Chapter 7 AC 800M Hardware Course T314

Overview Objectives Reference Documentation AC 800M Hardware Overview Objectives After this chapter you should be able to: Describe the AC 800M hardware components Check the hardware configuration Download and test hardware in online mode Reference Documentation 3BSE036351 IndustrialIT 800xA – Control and I/O AC 800M Controller - Hardware and Operation 3BSE035980 IndustrialIT 800xA – Control and I/O Basic Control Software – Introduction and Configuration 3BSE020923 IndustrialIT 800xA – Control and I/O S800 I/O – General Information and Installation 3BSE020924 IndustrialIT 800xA – Control and I/O S800 I/O – Modules and Termination Units

AC 800M Controller Hardware Overview AC 800M Controller Hardware Optional up to 12 Communication modules CPU S800 I/O RS-232 channels Redundant Ethernet

AC 800M Hardware CPU Communication Interfaces I/O Connections Hardware Redundancy Hardware Configuration Application Download Online Functions

Fuses for Modulebus and CEX-bus CPU CPU PM8xx Compact Flash Card Fuses for Modulebus and CEX-bus CPU Baseplate

Choice of speed, memory and availability CPU Choosing the Right CPU Choice of speed, memory and availability Redundant Redundant PM865 PM864 Redundant PM861 PM860 PM856 32MB 96 MHz SIL2 32MB 96 MHz PM851 16MB 48 MHz 8MB 48 MHz 8MB 24 MHz 8MB 24 MHz

Different Processor Units CPU Different Processor Units Unit Description On-line replacement Redundancy PM851 48 MHz / 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 PM856 2 Ethernet ports, 1 Serial port and 1 tool port. Application speed is half of PM860. PM860 2 Ethernet ports, 1 Serial port and 1 tool port. PM861 48 Mhz / 16 Mbytes RAM 2 Ethernet ports, 1 Serial port and 1 tool port. Singular or redundant. Yes PM861A Same as PM861 but can use redundant communication unit CI854A, CI860 and BC810. 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. PM864A Same as PM864 but can use redundant communication unit CI854A, CI860 and BC810. PM865 (PA/HI) 2 Ethernet ports, 1 Serial port and 1 tool port. PM865 can be used in an AC 800M High Integrity system.

Start Modes Warm restart Cold restart Reset CPU Start Modes Warm restart Power Off/On with a battery backed up CPU Applications restart with retain values Cold restart Press Init < 2.5 s Applications restart with cold retain values Reset Press Init > 3 s or until Run LED flashes Applications are deleted !!!

CPU Battery Compact Flash card available for non-volatile storage (application and data) Internal External

AC 800M Ports CPU Communication Expansion CEX-bus CPU S800I/O’s on the Electrical ModuleBus RCU link connection Fiber opticale ModuleBus Ethernet ports COM 3-4 ports

AC 800M High Integrity Controller CPU AC 800M High Integrity Controller 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 Support for SM810 Increased system diagnostic and online self tests

AC 800M Hardware CPU Communication Interfaces I/O Connections Hardware Redundancy Hardware Configuration Application Download Online Functions

Communication Interface Units Overview CI854A CI867 CI865 CI862 CI860 CI858 CI857 CI856 CI855 CI853 PM8xx Modbus TCP Satt I/O TRIO I/O FF HSE DriveBus INSUM S100 I/O MB300 PROFIBUS DP RS232

Refer to Manuals for Details Communication Interface Units Refer to Manuals for Details Unit Description On-line replacement Redundancy CI851 PROFIBUS DP-V0 communication interface unit. Only to use with S200 I/O. No CI853 RS-232C serial CI854 PROFIBUS DP-V1 communication interface unit. Redundant Profibus cabling possible. CI854A Redundant Profibus cabling and redundant interface cards. Yes CI855 MasterBus 300 communication interface unit for the AC 800M. 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. CI857 INSUM communication interface unit. CI858 Communication interface for ABB Drives using DriveBus CI860 Fieldbus Foundation HSE communication interface unit. Not possible to use in AC800M HI. CI865 Communication interface unit for older Satt I/O systems. CI867 Provides communication with Modbus TCP via Ethernet.

Communication Exchange Bus - CEX Bus Communication Interfaces Communication Exchange Bus - CEX Bus TB850 TK850 with DB25P and TB851 or

AC 800M Hardware CPU Communication Interfaces I/O Connections Hardware Redundancy Hardware Configuration Application Download Online Functions

I/O Connections Range of ABB I/O Units

I/O Connection Possibilities I/O Connections I/O Connection Possibilities

S800 I/O Connected with ModuleBus I/O Connections S800 I/O Connected with ModuleBus max. 2.5 meters Base cluster ModuleBus extension Termination TB807 I/O cluster 1 TB820 Optical modem I/O cluster 2 I/O cluster 3 I/O cluster 4 Duplex Simplex max. 15 or 200m max. 15 or 200m

S800 I/O Connected with Profibus I/O Connections S800 I/O Connected with Profibus CI801 Profibus slave with TB810 CI854 Profibus master Base cluster Max. 2.5 meters TB820 Optical modem I/O cluster 1 I/O cluster 2 I/O cluster 3 I/O cluster 4 Duplex Simplex max 15 or 200m max 15 or 200m

I/O Connections Limitations of CI801 + = ~ - 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. + = ~ - Compact MTU with 2-wire connection More compact, Requires external wiring Mix and match compact and extended termination block to the actual installation Extended MTU with 3-wire connection No external wiring required, i.e. cost saving of external marshalling Compact MTU´s TU810, Screw terminals, RIV 50V TU811, Screw terminals, RIV 250V TU812, 25 pol D-sub, RIV 50V (E.g. Exi) TU814, Crimp snap-in connector, RIV 50V Extended MTU´s TU830, Screw terminals, RIV 50V TU831, Screw terminals, RIV 250V TU835, Screw term, Ext. Fused RIV 50V TU836, Screw term, Ext. Fused RIV 250V (DO820) TU837, Screw term, Ext. Fused RIV 250V (DO820) TU838, Screw term, Ext. Fused RIV 50V

Module Termination Units I/O Connections Module Termination Units + = ~ - Compact Extended + = ~ - Compact MTU with 2-wire connection More compact, Requires external wiring Mix and match compact and extended termination block to the actual installation Extended MTU with 3-wire connection No external wiring required, i.e. cost saving of external marshalling Compact MTU´s TU810, Screw terminals, RIV 50V TU811, Screw terminals, RIV 250V TU812, 25 pol D-sub, RIV 50V (E.g. Exi) TU814, Crimp snap-in connector, RIV 50V Extended MTU´s TU830, Screw terminals, RIV 50V TU831, Screw terminals, RIV 250V TU835, Screw term, Ext. Fused RIV 50V TU836, Screw term, Ext. Fused RIV 250V (DO820) TU837, Screw term, Ext. Fused RIV 250V (DO820) TU838, Screw term, Ext. Fused RIV 50V

AC 800M Hardware CPU Communication Interfaces I/O Connections Hardware Redundancy Hardware Configuration Application Download Online Functions

Redundant Processor Unit Hardware Redundancy Redundant Processor Unit

Controller and I/O Redundancy Hardware Redundancy Controller and I/O Redundancy CEX - bus splitter BC810 Redundant S800 Redundancy Redundant I/O as direct I/O Lin k Cable PROFIBUS CI CI854A Redundant or Singular S800 I/O Optical ModuleBus Cable

ModuleBus I/O Redundancy Hardware Redundancy ModuleBus I/O Redundancy

PROFIBUS I/O Redundancy Hardware Redundancy PROFIBUS I/O Redundancy

AC 800M Hardware CPU Communication Interfaces I/O Connections Hardware Redundancy Hardware Configuration Application Download Online Functions

Hardware Configuration Adding a CPU ModuleBus Scan Cycle Time can be set in the range 0...100 ms default setting is 0 (as fast as possible) and can load the CPU significantly minimum scan time in practice will be 6 ms

Adding Communication Interface Hardware Configuration Adding Communication Interface

Hardware Configuration Hardware Libraries

Adding S800 I/O on ModuleBus Hardware Configuration Adding S800 I/O on ModuleBus

Adding S800 I/O on PROFIBUS Hardware Configuration Adding S800 I/O on PROFIBUS

Hierarchical Dot Notation Hardware Configuration Hierarchical Dot Notation position number for the CI851 is the physical location on the CEX-bus position for the CI830 is the PROFIBUS node number (set by switches)

Hardware Configuration Settings of I/O Units

Hardware Configuration Adding Compact Flash

Changing the IP address Hardware Configuration Changing the IP address System identity should normally correspond to the setting for Ethernet 1

AC 800M Hardware CPU Communication Interfaces I/O Connections Hardware Redundancy Hardware Configuration Application Download Online Functions

Application Download Download

Application Download Difference Report

Application Download Re-Authentication

AC 800M Hardware CPU Communication Interfaces I/O Connections Hardware Redundancy Hardware Configuration Application Download Online Functions

Online Functions Status of I/O-Signals

Online Functions Forcing

Online Functions SoftController