A Hardware Units Technical Data For technical data on PM861 and TP830, see Table 56 on page 252. Table 56. PM861 and TP830 – Technical data Item Memory Power Dissipation Value • 2 MB flash PROM (firmware storage). • 16 MB of SDRAM. 6 W typical 11 W typical (incl. full supply to ModuleBus and CEXBus, see Appendix B, Power Consumption). Current Consumption 250 mA typical (430 mA max.) (excl. supply of ModuleBus and CEX-Bus, see Appendix B, Power Consumption).
Appendix A Hardware Units Technical Data Table 56. PM861 and TP830 – Technical data (Continued) Item Value Weight Dimensions • 1200 g (2.6 lb) (package PM861K01). • 2800 g (6.1 lb) (package PM861K02). W 119 x H 186 x D 135 mm (4.7 x 7.3 x 5.3 in) Width is measured along the DIN-rail, depth from the wall, and height vertically, including lock mechanism. Communication Ports and Interfaces Technical data for communication ports and interfaces is described in Table 49 on page 241.
Performance Data Appendix A Hardware Units Table 51 on page 243 shows internal battery data. For external battery data, see SB821 External Battery – AC 800M Memory Back-up on page 392 and SB822 Rechargeable External Battery – AC 800M Memory Back-up on page 394 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.
Appendix A Hardware Units PM864/PM864A and TP830 – Processor Unit PM864/PM864A 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. • Four on-board communication ports: – CN1 + CN2, Ethernet ports (IEEE 802.
Technical Data Appendix A Hardware Units Technical Data For technical data on PM864 and TP830, see Table 58 on page 256. Table 58. PM864 and TP830 – Technical data Item Memory Power Dissipation Value • 2 MB flash PROM (firmware storage). • 32 MB of SDRAM. 6.9 W typical 11.9 W typical (incl. full supply to ModuleBus and CEXBus, see Appendix B, Power Consumption). Current Consumption 287 mA typical (487 mA max.) (excl. supply of ModuleBus and CEX-Bus, see Appendix B, Power Consumption).
Appendix A Hardware Units Technical Data Table 58. PM864 and TP830 – Technical data (Continued) Item Value Weight Dimensions • 1200 g (2.6 lb) (package PM864K01). • 2800 g (6.1 lb) (package PM864K02). W 119 x H 186 x D 135 mm (4.7 x 7.3 x 5.3 in) Width is measured along the DIN-rail, depth from the wall, and height vertically, including lock mechanism. Communication Ports and Interfaces Technical data for communication ports and interfaces is described in Table 49 on page 241.
Performance Data Appendix A Hardware Units Table 51 on page 243 shows internal battery data. For external battery data, see SB821 External Battery – AC 800M Memory Back-up on page 392 and SB822 Rechargeable External Battery – AC 800M Memory Back-up on page 394. 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.
Appendix A Hardware Units PM865 and TP830 – Processor Unit PM865 and TP830 – Processor Unit Key Features • MPC862P 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. • Four on-board communication ports: – CN1 + CN2, Ethernet ports (IEEE 802.
Technical Data Appendix A Hardware Units Technical Data For technical data on PM865 and TP830, see Table 60 on page 260. Table 60. PM865 and TP830 – Technical data Item Memory Power Dissipation Value • 4 MB flash PROM (firmware storage). • 32 MB of SDRAM. 6.9 W typical 11.9 W typical (incl. full supply to ModuleBus and CEX-Bus, see Appendix B, Power Consumption). Current Consumption 287 mA typical (487 mA max.) (excl. supply of ModuleBus and CEX-Bus, see Appendix B, Power Consumption).
Appendix A Hardware Units Technical Data Table 60. PM865 and TP830 – Technical data (Continued) Item Value Weight Dimensions • 1200 g (2.6 lb) (package PM865K01). • 2800 g (6.1 lb) (package PM865K02). W 119 x H 186 x D 135 mm (4.7 x 7.3 x 5.3 in) Width is measured along the DIN-rail, depth from the wall, and height vertically, including lock mechanism. Communication Ports and Interfaces Technical data for communication ports and interfaces is described in Table 49 on page 241.
Performance Data Appendix A Hardware Units Electro-magnetic Compatibility and Electrical Safety PM865/TP830 meets the requirements specified in EMC Directive 89/336/EEC. For more information regarding electrical safety, see Appendix D, Directive Considerations. LED Indicators See Table 20 on page 179. Performance Data The PM865 processor unit, in single configuration, has performance data which theoretically peaks at twice the performance compared to the PM860.
Appendix A Hardware Units PM866 and TP830 – Processor Unit PM866 and TP830 – Processor Unit Key Features • MPC866 Microprocessor running at 133 MHz. • 64 MB RAM with internal or external battery backup facility. • 12 x S800 I/O units can be connected to the electrical ModuleBus. • Four on-board communication ports: – CN1 + CN2, Ethernet ports (IEEE 802.
Technical Data Appendix A Hardware Units Technical Data For technical data on PM866 and TP830, see Table 62 on page 264. Table 62. PM866 and TP830 – Technical data Item Memory Power Dissipation Value • 4 MB flash PROM (firmware storage). • 64 MB of SDRAM. 5.1 W typical 8.6 W typical (incl. full supply to ModuleBus and CEXBus. For details, refer to 3BSE036351R, AC 800M Controller Hardware, Hardware and Operation). Current Consumption 210 mA typical (360 mA max.) (excl.
Appendix A Hardware Units Technical Data Table 62. PM866 and TP830 – Technical data (Continued) Item Value Weight Dimensions • 1200 g (2.6 lb) (package PM866K01). • 2800 g (6.1 lb) (package PM866K02). W 119 x H 186 x D 135 mm (4.7 x 7.3 x 5.3 in) Width is measured along the DIN-rail, depth from the wall, and height vertically, including lock mechanism.
Performance Data Appendix A Hardware Units Electro-magnetic Compatibility and Electrical Safety PM866/TP830 meets the requirements specified in EMC Directive 89/336/EEC. For more information regarding electrical safety, see Appendix D, Directive Considerations. LED Indicators See Table 20 on page 179. Performance Data The PM866 processor unit has performance data which is approximately 1.4 times the performance of PM864.
Appendix A Hardware Units PM891– Processor Unit PM891– Processor Unit Key Features • MPC8270 Microprocessor running at 450 MHz. • 256 MB RAM with integrity check (shadow memory). • Optical ModuleBus interface that is designed for a maximum of seven clusters, of twelve non-redundant or six redundant modules (that is, 7x12 = 84 modules). Redundant and nonredundant modules can be combined. • Three on-board communication ports: – CN1 + CN2 (built in, 10/100Mbit/s) Ethernet ports (IEEE 802.
Technical Data Appendix A Hardware Units Technical Data For technical data on PM891, see Table 64. Table 64. PM891 – Technical data Item Memory Power Dissipation Value • 16 MB flash PROM (firmware storage). • 256 MB of DDR2 SDRAM with integrity check. 15.8 W typical 19.5 W typical (incl. full supply to ModuleBus and CEXBus. Current Consumption 660 mA typical (750 mA max.) (excl. supply of ModuleBus and CEX-Bus). Power Input Connector Four pin, screw connector L+, L–, SA and SB.
Appendix A Hardware Units Performance Data Communication Ports and Interfaces For details on communication ports and interfaces, see Key Features on page 267 Battery The memory content is backed up with an external battery unit (SB822). For backup time, see Table 65. The figures in Table 65 are valid if the batteries have been installed after a normal CPU power-up, allowing for the memory backup function to be activated. Table 65.
BC810 and TP857 - CEX-Bus Interconnection Unit Appendix A Hardware Units BC810 and TP857 - CEX-Bus Interconnection Unit Key Features • Supports redundant communication interface units. • Supports on-line replacement of the CPU. • External power supply. • Supports hot swap. Description The BC810 unit consists of two basic parts: baseplate (TP857) and power supply/logic board. The baseplate is where the connectors to CEX-Bus and the external power reside.
Appendix A Hardware Units BC810 and TP857 - CEX-Bus Interconnection Unit Functional Block Diagram Communication Extension Bus Communication Extension Bus Bus interface Bus interface +24 V +3.3 V Interface BC810 Unit Baseplate Toward next BC810 +24 V Figure 66.
BC810 and TP857 - CEX-Bus Interconnection Unit Appendix A Hardware Units Indicators Table 66. BC810 – CEX-Bus Interconnection Unit LED Indicators Designation/Color Function F(ault) /Red Power supply error detected. Controlled by hardware. Set and cleared by the Hardware during power up. R(un) /Green Operating. Controlled by the Hardware. EPOK(external power OK) /Green Indicates that the external power is connected and powered up.
Appendix A Hardware Units SM810 and TP855 SM810 and TP855 Key Features • MPC862P Microprocessor running at 96 MHz. • 32 MB RAM • Provides supervision of the PM865 controller during SIL1-2 operations. • Over voltage protection. • Internal voltage monitoring. • Supports hot swap. • Supports redundancy. Description Physically SM810 Unit consists of two parts: Termination Plate (TP855) and SM810. The SM810 contains two pc-boards.
SM810 and TP855 Appendix A Hardware Units Functional Block Diagram Communication Extension Bus Communication Extension Bus CEX-Bus Interface DC/DC Converter FPGA System and user mem. Double inverted memory text CPU MPC862 Digital Digital Inputs Outputs Digital Inputs Digital Outputs Communication Extension Module Communication Extension Baseplate Figure 67.
Appendix A Hardware Units SM810 and TP855 Indicators Table 68. SM810 – 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 Operational. Controlled by the Control Software. Cleared by the Hardware during controller Reset. ACCESS EN(abled) /Yellow Access Enable switch active. DEGR(aded) MODE /Yellow Reserved for future use.
SM810 and TP855 Appendix A Hardware Units Table 69. SM810 Specifications (Continued) Item Value Weight 700 g (1.5 lb) (package SM810K01 with SM810 and TP855). Dimensions W 59 x H 185 x D 127.5 mm (W 2.9 x H 7.3 x D 5.0 in) Table 70. SM810 - Digital Input Specifications Item 276 Value Electric isolation Yes Overvoltage category II Rated insulation voltage 50 V Insulation test voltage 500 V a.c.
Appendix A Hardware Units SM810 and TP855 Table 71. SM810 - Digital Output Specifications Item Value Electric isolation Yes Overvoltage category II Rated insulation voltage 50 V Insulation test voltage 500 V a.c. 1 min Nominal voltage 24 V Process voltage range (UP) 12... 32 V On-state output voltage (UA) UP - 0.5 V < UA < UP Maximum continuous load current 0.5 A Off-state output leakage current < 10 mA Maximum short circuit current < 2.4 mA Output impedance < 0.
SM811 and TP868 Appendix A Hardware Units SM811 and TP868 Key Features • MPC862P Microprocessor running at 96 MHz. • 32 MB RAM • Provides supervision of the PM865 controller during SIL1-2 operations and together with the PM865 forms a 1oo2 diverse architecture for SIL3 applications. • Over voltage protection. • Internal voltage monitoring. • Supports hot swap. • Supports redundancy. • SM Link for synchronization of redundant pair.
Appendix A Hardware Units SM811 and TP868 Functional Block Diagram Figure 68.
SM811 and TP868 Appendix A Hardware Units Indicators Table 72. SM811 – 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 Operational. Controlled by the Control Software. Cleared by the Hardware during controller Reset. ACCESS EN(abled) /Yellow Access Enable switch active. DEGR(aded) MODE /Yellow Reserved for future use.
Appendix A Hardware Units SM811 and TP868 Table 73. SM811 Specifications (Continued) Item Value Weight 700 g (1.5 lb) (package SM811K01 with SM811 and TP868). Dimensions W 59 x H 185 x D 127.5 mm (W 2.9 x H 7.3 x D 5.0 in) Table 74. SM811 - Digital Input Specifications Item Value Electric isolation Yes Overvoltage category II Rated insulation voltage 50 V Insulation test voltage 500 V a.c.
SM811 and TP868 Appendix A Hardware Units Table 75. SM811 - Digital Output Specifications Item Value Electric isolation Yes Overvoltage category II Rated insulation voltage 50 V Insulation test voltage 500 V a.c. 1 min Nominal voltage 24 V Process voltage range (UP) 12... 32 V On-state output voltage (UA) UP - 0.5 V < UA < UP Maximum continuous load current 0.5 A Off-state output leakage current < 10 mA Maximum short circuit current < 2.4 mA Output impedance < 0.
Appendix A Hardware Units SM811 and TP868 This is performed by connecting a physical push-button to the digital input. The system waits for 30 minutes for the acknowledgement, if acknowledgement is not received the inserted SM811 will shut down. To recover, a new hot insert needs to be initiated i.e. the SM811 has to be removed and inserted again. Synchronization of the SM811 includes: 1.
CI851 and TP851 – PROFIBUS DP Interface Appendix A Hardware Units CI851 and TP851 – PROFIBUS DP Interface Key Features • Provides one PROFIBUS DP port, (a DB9 female connector located on the TP851 Baseplate). • Simple DIN-rail mounting • The CI851 handles cyclic read and write messages to the slaves on the PROFIBUS DP. The minimum cycle time can be 1 ms, however, but this will depend on the baud rate used and the number of attached slaves.
Appendix A Hardware Units CI851 and TP851 – PROFIBUS DP Interface ABB recommends the use of connectors with built-in termination since the fieldbus will always be terminated even if fully disconnected from the unit. CI851 has been replaced by the CI854 communication interface. CI851 is only described for legacy reasons.
CI851 and TP851 – PROFIBUS DP Interface Appendix A Hardware Units Indicators Table 76. 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. Controlled by the Control Software. Cleared by the Hardware during controller Reset. Rx/Tx /Yellow Transmission to or from the unit. RTS /Yellow Request to transmit from the unit.
Appendix A Hardware Units CI851 and TP851 – PROFIBUS DP Interface Table 77. 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). Dimensions W 59 x H 185 x D 127.5 mm (W 2.9 x H 7.3 x D 5.
CI852 and TP852 – FOUNDATION Fieldbus H1 Interface Appendix A Hardware Units CI852 and TP852 – FOUNDATION Fieldbus H1 Interface Key Features • One FOUNDATION Fieldbus port provides a communication speed of 31.
Appendix A Hardware Units CI852 and TP852 – FOUNDATION Fieldbus H1 Interface Functional Block Diagram Communication Extension Bus Communication 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 70.
CI852 and TP852 – FOUNDATION Fieldbus H1 Interface Appendix A Hardware Units Indicators The CI852 FOUNDATION Fieldbus H1 interface has the following LED indicators. Table 78. CI852 FOUNDATION Fieldbus H1 – LED Indications Indication/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. Controlled by the Control Software. Cleared by the Hardware during controller Reset.
Appendix A Hardware Units CI852 and TP852 – FOUNDATION Fieldbus H1 Interface Table 79. CI852 FOUNDATION Fieldbus H1 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 CEX-Bus 24 V 140 mA typical (200 mA max.). Power dissipation 3.4 W typical Protection Rating IP20 according to EN60529, IEC 529. Weight 700 g (1.
CI853 and TP853 – RS-232C Interface Appendix A Hardware Units CI853 and TP853 – RS-232C Interface Key Features • Two RS-232C ports implemented with RJ45 connectors, located on the TP853 Baseplate, (act as an extension of the onboard RS-232C port on PM8xx should more RS-232C ports be required). • Modem support • Simple DIN-rail mounting • Transmission speed selectable between 75 baud and 19200 baud.
Appendix A Hardware Units CI853 and TP853 – RS-232C Interface Functional Block Diagram Communication Extension Bus Communication Extension Bus +24 V DC/DC converter Bus interface +5 V Microprocessor with FPROM, SRAM, Dual Port RWM and two serial interfaces Communication Extension Unit Communication Extension Base plate Communication lines Figure 71.
CI853 and TP853 – RS-232C Interface Appendix A Hardware Units Indicators Table 80. CI853 RS-232C – 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. Controlled by the Control Software. Cleared by the Hardware during Reset of the controller. Tx1 /Yellow Flashes if transmission to the COM1 port.
Appendix A Hardware Units CI853 and TP853 – RS-232C Interface Table 81. CI853 – RS-232C Communication Interface Specifications (Continued) Item Description Galvanic isolation Unisolated Status indicators Running normally: Green. Exceptional fault: Red. Four traffic indictors - Rx and Tx - controlled by traffic pace: Flashing yellow. Connector Two RJ45 connectors on TP853. Current consumption (from CEX-Bus 24 V DC) 100 mA typical (150 mA max.) Power Dissipation 2.
CI854/CI854A and TP854 – PROFIBUS DP Interface Appendix A Hardware Units CI854/CI854A and TP854 – PROFIBUS DP Interface Key Features • PROFIBUS DP with redundant line interface (two DB9 female connector located on the TP854 Baseplate). • Simple DIN-rail mounting. • In addition to the cyclic data transfer the CI854/CI854A supports acyclic DP communication and slave redundancy.
Appendix A Hardware Units CI854/CI854A and TP854 – PROFIBUS DP Interface The CI854/CI854A expansion unit contains the CEX-Bus logic, the CPU-kernel with memory, the PROFIBUS interface with line redundancy unit and a DC/DC converter that supplies the appropriate voltages from the +24V supply, via the CEXBus. The PROFIBUS DP must always be terminated at the two outer nodes. This is usually done by using connectors with built-in termination.
CI854/CI854A and TP854 – PROFIBUS DP Interface Appendix A Hardware Units Functional Block Diagram Communication Extension Bus +24 V R DC/DC Converter CEX-Bus Interface F PRIM CPU-Kernel and Memory DUAL +5 V / +3.3 V PROFIBUS Master ASIC RxA Line Redundancy Unit RxB Communication Extension Unit PROFIBUS B PROFIBUS A Communication Extension Baseplate RS485 Figure 72. Block Diagram – CI854A.
Appendix A Hardware Units CI854/CI854A and TP854 – PROFIBUS DP Interface Indicators Table 82. CI854/CI854A – PROFIBUS DP LED Indicators Designation/Color Function F(ault) /Red Unit error detected. Set by the Hardware during controller Reset. Controlled by the Control Software after Reset. R(un) /Green Operating. Cleared by the Hardware during controller Reset. Controlled by the Control Software after Reset. RxA /Yellow Receive Data on Line A. For each telegram received the LED flashes.
CI854/CI854A and TP854 – PROFIBUS DP Interface Appendix A Hardware Units Table 83. CI854/CI854A PROFIBUS DP Interface Specifications (Continued) Item Value Galvanic isolation Yes Status indicators Running normally: Green. Exceptional fault: Red. Two traffic indictors - RxA and RxB controlled by traffic pace: Flashing yellow. Running as primary: Yellow. Running in a redundant configuration: Yellow. Connectors Two DB9, female on TP854. Current consumption 190 mA typical (max. 240 mA).
Appendix A Hardware Units CI855 and TP853 – Ethernet Interface for MasterBus 300 CI855 and TP853 – Ethernet Interface for MasterBus 300 Key Features • Provides two Ethernet ports, (two RJ45 connectors located on the TP853 Baseplate). • Simple DIN-rail mounting • Provides Redundant Ethernet networks for MasterBus 300. • Pre-set, two-letter Alpha code locking device installed in unit base prevents mounting of incompatible components. • Supports Hot swap.
CI855 and TP853 – Ethernet Interface for MasterBus 300 Appendix A Hardware Units Functional Block Diagram Communication Extension Bus Communication Extension Bus +24V DC/DC Converter Bus Interface +5V +5V 68360 QUICC Communication Processor Glue for Ethernet Communication Extension Module Communication Extension Baseplate Communication Ethernet Line Figure 73.
Appendix A Hardware Units CI855 and TP853 – Ethernet Interface for MasterBus 300 Indicators Table 84. CI855 – MasterBus 300 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. Controlled by the Control Software. Cleared by the Hardware during controller Reset. Tx1 /Yellow flashing A yellow LED indicating transmission from the communication unit COM1 port.
CI855 and TP853 – Ethernet Interface for MasterBus 300 Appendix A Hardware Units Table 85. CI855 MasterBus 300 Interface Specifications (Continued) Item Current consumption Value 150 mA typical (200 mA max.) (from CEX-Bus 24 V DC) Power dissipation 3.6 W typical Protection Rating IP20 according to EN60529, IEC 529 Weight 700 g (1.5 lb) (package CI855K01 with CI855 and TP853) Dimensions W 59 x H 185 x D 127.5 mm (W 2.9 x H 7.3 x D 5.
Appendix A Hardware Units CI856 and TP856 – S100 I/O Interface CI856 and TP856 – S100 I/O Interface Key Features • Provides one S100 I/O port, (a 36 pin centerline miniature ribbon connector located on the TP856 Baseplate). • Simple DIN-rail mounting • The CI856 handles I/O scanning and updating of S100 I/O units located in up to five I/O racks. The minimum cyclic scan/update interval is 0.2ms, though this will depend on I/O type and number of I/O points.
CI856 and TP856 – S100 I/O Interface Appendix A Hardware Units Functional Block Diagram Communication Extension Bus Communication Extension Bus +24 V DC/DC converter CEX-Bus interface +2.5 V +3.3 V SDRAM 8 MB ColdFire µP MCF5307 Flash 2 MB +5 V S100 I/O-bus interface Communication Extension Unit Communication Extension Baseplate S100 communication cable Figure 74.
Appendix A Hardware Units CI856 and TP856 – S100 I/O Interface Indicators Table 86. 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. R(un) /Green Operating. Controlled by the Control Software. Cleared by the Hardware during controller Reset. TO /Yellow Flashes at S100 I/O access time-outs. Technical Data Table 87.
CI856 and TP856 – S100 I/O Interface Appendix A Hardware Units Table 87. CI856 S100 I/O Interface Specifications (Continued) Item Value Weight 700 g (1.5 lb) (package CI856K01 with CI856 and TP856) Dimensions W 59 x H 185 x D 127.5 mm (W 2.9 x H 7.3 x D 5.
Appendix A Hardware Units CI857 and TP853 – INSUM Interface CI857 and TP853 – INSUM Interface Key Features • Provides one Ethernet port, (RJ45 connector located on the TP853 Baseplate). Only COM1 is used for INSUM. • Simple DIN-rail mounting • Provides communication with INSUM via Ethernet/LON Gateway • Pre-set, two-letter Alpha code locking device installed in unit base prevents mounting of incompatible components. • Supports Hot swap.
CI857 and TP853 – INSUM Interface Appendix A Hardware Units Functional Block Diagram Communication Extension Bus Communication Extension Bus +24V DC/DC Converter Bus Interface +5V +5V 68360 QUICC Communication Processor Glue for Ethernet Communication Extension Module Communication Extension Baseplate Communication Ethernet Line Figure 75.
Appendix A Hardware Units CI857 and TP853 – INSUM Interface Indicators Table 88. CI857 – INSUM Interface 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. Controlled by the Control Software. Cleared by the Hardware during controller Reset. Tx1 /Yellow flashing A yellow LED indicating transmission from the communication unit COM1 port.
CI857 and TP853 – INSUM Interface Appendix A Hardware Units Table 89. CI857 INSUM Interface Specifications (Continued) Item Current consumption Value 150 mA typical (200 mA max.). (from CEX-Bus 24 V DC) Power dissipation 3.6 W typical. Protection Rating IP20 according to EN60529, IEC 529. Weight 700 g (1.5 lb) (package CI857K01with CI857 and TP853). Dimensions W 59 x H 185 x D 127.5 mm (W 2.9 x H 7.3 x D 5.
Appendix A Hardware Units CI858 and TP858 – DriveBus Interface CI858 and TP858 – DriveBus Interface Key Features • Provides three optical connectors for DriveBus, I/O bus and PC tools. • Simple DIN-rail mounting. • Pre-set, two-letter Alpha code locking device installed in unit base prevents mounting of incompatible components. Description The CI858 unit consists of a communication expansion base plate, a communication expansion unit.
CI858 and TP858 – DriveBus Interface Appendix A Hardware Units Functional Block Diagram Figure 76.
Appendix A Hardware Units CI858 and TP858 – DriveBus Interface Indicators Table 90. CI858 – DriveBus Interface LED Indicators Designation/Color Function F(ault) /Red Unit error detected. R(un) /Green Operating. Dbus; Rx /Yellow RECIEVE LED indicating reception of data frames on the DriveBus. Dbus; Tx /Yellow TRANSMIT LED indicating transmission of data frames on the DriveBus. I/O; Rx /Yellow RECIEVE LED indicating reception of data frames on the I/O bus.
CI858 and TP858 – DriveBus Interface Appendix A Hardware Units Table 91. CI858 – DriveBus Specifications (Continued) Item Current consumption Value 200 mA max. (from CEX-Bus 24 V DC) 316 External supply voltage 17 V minimum 25 V typical 30 V max Protection Rating IP20 according to EN60529, IEC 529. Approval CE-marked and meets the requirements specified in EMC Directive EMCD 2004/108/EC according to the standards EN 50081-2 and EN 61000-6-2.
Appendix A Hardware Units CI860 and TP860 – FOUNDATION Fieldbus High Speed Ethernet CI860 and TP860 – FOUNDATION Fieldbus High Speed Ethernet Key Features • Provides one Ethernet port, (RJ45 connector located on the TP860 Baseplate). • Simple DIN-rail mounting. • Provides communication with FOUNDATION Fieldbus High Speed Ethernet devices via Ethernet. • Pre-set, two-letter Alpha code locking device installed in unit base prevents mounting of incompatible components. • Supports FF HSE redundancy.
CI860 and TP860 – FOUNDATION Fieldbus High Speed Ethernet Appendix A Hardware Units Functional Block Diagram Communication Extension Bus +24 V R DC/DC Converter CEX-Bus Interface F PRIM CPU-Kernel and Memory DUAL +2.5 V / +3.3 V RxTx Ethernet Transceiver 100 MBit/s Communication Extension Unit Communication Extension Baseplate COM Figure 77.
Appendix A Hardware Units CI860 and TP860 – FOUNDATION Fieldbus High Speed Ethernet Indicators Table 92. CI860 – FOUNDATION Fieldbus High Speed Ethernet Interface 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. Controlled by the Control Software. Cleared by the hardware during controller Reset.
CI860 and TP860 – FOUNDATION Fieldbus High Speed Ethernet Appendix A Hardware Units Technical Data Table 93. CI860 – FOUNDATION Fieldbus High Speed Ethernet Specifications Item Value Type Ethernet unit. Protocol FOUNDATION Fieldbus High Speed Ethernet, TCP/IP. Communication speed 10 Mbit/s / 100 Mbit/s defined in IEEE 802.3 100baseTX. Status indicators Running normally: Green. Exceptional fault: Red. One traffic indictor - RxTx - controlled by traffic pace.
Appendix A Hardware Units CI862 and TP862 - TRIO/Genius Interface CI862 and TP862 - TRIO/Genius Interface Key Features • CEX-Bus interface for communication to AC 800M • LED indicators for R(un), F(ault), Communication Error, Primary (Bus Master), and Dual (redundancy) • Motorola MCF5307 Microcontroller running at 32 MHz • 2 MByte Flash memory for code • 8 MByte SDRAM for configuration and dynamic data, also used as Dual Port Memory between CI862 and AC 800M • Power supply from the CEX bus +24
CI862 and TP862 - TRIO/Genius Interface Appendix A Hardware Units F R COM ERROR PRIM DUAL Bus Termination Dip Switch Location CI862 X1 X2 SI SO HHM TRL LAN Figure 78. CI862 TRIO/Genius interface. TRIO blocks, Figure 79, are self-contained, configurable I/O blocks used to interface field devices to the CI862 communications bus. These blocks can be individually installed on machines, in junction boxes, or grouped in racks or panels. A TRIO block is made of cast aluminum, and weighs approximately 1.
Appendix A Hardware Units CI862 and TP862 - TRIO/Genius Interface Figure 79. TRIO block. Table 94. TRIO block types.
CI862 and TP862 - TRIO/Genius Interface Appendix A Hardware Units Table 94. TRIO block types.
Appendix A Hardware Units CI862 and TP862 - TRIO/Genius Interface Functional Block Diagram A complete CI862K01 unit consists of a TP862 baseplate, a CI862 communication interface board, and their mechanics, Figure 80. All electronic devices and all functions are located on the board which also includes the µGenie slave module. The baseplate and CI862 are connected via an 80-pin edge connector. Connections to the outside world are made on the baseplate.
CI862 and TP862 - TRIO/Genius Interface Appendix A Hardware Units CI862 contains the Coldfire MCF5307 Microcontroller with Flash memory, RAM, LED indicators, power supply, and CEX-Bus interface with dual port memory, bridged to a GE/Fanuc µGenie Communication Module. The µGenie handles all data transfer between the CI862 Carrier module and the TRIO FIELD BUS, allowing the Carrier CPU to control the remote I/O.
Appendix A Hardware Units CI862 and TP862 - TRIO/Genius Interface Table 95. TRIO/Genius interface CI862 Item Connector Value one 4 pin (connects TRIO FIELD BUS) one DB9S (male) (connects Hand-held Monitor) one DB9, female (connects CEX expansion bus) Current Consumption Typical 190 mA (max. 200 mA) from CEX-Bus 24 V d.c. Dimensions W 58 x H 165 x D 122 mm (W 2.3 x H 6.4x D 4.
CI865 and TP865 – Satt I/O Interface Appendix A Hardware Units CI865 and TP865 – Satt I/O Interface Key Features • Provides one ControlNet port, (a BNC connector located on the TP865 Baseplate). • Simple DIN-rail mounting. • Handles I/O scanning of up to 31 distributed I/O nodes. • Pre-set, two-letter Alpha code locking device installed in unit base prevents mounting of incompatible components. • Supports Hot swap. Description The CI865/TP865 connects ControlNet to AC 800M.
Appendix A Hardware Units CI865 and TP865 – Satt I/O Interface Functional Block Diagram CEX bus LVDS trancievers DC/DC Reset Circuits SDRAM 8MB +5.0V +3.3V +2.5V JTAG FLASH 2MB CEX interf. FPGA Spartan-II 256BGA Processor ColdFire MCF5307 RS232 LANXCVR trancievers ControlNet ASIC SMAC BDM CN bus Figure 81.
CI865 and TP865 – Satt I/O Interface Appendix A Hardware Units Indicators Table 96. Satt I/O CI865 – Fault Finding Designation/Color Neither R(un) nor F(ault) LED’s are ON Function The CI865 unit is in the process of being configured. Allow time for this to finalize.
Appendix A Hardware Units CI865 and TP865 – Satt I/O Interface Technical Data Table 97. Satt I/O CI865 Interface Specifications Item Value Type Satt I/O Communication Interface Galvanic isolation Yes Status indicators Run normally green, FAIL exceptionally red, COM A/COM B Connector BNC Current consumption 120 mA typical (200 mA max.) (from CEX-Bus 24 V DC) Power dissipation 2.
CI867 and TP867 – Modbus TCP Interface Appendix A Hardware Units CI867 and TP867 – Modbus TCP Interface Key Features • Provides one 10/100Mbps Fast Ethernet port, (RJ45 connector located on the TP867 Baseplate). • Provides one 10Mbps Ethernet port, (RJ45 connector located on the TP867 Baseplate). • Simple DIN-rail mounting. • Provides communication with Modbus TCP protocol via Ethernet.
Appendix A Hardware Units CI867 and TP867 – Modbus TCP Interface Functional Block Diagram Figure 82.
CI867 and TP867 – Modbus TCP Interface Appendix A Hardware Units Indicators Table 98. Modbus TCP Interface CI867 - LED indicators Designation/Color Function F(ault) / Red Unit error detected. Set by the Hardware during Controller Reset. Controlled by Control Software after Reset. R(un) / Green Operating. Cleared by the Hardware during Controller Reset. Controlled by Control Software after Reset. RxTx1 / Yellow When flashing. Ethernet packages are sent/received at CH 1.
Appendix A Hardware Units CI867 and TP867 – Modbus TCP Interface Table 99. Modbus TCP Interface CI867 - Technical Specification Status indicators Running normally: Green. Exceptional fault: Red. Two traffic indictors – RxTx1 and RxTx2 -- controlled by traffic pace: Flashing Yellow Traffic indictor CH2 – RxTx2 - controlled by traffic pace. Running as primary: Yellow. Running in a redundant configuration: Yellow.
CI868 and TP867 – IEC 61850 Interface Appendix A Hardware Units CI868 and TP867 – IEC 61850 Interface Key Features • CEX-Bus Module. • MPC862P 96MHz. • 32 MB SDRAM with integrity check. • 4 MB Flash PROM. • Ethernet/IEEE 802.3u supporting full Fast Ethernet 10/100Mbps operation.
Appendix A Hardware Units CI868 and TP867 – IEC 61850 Interface Functional Block Diagram Figure 83.
CI868 and TP867 – IEC 61850 Interface Appendix A Hardware Units Indicators There are six LED indicators on the front panel of CI868 that indicate various states and conditions on the CI868. Table 100. IEC 61850 Interface CI868 - LED indicators Designation/Color Function F(ault) / Red The red F(ault) LED indicates a fault condition on CI868. Reset turns the F LED on. Software can turn it on and off via a register in the CEX-Bus controller.
Appendix A Hardware Units CI868 and TP867 – IEC 61850 Interface Table 101. IEC 61850 Interface CI868 - Technical Specification Communication speed CH1 10 Mbit/s / 100 Mbit/s defined in IEEE 802.3u 10/100BaseTx Status indicators Running normally: Green. Exceptional fault: Red. Two traffic indicators – RxTx1 and RxTx2(LED will always be switched off) -- controlled by traffic pace: Flashing Yellow Running as primary: Yellow. Running in a redundant configuration: Yellow.
CI869 and TP869 - AF 100 Interface Appendix A Hardware Units CI869 and TP869 - AF 100 Interface Key Features • CEX-Bus Module. • Simple DIN rail mounting • Supports communication interface redundancy • Supports redundant connections to AF 100 Bus through twisted wire pair. Description The CI869 is an AC 800M communication interface that connects to the AF 100 field bus through the twisted pair (TWP) cable.
Appendix A Hardware Units CI869 and TP869 - AF 100 Interface Functional Block Diagram Figure 84. Block Diagram - CI869 Indicators There are six LED indicators on the front panel of CI869. The Mast LED is not used as CI869 cannot function as bus master. The other LEDs indicate the various states and conditions of the CI869 unit.
CI869 and TP869 - AF 100 Interface Appendix A Hardware Units Table 102. AF 100 Interface, CI869 - LED indicators Designation/Color Function F(ault) / Red The red F(ault) LED indicates a fault condition on CI869. A reset turns the F LED ON, till the unit is initialized. R(un) / Green The green R(un) LED indicates that the CI869 is operational. A reset turns the R LED OFF. Rx / Yellow The yellow Rx LED indicates that the CI869 receives traffic.
Appendix A Hardware Units CI869 and TP869 - AF 100 Interface Technical Data Table 103. AF100 Interface CI869 - Technical Specification Item Value Type AF 100 Communication Interface Protocol Advant Fieldbus 100 Communication speed TWP 1.5 Mbit/s Status indicators Running normally: Green. Exceptional fault: Red. Traffic indicator – Rx -- controlled by traffic pace: Flashing Yellow Running as primary: Yellow. Running in a redundant configuration: Yellow.
CI871 and TP867 – PROFINET IO Interface Appendix A Hardware Units CI871 and TP867 – PROFINET IO Interface Key Features • Provides one 10/100 Mbps fast Ethernet port for PROFINET IO (RJ45 connector located on the TP867 base plate). • Simple DIN-rail mounting. • Provides communication with PROFINET IO protocol through Ethernet with 100 Mbps. • Preset, two letter Alpha code locking device installed in the unit base, which prevents mounting of incompatible components. • Supports hot swap.
Appendix A Hardware Units CI871 and TP867 – PROFINET IO Interface Functional Block Diagram Figure 85.
CI871 and TP867 – PROFINET IO Interface Appendix A Hardware Units Indicators There are six LED indicators on the front panel of CI871 to indicate various states and conditions of CI871. Table 104. PROFINET IO Interface CI871 - LED indicators Designation/Color Function F(ault) / Red The red F(ault) LED indicates a fault condition on CI871. Reset turns the LED on. Software can turn it on and off through a register in the CEX-Bus controller.
Appendix A Hardware Units CI871 and TP867 – PROFINET IO Interface Technical Data Table 105. PROFINET IO Interface CI871 - Technical Specification Item Value Type Ethernet unit Protocol PROFINET IO Communication speed CH1 10 Mbps / 100 Mbps defined in IEEE 802.3u 10/100 Base-Tx. Status indicators Running normally: Green. Exceptional fault: Red. Two traffic indicators – RxTx1 and RxTx2(LED is always switched off) controlled by traffic pace: Flashing Yellow. Running as primary: Yellow.
CI872 and TP858 - MOD5 Interface Appendix A Hardware Units CI872 and TP858 - MOD5 Interface Key Features • CEX-Bus Module • Simple DIN rail mounting • Supports communication interface redundancy • Three full duplex fiberoptic ports • Supports MOD5-to-MOD5 protocol Description The MOD5 communication interface, type - CI872, connects the AC 800M controller to the MOD5 controllers. The baseplate has a code lock that prevents the installation of an incorrect unit onto the TP858 baseplate.
Appendix A Hardware Units CI872 and TP858 - MOD5 Interface Functional Block Diagram Figure 86.
CI872 and TP858 - MOD5 Interface Appendix A Hardware Units Indicators There are six LED indicators on the front panel of CI872 that indicate different states of the CI872 module including communication on the optical ports states. Table 106. MOD5 Interface CI872 - LED indicators Designation/Color Function F(ault) / Red The red F(ault) LED indicates a fault condition on CI872. R(un) / Green The green R(un) LED indicates that CI872 is operational.
Appendix A Hardware Units CI872 and TP858 - MOD5 Interface Table 107. MOD5 Interface CI872 - Technical Specification Status indicators Running normally: Green. Exceptional fault: Red. Three traffic indicators – RxTx1, RxTx2 and RxTx3 controlled by traffic pace: Flashing Yellow. Running in a redundant configuration: Yellow. Connectors Wavelength: 820 nm. Fiber size: 62.5/125 m multimode glass fiber. Connector type: ST - non threaded. Max nominal fiber damping including connectors: 11 dB.
CI873 and TP867 - EtherNet/IP Interface Appendix A Hardware Units CI873 and TP867 - EtherNet/IP Interface Key Features • CEX-Bus Module. • MPC862P 96MHz. • 32 Mbps SDRAM with integrity check. • 4 Mbps Flash PROM. • Ethernet/IEEE 802.3u supporting full Fast Ethernet 10/100Mbps operation. • Supports EtherNet/IP protocol.
Appendix A Hardware Units CI873 and TP867 - EtherNet/IP Interface Functional Block Diagram Figure 87.
CI873 and TP867 - EtherNet/IP Interface Appendix A Hardware Units Indicators There are six LED indicators on the front panel of CI873 that indicate the various states and conditions on the CI873. Table 108. EtherNet/IP Interface CI873 - LED indicators 354 Designation/Color Function F(ault) / Red The red F(ault) LED indicates a fault condition on CI873. Reset turns the LED ON. Software can turn it On and OFF through a register in the CEX-Bus controller.
Appendix A Hardware Units CI873 and TP867 - EtherNet/IP Interface Technical Data Table 109. EtherNet/IP Interface CI873 - Technical Specification Item Value Type Ethernet unit. Protocol EtherNet/IP. Communication speed CH1 10 Mbps / 100 Mbps defined in IEEE 802.3u 10/100 Base-Tx. Status indicators Running normally: Green. Exceptional fault: Red. Two traffic indicators – RxTx1 and RxTx2(LED will always be switched off) -- controlled by traffic pace: Flashing Yellow Running as primary: Yellow.
Power Supply Units – Types SD821, SD822 and SD823 Appendix A Hardware Units Power Supply Units – Types SD821, SD822 and SD823 Key Features • Simple DIN-rail mounting • Class I Equipment (when connected to Protective Ground, (PE)) • Overvoltage Category III for connection to primary main TN network of Installation Category III • Protective separation of secondary circuit from primary circuit • Secondary outputs; – SD823 = 24 Volts DC regulated @ 10 A – SD822 = 24 Volts DC regulated @ 5 A – S
Appendix A Hardware Units Power Supply Units – Types SD821, SD822 and SD823 110 mm (4.3 in) 50 mm (2.0 in) 103 mm (4.1 in) 97 mm (3.8 in) SD821 N L PE 230 44 mm (1.7 in) 125 mm (4.9 in) L+ L+ L– L– OK Mains Voltage Selection Switch (115 / 230) Figure 88. SD821 Connections for 2.
Power Supply Units – Types SD821, SD822 and SD823 Appendix A Hardware Units 110 mm (4.3 in) 103 mm (4.1 in) 65 mm (2.6 in) 97 mm (3.8 in) SD822 N 230 L PE 44 mm (1.7 in) 125 mm (4.9 in) L+ L+ L– L– OK Mains Voltage Selection Switch (115 / 230) Figure 89.
Appendix A Hardware Units Power Supply Units – Types SD821, SD822 and SD823 110 mm (4.3 in) 120 mm (4.7 in) 103 mm (4.1 in) 125 mm (4.9 in) 97 mm (3.8 in) SD823 N L PE OK L+ L+ L– L– 44 mm (1.7 in) 115V 230V Figure 90.
Power Supply Units – Types SD821, SD822 and SD823 Appendix A Hardware Units The output voltage of all three PSUs is a regulated, low noise, 24 V DC. A green LED on the PSU front panel indicates that the output circuit is providing the correct output voltage level. The double connectors provided on the 24 V DC output terminals allow for connecting more than one piece of equipment. A surge current limiter within the PSU circuit provides a soft-start feature.
Appendix A Hardware Units Power Supply Units – Types SD821, SD822 and SD823 Dielectric test voltage 3000 V AC (EN 60950). Fuses and Protective Devices Internal primary main fuses are arranged to meet the requirements of electrical safety publications for connection to the Phase – Neutral terminals of the primary main network; TN network, 1 (one) fuse. Recommended primary external fuse: • Micro Circuit Breaker (MCB) 10 Amperes, characteristic B. Table 110.
Power Supply Units – Types SD821, SD822 and SD823 Appendix A Hardware Units Technical Data Table 111. PSU’s SD821, 822 and 823 – Technical Data Parameter SD821 Converter SD822 Converter SD823 Converter Rated output current (A) 2.5 A 5A 10 A Rated output power 60 W 120 W 240 W Rated output voltage 24 V 24 V 24 V Rated input power 160 VA 70 W 280 VA 135 W 690 VA 265 W Mains/input voltage, nominal 115/230 V AC 115/230 V AC 115/230 V AC Mains voltage variation allowed a.c.
Appendix A Hardware Units Power Supply Units - Types SD831, SD832, SD833, and SD834 Table 112. PSU’s SD821, 822 and 823 – Mounting Dimensions SD821 Converter SD822 Converter Dimensions, Width 50 mm (2.0 in) 65 mm (2.6 in) 120 mm (4.7 in) Parameter SD823 Converter HxD = 125 x 110 mm (4.9” x 4.3”) Mounting spacing W mm 10 mm (0.4 in) 15 mm (0.6 in) 15 mm (0.6 in) Mounting spacing H mm 25 mm (1.0 in) 25 mm (1.0 in) 25 mm (1.0 in) Weight (lbs) 600 g (1.3 lb) 700 g (1.5 lb) 1100 g (2.
Power Supply Units - Types SD831, SD832, SD833, and SD834 Appendix A Hardware Units Equipment Class The Power Supply Units, (PSU), are designed to meet all the applicable electrical safety data stated by the EN 50178 harmonized European Standard Publication and the additional safety and function data required by EN 61131-2 and UL 508. The secondary output circuitry is accepted for SELV or PELV applications. SELV according to EN 50178, EN 60950 and VDE 0100 Part 410.
Appendix A Hardware Units Power Supply Units - Types SD831, SD832, SD833, and SD834 Dimensions and Connections Figure 92. SD831 Dimension and Connections for 3 A Power Supply Figure 93.
Power Supply Units - Types SD831, SD832, SD833, and SD834 Appendix A Hardware Units Figure 94. SD833 Connections for 10 A Power Supply Figure 95.
Appendix A Hardware Units Power Supply Units - Types SD831, SD832, SD833, and SD834 Power Supply Units Types SD831 / 832 / 833 / 834- Description ABB recommend the use of robust and reliable power supply units, (PSUs), for providing power to the AC800 and S800I/O system, when connected to an industrial mains network of installation category III. PSUs can be used for both non-redundant and redundant applications. The four PSUs are designed as switch mode power converters. They converting a.c. or d.c.
Power Supply Units - Types SD831, SD832, SD833, and SD834 Appendix A Hardware Units Figure 96.
Appendix A Hardware Units Power Supply Units - Types SD831, SD832, SD833, and SD834 Figure 97.
Power Supply Units - Types SD831, SD832, SD833, and SD834 Appendix A Hardware Units Figure 98. Functional Diagram SD834 for a 20 A Power Supply Dielectric strength Basic with protective conductor. The primary circuit is separated from all other live circuits by reinforced insulation.
Appendix A Hardware Units Power Supply Units - Types SD831, SD832, SD833, and SD834 Table 113. Dielectric Strength A Dielectric test B C a.c. 2500V a.c. 3000V a.c. 500V a.c. 2000V a.c. 2000V a.c. 500V voltage Field test Rules for Field test: Use appropriate test equipment which applies the voltage with a slow ramp. Connect L and N together as well as all output poles. DC-OK relay contact (SD834 only) This feature monitors the output voltage, which is produced by the power supply itself.
Power Supply Units - Types SD831, SD832, SD833, and SD834 Appendix A Hardware Units SD834 in parallel to increase output power Table 114. SD834 Schematic and Instructions for parallel use. Schematic for parallel operation Instructions for parallel use a) Only SD834 can be used in parallel connection. b) Adjust the output voltages of all power supplies to approximately the same value (±500mV). Otherwise, the DC-OK signal might not work properly.
Appendix A Hardware Units Power Supply Units - Types SD831, SD832, SD833, and SD834 Technical Data Table 116. Technical Data PSU’s SD831, 832, 833 and 834 Parameter SD831 Converter SD832 Converter SD833 Converter SD834 Converter Rated output current (A) 3A 5A 10 A 20 A Rated power output 72 W 120 W 240 W 480 W Rated output voltage d.c. 24 V d.c. 24 V d.c. 24 V d.c. 24 V Rated input power 134/143 VA 240/283 VA 447/514 VA 547/568 VA a.c.
SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) Appendix A Hardware Units Table 116. Technical Data PSU’s SD831, 832, 833 and 834 (Continued) Parameter Maximum output current SD831 Converter 3.3 A SD832 Converter SD833 Converter 6A 12 A At ambient temp < 45 oC At ambient temp < 45 oC 55 oC 55 oC Maximum ambient temperature(1) 55 oC Acceptable wire sizes Power connection terminals Solid: 0.5 – 6 mm2 SD834 Converter 30 A < 4 s 55 oC Stranded wire: 0.
Appendix A Hardware Units SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) SS832 up to 10A. See Table 117 for the selection of voting unit based on the type of power supply. Table 117. Selection of Voting Unit SS822 SS832 SS823 SD831 (x1) x1 x2 SD832 (x1) x1 x2 SD833 (x1) x2 x2 SD834 (x2) x2 x2 (x#) not preferred solution, x2 it needs two in parallel. SS822 For SS822 Block diagram and Dimensions see Figure 99 and Figure 100.
SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) X1 Appendix A Hardware Units X2 A+ OK B+ + A F L+ A+ OK L+ + B F B+ L- Figure 99.
Appendix A Hardware Units SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) 110 103 50 97 OK+ F OK+ F A B 125 SS822 44 A+B+L+L+L- Figure 100. SS822 Voting Unit Connections Table 118. SS822 Voting Unit - Supervision Data SS822(1) Supervision Data Voltage, low trip level (for decreasing voltage) 22 V Voltage, low trip hysteresis 0.7 V Voltage, high trip level for rising voltage 30 V High trip hysteresis 0.7 V Contact rating a.c. Max. 120 V and max. 0.5 A Contact rating d.c. Max.
SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) Appendix A Hardware Units Table 119. SS822 - Technical Data and Mounting Dimensions Parameter SS822 Voter Rated output current (A) 20 A Rated output voltage 35 V Rated input power 500 W Mains/input voltage, nominal 2 x 24 V d.c. Rated/input voltage 35 V d.c. Heat dissipation 10 W at 20 A and 2,5 W at 5 A Output voltage regulation at max.
Appendix A Hardware Units SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) SA SB L+ L+ LOK L- L+ L+ LOK SD821 N L PE L- SD821 N L PE Supervision signals to CI8X0/TB8X0 OK+ F OK + F A B SS822 A+ B+ L+ L+ L- L+ Mains Input L- Protective Earth +24V 0V Figure 101. SS822 - Used in Redundant SD821 Configuration SS823 The SS823 Voting Unit has double overvoltage protection circuit on both inputs. It is also able to detect both short and open circuit in the voting element.
SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) Appendix A Hardware Units Figure 102.
Appendix A Hardware Units SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) Figure 103. SS823 Power Voter Unit Connections Table 120. SS823 Power Voter Unit - Supervision Data Supervision Data SS823 Voltage, low trip level (for decreasing voltage) 22 V Voltage, low trip hysteresis 0.7 V Voltage, high trip level for rising voltage 30 V High trip hysteresis 0.7 V Contact rating a.c. Max. 120 V and max. 0.5 A Contact rating d.c. Max. 28 V and max. 1 A; min. 1 mA, recommended min.
SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) Appendix A Hardware Units Table 121. SS823 - Technical Data and Mounting Dimensions Parameter SS823 Voter Rated output current (A) 20 A Rated output voltage 24 V Rated input power 500 W Mains/input voltage, nominal 24 V d.c. Mains/input voltage, max 30 V d.c.(1) Dual level OVP (Overvoltage protection) Trip 32.0 V nominal Return 31.5 V nominal Heat dissipation 24 W max Output voltage regulation at max. 1.
Appendix A Hardware Units SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) SA SB From Mains Breaker L+ L- From Mains Breaker Figure 104.
SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) Appendix A Hardware Units SS832 SS832 is can be used directly for load up to 10 A and for loads up to 20 A two SS832 modules must be used. See Figure 106 and Figure 107. For Block diagram and connections of SS832 see Figure 105 and Figure 108. Table 122 and Table 123 shows supervision data and technical data respectively. Figure 109 shows connection of SS832 in redundant configuration with maximum 10 A load, see Figure 110 for load up to 20 A.
Appendix A Hardware Units SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) AC AC DC DC IN 1 IN 2 OUT OUT + IN 1 IN 2 - Load Figure 107.
SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) Appendix A Hardware Units Figure 108. SS832 Voting Unit Dimensions and Connections Table 122. SS832 Voting Unit - Supervision Data Supervision Data 386 SS832 Voltage, low trip level (for decreasing voltage) 21.5 +- 0.5V Voltage, low trip hysteresis 0.7 V High trip hysteresis 0.
Appendix A Hardware Units SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) Table 122. SS832 Voting Unit - Supervision Data (Continued) Supervision Data SS832 Contact rating a.c. Max. 30 V and max. 0.5 A, resistive load Contact rating d.c. Max. 60 V and max 0.3 A, 30 V max 0.5 A resistive load min. 1 mA at 5 V d.c. Acceptable wire sizes 0.2 -1.5 mm2, 22 - 14 AWG Recommended torque: 0.4 Nm Table 123.
SS822/SS823/SS832 Voting Unit (for Redundant Power Supply) Appendix A Hardware Units Table 123. Technical Data and Mounting Dimensions (Continued) Parameter SS832 Voter Dimensions Width Depth Height 32 mm (1.26”) 117 mm (4.6") 124 mm (4.9") Mounting spacing W 5 mm (0.2"), In case the adjacent device is a heat source 15 mm (0.59") Mounting spacing H 40 mm (1.57") on the top, 20 mm (0.79") on the bottom Weight 350 g (0.77 lbs.) (1) Mounting on a horizontal DIN rail Figure 109.
Appendix A Hardware Units TC562 Modem Unit – (Westermo MD-12DC) Figure 110. SS832 Redundant Configuration up to 20 A TC562 Modem Unit – (Westermo MD-12DC) TC U J Figure 111.
TC562 Modem Unit – (Westermo MD-12DC) Appendix A Hardware Units equipment or units, for example a computer and printer or a robotic device. ABB recommends their use when the distance between units/equipment exceeds 15 m. For further details refer to the manufacturer's documentation (Westermo). Using a modem allows distances between pieces of equipment to be as much as 18000 m, and, depending on the distance, can provide a data transmission speed of up to 38400 bit/s.
Appendix A Hardware Units TC562 Modem Unit – (Westermo MD-12DC) Technical Data Table 124. TC562 – Technical Data TC562 – Short Distance Modem Manufacturer – Westermo – MD-12DC Type Transfer Asynchronous, full/half duplex/simplex Power Supply 24 V DC (Min. 12 V DC – Max 36 V DC) Power Consumption 3W Dimensions 55 x 100 x 128 mm (2.2 x 3.9 x 5.0 in.) Weight 400 g (0.9 lb) Table 125. Transfer Distance (Cable 0.3 mm2/42 pF/m) 3BSE036351-510 A Meters (yd.
SB821 External Battery – AC 800M Memory Back-up Appendix A Hardware Units SB821 External Battery – AC 800M Memory Back-up Description The SB821 battery unit is used as an external power supply to provide extended memory backup for the AC 800M Controller. The unit is DIN-rail mounted and provided with a separate connecting cable (TK821V020), 2 m (2.2 yd.) in length. SB821 SB821 3.6V Lithium Battery Unit Note the warning text on the battery.
Appendix A Hardware Units SB821 External Battery – AC 800M Memory Back-up Technical Data Table 126. SB821 – External battery data Item Value Battery Type Low rate lithium, 3.6 V, 16 Ah Size ANSI size D IEC size R20 Lithium content 5.6 g (0.18 oz.) Back-up-time See data for the PM8xx unit Dimensions W 85.6 x D 51 x H 136 mm (3.4 x 2 x 5.4 in) Weight 600 g (1.
SB822 Rechargeable External Battery – AC 800M Memory Back-up Appendix A Hardware Units SB822 Rechargeable External Battery – AC 800M Memory Back-up Description The SB822 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) 2 m (2.2 yd.) in length.
Appendix A Hardware Units SB822 Rechargeable External Battery – AC 800M Memory Back-up Technical Data Table 127. SB822 – Rechargeable External battery data Item Value Battery type Rechargeable Lithium-Ion 3.75V 2.3 Ah Battery size Prismatic 14.5x43x50 mm Lithium equivalent content 0.8g Back-up-time See data for the PM8xx unit Dimensions W 85.6 x D 51 x H 136 mm (3.4 x 2 x 4.4 in) Weight 600 g (1.
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 2 m (6.6 ft.) (to standard DIN 46 277, EN 50 022). 7.5 (0.3”) 7.5 (0.3”) 35 (1.4”) 6 27 (0.2”) (1.1”) 15 (0.6”) 10 (0.4”) Figure 112. DIN-rail TS 35/7.
Appendix A Hardware Units Miscellaneous Equipment Miscellaneous Equipment TB850 Terminator for CEX-Bus (Male) Terminator TB850 Figure 113.
TB850 Terminator for CEX-Bus (Male) Appendix A Hardware Units BC810 PM861A/PM864A/PM865 Terminator TB850 RCU Link Cables Terminator TB850 BC810 PM861A/PM864A/PM865 Figure 114.
Appendix A Hardware Units TB851 Terminator for CEX-Bus (Female) TB851 Terminator for CEX-Bus (Female) A TB851 (female) Terminator for CEX-Bus is required when a TK850 extension cable is used. TK850 Cable Terminator TB851 Figure 115.
TB807 ModuleBus Terminator Plug Appendix A Hardware Units 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. TB852 RCU Link Terminator Plug The TB852 RCU Link Terminator Plug is required when the PM861/PM864 processor unit operates in single configuration.
Appendix A Hardware Units TK853 TK853 Technical Data Table 128. TK853 – Technical Data Item Value Connectors • • AC 800M RJ45 plug 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) RTS 1 DTR 2 TD 3 0V 4 0V 5 RD 6 DCD 7 CTS 8 Shield 7 RTS 4 DTR 3 TD 50V 2 RD 1 DCD 8 CTS Shield Modem Male 9-pole, D-sub connector (DE9P) Figure 116.
TK856 RCU Control Link Cable Appendix A Hardware Units TK856 RCU Control Link Cable The TK856 Redundant Control Unit Control Link Cable, connected between redundant PM891 units, provides role selection and CPU identity assignment (UPPER/LOWER). TK212A Tool Cable Technical Data Table 129. TK212A Tool Cable – Technical Data Item Value Connectors • • One 9-pole female D-type One 8-pole RJ45 plug Weight 125 g (0.3 lb) Length 3.0 m (9.
Appendix A Hardware Units Al-Profile Support For DIN-Rail 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 designed for supporting DIN-rails (see Figure 118 on page 403 and Figure 119 on page 404). Key features of the Al-profile are: • Simple mounting.
Al-Profile Support For DIN-Rail Appendix A Hardware Units See detail A 215 mm 4 mm 15 mm 30 mm 20 mm F F F 2 mm 2 mm F 9 mm F 2 mm 248.3 mm 30.8 mm 2.5 mm 4 x for screw ST 4.8x9.5 15 mm 2 2x1.5 2x1.9 Detail A Figure 119.
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 is: Table 130.
Current Consumption and Power Dissipation Appendix B Power Consumption Current Consumption and Power Dissipation See Table 131 on page 406 for typical current consumption and power dissipation data for AC 800M units. Table 131. Current Consumption and Power Dissipation Data for AC 800M Units Unit 406 Current at 24 V Power Dissipation Remarks Typical Max Typical Max PM851 180 mA 300 mA 5.0 W 8.0 W (1) PM856 180 mA 300 mA 5.0 W 8.0 W (1) PM860 180 mA 300 mA 5.0 W 8.
Appendix B Power Consumption Current Consumption and Power Dissipation Table 131. Current Consumption and Power Dissipation Data for AC 800M Units Current at 24 V Unit Power Dissipation Typical Max Typical Max CI855 150 mA 200 mA 3.6 W 5.0 W CI856 120 mA 200 mA 2.9 W 5.0 W CI857 150 mA 200 mA 3.6 W 5.0 W CI858 150 mA 200 mA 3.6 W 5.0 W CI860 100 mA 150 mA 2.4 W 3.6 W CI862 190 mA 200 mA 3.0 W 4.0 W CI865 120 mA 200 mA 2.9 W 5.0 W CI867 160 mA 250 mA 3.8 W 6.
Current Consumption and Power Dissipation Appendix B Power Consumption (1) Not for PM891 (2) Corresponds to additional 0.5 A on +24 V. Maximum current of the +24 V supplied to the CPU (incl. ModuleBus and CEXBus) is shown in Table 133 on page 408: Table 133. Maximum Current Supply to CPU incl. ModuleBus and CEX-Bus (24 V) CPU PM851 2.2 A PM856 4.2 A PM860 4.2 A PM851A 2.2 A PM856A 4.2 A PM860A 4.2 A PM861 (single) 4.3 A PM861 (redundant pair) 3.3 A (no ModuleBus) PM861A 4.
Appendix B Power Consumption Current Consumption and Power Dissipation Calculations 1. Calculate the current requirements for each bus (ModuleBus and CEX-Bus). Be sure not to exceed the limits given in Table 132 on page 407. Data relating to TB820, TB840, CI801 and CI840 is accessible from the S800 I/O documentation. 2. Calculate the current consumption at 24 V, for each electrical ModuleBus, by adding: Im = I (24 V) + I (5 V) x 0.3 3.
Current Consumption and Power Dissipation 410 Appendix B Power Consumption 3BSE036351-510 A
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 134. Recommended Components – PROFIBUS DP Component PROFIBUS DP Description Due to the large selection of commercially available equipment manufactured to PROFIBUS DP Standard, there is no recommendation for specific PROFIBUS DP components. For further details refer to PROFIBUS DP Web Site.
Recommended Components Appendix C Recommended Components Table 134. Recommended Components – PROFIBUS DP (Continued) Component PROFIBUS DP/PA Linking Device (LD 800P) Description LD 800P performs the following tasks: • Potential separation between the PROFIBUS DP and the PROFIBUS PA • Conversion of the RS 485 physical arrangement of the PROFIBUS DP to the physical arrangement based on IEC 61158-2 of the PROFIBUS PA. • Adapting the PROFIBUS DP transfer rate to the PROFIBUS PA transfer rate of 31.
Appendix C Recommended Components Recommended Components Table 134. Recommended Components – PROFIBUS DP (Continued) Component PROFIBUS DP/PA Linking Device (LD 800P) (cont.) Description The way in which LD 800P works is essentially transparent. This means that PROFIBUS DP masters have direct access to PROFIBUS PA slaves.
Recommended Components Connection PROFIBUS DP redundant (optional) Connection PROFIBUS DP Head station HS 840 Appendix C Recommended Components Connection PROFIBUS PA Segment non-intrinsically safe Power Link Module PL 810 Connection PROFIBUS PA Segment intrinsically safe Power Link Module PL 890 Figure 120.
Appendix C Recommended Components Recommended Components Table 135. Recommended components - PROFINET IO Component MNS iS Description MNS iS is a motor control center solution that can be used in PROFINET IO network. MNS iS delivers all the functions for control, protection and monitoring of motors and motor starters using software and hardware modules for the specific tasks.
Recommended Components Appendix C Recommended Components Table 137. Recommended Components – FOUNDATION Fieldbus Component FOUNDATION Fieldbus Description Due to the large selection of commercially available equipment manufactured to FOUNDATION Fieldbus Standard (IEC 11582), there is no recommendation for specific FOUNDATION Fieldbus components. This statement covers all FOUNDATION Fieldbus equipment, including: • FOUNDATION Fieldbus filters. • FOUNDATION Fieldbus bus spur distribution terminals.
Appendix C Recommended Components Recommended Components Table 138. Recommended Components – FOUNDATION Fieldbus High Speed Ethernet Component FOUNDATION Fieldbus High Speed Ethernet Description All used components must be compatible with the FOUNDATION Fieldbus High Speed Ethernet specification. FOUNDATION Fieldbus High Speed Ethernet use a high speed bus (for example 100 Mbit/s) and in addition providing redundancy. The HSE architecture is effectively an enhanced standard Ethernet model (IEEE 802.3).
Recommended Components Appendix C Recommended Components Table 138. Recommended Components – FOUNDATION Fieldbus High Speed Ethernet (Continued) Component FOUNDATION Fieldbus Linking Device (LD 800HSE) Description The LD 800HSE is a gateway between an FF High Speed Ethernet (FF-HSE) subnet and FF-H1 links. It supports device redundancy. The Linking Device is designed according to class 42c of the HSE profile, therefore providing the following functions: • It supports up to four separate FF-H1 links.
Appendix C Recommended Components Recommended Components Figure 121.
Recommended Components Appendix C Recommended Components Table 139.
Appendix C Recommended Components Recommended Components Table 140. Recommended Components – Miscellaneous Component DIN-rail DIN-rail Accessories Description Phoenix: • TS 35/7.5 • Steel, yellow chromated with holes • DIN 46 277, EN 50 022 DIN-rail end support device 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.
Recommended Components Appendix C Recommended Components Table 141. Recommended Components – Process Cables Component Mains Description Various Manufacturers, to Standard; • RS-232C RKFK 3x1.5 mm2 Unitronic • CY 3 x 0.25 mm2 • CY 7x 0.25 mm2 Belden FOUNDATION Fieldbus • Belden 8723 2 pair (0.34 mm2) • Belden 9729 2 pair (0.22 mm2) • Belden 9730 3 pair (0.34 mm2) Unitronic • Suitable Commercially Available Cable.
Appendix C Recommended Components Recommended Components Table 141. Recommended Components – Process Cables (Continued) Component Description PROFINET IO Interface CI871 • Use in minimum cable of category 5 (STP cables). For more information, refer to Automation System Network Design and Configuration (3BSE034463*). TRIO Fieldbus CI862 • See Table 142 Modbus TCP Interface CI867 • Use in minimum cable of category 5 (STP cables). • Max. length 30 m from CI867 to next Ethernet device.
Recommended Components Appendix C Recommended Components Table 142. Cables for the CI862 TRIO Field Bus Cable Outer Diameter in (mm) TerminatConducing Indoor tors / Resistor Installation AWG () DiElectric Voltage Ambient Temp. Rating (C) NEC Rating Taylor 6201C .35 (8.89) 150 in conduit 2 / #22 30 60 CL2(1) B3078F(2) .385 (9.78) 150 cable tray(3) 2 / #22 300 75 PLTC/CM .35 (8.89) 150 in conduit 2 / #22 30 60 CL2 C4596(5) .35 (8.
Appendix C Recommended Components 3BSE036351-510 A Recommended Components 425
Recommended Components 426 Appendix C Recommended Components 3BSE036351-510 A
Appendix D Directive Considerations Relevant products comply with EMC Directive EMCD 2004/108/EC and Low Voltage Directive LVD 2006/95/EC. The products are provided with a CE marking.
Low-Voltage Directive (LVD) Appendix D Directive Considerations page 356and Power Supply Units - Types SD831, SD832, SD833, and SD834 on page 363. If you use other power supplies, except SD82X and SD83X, to provide the 24V d.c. for AC 800M it is required that they also are CE marked, Underwriters Laboratories (UL ) listed and fulfill the LVD (SELVandPELV) criteria. The AC 800M modules are IP20 semi-protected equipment and must be mounted in non-public localities.
Appendix E Standards The information below is applicable to products approved for hazardous locations according to CSA and/or UL standard UL60079-15 (2002). Hazardous Location Approval To comply with CSA and/or UL certification for use at hazardous locations, the following information is relevant for CSA and/or UL-certified ABB industrial control products.
Hazardous Location Approval Appendix E Standards Explosion hazard - Do not disconnect equipment unless the power has been switched off or the area is known to be non-hazardous.
Appendix F Environmental Data Environmental Data for AC 800M Products The immunity of products to environmental factors met during operation, transportation and storage is summarized in this section. Industrial environment are supplied with power from a high-voltage or mediumvoltage transformer dedicated to supplying installations feeding manufacturing or similar plants. The existence of industrial apparatus and heavy, frequently-switched inductive or capacitive loads characterize an Industrial environment.
Climatic and Mechanical Environmental Conditions Appendix F Environmental Data Climatic and Mechanical Environmental Conditions Industrial Environment Table 143. Industrial Environment Environmental Specification Environment Factor Climatic Conditions Operative Range Compliance with Standard –40 to +70°C Cabinets(1): +5 to +40°C –40 to +60°C Units(2): +5 to +55°C +10 to +40°C (3) Temp. change Min. 3 min within temp. range 3°C/min.
Appendix F Environmental Data Climatic and Mechanical Environmental Conditions Table 143. Industrial Environment (Continued) Environmental Specification Environment Factor Mechanical Conditions Vibration Transportation and Storage Operative Range 10< f <50 Hz, Continuous: 0.0375 mm amplitude (Occasional: 0.075 mm amplitude) Compliance with Standard EN 61131-2 50< f <150 Hz, Continuous: 0.5 g acceleration (Occasional: 1.0 g acceleration) Emitted noise – <55dB (A) Shock, no package 5> f < 8.
CE Compliance Appendix F Environmental Data CE Compliance All products comply with EMC Directive EMCD 2004/108/EC and Low Voltage Directive LVD 2006/95/EC. 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: 434 • EMC Directive EMCD 2004/108/EC. • EN 61131-2 Product standard, Programmable controllers. • EN 61000-6-4 Generic emission standard.
Appendix F Environmental Data Electromagnetic Compatibility and Main Voltage Conditions Electromagnetic Compatibility and Main Voltage Conditions Table 144. Electromagnetic Compatibility and Main Voltage Conditions Environmental Specification Industrial Environment Environment Factor Emission Compliance with Standard Class A EN 55011 Immunity 10V/m 80M - 1000MHz EN 61000-4-3 –Radiated RF field 3V/m 1.4G - 2.
Electromagnetic Compatibility and Main Voltage Conditions Appendix F Environmental Data Table 144. Electromagnetic Compatibility and Main Voltage Conditions Environmental Specification Electromagnetic Compatibility Conditions Environment Factor 436 Industrial Environment Compliance with Standard Main voltage a.c Unom: –15% to +0% Main voltage DC –15% to 20% of rated value Main frequency a.c. 47–63 Hz, ±5% IEC 60255-6 Main voltage interruption, a.c.
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. However: Cables for short-distance communication without modems should always be routed at a distance of 10 cm (4 in.) from other cables.
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: • Cables extend beyond the area covered by the ground line network • Cables are located above ground • Overhead cables are used.
INDEX A ABB Drives 168 AC 800M I/O systems 158 safety 13 adapters CI840 158 to 159 addressing Ethernet 52 Alpha code lock 75, 124 Al-profile 403 applicable specifications 27 B baseplates TP830 33 battery external change 195 internal 192 change 192 battery back-up units SB821 29 BC810 29 CEX-Bus interconnection unit 270 fault-finding 206 indicators 272 installation 97 technical data 272 C cabinet 65 cabinets installation in 145 cables 3BSE036351-510 A RCU Link 91 CEX-Bus BC810 270 BC810 interconnection u
Index technical data 299 CI854A communication interface fault-finding 214 indicators 299 installation 116 technical data 299 CI855 communication interface fault-finding 216 indicators 303 installation 119 technical data 303 CI856 communication interface fault-finding 217 indicators 307 installation 120 technical data 307, 331 CI857 communication interface fault-finding 218 indicators 311 installation 121 technical data 311 CI858 communication interface fault-finding 219 indicators 315 installation 122 tech
Index CI852 29 CI853 29, 292 CI854 29, 158 to 159 CI854A 29, 158 to 159, 296 CI855 29 CI856 29, 158 CI857 29 CI858 29, 313 CI860 29 communication ports 84 compatibility electro-magnetic 61, 243, 249, 427 compliance standards 27 configure power supply 173 connect to SM810 104 to SM811 107 connect to Control Builder 151 Control Network 153 to 154 DriveBus 122, 169 FOUNDATION Fieldbus H1 113 FOUNDATION Fieldbus HSE 123 INSUM 121 MasterBus 300 119 PROFIBUS DP 111, 117 RS-232C 115 S100 I/O 120 Control Builder 3
Index external battery unit installation 143 external mains supply cable fusing 64 external power source 176 F fault-finding AF 100 228 BC810 206 CI851 209 CI852 210 CI853 213 CI854 214 CI854A 214 CI855 216 CI856 217 CI857 218 CI858 219 CI860 221 CI862 223 CI865 224 CI867 225 CI868 227 CI869 228 CI871 231 CI872 232 CI873 236 DriveBus 219 EtherNet/IP 236 external battery 208 FOUNDATION Fieldbus 210 FOUNDATION Fieldbus HSE 221 IEC 61850 227 INSUM 218 internal battery 208 MasterBus 300 216 MOD5 232 Modbus TC
Index S100 158 S800 158 I/O units safety 16 Indicators 350 indicators BC810 272 CI851 286 CI852 290 CI853 294 CI854 299 CI854A 299 CI855 303 CI856 307 CI857 311 CI858 315 CI860 319 CI862 326 CI865 330 CI871 346 PM8xx 179 SM810 275 SM811 280 installation BC810 97 CEX-Bus 97 CEX-Bus interconnection 97 CI851 111 CI852 113 CI853 115 CI854 116 CI854A 116 CI855 119 CI856 120 CI857 121 CI858 122 CI860 123 CI862 124 CI871 129 DriveBus 122 3BSE036351-510 A external battery unit 143 FOUNDATION Fieldbus H1 113 FOUN
Index locking device 68, 70 low-voltage directive 427 M mains breaker 63 installation 134 mains net filter 63 mains supply cable external 64 MasterBus 300 connect to 119 installation 119 ModuleBus 158 electrical 159 installation 131 to 132 optical 159 modules powering 173 remove 72 mounting DIN-rail 65 mounting dimensions DIN-rail 149 N noise signal 17 P performance data PM851/PM856/860 244, 250 PM861 254 PM864 258 PM865 262 PM866 266, 269 planning cable routing 61 cooling 60 field cable types 62 field
Index CPU unit 259 installation in redundant configuration 90, 94 installation in single configuration 78 performance data 262 redundancy 47 technical data 260 PM866 CPU unit 263 installation in redundant configuration 90 installation in single configuration 78, 87 performance data 266, 269 redundancy 47 technical data 264, 268 PM86x fault-finding 204 installation in redundant configuration 90, 94 PM891 General 40 installation redundant 94 single 87 mounting 70 PM8xx indicators 179 PM8xx units see CPU unit
Index SD822 356 technical data 362 SD823 356 technical data 362 SD831 363 signal noise 17 single configuration cold restart 183 controller reset 184 PM861 78, 87 PM864 78 PM865 78 PM866 78, 87 SM810 29, 273, 278 connect to 104 indicators 275 installation 104, 107 technical data 275 SM811 29, 278 connect to 107 Functional Block Diagram 279 indicators 280 installation 107 technical data 280 specifications 27 SS823 374 standards compliance 27 EU 27 TÜV 28 UL 429 standards.
Index TK212 technical data 402 tool cable 91, 95 TK850 CEX-Bus extension cable 97, 400 CEX-bus extension cable 400 TK851 RCU Link cable 91, 400 TK853 115 technical data 401 TP851 111, 284 TP852 113, 288 TP853 115, 292, 309 TP854 296 TRIO Fieldbus installation 124 TRIO/Genius Remote I/O 167 TÜV 28 TUV-Technischer Überwachungs-Verein or Technical Inspection Association 50 Type Designation SS823 136 type designations SB821 195 SS822 136 W warm start 183 U UL 27 UL standards 429 unit to baseplate Alpha code
Index 448 3BSE036351-510 A
Revision History Introduction This section provides information on the revision history of this User Manual. The revision index of this User Manual is not related to the 800xA 5.1 System Revision. Revision History The following table lists the revision history of this User Manual. Revision Index Description Date - First version published for 800xA 5.1 June 2010 A Added new contents for AC 800M 5.1.1 and 5.1.
Updates in Revision Index A Updates in Revision Index A The following table shows the updates made in this User Manual for Revision Index A. Updated Section/Sub-section Description of Update Section 1, Introduction Section 2. Installation Section 3, Configuration Appendix A, Hardware Units Appendix B, Power Consumption Added contents for the new AC 800M controllers PM851A/PM856A/PM860A. Section 5, Maintanence Updated contents for the redundancy support of CI873.
ABB AB Control Technologies Västerås, Sweden Phone: +46 (0) 21 32 50 00 e-mail: processautomation@se.abb.com www.abb.com/controlsystems ABB Automation LLC Control Technologies Abu Dhabi, United Arab Emirates Phone: +971 (0) 2 4938 000 e-mail: processautomation@ae.abb.com www.abb.com/controlsystems ABB Automation GmbH Control Technologies Mannheim, Germany Phone: +49 1805 26 67 76 e-mail: marketing.control-products@de.abb.com www.abb.
