1. Control IT Hardware (AC800 M/C) & SoftController
Good morning.
It is my pleasure to join you today for a brief update on ABB, and some of the steps we are taking to strengthen our customer focus, our performance, and our growth prospects.

2. A suite of IEC 61131-3 compatible controllers
AC 800M – the new Modular Controller designated for binary control as well as advanced control applications
AC 800C – the Compact Controller for small, yet advanced applications
SoftControl – the controller that runs on a PC providing high performance at low cost
<Talk about a family with a number of members and each member has it own personalities.

3. AC 800 M

4. ControlIT AC 800M Hardware
Modular and flexible concept, DIN-rail mounted
Built in redundant Ethernet
Very low power consumption
Hot swap of communication- and I/O modules
Local and remote I/O options
Industry quality hardware with excellent EMC and MTBF properties

5. AC 800M Controller with a S800 I/O Module
I/O System
Communication Interface
Processor Module
S800 I/O
Module
<Talk about a family with a number of members and each member has it own personalities.

6. Processor Module

7. Processor Module

8. Hardware mapped to Control Builder1 2 3 4 5 6 7 8 1 6 5 4 3 2 7 8

9. Base components for AC 800M
Processor Module
PM860 - Processor
TP830 - Baseplate
Communication Interfaces
CI851 – Profibus
CI852 – Foundation Fieldbus
CI853 – RS232-C
Power Supply
SD V d.c. 2.5 A
SD V d.c. 5 A
SD V d.c. 10 A
Battery Backup
SB821- External Backup

10. Processor Module MPC860/48MHZ 8 MB RAM 2 MB System FLASH PROM
Motorola Power PC
8 MB RAM
5 MB for application program
3 MB for executable firmware
Mounted on the module
2 MB System FLASH PROM
For non-volatile storage of firmware and license key
Optical Modulebus to connect clusters of S800 I/O modules
A connector for Compact Flash (not included in this release)
Two Ethernet ports for connection to the control network
CN1, CN2
Two serial ports (COM3, COM4)
COM3 is an RS232-C port with modem control signals
COM4 is isolated and used for the connection of the configuration tool
Electrical Modulebus is used for connection clusters of S800 I/O directly to the baseplate
CEX-bus is used for extending the on-board communication ports with communication interface modules

11. Power Supply Switch-mode power converters
Converting a.c. Mains supply voltage to a regulated 24 V d.c.
Input can be either 115 V a.c. or 230 V a.c
Redundant or non redundant
When a redundant power supply is connected to a common load, you need a voting device, SS822, to combine two outputs into one via diodes
The CPU module does has no requirement for a UPS
It has a 5 ms reservoir to safely shutdown
The power supply handles short power interruptions (<20 ms)
Available modules
SD 823
24 V d.c. 10 A
SD 822
24 V d.c. 5 A
SD 821
24 V d.c. 2.5 A

12. External battery Connection
Battery Backup
External battery
Internal battery
Up to one month (720 hours)
Lithium Battery 3.6 V, 950 mAh.
External battery module - SB821
Lithium battery, 3.6 V 16 Ah
A minimum of 18 months
Mounted on the DIN rail and connected to the CPU via cable
Internal battery
External battery Connection

13. I/O System Local I/O – S800 Remote I/O via Profibus
12 local I/O modules per cluster
24 with optical modem
7 clusters x 12 I/O modules of local on the Modulebus
Up to 96 local I/O Modules
Remote I/O via Profibus
Foundation Fieldbus and Advant Fieldbus to come
Recommened to use ABB I/O S900, S800 and S200
Field Communication Interface (FCI) is used to connect the I/O modules to the PROFIBUS
There is no physical limit for the number of I/Os that can be connected to AC 800M
Recommendation
~ I/O per controller
The memory for the application sets the limit
The hardware is relatively cheap
Buy an extra controller

14. I/O System Local I/O Remote I/O via Profibus CI851 Profibus PM860 CPU
Up to 96 modules
Remote I/O via Profibus
CI851
Profibus
PM860
CPU
PM860
CPU
12 I/O Modules
Optical
CI830
FCI
12 I/O modules
TB820
Optical Modem
12 I/O modules
Up to 24 modules per stations
Optical
CI830
FCI
12 I/O modules
TB820
Optical Modem
12 I/O modules
TB820
Optical Modem
12 I/O modules
Up to 7 clusters and 200m between clusters
Up to 5 PROFIBUS segments
Up to 32 stations per segment
Up to 24 modules per stations
Up to 384 DI/DO and 192AI/AO per station

15. AC 800M / S800 I/O Interconnection
<Talk about a family with a number of members and each member has it own personalities.

16. AC 800M / S800 I/O Interconnection
TB805
CI851
PM810
AI810
AI810
AO810
AO810
AO810
AO810
TB850V007
TK801V003/6/12
TB851
See note 1
TB806
CI851
AI810
AI810
AO810
AO810
AO810
AO810
See note 3
See note 2
TB820
DI810
DI810
DO810
DO810
TK811V015/050/150
See note 5
To addition module clusters
CI830
DI810
DI810
DO810
DO810
TB810
See note 4
TB820
DI810
DI810
DO810
DO810

17. Modulebus Extension & Termination
TB805
TB806
DIN-Rail
TK801V003/006/012
Note 3

18. I/O Module on Compact & Extended MTUs
I/O Modules
Extended MTU
Typical Compact MTU with I/O Module
CI830
Compact MTU
<Talk about a family with a number of members and each member has it own personalities.
Typical Extended MTU with I/O Module

19. AC 800M Connectors for Optical Modulebus
Duplex Fiber Optic Cable Connector
TK811V015/050/150 Rx Tx
TK812V015/050/150
Simplex Fiber Optic Cable Connector
<Talk about a family with a number of members and each member has it own personalities.
Front View
Note 1
For connection from PM810 to TB820

20. TB820 Optical Modulebus Connection
Interface Connectors
(X4, X5)
TK811V015/050/150 Rx X4 Tx
Duplex Fiber Optic Cable Connector Rx X5
TK812V015/050/150 Tx
Simplex Fiber Optic Cable Connector
Front View
Note 5

21. CEX Extension & Termination
Note 2

22. CEX Extension & Termination
<Talk about a family with a number of members and each member has it own personalities.
Note 2

23. Supported S800 I/O Modules (Local & Remote)
S800 I/O I.S. Modules
S800L I/O Modules

24. Supported S200 I/O Modules (Remote I/O)
Via 200-APB12 PROFIBUS Adapter
S200L I/O Modules
S200 I/O Modules
S200L I/O Modules

25. PROFIBUS Support CI851 – Profibus Interface TP851 – Baseplate
Power from the processor module
TP851 – Baseplate
Profibus DP must be terminated on both sides
It is possible to connect any standard PROFIBUS I/O via CI851
For example S800 I/O or S200 I/O

26. PROFIBUS Connection - CI830 & TB820
Connector for TB810
TB820
Modulebus Optical Port
Power Supply
Connections
<Talk about a family with a number of members and each member has it own personalities.
Profibus-DP Connector
Note 4
CI830

27. AC 800M, Profibus integration
S800 I/O
Profibus-PA via standard segmentcoupler
Profibus-DP
S900 I/O
Profibus-PA
DP/PA Converter

28. Foundation Fieldbus (In future release)
CI852 – Foundation Fieldbus H1 Interface
Power from the processor module
TP852 – Baseplate
Up to 32 Foundation Fieldbus Devices

29. AC 800M ,FF integration
Communication with FF-instruments is easily performed via IEC function blocks
FF H1

30. Serial Interface – RS232-C
CI853 – RS232-C
Two serial ports
Power from the processor module
TP853 – Baseplate
A RS232-C channel, with full modem support, can be connect to COM1 or COM2
For cables longer than 15m a short distances modem, TC562, must be used
Up to 12 km, depending on the transmission speed
Available Protocols
Please see screen dump to the right

31. CEX Extension and Termination
CEX Bus in the communication bus
TB 850 CEX-bus termination shall always be installed on the last unit
CEX extension cable TK850 (0.7m) to mount the modules on another DIN-rail

32. Modulebus Extension and Termination
The Modulebus connects the local I/O
A terminator, TB807, must always be mounted on the last I/O module on the Modulebus
Will support direct connection to Drives in the future

33. Example of Wall mounted
Installation
Mounted on a horizontal DIN rail
Locking device to connect to the DIN rail to get grounding
The locking device can be in OPEN, SLIDE or LOCKED
AC800M & S800I/O has protection class IP20
To get higher protection we recommend the following cabinets with protection class IP54
RM550 – Floor mounted
RE820 – Wall mounted
Example of Wall mounted

34. Environmental Specifications

35. CE Compliance

36. Electromagnetic Compatibility and Main Voltage Conditions

37. AC 800 C

38. AC 800C Main Module Processor Module – PM210 On board I/O Modules
18,432 MHz
2 Mb RAM and 2 Mb Flash PROM
On board I/O Modules
10 DI, 6 DO
Two on-board RJ-45 jacks for RS-232 channels
COM 0 – The port for the Control Builder
COM 1- full set of modem control signals
Two slots for optional communication plug-in boards are provided
Serial Links
Ethernet
PROFIBUS-DP master of class 1
FOUNDATION Fieldbus link master (future)
Battery back-up module - SB210
1 slot for an optional battery plug-in board with a real-time clock and a lithium battery

39. AC 800C Hardware Layout

40. Hardware mapped to Control Builder8 7 1 1 2 3 4 5 6 7 8 6 5 2 4 3

41. Installation Horizontally and vertically mounted on the DIN rail
The AC 800C, S200, S200L and S800 I/O-unit have all protection class IP 20

42. AC 800C / S200/S200L/ S800 I/O Modules Interconnection
Programming Terminal
Central I/O
Remote I/O
AC 800C
S800 I/O
S200/S200L I/O
Profibus-DP
S200/S200L I/O

43. How to connect I/O Modules
On-board I/O
10 DI and 6 DO on board
24 V DC
The inputs and outputs are filtered and galvanically isolated by optocouplers
Local Input/Output (I/O) units
8 S200 Local I/O Modules
two rows by means of the extension cables CE1 or CE3.
8 Extra via a TK210 cable and a 200 AIO adapter
Remote I/O Modules
PROFIBUS-DP can be used for connection of remote I/O units, for instance S200/S200L and S800 I/O units
The total number of I/O units connected (central and remote) to the controller are 32 I/O units

44. On board I/O On-board I/O 10 DI and 6 DO on board
24 V DC
The inputs and outputs are filtered and galvanically isolated by optocouplers
A separate two-pole plug-in screw connector for the external +24 V DC power supply
The unit is not damaged if the polarity is reversed

45. Local I/O Local Input/Output (I/O) units 8 S200 Local I/O Modules
two rows by means of the extension cables CE1 or CE3 0.3 and 0.9 m respectively
8 Extra via a TK210 cable and a 200 AIO adapter
(length 0.5, 1.0, or 2.5 m)
Note that a TK210 cable longer than 0.9 m is not allowed in hazardous locations according to UL1604

46. Supported S200 I/O (Local & Remote)
S200C I/O Modules
S200 I/O Modules
S200L I/O Modules

47. AC 800C Communication Possibilities
To Control Builder
Via a serial port using the PPP protocol, or alternatively via Ethernet
Serial Interfaces
Available protocols are Siemens 3964R (as master),
COMLI, MODBUS RTU (as master) and MMS. User-defined protocols may also be used
Fieldbus Support
PROFIBUS
FOUNDATION Fieldbus
On-board serial Communication
COM 0 can receive and transmit signals
COM 0 is the default channel for the programming station tool port
COM 1 has a full set of modem control signals
Each channel has LEDs indicating the status of transmit and receive activities
RS-232 is a point-to-point communication standard with a maximum cable length of 15 meters

48. Communication Extensions
Ethernet Communication Board CI272
Profibus Communication Board CI274
RS-232 Communication Board CI271

49. Communication Extensions - Serial
RS-232 Communication Board CI271 (Option)
There are two RJ-45 jacks for RS-232 channels
Full set of modem control signals
This gives a multiple RS-232 point-to-point communication with e.g. printers, scales, bar codes, controllers, and for multiple protocols (COMLI, Modbus, etc)

50. Communication Extensions - Ethernet
Ethernet Communication Board CI272 (Option)
Enables a network consisting of many interconnected controllers, operator stations and servers
Communication via MMS
It has one RJ-45 jack for Ethernet 10BASE-T (twisted pair, max. cable length 100 m)

51. PROFIBUS Board – CI274 PROFIBUS Board - CI274
A fast (12 Mb/s) PROFIBUS-DP master
A PROFIBUS-PA can also be used, via a segment coupler 1, in heavy industries with intrinsically safe I/Os
The CI274 board acts as a PROFIBUS-DP master of class 1 and up to two of them can be installed on the AC 800C controller

52. PROFIBUS Board – CI274
Can be used to connect remotely installed S800 I/O, S200 I/O, S200L I/O and third party I/O units
Maximum length of 100 to 1200 meters, depending on the transmission rate
S800/S800L I/O
The S800 I/O units are connected to one or more I/O adapters, CI830
These I/O units are connected to one or more I/O adapters, with a maximum of twelve I/O units per adapter.
Additional units can be connected to the same adapter via optical cables and optical interface units, TB820.
S200/S200L I/O
These I/O units are connected to one or more I/O adapters, 200-APB12, with a maximum of eight I/O units per adapter

53. FOUNDATION Fieldbus – CI 275 (future release)
The CI275 board is an optional interface for remote connection of Kb/s FOUNDATION Fieldbus devices
A maximum length of 200 to 1900 meters, depending on cable type
The CI275 board acts as link master device
Used to connect remotely installed I/O and third-party units and which comply with its specifications

54. Battery Backup - SB210
At least a year with the battery and 20 minutes without
Low battery voltage, such as after a power failure, is indicated by flashing PWR
Battery replacement can be performed during operation by lifting a small lid in the controller cover. UL-approved 3 V batteries of type CR2430 must be used

55. Power Supply
Note
The controller and the I/O systems should, if possible, have separate 24 V DC supplies

56. Technical Data

57. Environmental Specification - Climate

58. Environmental Specification - Mechanical

59. CE - Compliance

60. Electro Magnetic Compatibility

61. Electro Magnetic Compatibility

62. SoftController For future release

63. SoftControl – An Overview
A personal computer can be turned into a controller by means of Control Builder software and communication plug-in boards
Central I/O
S200 and S200L I/O units
Remote I/O
Via PROFIBUS-DP and FOUNDATION Fieldbus. SattBus (developed by ABB Automation Products) and DataHighway Plus (from Allen-Bradley)

64. Hardware mapped to Control Builder

65. Communications – Serial Interface
S-232 Protocols
A PC is usually delivered with one or two RS-232 COM-ports (COM1 and COM2)
You can add more interface boards
Standard protocols such as PPP is specified by use of standard Windows installation software
A range of other protocols can be defined by the Project Explorer

66. Local I/O S200/S200L I/O units
Up to four plug-in boards can be handled by the Soft Controller
each of them capable of connecting up to sixteen I/O units
Use the ISA CIIO Board
Alternatively, the units can be connected via PROFIBUS-DP

67. Supported S200 I/O (Local & Remote)
S200C I/O Modules
S200 I/O Modules
S200L I/O Modules

68. Ethernet Communication
A standard Ethernet PC board can be used if the controller is to be connected to Ethernet
Use standard network components to build your network

69. PROFIBUS-DP Communication
A plug-in board a PROFIBUS-DP network.
Up to four board per SoftController
Two adapters
one for connection of up to eight S200/S200L I/O units
The other for connection of up to twelve S800 I/O units
S200 I/O Modules via PROFIBUS
S800 I/O Modules via PROFIBUS

70. FOUNDATION Fieldbus FOUNDATION Fieldbus
Up to thirty-two FOUNDATION Fieldbus devices can be connected to a plug-in board. Up to four such boards can be handled by the SoftControl

71. SattBus
SattBus is a communication protocol and a physical layer, both developed by ABB Automation Products
Up to 120 nodes can be connected to a SATTBUSPC board, and up to four such boards can be handled by the SoftController
COMLI can be used for communication on SattBus

72. DataHighway Plus
DataHighway Plus is a multi-master communication protocol from Allen-Bradley
Up to 63 Allen-Bradley PLC-5 systems can be connected to a DataHighway Plus board, and up to four such boards can be handled by the SoftController.

73. Hardware Requirements