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Table of Contents

3BSE036351-510 A

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 ............................................................................132

Installing the SD83x Power Supply...............................................................................133

Installing the Mains Breaker Unit .................................................................................134

Installing the SS823/SS832 Voting Unit .......................................................................136

Installing the SB821 External Battery Unit...................................................................143

Installing the SB822 Rechargeable External Battery Unit ............................................144

Installation of I/O Units.................................................................................................145

Installation in Cabinets ..................................................................................................145

Mounting Dimensions for Proper Ventilation ...............................................................149

Section 3 - Configuration

General Information ......................................................................................................151

Connecting Control Builder ..........................................................................................152

Connection to a Control Network..................................................................................153

Communication Possibilities .........................................................................................154

Controller IP Addresses .....................................................................................157

I/O Systems ...................................................................................................................158

Drive System .................................................................................................................168

Power Supply System ....................................................................................................173

Powering Units in the Cabinet ...........................................................................174

Powering Field Equipment outside the Cabinet .................................................174

Powering from an External Source ....................................................................176

Section 4 - Operation

AC 800M Controller (PM8xx) ......................................................................................179

Start-up ..........................................................................................................................182

Start-up in Redundant Configuration (CEX Bus Considerations) .....................182

Start Modes....................................................................................................................183

Automatic Switch-Over to Backup CPU.......................................................................184

Summary of Contents for AC 800M

Page 1: ...Power and productivity for a better worldTM AC 800M Controller Hardware System Version 5 1...

Page 2: ......

Page 3: ...AC 800M Controller Hardware System Version 5 1...

Page 4: ...ssumes no responsibility for any errors that may appear in this document In no event shall ABB be liable for direct indirect special incidental or consequential damages of any nature or kind arising f...

Page 5: ...val 28 Released User Manuals and Release Notes 28 Section 1 Introduction Product Overview 29 AC 800M General 29 PM8xx TP830 Processor Unit General 33 PM891 Processor Unit General 40 PM891 PM86x TP830...

Page 6: ...ng the PROFIBUS DP Interface CI851 TP851 111 Installing the FOUNDATION Fieldbus H1 Interface CI852 TP852 113 Installing the RS 232C Interface CI853 TP853 115 Installing the PROFIBUS DP Interface CI854...

Page 7: ...e External Battery Unit 144 Installation of I O Units 145 Installation in Cabinets 145 Mounting Dimensions for Proper Ventilation 149 Section 3 Configuration General Information 151 Connecting Control...

Page 8: ...nk Cables Online 202 In Configuration with BC810 202 In Configuration without BC810 202 Corrective Maintenance Procedures 203 Fault Finding Procedures 204 PM8xx Processor Unit in Single CPU Configurat...

Page 9: ...Data 244 PM851A PM856A PM860A and TP830 Processor Unit 245 Technical Data 246 Performance Data 250 PM861 PM861A and TP830 Processor Unit 251 Technical Data 252 Performance Data 254 PM864 PM864A and TP...

Page 10: ...850 Interface 336 CI869 and TP869 AF 100 Interface 340 CI871 and TP867 PROFINET IO Interface 344 CI872 and TP858 MOD5 Interface 348 CI873 and TP867 EtherNet IP Interface 352 Power Supply Units Types S...

Page 11: ...411 Appendix D Directive Considerations Electro Magnetic Compatibility EMC 427 Low Voltage Directive LVD 427 Appendix E Standards Hazardous Location Approval 429 Appendix F Environmental Data Environ...

Page 12: ...Table of Contents 12 3BSE036351 510 A Revision History Introduction 449 Revision History 449 Updates in Revision Index A 450...

Page 13: ...ctions given here Warnings and Information Symbols in the Text Margin Observe the symbols for warnings and information located in other Chapters and Appendices of this book The symbols are placed in t...

Page 14: ...witching units to manual operation For hazardous locations special restrictions apply see Appendix E Standards Never connect the equipment to the mains power supply during installation work Take extre...

Page 15: ...ety when power supplies communication links or parts of the control system fail Such steps may require for example the installation of valves or relays that automatically return to a fail safe positio...

Page 16: ...o 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 17: ...Check Use the system s fault monitoring facilities to prevent accidents or mishaps When in doubt ALWAYS CHECK before executing changes Important Hardware Notice DO NOT under any circumstances disconne...

Page 18: ...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 Page 72 AC 800M units must b...

Page 19: ...not replace batteries unless the power has been switched off or the area is known to be non hazardous Page 430 Explosion hazard Do not disconnect equipment unless the power has been switched off or t...

Page 20: ...n sin gle configuration the RCU Link Cable TK851 might temporarily be used to perform the function of a termination plug Page 98 Do not connect the two CEX Bus segments separated with BC810 to each ot...

Page 21: ...memory will immediately start to consume battery power when the cable is connected Page 157 When setting the IP address of the primary CPU in Control Builder the backup CPU must be turned off powered...

Page 22: ...d use the Restore factory settings option subsequently followed by reassignment of the IP address or assignment of a new IP address Page 200 Do not under any circumstances remove the RCU Link Cable fr...

Page 23: ...eased User Manuals and Release Notes on page 28 User Manual Conventions Microsoft Windows conventions are normally used for the standard presentation of material when entering text key sequences promp...

Page 24: ...nology A complete and comprehensive list of terms is included in System 800xA System Guide Functional Description 3BSE038018 The listing includes terms and definitions that apply to the 800xA System w...

Page 25: ...ller Firmware for AC 800M HI Central I O Input Output units mounted onto a DIN rail and directly connected to the AC 800M controller via ModuleBus CEX Bus Communication Expansion Bus for communication...

Page 26: ...dant system the backup unit can be replaced without any disturbances to the primary unit This includes that the unit can be replaced online if it becomes faulty IEC International Electrotechnical Comm...

Page 27: ...the USA The logo indicates UL approval for Canada only The applied standard is UL508 Industrial Control Equipment Units approved for use at hazardous locations also comply with the standard UL60079 15...

Page 28: ...0263 System 800xA Released User Manuals and Release Notes 3BUA000263 is updated each time a document is updated or a new document is released It is in pdf format and is provided in the following ways...

Page 29: ...cessor units including baseplate PM851 PM851A PM856 PM856A PM860 PM860A PM861 PM861A PM864 PM864A PM865 PM866 PM891 High Integrity Processor Unit consists of PM865 and SM810 SM811 with corresponding b...

Page 30: ...always mounted onto the DIN rail carries the majority of the connections to processor power supplies and communication interfaces as well as the connections to the external buses and systems The AC 8...

Page 31: ...hows the physical appearance of an AC 800M Controller with an S800 I O Unit This physical appearance does not apply to PM891 Figure 2 shows the PM861 processor unit that is part of the AC 800M control...

Page 32: ...Tx Rx Optical ModuleBus External Battery Supply Socket Power Supply and Supervision Signal Socket COM3 COM4 Ports DIN rail Locking Device CN1 CN2 Ports Tx Rx Status INIT Push button LED Status Indicat...

Page 33: ...holder for memory real time clock RTC The termination board housed in the TP830 Baseplate is where the majority of the external connections terminates The board is grounded to the DIN rail through of...

Page 34: ...Section 1 Introduction 34 3BSE036351 510 A Figure 3 Processor Unit Assembly General View here shown with PM860 TP830 Cover Release Screw Cover Assembly CEX Bus Electrical ModuleBus Fuses CEX Bus Modul...

Page 35: ...ram PM851 PM851A is restricted to one Ethernet CN1 port 4 Power 5V DC 3 3V DC Battery 3 3V System and user mem CEX bus controller ModuleBus controller Electrical Optical DC Compact Flash Logic Communi...

Page 36: ...ock Diagram RTC CPU Communication Controllers System and user mem Logic 2 1 3 L L SA SB 1 2 4 3 B B S Ethernet Ethernet CN1 CN2 FPGA Shadow memory CEX Bus Electrical Optical RCU Link RS232 COM4 RS232...

Page 37: ...12 units can be added to the optical ModuleBus thus achieving a total count of 96 units per AC 800M Controller when using only the ModuleBus To the left on Figure 6 on page 38 there is a PROFIBUS DP...

Page 38: ...2 Remote S800 I O Maximum 24 modules station 12 cluster 24 x 32 768 modules per segment 1 cluster only for PM851 Restrictions apply see I O documentation Additional stations up to maximum of 32 stati...

Page 39: ...odulebus Clusters See Note 1 See Note 2 Note 3 For example FOUNDATION Fieldbus Optical Optical PROFIBUS DP Max 12 units FOUNDATION Fieldbus HSE LD 800HSE see Note 3 High Speed Ethernet FOUNDATION Fiel...

Page 40: ...ol network connectivity is obtained by two built in IEEE802 3 Ethernet channels on PM891 PM891 also provides a communication expansion bus CEX Bus to which a number of expansion modules can be connect...

Page 41: ...ront view Figure 9 shows the top view and Figure 10 shows the bottom view of PM891 Figure 8 PM891 Front view Com Port External Battery Supply Socket Power supply and Supervision Signal Socket CN1 and...

Page 42: ...nals 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 Figure...

Page 43: ...Unit General 3BSE036351 510 A 43 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 Figure 10 PM891 Bott...

Page 44: ...PM891 Processor Unit General Section 1 Introduction 44 3BSE036351 510 A Figure 11 Block diagram of PM891...

Page 45: ...S800 I O Maximum 24 modules station 12 cluster 24 x 32 768 modules per segment 1 cluster only for PM851 Restrictions apply see I O documentation Additional stations up to maximum of 32 stations per R...

Page 46: ...sters See Note 1 See Note 2 Note 3 For example FOUNDATION Fieldbus Optical Optical PROFIBUS DP Max 12 units FOUNDATION Fieldbus HSE LD 800HSE see Note 3 High Speed Ethernet FOUNDATION Fieldbus H1 Link...

Page 47: ...he backup unit while the system is running Errors which occur in the backup unit can never affect the primary unit s operation The primary unit and the backup unit are logically separated from one ano...

Page 48: ...ion of the program execution into execution units and the creation of rollback points at which the processor unit s status is completely defined In this context the processor unit s total status is de...

Page 49: ...occurs The RAM included in the processor unit provides an automatic double inverted memory function for detection of arbitrary bit errors in the memory All memory updates are written to both the prim...

Page 50: ...a High Integrity version of Control Software The PM865 processor unit has increased internal diagnostics compared to PM864 The added functionality on PM865 includes Double over voltage protection on i...

Page 51: ...egrity modules over the ModuleBus have the safety header independently verified by both SM810 SM811 and PM865 Any CRC32 or other faults in the safety header will result in a retry transmission and if...

Page 52: ...re 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 adh...

Page 53: ...Section 1 Introduction Ethernet Address for PM8xx Except PM891 3BSE036351 510 A 53 Figure 14 Identification Labels and their position on PM8xx except PM891...

Page 54: ...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 cov...

Page 55: ...Section 1 Introduction Ethernet Address for PM891 3BSE036351 510 A 55 Figure 15 Identification Labels and their position on PM891...

Page 56: ...EMC certified Connection of up to 192 I O signals via Electrical ModuleBus is available Connection of up to 1344 I O signals via Optical ModuleBus is available Connection of S100 I O is available Conn...

Page 57: ...rsion number 1 0 This number is required to keep the configuration of all units and components on the AC 800M platform together and to act as a reference in the future between different documents As t...

Page 58: ...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 R1...

Page 59: ...ection also describes practical on site installation procedures specific to AC 800M units see Mounting AC 800M Units onto DIN Rail on page 65 Site Planning Site Selection and Building Requirements The...

Page 60: ...rol room adjacent to large machinery such as shakers or large presses where frequent major vibration is expected then shock absorbers or an isolation pad may be required to protect system equipment Sh...

Page 61: ...ding through a net of copper bars Cable routing observing standard installation regulations Availability of power and other necessary utilities Observation of standards and legal regulations Sufficien...

Page 62: ...xample Pt100 and thermocouples Unshielded cables may be used for other applications The signal and return conductor should be located in the same cable Lightning Protection Industrial installations an...

Page 63: ...led in a location where it is both easily accessible and clearly visible that is outside any enclosure or cabinet Protective Earth PE Always install a protective earth connection on equipment connecte...

Page 64: ...voltage failures by the installation of an Uninterruptable Power Supply UPS device The AC 800M controller will shut down safely in the event of a power failure During down time the application memory...

Page 65: ...apted for mounting the AC 800M Controller and S800 I O Both are sealed to protection class IP54 and can support the Controller and S800 I O units with no requirement for additional cooling equipment R...

Page 66: ...nd conductor between the interconnected devices This is to ensure a good ground connection both for the internal logic and for the EMI immunity and RF emission of the modules The DIN mounting rail mus...

Page 67: ...oducts concerned The aluminum profile shall be fastened to the cabinet with at least 4 self tapping screws The profile has grooves for screws that can be used for fastening the modules in an environme...

Page 68: ...fully into the mounting position 2 Rotate the locking device to the SLIDE position 2 slide the unit along the DIN rail to the desired mounting position and using the connector plugs and sockets gently...

Page 69: ...icated aluminum profile 3BSE036351 510 A 69 Figure 17 Baseplate Locking Device Figure 18 DIN rail Mounting of AC 800M Units 1 OPEN 2 SLIDE 3 LOCKED Lugs for extra screws to provide secure mounting in...

Page 70: ...e 71 To mount the PM891 unit on the DIN rail 1 Rotate the locking device to the OPEN position 1 hook the upper lip at the rear of the unit securely over the upper edge of the DIN rail and gently snap...

Page 71: ...ion 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 p...

Page 72: ...disconnect the power supply to the controller units 2 Remove any detachable cables from the appropriate unit baseplate Figure 22 PM891 Side view AC 800M units must be disconnected from the power sourc...

Page 73: ...he 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 AC 800M units must be disconnected from the power source before removing...

Page 74: ...refabricated aluminum profile Section 2 Installation 74 3BSE036351 510 A Figure 23 Separating the Baseplates F R Rx Tx RTS F R Rx1 Tx1 Rx2 Tx2 CI853 COM1 COM2 F R P INIT B PM860 CN1 CN2 COM3 COM4 CI85...

Page 75: ...wo part pre set Alpha code locking devices installed see Table 4 on page 75 Table 4 Factory Pre set Alpha Codes Unit Key Position 1 Key Position 2 CI851 PROFIBUS DP Interface A A CI852 FOUNDATION Fiel...

Page 76: ...nnection Unit C A SM810 C B SM811 D D S800 I O Units Various see S800 I O Product User s Guide Various see S800 I O Product User s Guide 1 The key positions are common to CI867 CI868 CI871 and CI873 H...

Page 77: ...Section 2 Installation Prefabricated aluminum profile 3BSE036351 510 A 77 Figure 24 Unit Baseplate Alpha Code Lock Arrangement Pre Set Alpha Code Keys...

Page 78: ...via baseplate connectors 4 Reinsert the bus terminations into the communication units at farthest away from the processor unit a For CEX Bus TB850 TB851 if cable TK850 is used see Figure 25 on page 80...

Page 79: ...nd cable length is provided in the S800 I O documentation 7 The PM8xx is supplied with an internal back up battery When the battery is to be used place it in the Internal Battery Holder see Figure 63...

Page 80: ...battery is heavily utilized due to frequent blackouts during system installation Figure 25 TB850 Terminator for CEX Bus male A TB850 male CEX Bus termination unit is supplied with each package PM851K...

Page 81: ...Section 2 Installation Installing the PM86x TP830 Processor Unit in Single Configuration 3BSE036351 510 A 81 Figure 26 TB851 Terminator for CEX Bus female Terminator TB851 TK850 Cable...

Page 82: ...6x TP830 Processor Unit in Single Configuration Section 2 Installation 82 3BSE036351 510 A Figure 27 CEX Bus Terminator when using BC810 BC810 BC810 RCU Link Cable PM861A PM864A PM865 Terminator TB850...

Page 83: ...Section 2 Installation Installing the PM86x TP830 Processor Unit in Single Configuration 3BSE036351 510 A 83 Figure 28 SA SB Connectors for Supervision Signals...

Page 84: ...d Pair cable STP class 5 Class 5 or higher cable 10 100BaseT TX max 100 m 110 yd ABB recommends the use of optical fiber in an industrial environment for example 62 5 125 100BaseFX max distance 1500 m...

Page 85: ...is used for serial protocols such as Modbus Siemens 3964R COMLI or custom design Table 6 TP830 COM3 Connections RJ45 connector Pin Designation Direction Description 1 RTS Out Request To Send 2 DTR Out...

Page 86: ...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 TP830 COM4 Connections RJ4...

Page 87: ...bus terminations into the communication units farthest from the processor unit For CEX Bus use the TB850 termination plug TB851 if CEX Bus Extension cable TK850 is used If no units are used on the CE...

Page 88: ...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 clas...

Page 89: ...der 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 PM891 COM4 Connections RJ45 connect...

Page 90: ...ces can be divided between the two CPUs in any preferred way 3 Press the units gently together and make sure that the CEX Bus is correctly connected via the connectors on the baseplates 4 If BC810s ar...

Page 91: ...optical contacts on the processor units see Figure 2 on page 32 and Figure 40 on page 131 Information regarding optical cable selection and cable length is provided in the S800 I O documentation Note...

Page 92: ...ge 143 Installing the SB822 Rechargeable External Battery Unit on page 144 Do not place the internal back up battery in the battery holder until the AC 800M Controller has been powered up normally and...

Page 93: ...or Unit in Redundant Configuration 3BSE036351 510 A 93 Communication Ports Same as for single configuration see Table 5 on page 84 Table 6 on page 85 and Table 7 on page 86 Figure 29 Connection of CPU...

Page 94: ...ed through the connector on the unit 4 If BC810s are used connect the TK851 cable to the two BC810s If no BC810s are used mount the CEX Bus extension cable TK850 to the units at farthest away from the...

Page 95: ...ress etc Otherwise connect the Control Builder to the Control Network 7 Connect the optical ModuleBus to the optical contacts on the processor units see Figure 2 on page 32 and Figure 40 on page 131 I...

Page 96: ...sor Unit in Redundant Configuration Section 2 Installation 96 3BSE036351 510 A Communication Ports Same as for single configuration see Table 8 on page 88and Table 9 on page 89 Figure 30 Example of PM...

Page 97: ...tension cable TK850 CEX Bus Extension Cable Only one TK850 CEX Bus extension cable may be used in any one CEX Bus Cable length 0 7 m 2 3 ft Installing the CEX Bus Interconnection Unit BC810 TP857 The...

Page 98: ...and B See Figure 33 on page 102 One power source SD8xx or SS8xx for the processor unit on segment A and the BC810 on segment B and another power source SD8xx or SS8xx for the processor unit on segment...

Page 99: ...le on the CEX Bus are in a non operating state Note In an AC 800M HI controller this is unconditionally and intentionally leading to a shutdown of the controller Hot swap of the BC810 not located next...

Page 100: ...nstallation 100 3BSE036351 510 A Figure 31 Redundant Communication Interface Units and Controllers BC810 PM861A PM864A PM865 PM866 PM861A PM864A PM865 PM866 TK851 Cables 1 Only for High Integrity Syst...

Page 101: ...Unit BC810 TP857 3BSE036351 510 A 101 Figure 32 Redundant Communication Interface Units and Single Controller SM810 SM811 1 BC810 PM861A PM864A PM865 PM866 SM810 1 BC810 RCU Link Cable CI854A CI854A 1...

Page 102: ...stallation 102 3BSE036351 510 A 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 p...

Page 103: ...51 510 A 103 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 CEX Bus...

Page 104: ...ocess I O See Table 10 The input signals are used for system function see AC 800M High Integrity documentation In a redundant configuration the corresponding digital inputs to both the SM810 s must be...

Page 105: ...Installation Installing SM810 TP855 3BSE036351 510 A 105 Connection of Input Signals to SM810 Figure 35 Connection of input signals to redundant SM810 0V A 0V B 24V A 24V B I1 Reset all forces I2 Acce...

Page 106: ...ng SM810 TP855 Section 2 Installation 106 3BSE036351 510 A Connection of Output Signals to SM810 Figure 36 Connection of output signals from redundant SM810 24V A 24V B O1 Any force active O2 System a...

Page 107: ...The Access Enable input I2 must be connected to a key switch in the operator s panel The Reset all Forces input I1 and Hot insert input I3 must be connected to impulse type panel if they are used The...

Page 108: ...Installing SM811 TP868 Section 2 Installation 108 3BSE036351 510 A 6 O2 Digital output 2 System alarm 7 ZP Common I O return Table 11 SM811 Digital I O Connector PIN Designation Description...

Page 109: ...on Installing SM811 TP868 3BSE036351 510 A 109 Connection of Input Signals to SM811 Figure 37 Connection of input signals to redundant SM811 0V A 0V B 24V A 24V B I1 Reset all forces I2 Access enable...

Page 110: ...ng SM811 TP868 Section 2 Installation 110 3BSE036351 510 A Connection of Output Signals to SM811 Figure 38 Connection of output signals from redundant SM811 24V A 24V B O1 Any force active O2 System a...

Page 111: ...and Installing the PM86x TP830 Processor Unit in Single Configuration on page 78 2 Install a connector on the PROFIBUS DP cable Connect the cable screen to the ground terminal within the connector to...

Page 112: ...ive Transmit Data B line 4 RTS TTL Indicates direction RTS TTL Indicates direction 5 GND Bus GND Bus 6 5 V Bus For terminating resistors 7 Not used 8 A line Receive Transmit Data A line 9 Not used For...

Page 113: ...age 65 and Installing the PM86x TP830 Processor Unit in Single Configuration on page 78 2 Install a connector on the FOUNDATION Fieldbus H1 cable Connect the cable screen to the ground terminal within...

Page 114: ...al power supplies connected to the data wires in the same way as a field device To avoid short circuiting of fieldbus signals use only power supplies with impedance characteristics specifically design...

Page 115: ...creen via CI583 3 If cables longer than 15 m 16 4 yd are required then a short distance modem TC562 must be used In this case mount the modem onto a DIN rail in a suitable position connect a 24 V DC p...

Page 116: ...minal PIN8 RxD TxD N and the data cable wire B to the terminal PIN3 RxD TxD P If the data transfer cable has data wires with red and green insulation then the following assignment should be used Data...

Page 117: ...A 117 PROFIBUS DP Connection The PROFIBUS DP cable is connected via the 9 pin female D type connector located on TP854 Figure 39 Connection of Redundant PROFIBUS DP CI854A F R RxA RxB CI854A PROFIBUS...

Page 118: ...t be connected with shielded twisted pair cables Table 15 CI854 CI854A PROFIBUS DP Connector PIN Designation Description 1 Shield Shield protective ground 2 Not Used 3 RxD TxD P Receive Transmit Data...

Page 119: ...Units onto DIN Rail on page 65 and Installing the PM86x TP830 Processor Unit in Single Configuration on page 78 2 Connect the Ethernet twisted pair cable to the contact on the baseplate 3 Connect the...

Page 120: ...M Units onto DIN Rail on page 65 and Installing the PM86x TP830 Processor Unit in Single Configuration on page 78 2 Connect the S100 I O cable TK575 TK580 to the contact on the baseplate A bus extende...

Page 121: ...nits onto DIN Rail on page 65 and Installing the PM86x TP830 Processor Unit in Single Configuration on page 78 2 Connect the Ethernet twisted pair cable to the COM1 connector on the baseplate COM2 is...

Page 122: ...Unit in Single Configuration on page 78 and CI858 and TP858 DriveBus Interface on page 313 Optical Connectors The CI858 board connects to the drive system via three optical receiver transmitter pairs...

Page 123: ...ounting 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 Ethernet twisted pair cable to the COM connector on the ba...

Page 124: ...e electronics will not allow the CI862 unit to be installed in any baseplate with a locking device However other units could be inserted into the CI862 baseplate Bus Termination The appropriate termin...

Page 125: ...itch 1 is towards the top of the housing 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 b...

Page 126: ...the routing of the drop and trunk cables They should not be routed close to high voltage cables Avoid bending the trunk cable too much 2 The tap can be mounted in various ways for example using a DIN...

Page 127: ...2 Connect the 10 100Mbps Ethernet twisted pair cable to the CH1 connector on the baseplate 3 Connect the other end of the Ethernet cable to a Fast Ethernet network via standard Ethernet components 4 C...

Page 128: ...a standard Ethernet components Refer to PTUST04 3211 Switch Management for IEC 61850 for switches that are certified for IEC 61850 Installing the AF 100 Interface CI869 The CI869 unit is powered from...

Page 129: ...D5 Interface CI872 The CI872 unit is powered from the processor unit through the CEX bus and does not require any additional external power source To install CI872 1 Mount the unit onto the DIN rail 2...

Page 130: ...cessor unit through the CEX Bus which requires no additional external power source Follow the steps below to install CI873 1 Mount the unit onto the DIN rail 2 Connect the 100 Mbps Ethernet twisted pa...

Page 131: ...oduleBus The fiber optical interface is intended for local distribution of I O clusters and for connection of engineered and standard drives Figure 40 on page 131 provides details of the fiber optic c...

Page 132: ...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 Figure 4...

Page 133: ...d c 24 Volts regulated 20 A Internal primary main fuses are arranged to meet the requirements of electrical safety publications for connection to the Phase Neutral terminals of primary main network T...

Page 134: ...A DIN rail end stop 1 b The terminal for the incoming protective ground 2 c The two terminals for the incoming Live and Neutral mains power 3 These terminals are equipped with built in jumpers which i...

Page 135: ...ication if the power supply has been disconnected The fuse holders have built in red LEDs to indicate a ruptured defective fuse Figure 42 Installation of Mains Breaker Assembly MAINS To Power 1 2 3 4...

Page 136: ...pplies 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 Use the...

Page 137: ...Section 2 Installation Installing the SS823 SS832 Voting Unit 3BSE036351 510 A 137 Figure 43 Redundant Power Supply for SS823...

Page 138: ...Installing the SS823 SS832 Voting Unit Section 2 Installation 138 3BSE036351 510 A Figure 44 SS832 Redundant Configuration up to 10 A...

Page 139: ...S823 SS832 Voting Unit 3BSE036351 510 A 139 3 Connect the SS82x voting unit to the processor unit Figure 46 on page 140 shows the connection to PM861 PM864 PM865 in redundant configuration Figure 45 S...

Page 140: ...Installing the SS823 SS832 Voting Unit Section 2 Installation 140 3BSE036351 510 A Figure 46 Redundant Power Supply Powering Redundant CPUs From Mains Breaker Protective Ground...

Page 141: ...is shown in Figure 46 on page 140 Figure 47 on page 141 and Figure 48 on page 142 Figure 46 on page 140 show redundant power supplies powering AC 800M units Here the SA SB signals also indicate physic...

Page 142: ...ent OK F OK A B L SS822 F A B L L L L L L N L PE OK SD821 L L L L N L PE OK SD821 OK F OK A B L SS822 F A B L L L L L L N L PE OK SD821 L L L L N L PE OK SD821 SA SB L L Supervision signals to CPU uni...

Page 143: ...use also two SB821 battery units one for each processor unit 4 Due to the batteries being connected in parallel it is necessary when using the external battery to remove the internal battery from the...

Page 144: ...rgeable 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 pa...

Page 145: ...rollers Power Supply units Voting units and S800 I O units can be configured and mounted within cabinets Figure 49 on page 146 Wall Cabinet Single Power Supply Arrangement Figure 50 on page 147 Wall C...

Page 146: ...Cabinets Section 2 Installation 146 3BSE036351 510 A Figure 49 Wall Cabinet Single Power Supply Arrangement 24 V Distribution Terminals SD831 Mains Breaker Unit Cable Duct Aluminum Profile Cable Expa...

Page 147: ...Installation in Cabinets 3BSE036351 510 A 147 Figure 50 Wall Cabinet Dual Power Supply Local Field Arrangement Mains Breaker Unit SD831 24 V Distribution Units Units in Cabinet SD831 Field 24 V Distri...

Page 148: ...Section 2 Installation 148 3BSE036351 510 A Figure 51 Floor Mounted Cabinet Horizontal Unit Arrangement Voting Units SS832 Breakers Mains SD832 Redundant Power Supply Units Redundant Power Supply Uni...

Page 149: ...ntroller 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...

Page 150: ...Mounting Dimensions for Proper Ventilation Section 2 Installation 150 3BSE036351 510 A...

Page 151: ...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 Simply select the opti...

Page 152: ...figuration the Control Builder is connected to the Primary CPU COM4 port The Backup CPU cannot communicate with Control Builder PM851 PM851A is restricted to one Ethernet CN1 port thus redundant Ether...

Page 153: ...le of AC 800M Controllers Connected to a Control Network I O AC 800M I O AC 800M STP AC 800M I O Switch Hub I O AC 800M I O AC 800M STP Switch I O AC 800M I O AC 800M STP Hub Within industrial environ...

Page 154: ...830 or PM891 contains the following communication ports offering the following functions CN1 and CN2 are used for connection to the Control Network Both are RJ45 ports for Ethernet IEEE802 3 and conne...

Page 155: ...re details see protocol specific documentation COM4 is an RJ45 port for connection of service tools see Connecting Control Builder on page 152 The port has no modem signals By adding communication int...

Page 156: ...1 PM851A is restricted to a maximum of one CEX module CI851 PROFIBUS DP 12 12 1 CI852 FOUNDATION Fieldbus H1 12 1 CI853 RS 232C 12 2 CI854 CI854A PROFIBUS DP 12 2 CI855 Ethernet for MasterBus 300 12 2...

Page 157: ...s of the CN1 port on the primary CPU See IPConfig online help 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 O...

Page 158: ...0 I O via CI856 S800 I O units via the ModuleBus Support for hot configuration during run redundancy on all levels HART routing and Sequence of Events SOE S800 I O units via CI854 CI854A and CI840 CI8...

Page 159: ...ported I O systems and units see I O documentation ModuleBus The ModuleBus in the AC 800M controller except PM891 consists of one electrical and one optical unit The PM891 consists of optical ModuleBu...

Page 160: ...6 S800 I O units connected to an AC 800M Controller with single CPU configuration Figure 54 Electrical and Optical ModuleBus Configuration Maximum of 7 clusters groups Maximum of 12 x I O units PM8xx...

Page 161: ...duleBus Each CPU is connected to one TB840 on each cluster see Figure 55 on page 161 Figure 55 Optical ModuleBus connection in redundant CPU configuration Maximum of 7 clusters groups Maximum of 12 x...

Page 162: ...ernet site It is possible to connect the following I O systems to the PROFIBUS DP S800 I O and or S800L I O via FCI refer to S800 I O documentation S900 I O via FCI CI920 refer to S900 I O documentati...

Page 163: ...ted 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...

Page 164: ...I O Systems Section 3 Configuration 164 3BSE036351 510 A The PROFINET IO is interfaced to the AC 800M controller using the PROFINET IO commmunication interface CI871 Figure 57 PROFINET IO with AC 800M...

Page 165: ...e AC 800M via the high performance HSE bus using FF linking devices More detailed information on the HSE profile can be found in the FF specifications The fundamental concepts behind HSE are explained...

Page 166: ...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...

Page 167: ...51 510 A 167 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 a...

Page 168: ...84 12 x No of TB820s that is each Drive uses one ModuleBus cluster PROFIBUS DP and CI801 In single and redundant CPU configuration ABB Drives can be connected via PROFIBUS DP and CI801 See Figure 59...

Page 169: ...for controlling up to 24 drives or inverter units Main communication functions of the drive connection are Dataset communication Broadcast system time Supervision and diagnostics functions The data ex...

Page 170: ...Drive System Section 3 Configuration 170 3BSE036351 510 A ACS 1000 product family See also CI858 and TP858 DriveBus Interface on page 313...

Page 171: ...t of PROFIBUS DP Optical Optical See DriveBus topology Max 12 Modules per Cluster ABB Std Branching ABB Std Drive ABB Std Drive ABB Std Drive Drive Unit CI858 Optical ABB Std Branching ABB Std Drive A...

Page 172: ...3 Configuration 172 3BSE036351 510 A Figure 60 DriveBus Topology Drive Drive DRIVEBUS CI858 NDBU Drive CH1 MSTR CH2 CH3 CH0 CH0 CH0 Drive Drive NDBU Drive CH1 CH2 CH3 CH0 CH0 CH0 CH0 MSTR Up to 24 Dr...

Page 173: ...electrical ModuleBus the optical ModuleBus or the communication interfaces for PROFIBUS DP Cabinet Containing AC 800M Controller From this cabinet power may be required for Powering Units power to the...

Page 174: ...unit Communication modems located in the cabinet The main configuration rule for this power supply is to retain the 24 V cables within the cabinet Powering Field Equipment outside the Cabinet This is...

Page 175: ...then voltage will most likely drop before a fuse blows consequently all groups will experience a drop in voltage Cable Protection 24 V DC distribution system cables must be fuse protected In order to...

Page 176: ...r supply voltage making it necessary to take precautions against low voltage in order to prevent controller malfunction Should there be a risk that the 24 V at the PM8XX power terminals could drop bel...

Page 177: ...24 V DC Distribution SD Voting Redundant Power Supplies Redundant Mains Power Supplies Terminals 24 V DC Distribution Terminals 24 V DC Distribution Terminals 8xx Supply Power SD 8xx SD 8xx SD 8xx SS...

Page 178: ...o Supply to 24 V DC Distribution 24 V DC Distribution Independent 8xx SD Mains Mains Breaker Mains Breaker Supply to Units 24 V DC Distribution 24 V DC Distribution Independent Power Supplies Independ...

Page 179: ...Software the basic PM8xx TP830 or PM891 hardware units mounted on the AC 800M hardware platform constitute an AC 800M Controller LED Indicators See Figure 2 on page 32 for description of placement Ta...

Page 180: ...U in redundant configuration Controlled by software DUAL Yellow Lit when the CPU is running in redundant configuration and synchronized state 1 The software performs cyclic battery voltage level tests...

Page 181: ...ion a switchover to the backup CPU will be initiated Table 22 PM8xx TP830 and PM891 Connectors Marking Function L L SA SB External Power Supply Connection 24 V DC supply 0 V Redundant Power Supply mon...

Page 182: ...redundant AC 800M system Without using BC810 units At least one CEX module must be inserted if there are base plates without inserted modules in other positions CEX BUS Provides extension of on board...

Page 183: ...d on power restoration Cold Restart The application program restarts Variable values are initialized unless marked Cold retain To initiate a cold restart the Controller must be restarted by briefly pr...

Page 184: ...it a few seconds and then perform a Controller Reset on the Primary CPU Automatic Switch Over to Backup CPU In a redundant configuration an automatic switch over from the Primary CPU to the Backup CPU...

Page 185: ...ing Procedures on page 204 Table 23 AC 800M Controller Verification of Satisfactory System Operation LED Indicator Status AC 800M Controller Status PM8xx Processor Unit F ault Red LED must be OFF OK R...

Page 186: ...ON steady OK CI855 Ethernet Interface Unit for MasterBus 300 F ault Red LED must be OFF OK R un Green LED must be ON steady OK CI856 S100 I O Interface Unit F ault Red LED must be OFF OK R un Green LE...

Page 187: ...Unit F ault Red LED must be OFF OK R un Green LED must be ON steady OK CI867 Modbus TCP Interface Unit F ault Red LED must be OFF OK R un Green LED must be ON steady OK CI868 F ault Red LED must be OF...

Page 188: ...Green LED must be ON steady OK Table 24 AC 800M Controller PM861 PM864 PM865 PM866 PM891 SM810 SM811 Verification of Satisfactory System Operation in Redundant configuration LED Indicator Status AC 8...

Page 189: ...hts up on the former Backup CPU now acting as Primary CPU For other units see Table 23 on page 185 To check that the redundancy is working correctly perform a manual switch over from the Primary CPU t...

Page 190: ...Verification of Redundant CPU Section 4 Operation 190 3BSE036351 510 A...

Page 191: ...afety Summary on page 13 Failure to do so could lead to personal injury or damage to equipment Table 25 Preventive Maintenance Frequency Schedule Frequency Equipment Procedure At regular user defined...

Page 192: ...hium contents 0 3 g 5 Years SB821 External Battery if fitted Change battery See SB821 External Battery Unit on page 195 3 years or 400 discharge cycles SB822 Rechargeable External Battery if fitted Ch...

Page 193: ...s 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 whe...

Page 194: ...is re established ensure that the B attery LED is illuminated 4 Replace the PM8xx right hand cover and tighten the screw 5 Dispose of the run down Lithium battery in an approved manner Insert a servic...

Page 195: ...r is extinguished Multiple or extended power cuts have occurred Extended periods of system downtime have occurred for maintenance or malfunctions Replacing the Battery in an SB821 External Battery Uni...

Page 196: ...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 Figure 65 SB821 External...

Page 197: ...in an SB822 Rechargable External Battery Unit To replace the Li Ion battery 1 Disconnect the TK821V020 cable connector 2 Disconnect the 24V supply cable connector 3 Release the SB822 unit from the DI...

Page 198: ...I8xx TP8xx Must not be replaced online ModuleBus S800 I O units Can be removed or replaced online Module Terminal Units MTUs Must not be replaced online Redundant CPUs Processor unit Can be removed or...

Page 199: ...push button on the replaced processor unit 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...

Page 200: ...onization 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...

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