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TABLE OF CONTENTS
Chapter 5 - 1
05 AC800M Hardware - RevC.doc
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5.1.1 Objectives
Upon completion of this chapter, you will be able to:
• Describe the AC 800M hardware components
• Set up communication to controller AC 800M
• Upgrade the controller firmware
• Configure the hardware in the Control Project
• Download and test hardware in online mode
5.1.2 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
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RS-232 channels
Redundant Ethernet
Various I/O systems can be connected to the AC 800M controller, either directly
(S800 I/O) or via PROFIBUS or FOUNDATION Fieldbus.
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5.3.1 Components
The CPU consists of a base plate TP830 and a replaceable processor module PM8xx
with various speed and memory combinations.
CPU Baseplate
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.
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.
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Redundant Redundant
PM864 PM865
Redundant
PM861
PM860
PM856 32MB
32MB
PM851 96 MHz
96 MHz
SIL2
16MB
48 MHz
8MB
48 MHz
8MB
24 MHz
8MB
24 MHz
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5.3.4 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.
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Communication CPU
Expansion CEX-bus
S800I/O’s on the
Electrical ModuleBus
RCU link
connection
Fiber opticale
Ethernet ports COM 3-4 ports ModuleBus
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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.
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5.4.1 Overview
A number of communication modules can be connected to the CEX bus.
CI854A
PM8xx
CI867
CI865
CI862
CI860
CI858
CI857
CI856
CI855
CI853
PROFIBUS DP
Modbus TCP
DriveBus
TRIO I/O
S100 I/O
FF HSE
Satt I/O
INSUM
MB300
RS232
The table below is a summary of the interfaces (for details refer to hardware manual):
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TB850
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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.
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Base cluster
Modulebus
extension
Termination
TB807
I/O cluster 1
TB820
Optical modem
Duplex
Simplex max. 15 or 200m
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.
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CI801
Profibus slave
with CI854
TB810 Profibus
master
Base cluster
Duplex
Simplex max 15 or 200m
max 15 or 200m
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Compact Extended
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RCU Link
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.
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Redundant or Singular
S800 I/O
Optical ModuleBus
Cable
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TU846 or TU847
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As you can see on the example of a hardware configuration above, there are 4 I/O
modules connected to ModuleBus and 5 I/O modules connected to PROFIBUS.
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Then choose the new CPU type that you wish to insert.
The parameter “Scan Cycle Time” for the cycle time of the ModuleBus can be set in
the range 0...100 ms. Default setting is 0 (as fast as possible) and can load the CPU
significantly. The minimum scan time in practice will be 6 ms.
NOTE! It is recommended to change the default settings in order
to reduce the CPU load.
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Choose the communication interface module that you want and click “Insert”
Note that you are not able to insert any other communication unit by default. To do
this, we need first to connect the required hardware libraries.
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The library needs then to be connected to the controller. Select Connected Libraries,
right click and choose “Connect Library”.
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Then choose the appropriate S800 I/O and the position (slot).
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Controller_1.0.11.3.1
Channel 1
Note that the position number for the CI851 is the physical location on the CEX-bus,
while the position for the CI830 is the PROFIBUS node number (set by switches).
Note that an optical modem TB820 is not visible in the Project Explorer. The I/O
cluster is only indicated by the position of the I/O modules e.g. I/O modules in cluster
number 3 have positions from 301 to 312.
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Preset Values/OSP/ISP
You can specify what value to assign to an I/O channel in case the I/O unit loses
communication with the CPU or PROFIBUS slave. The choices are: Keep last value,
Reset output/input or Assign OSP/ISP value. The last is a preset value, specified in the
editor for the I/O unit. The degree of configuration you can make for a particular I/O
channel depends on the type of I/O unit.
Signal Range
This setting specifies the electrical signal range; 0-20 mA, 0-10 V etc.
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Make sure your project is in offline mode and insert a Compact Flash card in the
Writer slot. Right-click on the controller item and select “Compact Flash” from the
context-menu to pick the writer.
For a redundant CPU configuration, you need to write the same application twice (two
CF cards, one in each CPU). Copy (in Windows Explorer) the downloaded application
(two folders) from the CF card and paste them temporarily on your local disk. Insert
the next memory card into the writer and drag your two folders from the hard disk and
drop them on the new CF memory card.
NOTE! Backup of cold retain values to Compact Flash is not
supported for redundant CPU’s.
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1. Connect your PC with the controller using a TK212 cable connected to serial port
on your PC and to the toolport (COM4) on the AC 800M controller.
2. Choose the COM port on your PC by click on “Settings”
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3. Press “Connect”
The IPConfig status bar will change from Not Connected to Connecting.
4. Make a long (more than 3 seconds) Init of the controller, release the init button
when the Run LED start to blink.
After the system-reset button has been pushed it takes approximately 10s before
IPConfig detects the system reset and the status bar changes to System reset
detected waiting for controller start-up.
If the connection fails, a message box will indicate Connect failed, Time-Out. The
reason may be the following:
- The serial cable is not connected correctly.
- Too long time elapsed between clicking the Connect button and the
system reset of the controller.
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7. Modify IP address, press “Set IP” and the text boxes will show the current
controller IP address settings.
When the new IP address has been stored successfully the status bar will show
“Controller IP configuration updated”.
NOTE! Do not use IPConfig for a controller when an application
is running in it. IPConfig will delete every application in
the controller.
Ethernet addresses are kept in the flash memory. Always close IPConfig when you are
done with it, because IPConfig uses the tool port (Com4) and the rest of the CPUs
channels will be locked.
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The System Identity is the network address of the selected controller. The network
address is shown beside the controller icon in the Project Explorer tree.
NOTE! The default address is 172.16.0.0
2. Open the controller’s PM8xx/TP830 and then double click the first Ethernet.
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This will open a new window, click on the “Settings” tab, then set the same IP address
and subnet mask as you have set with the IPConfig tool.
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Note that once the firmware has been upgraded to version 5.0, further controller
upgrades and system upgrades can be done online without shutting down the whole
system.
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5.9.1 General
During a download, the code that has been written is checked and compiled. The
controller receives the compiled application and begins executing it immediately.
Once your application has been compiled, you can:
• Download the application and go Online.
This updates the application in the controller.
• Go online without download of the application.
Useful when, for example, monitoring values in the controller without disturbing
the controller.
A version analysis of the applications is made when you download. The analysis
results are used to determine if and how applications shall be updated to new versions
in the controllers.
WARM RESTART
At a warm restart, variables with the attribute <retain> or <coldretain> are protected
by the battery during restart. During the time that the controller is stopped, all output
I/Os will keep their last value.
COLD RESTART
At a cold restart, variables with the attribute <coldretain> keep their values, since they
are stored on the hard disk. Variables without the attribute <coldretain> lose their
values. During the stop time, all output I/Os will keep their last safe state/OSP values.
INIT RESTART
At a Init restart, variables with the attribute <coldretain> or <retain> are returned to
the initial value
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5.9.3 Download
Select “Tools > Download Project and go Online” in the CBM.
If changes have been made to one or several applications in Offline mode, the version
analysis detects it. You can then decide how to restart the changed applications.
Independent of how you restart the applications, the changed application parts are
downloaded to the controllers. The controller will stop the applications and restart
with the new and changed application.
NOTE! Following download the last message should be:
You are now Online!
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You may disable the difference report function in project context menu “Settings >
Difference Report”.
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5.9.5 Re-Authentication
If the Re-authenticate function is enabled, the user will be asked to enter user name
and password, before download is completed.
You may disable this function by setting the corresponding system variable to “False”.
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5.10.1 General
In Online mode the Control Builder is connected to one or more controllers and offers
many diagnostic and inspection features when online to the controller. You can:
• View the executing code dynamically
• Force inputs and outputs at the I/O modules
• Rescale analogue input and output channels
• Change values of variables
• Inspect values of variables
To enter Online mode, go to the tool bar menu of the Control Builder, click on
“Tools” and then click on “Online”.
Underflow, overflow, channel and unit errors in online mode are indicated in the
Channel value cell by the following icons:
Signal Errors
underflow The signal is below the range.
overflow The signal is above the range.
Hardware Errors
channel error The channel can have under range, power-up or field power errors.
Unit error The unit can be missing or of the wrong type.
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5.10.3 Forcing
Forcing of I/O is possible in online mode. Check a check box in the Forced column
and then type in a value in the Channel value column for outputs and in the Variable
value column for inputs. This value overrides the values in each of those columns.
When a channel is forced all copying between the I/O value and the application value
is stopped. The forced value is different for inputs and outputs.
• For inputs the forcing changes the variable value to the application.
• For outputs the forcing changes the physical I/O channel value.
Forcing is performed in the hardware configuration editor under the “Status” tab or the
POU editor.
Normally only channels with variable connections to application programs can be
forced. However, if no variable is connected you have to change the parameter Copy
Unconnected Channels under the “Settings” tab for the current controller to get a
status update.
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3. Start the SoftController by double-click the icon on the desktop or choose the path
below:
4. Click “Start”.
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