1. Chapter 7 AC 800M Hardware
Course T314

2. 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
3BSE IndustrialIT 800xA – Control and I/O AC 800M Controller - Hardware and Operation
3BSE IndustrialIT 800xA – Control and I/O Basic Control Software – Introduction and Configuration
3BSE IndustrialIT 800xA – Control and I/O S800 I/O – General Information and Installation
3BSE IndustrialIT 800xA – Control and I/O S800 I/O – Modules and Termination Units

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

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

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

6. 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

7. 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.

8. 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 !!!

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

10. 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

11. 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

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

13. 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

14. 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.

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

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

17. I/O Connections
Range of ABB I/O Units

18. I/O Connection Possibilities
I/O Connections
I/O Connection Possibilities

19. 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

20. 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

21. 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

22. 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

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

24. Redundant Processor Unit
Hardware Redundancy
Redundant Processor Unit

25. 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

26. ModuleBus I/O Redundancy
Hardware Redundancy
ModuleBus I/O Redundancy

27. PROFIBUS I/O Redundancy
Hardware Redundancy
PROFIBUS I/O Redundancy

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

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

30. Adding Communication Interface
Hardware Configuration
Adding Communication Interface

31. Hardware Configuration
Hardware Libraries

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

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

34. 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)

35. Hardware Configuration
Settings of I/O Units

36. Hardware Configuration
Adding Compact Flash

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

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

39. Application Download
Download

40. Application Download
Difference Report

41. Application Download
Re-Authentication

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

43. Online Functions
Status of I/O-Signals

44. Online Functions
Forcing

45. Online Functions
SoftController