T308-04 AC800M Hardware - RevC

System 800xA training

Chapter 4 - 1

Chapter 4 AC800M Hardware

TABLE OF CONTENTS Chapter 4 AC800M Hardware................................................................................................................................................ 1

4.1 General Information ..................................................................................................................................................... 2 4.1.1 Objectives.............................................................................................................................................................. 2 4.1.2 Legend .................................................................................................................................................................. 2 4.1.3 Reference Documentation ...................................................................................................................................... 2

4.2 Overview AC 800M Hardware ..................................................................................................................................... 3 4.3 Central Processing Unit ................................................................................................................................................ 4

4.3.1 Components........................................................................................................................................................... 4 4.3.2 Different Processor Units ....................................................................................................................................... 5 4.3.3 Start Modes ........................................................................................................................................................... 6 4.3.4 Battery................................................................................................................................................................... 7 4.3.5 AC 800M Communication Ports............................................................................................................................. 8 4.3.6 AC 800M High Integrity Controller........................................................................................................................ 9

4.4 Communication Interface Units ...................................................................................................................................10 4.4.1 Overview..............................................................................................................................................................10 4.4.2 Communication Exchange Bus - CEX Bus ............................................................................................................11

4.5 Input / Output Modules................................................................................................................................................12 4.5.1 Range of ABB I/O modules...................................................................................................................................12 4.5.2 I/O Connection Possibilities ..................................................................................................................................13 4.5.3 S800 I/O Connected with ModuleBus....................................................................................................................14 4.5.4 S800 I/O Connected with PROFIBUS ...................................................................................................................15 4.5.5 Limitations of CI801.............................................................................................................................................16 4.5.6 Module Terminal Unit for S800I/O .......................................................................................................................16

4.6 LED indications ..........................................................................................................................................................18 4.6.1 PM8xx Controller Indications ...............................................................................................................................18 4.6.2 S800 IO Module LEDs..........................................................................................................................................21 4.6.3 S800L IO Module LEDs .......................................................................................................................................22

4.7 Hardware Redundancy.................................................................................................................................................24 4.7.1 Redundant Processor Unit - PM861/PM864/PM865 ..............................................................................................24 4.7.2 Controller and I/O Redundancy.............................................................................................................................25 4.7.3 Module Terminal Unit for S800I/O .......................................................................................................................25 4.7.4 Redundant ModuleBus I/O Connections................................................................................................................26 4.7.5 Redundant PROFIBUS I/O Connections................................................................................................................27 4.7.6 Redundant Power Supply ......................................................................................................................................29

T308-04 AC800M Hardware - RevC

Chapter 4 - 2

4.1 General Information

4.1.1 Objectives

Upon completion of this chapter, you will be able to:

Describe the AC 800M hardware components

Explain the interconnections between hardware modules

Explain the LED indications

Describe the redundant hardware

4.1.2 Legend

> Indicates when you go from one menu to a sub-menu

Italic Indicates object and file names

Indicates dialog box buttons, tabs, menus etc.

Bold Indicates important topics

Indicates start/explanation of student activity

4.1.3 Reference Documentation

3BSE036351 Industrial IT 800xA Control and I/O AC 800M Controller - Hardware and Operation

3BSE035980 Industrial IT 800xA Control and I/O Basic Control Software Introduction and Configuration

3BSE020923 Industrial IT 800xA Control and I/O S800 I/O General Information and Installation

3BSE020924 Industrial IT 800xA Control and I/O S800 I/O Modules and Termination Units


Chapter 4 - 3

4.2 Overview AC 800M Hardware

The AC 800M controller consists of a selection of units mounted on horizontal DIN-rails, which can be housed within an enclosure. The majority of units consist of a base mounting plate and removable cover attached with screws.

The hardware units that form the AC 800M controller are:

Central Processor Unit (CPU)

Communication interface modules for different protocols

S800 I/O modules

Power supply modules

RS-232 channels

Optional up to 12 Communication modules

Redundant Ethernet

CPU S800 I/O

Various I/O systems can be connected to the AC 800M Controller, either directly (S800 I/O) or via PROFIBUS or FOUNDATION Fieldbus.


Chapter 4 - 4

4.3 Central Processing Unit

4.3.1 Components

The CPU consists of a base plate TP830 and a replaceable processor module PM8xx with various speed and memory combinations.

CPU Baseplate

Fuses for Modulebusand CEX-bus

Compact Flash Card

The base plate TP830 carries the majority of the connections to processor, the power supplies and communication interfaces, as well as to the external buses.

Compact Flash Card

A Compact Flash (CF) can be inserted to the card slot located at the front of AC 800M controllers.

The card will be activated and read after a long controller reset (or power failure) and your application(s) can be loaded into the controller without performing an application download from a Control Builder station.

NOTE! Compact Flash cannot be used in an AC 800M High Integrity controller.


Chapter 4 - 5

4.3.2 Different Processor Units

The key differences between the different CPUs are memory and frequency, also some can only be used in stand alone mode and others can be used in redundant mode.

PM856

8MB24 MHz

PM851

8MB24 MHz

PM865Redundant

32MB96 MHz

SIL2

PM864Redundant

32MB96 MHz

PM861Redundant

16MB48 MHz

PM860

8MB48 MHz

Unit Description On-line replacement

Redundancy

PM851 24 MHz (48MHz for communication) / 8 Mbytes RAM 1 Ethernet port, 1 Serial port and 1 tool port. Application speed is half of PM860. Maximum one CEX bus module.

No No

PM856

24 MHz (48MHz for communication) / 8 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port. Application speed is half of PM860.

No No

PM860 48 MHz / 8 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port.

No No

PM861 48 MHz / 16 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port. Singular or redundant.

Yes Yes

PM861A Same as PM861 but can use redundant communication unit CI854A, CI860 and BC810.

Yes Yes

PM864 96 MHz / 32 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port. Singular or redundant. PM864 is 50% faster than PM861 in executing an application.

Yes Yes

PM864A Same as PM864 but can use redundant communication unit CI854A, CI860 and BC810.

Yes Yes

PM865 (PA/HI) 96 MHz / 32 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port. PM865 can be used in an AC 800M High Integrity system.

No Yes


Chapter 4 - 6

4.3.3 Start Modes

The controller may be started with the following start modes:

Mode Invoked by Description Warm Init Power Off/On with a

battery backed up CPU Applications restart with retain values.

Cold Init Press Init < 2.5 s Applications restart with cold retain values. Reset Press Init > 3 s or until

Run LED flashes Applications are deleted in controller.


Chapter 4 - 7

4.3.4 Battery

The memory is backed up by an internal or an external battery. You should mount the battery when the CPU is up and running with a loaded application.

Internal External The backup time varies depending on CPU type and battery types.

NOTE! A Compact Flash card can be used for non-volatile storage of application and data.

The battery must be exchanged whenever:

the battery LED flashes

multiple or extended power cuts have occurred

extended periods of system downtime have occurred

at least every second year (1Ah cell) or fifth year (18 Ah cell), regardless of whether the battery has been considerably used or not

CPU Type Internal Battery min time (hours)

External Battery min time (weeks)

PM851/PM856/PM860 48 4

PM861 36 4

PM864 36 3

PM861A 118 12

PM864A 235 24

PM865 HI 235 24

PM865 PA 235 24


Chapter 4 - 8

4.3.5 AC 800M Communication Ports

Detailed description of the communication ports of the CPU:

RCU linkconnection

CommunicationExpansion CEX-bus

CPU

S800I/Os on theElectrical ModuleBus

Ethernet ports COM 3-4 portsFiber opticaleModuleBus

Two built-in RS-232 serial ports: COM3 with modem support for several protocols COM4 intended as tool port for Control Builder

Two built-in Ethernet ports (IEEE 802.3, 10BaseT with TCP/IP): CN2 used for redundancy or routing

Built-in ModuleBus for optical or electrical connection to I/O communication

Built-in CEX-bus (Communication Extended Bus) for external communication modules

NOTE! In a configuration with redundant CPUs, COM3 and the electrical ModuleBus cannot be used.


Chapter 4 - 9

4.3.6 AC 800M High Integrity Controller

AC 800M can easily be configured for usage in safety critical applications. The main components of such a system are PM865, SM810, SS823 and the S800 I/O High Integrity system, running a High Integrity version of Control Software.

The PM865 processor unit has higher HW fault tolerance, compared to PM864. The added functionality on PM865 includes:

Double over voltage protection on internal voltages

Additional watchdog timer updated with data from SM810

Increased oscillator supervision

Support for S800 I/O High Integrity system

Increased system diagnostic and online self tests

The main function of the SM810 is to act as a monitor for the HW and SW execution of PM865 and these two modules together are a SIL2 compliant system according to IEC61508. The SM810 is running a SIL2 certified operating system and have a very high degree of self-diagnostic.


Chapter 4 - 10

4.4 Communication Interface Units

4.4.1 Overview

A number of communication modules can be connected to the CEX bus.

RS

232

CI8

53P

RO

FIB

US

DP

CI8

54A

MB

300

CI8

55

S10

0 I/O

CI8

56

INS

UM

CI8

57

Driv

eBus

CI8

58

FF H

SE

CI8

60

PM8x

x

TRIO

I/O

CI8

62

Sat

t I/O

CI8

65

Mod

bus

TCP

CI8

67

The table below is a summary of the interfaces (for details refer to hardware manual):

Unit Description On-line replacement

Redundancy

CI851 PROFIBUS DP-V0 communication interface unit. Only to use with S200 I/O.

No No

CI853 RS-232C serial communication interface unit. No No

CI854 PROFIBUS DP-V1 communication interface unit. Redundant Profibus cabling possible.

No No

CI854A PROFIBUS DP-V1 communication interface unit. Redundant Profibus cabling and redundant interface cards.

Yes Yes

CI855 MasterBus 300 communication interface unit for the AC 800M. Yes No

CI856 S100 I/O system communication interface unit. Up to five S100 I/O racks can be connected to one CI856 where each I/O rack can hold up to 20 I/O boards.

Yes No

CI857 INSUM communication interface unit. Yes No

CI858 Communication interface for ABB Drives using DriveBus No No

CI860 Fieldbus Foundation HSE communication interface unit. Not possible to use in AC800M HI.

Yes No

CI865 Communication interface unit for older Satt I/O systems. Yes No

CI867 Provides communication with Modbus TCP via Ethernet. Yes No


Chapter 4 - 11

4.4.2 Communication Exchange Bus - CEX Bus

TB850

TK850 with DB25P and TB851or

TB850

TK850 with DB25P and TB851or

Up to 12 communication units can be placed on the CEX bus

The CEX-bus must be terminated if a communication unit is connected. A CEX-bus termination is delivered with the CPU: TB850 (male) or TB851 (female).

An extension cable TK850 with connector DB25P with metal housing and a length of 0.7 meter (2.3) can be used for extending the CEX bus to a second DIN rail.


Chapter 4 - 12

4.5 Input / Output Modules

4.5.1 Range of ABB I/O modules

The following I/O types can be connected to an AC 800M system:

S800 modular I/O

S800 modular I/O with intrinsic safety (IS)

S800L I/O This is a compact I/O with an integrated I/O and terminal unit. This I/O cannot be replaced on-line.

S200 I/O This I/O must be connected through communication module CI865

S900 I/O This I/O must be connected through a CI920 PROFIBUS module. The I/O is suitable for use in hazardous areas.

S100 I/O This I/O must be connected through communication module CI856


Chapter 4 - 13

4.5.2 I/O Connection Possibilities

I/O units are connected in two ways:

ModuleBus (electrical or optical)

PROFIBUS DP

An I/O cluster consists of one CI830/CI801 or TB820 and a number of I/O modules. Max. 12 I/O modules can be included in one I/O cluster.

S900 I/O can only be connected through PROFIBUS DP.

The PROFIBUS slave CI830/CI801 can be also be supplied with an adapter TB810 to extend the ModuleBus by optical cable.

NOTE! CI830 is replaced by CI801 to support the HART protocol.


Chapter 4 - 14

4.5.3 S800 I/O Connected with ModuleBus

The ModuleBus interface is used for handling local S800 I/O on the AC 800M controller. I/O units connected to ModuleBus are organized into clusters. The ModuleBus in the AC 800M controller consists of:

Electrical ModuleBus (base cluster) not extensible and maximum of twelve S800 I/O units

Optical ModuleBus maximum of seven TB820 cluster modems

Max. 96 I/O modules

1-12* S800 I/O modules per cluster

Base cluster

Modulebusextension

max. 2.5 meters

I/O cluster 1TB820

Optical modem

TerminationTB807

max. 15 or 200m

I/O cluster 2

Simplex

I/O cluster 3

Duplex

I/O cluster 4

max. 15 or 200m

The optical modem TB820 acts as an adapter from optical to electrical ModuleBus. A maximum of 7 optical modems can be connected to the CPU.


Chapter 4 - 15

4.5.4 S800 I/O Connected with PROFIBUS

The CI854 unit is the main PROFIBUS DP-V1 communication interface and it can be used to communicate with remote I/O or with actual PROFIBUS devices.

Max. 24 I/O modules / I/O Station

1 base cluster

1-7 I/O cluster

1-12* S800 I/O modules per cluster *The memory size and bus load in the CI830/CI801 or TB820 limits the number of I/O modules per cluster

Max. cluster length 2.5m (electrical ModuleBus)

Base cluster

CI801Profibus slave

CI854Profibus master

Max. 2.5 meters

I/O cluster 1

withTB810

I/O cluster 2

Simplex

I/O cluster 3

max 15 or 200m

Duplex

I/O cluster 4

max 15 or 200m

TB820Optical modem

NOTE! CI840 is the redundant version of CI801.


Chapter 4 - 16

4.5.5 Limitations of CI801

The maximum number of I/O modules you can connect to a station is 24 modules.

Due to the PROFIBUS-DPV1 specification it is not possible to always connect 24 I/O modules. The reason is that the S800 I/O system includes more data and user parameters than PROFIBUS-DPV1 can handle. The table below shows the maximum number of I/O modules that can be connected to one CI801.

NOTE! Please refer to the manual for more information.

4.5.6 Module Terminal Unit for S800I/O

The S800 I/O unit is attached to an MTU, Module Terminal Unit. A number of MTUs are available. They can however be divided into two major groups, depending on the physical layout:

Compact / 1 connection per channel

Extended / 3 connections per channel

Compact Extended NOTE! Mechanical key protection prevents wrong I/O module

type from being inserted.


Chapter 4 - 17

The table below gives an overview of which MTU could be used for the different I/O-modules.


Chapter 4 - 18

4.6 LED indications

All hardware units have LED indicators on the front panel. These indicators can be used to diagnose different error conditions in the hardware. Typically after reading the status of the unit by looking at the LED, a number of different actions should be tried to remedy the problem.

4.6.1 PM8xx Controller Indications

On the front of the controller there are a series of LED indications as shown in the diagram below.

Fault

Run

Power

Battery

Primary

Dual

4 x Tx and Rx LEDs


Chapter 4 - 19

4.6.1.1 Running Conditions

Under normal running conditions the LED indications should be indicated in the following table.

Name Color Function

F(ault) Red Normal State OFF Self check OK

P(ower) Green 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 condition of internal or external battery is satisfactory. The LED is controlled by a software battery voltage test BATTOK (1)

Tx Yellow Data Transmission(2) for CN1,CN2 ,COM3 and COM4 Flashes in synchronization with Tx traffic

Rx Yellow Data Reception(2) for CN1,CN2 ,COM3 and COM4 Flashes in synchronization with Rx traffic

Valid for PM861/PM864/PM865

PRIM(ary) Yellow Lit in single and redundant configuration. Indicates Primary CPU in redundant configuration. Controlled by software

DUAL Yellow Lit when the CPU is running in redundant configuration and synchronized state.

(1) The battery provides back-up power for both the application memory and the real time clock during power down. The battery is either accessible via the PM8xx cover panel or externally connected to the external battery connector. Battery voltage is cyclically checked by the software. Voltage is common for both the internal and external battery. For this reason the internal battery should be removed when using the external battery, since having two batteries connected in parallel will result in greatly reduced capacity.

(2) Only CN1 for PM851. Do not connect to CN2.


Chapter 4 - 20

4.6.1.2 Fault Conditions

In the event of a suspected controller malfunction, refer to the table below for LED indications and possible corrective action.

Fault Possible Cause & Corrective Action F(ault) LED is ON Controller Re-start, (INIT), in progress.

Wait for Controller restart to finalize. If condition persists:

Check that the CEX-bus fuse is serviceable. Check for a module failure on the CEX-bus.

R(un) LED is OFF No application loaded on the Controller. Load application. Restart Controller (INIT push button).

Controller application failed. Reload application. Restart Controller (INIT push button).

B(attery) LED is flashing Battery power (Internal or External) is below an acceptable level or non-existent.

Install new battery. External battery cable disconnected.

Connect external battery cable.

Rx is off CN ports: Telegrams from other station cannot be received on the controller. Check IP addresses and Network cables.

COM ports: Telegrams from slaves are not received. Check COM port and protocol settings. Check serial cables and modems.

DUAL LED is OFF on both CPUs (PM861 and PM864 only)

The CPUs are in the process of being re-started or configured. Allow time for this to finalize. RCU Link Cable disconnected.

Connect the RCU Link Cable. Different Control Software in the two CPUs.

Upgrade the CPUs with the same control software.

NOTE! Refer to section Maintenance in manual 3BSE036351 Controller Hardware - Hardware and Operation!


Chapter 4 - 21

4.6.2 S800 IO Module LEDs

The S800 modules are the most widely used for general applications due to their ability to be replaced online.

The figure below shows examples of front panels for different types of IO modules. On the front of each IO module there are three LEDs (F)ault, (R)un and (W)arning indicating the module status. One additional LED (O)utput Set as Predetermined is included on output modules.

For modules with special LED indications, refer to manual S800 IO - Modules and Termination Units for explanation.

The FAULT LED will indicate when the IO module detects a fatal error or before first access after power up. The RUN LED indicates when the IO module is operational. The WARNING LED indicates when a non-fatal error is detected, for example, an out of range analog channel, and the module continues to run.

The OSP LED indicates when the IO module is in OSP state, that is, when the module is commanded to OSP or when automatically set to OSP state due to communication error. The OSP value can be set on individual channels, which for a digital output can be 0 or 1, or the last known valid value. Similarly an analog output can have an OSP value of anything between 0 and 100% or the last known valid value.

In addition to the general LEDs, each digital channel has one amber LED indicating current state (on/off).


Chapter 4 - 22

The table below shows the status of the LEDs during different states of the IO unit.

4.6.3 S800L IO Module LEDs

The low cost version can be distinguished by the fact that the base is integral with the unit. S800L IO units have fewer LED indicators than S800 IO.


Chapter 4 - 23

On the front of each IO module there is one LED indicating the module status.

Some IO modules also have LED indicators that are specific for that module. Digital IO units also have one LED for each channel.

The table below shows the LED indication during different conditions of the IO unit.


Chapter 4 - 24

4.7 Hardware Redundancy

4.7.1 Redundant Processor Unit - PM861/PM864/PM865

In a system with redundant Processors, the controller contains two processor units, each including memory for system and application software. In a redundant system the two processor units are linked together with the RCU Link Cable (max 1 m).

One unit is acting as primary, the other is backup (hot stand-by). The primary processor unit controls the process. The backup stands by to take over in case of a fault in the primary. The primary CPU is always updating the backup CPU.

You can select late in your project if you need redundancy option.

Both CPUs are connected to the CEX bus and either of the two can control the communication interfaces. BC810 supports online replacement of the CPU baseplate without disturbing the CEX traffic.

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

Memory or other hardware error in the Primary CPU.

Severe communication errors on the Control network, that is, loss of both network ports in the Primary CPU.

Severe communication errors on the ModuleBus

NOTE! The changeover is done bumpless and in less than 10 ms.

RCU Link


Chapter 4 - 25

4.7.2 Controller and I/O Redundancy

Use of redundancy will reduce the maximum number of S800 channels. Each cluster may contain up to 12 single S800 I/O units or up to 6 redundant S800 I/O units.

Optical ModuleBusCable

RedundancyLink Cable

CEX -bus splitter BC810

Redundant PROFIBUS CICI854A

Redundant or SingularS800 I/O

Redundant S800 I/O as direct I/O

4.7.3 Module Terminal Unit for S800I/O

For redundant S800 DI, DO, DP and AO modules the MTU842 and MTU843 are used. For the redundant S800 AI modules the MTU844 and MTU845 are used. On these MTUs there is one shunt-stick for each channel for configuration of mA or voltage input.

Use of redundancy will reduce the maximum number of S800 channels on the ModuleBus. Each cluster may contain up to 12 single S800 I/O units or up to 6 redundant S800 I/O units.


Chapter 4 - 26

4.7.4 Redundant ModuleBus I/O Connections

When you use redundant I/O module configuration, the maximum number of I/O modules in one cluster is 6 pairs.


Chapter 4 - 27

4.7.5 Redundant PROFIBUS I/O Connections

When you use redundant I/O module configuration, the maximum number of I/O modules in one cluster is 6 pairs.

TU846 is used for Redundant I/O modules

TU847 is used for non redundant I/O modules

CI840 is connected to CI854 PROFIBUS master

TU846 or TU847


Chapter 4 - 28

For PROFIBUS it is possible to have different levels of redundancy:

Line redundancy

Master redundancy

For a redundant master solution the CI854A is installed in a redundant configuration. The Profibus DP-V1 cable is connected to both primary and backup module. When a CI854A module fails or bus communication is interrupted, the redundancy partner is automatically activated. A CI854A pair balances the data cyclically over a fast link.

CI854A Master CI854A Master


Chapter 4 - 29

4.7.6 Redundant Power Supply

In the figures below, there are two examples of redundant power solutions. The SS82x voting unit is used to connect two redundant power supplies to a common load.

Redundant power supplies connected to the SS82x voting device with one common main.

OKL+ L+ L- L-

N L PESD821

OKL+ L+ L- L-

N L PESD821

OKL+ L+ L- L-

N L PESD821

OKL+ L+ L- L-

N L PESD821

OK+ F

A+B+L+L+L-SS822

OK+ FA B

OK+ F

A+B+L+L+L-SS822

OK+ FA B

Main

L+ to +24VL- to 0VSA & SB to supervision inputs on PM860 or CI830

Redundant power supplies connected to the SS82x voting device with two separate mains.

OKL+ L+ L- L-

N L PESD821

OKL+ L+ L- L-

N L PESD821

OKL+ L+ L- L-

N L PESD821

OKL+ L+ L- L-

N L PESD821

OK+ F

A+B+L+L+L-SS822

OK+ FA B

OK+ F

A+B+L+L+L-SS822

OK+ FA B

Mains 1

L+ to +24VL- to 0VSA & SB to supervision inputs on PM860 or CI830

Mains 2


Chapter 4 - 30

T308-04 AC800M Hardware - RevC

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