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System 800xa Control and I o DESIGN
System 800xa Control and I o DESIGN
Overview
Integrating, for Plug-and-produce Con- Continuous productivity improvements and increased protabil-
nectivity: Industrial IT-enabled Control ity are the driving forces behind the selection of todays plant
and I/O results in easy integration with
automation system. Traditionally, production facilities main-
similarly certied products such as drives,
motors, valves, instrumentation, and tained many controller subsystems; each meeting specic plant
higher-level applications. needs. However, as business goals have changed, using a scal-
able controller platform possessing multi-functional capabilities,
Comprehensive Maintenance Features adaptability to changing requirements, openness, and maximum
Reduce Downtime: Comprehensive self- availability, is paramount to success.
diagnostics and hot-swap capability reduce
maintenance costs and increase uptime The Industrial IT System 800xA family of controllers, commu-
and plant productivity.
nication interfaces and I/O modules match the most challeng-
Flexible I/O for all Plant Environ- ing requirements in all these areas. Combined with ABBs rich
ments: A full line of industrial I/O types experience in general and industry-specic process automation,
including intrinsically safe and SIL-rated. AC 800M Control and I/O products deliver powerful and versa-
Packaging and mounting options are avail- tile solutions that are equally effective for small hybrid systems
able for remote and local I/O installations. as for large, integrated, automation applications. Thereby, the
products contribute to higher return on assets by improving
Wide-ranging Control Functionality overall production control, maximizing process availability, and
Meeting all Needs: Controller software to
minimizing maintenance.
t all control and safety applications, from
simple to complex, discrete to continuous,
and basic regulatory to advanced expert
applications.
Introduction
Industrial IT 800xA Control and I/O products extend continuous productivity
improvement opportunities with options to meet all needs for control in manu-
facturing and processing. ABB controllers feature an extensive software library
of pre-dened and user-dened control elements. These can be used to easily
design simple to complex control strategies to t any application, including con-
tinuous, sequential, batch, and advanced control. Designed from the ground up
to leverage the power of industry-standard eld buses and open communication
protocols, ABB controllers provide a full range of controls, scalability, and fault-
tolerant redundancy options. In addition, a full line of industrial I/O is offered
that provides: remote and local installations, small footprints, rail mounting, and a
broad range of I/O types, including intrinsically safe I/O.
For example, a basic controller station may consist of a power supply module, a
controller, and local I/O modules. A large system can consist of several AC 800M
controller stations that communicate over an Ethernet-based control network.
These stations may employ subclustered I/O assemblies connected to their host
controllers via ber-optic or industry-standard eldbuses.
Common The AC 800M HI can host safety and control applications within the same control-
Environment for ler. When safety and process applications are executed within the same control-
ler or within the same system, they can freely exchange signals and data without
Plant Automation
the need for external, complex interface hardware, software, and mirroring of
and Safety data. However, safety integrity is secured by certied embedded rewalls. The
AC 800M HIs extensive diagnostics and rewall mechanisms eliminate common-
cause failures of control and safety circuits.
With these scalability options, undue redundancies can be avoided, process con-
trol requirements can be met with less hardware, with similar software applica-
tions be applied to all system congurations, both large and small.
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AC 800M Control and I/O
At the core, the base controllers inherent reliability features contribute to high
availability. Industrial-grade, conservatively loaded, on-board electronics result in
a controller designed for installation in harsh environments. Low power consump-
tion allows for installation in sealed enclosures without requiring fans, louvers, air
lters or other forced cooling techniques. This simplicity eliminates many potential
trouble-factors and thus contributes to the controllers high reliability.
Figure 3. Optional redundancy in all areas of importance: power supply, CPUs, commu-
nication links and I/O circuits, is only one of many features of AC 800M Control and I/O
that contributes to the highest possible plant availability.
The Load Evaluate Go function* takes this handling ease a step further by sup-
porting actions such as Modify, Download and Evaluate, making it possible to
download a new version of the running application to the controller without it in-
terfering with the running version. The modied version is started in passive mode
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IndustrialIT System 800xA
in parallel with the running version and an Evaluation Report shows the differences
in real time. For more details see 800xA Engineering Overview.
The application(s) and data can optionally be stored in Compact Flash memory to
secure its contents e.g. after a power failure or during transport.
The open design of AC 800M Control and I/O ensures peer-to-peer communica-
tion with existing, distributed control systems by ABB. Communication and eld-
bus options exist at both at the controller and I/O levels.
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AC 800M Control and I/O
ABBs Aspect Object technology makes all information in plant devices available
and presented in a consistent, ready-to-use manner at the controller, engineering,
and process visualization levels. Process objects include familiar items such as
motor and valve controls. They can also include Operator interface objects, such
as faceplates, trend displays, and other graphic elements, engineering objects and
maintenance support objects. In this manner, AC 800M Control and I/O provide
system applications with transparent, real-time access to all connected eld de-
vices, for everything from conguration and setup to production monitoring and
maintenance.
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IndustrialIT System 800xA
All modules are equipped with front-panel LED displays that show faults and
degraded performance.
Modules can report these errors to operators and maintenance personnel as alarm
and event messages - and the system forwards them to key plant personnel by
e-mail and/or SMS. For information on reporting features, see the 800xA Opera-
tions Overview document.
AC 800M Control and I/O can be fully integrated with the 800xAs Asset Optimi-
zation features to electronically submit fault reports to a computerized mainte-
nance management system as a basis for work orders, thereby streamlining main-
tenance processes. For more information on 800xA Computerized Maintenance
Management System (CMMS) integration features, please refer to the 800xA Asset
Optimization Overview document.
Modules can be replaced under power and are keyed to ensure replacement with
the proper module types.
The application and data can also be stored in Compact Flash memory to secure
its contents e.g. after a power failure or during replacement or transportation.
AC 800M Control and I/O also support on-line upgrading of embedded rmware
in CPUs and communication modules to avoid downtime.
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AC 800M Control and I/O
To this module, a number of communication and I/O modules can be added, for example:
PROFIBUS DP, DP-V1 interfaces, providing integration of S200, S800 and S900 I/O
systems and access to the wide range of eld devices, supporting these protocols,
S100 I/O interface, making it possible to upgrade from existing Advant Con-
troller 410 or 450 - or even MasterPiece 200 - systems to AC 800M and retain
existing I/O sections,
TRIO I/O interface, making it possible to upgrade from existing MOD300 Con-
trollers to AC 800M and retain existing TRIO I/O sections,
Satt I/O interface, making it possible to upgrade from existing Satt Controllers
to AC 800M and retain existing Satt I/O sections,
Modbus TCP interface, combining the MODBUS RTU with the Ethernet and
TCP standards, thus providing communication with 3rd-party equipment,
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IndustrialIT System 800xA
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AC 800M Control and I/O
These connectivity and expansion options make the AC 800M exceptionally open
and scalable, that is, easy to connect to the surrounding world of supervisory
systems and intelligent devices of all kinds - and adaptable to changing require-
ments as the process it controls changes, expands or contracts.
Comprehensive:
The S800 family of
I/O covers virtually
all conceivable signal
types and ranges. From Figure 10. S800 I/O is available in three different
designs: Compact, Extended, and S800L.
basic analog and digi-
tal inputs and outputs
to pulse counters and
intrinsic-safety I/O.
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IndustrialIT System 800xA
Easy to set up: Once station numbers have been allocated and set, all
other settings can be made from a network-connected engineering tool. A
pass-through feature makes it possible to congure and examine all HART-
compliant eld devices in a similar way,
Accurate: S800 I/O modules can time-stamp events, i.e. input signal transi-
tions, at the source with millisecond accuracy. Thereby providing the basis
for meaningful sequence-of-events recording by the host system. In tightly
interlocked processes this is essential to nding the root causes of production
disturbances.
For harsh environments, S800 modules are also available in variants satisfying the
G3 severity level of ISA-S71.04, Environmental Conditions for Process Measure-
ment and Control Systems.
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AC 800M Control and I/O
Table 1.
Field housing - for wall mounting and eld mounting in Zone 1 installations
with system approval fully certied in accordance with ATEX. The high-grade
steel housing is prepared for wall-mounting with facility for insulated screen
rails or terminals.
CB220 compact box - S900 in compact form (with up to 4 I/O modules). This
variant is suitable for use in applications such as temperature multiplexers and
solenoid valve circuits.
The S900 components are based on a passive backplane suitable for mount-
ing on a DIN rail or directly in a sub-distribution board. The passive backplane
includes internal bus communication, terminals for eld circuits, communication,
and power supply. The function modules are plugged into the backplane in their
appropriate slots. The redundant backplane has two slots for power supply units,
two slots for communication interfaces, and 16 slots for function modules. Digital
function modules have up to 8 channels, analog modules up to four. Therefore,
when using a redundant backplane, 128 digital or 64 analog channels can be con-
nected per station. In the case of the S and B series, up to ten S900 stations can
be connected on a single eldbus line.
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IndustrialIT System 800xA
Easy conguration using either FDT/DTM or GSD les, allowing easy inte-
gration with 800xA process control systems,
Control Software Control Software includes an extensive library of control elements, ranging from
simple AND gates to powerful adaptive PID controllers, predened and ready-
to-use process objects and control functions e.g. for motors, valves and INSUM
switchgear. It also supports the development of user-dened control elements.
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AC 800M Control and I/O
For details on controller conguration features, see the 800xA Engineering Over-
view document.
Figure 14. Control Software and its engineering tools support all ve of
the IEC 61131-3 programming languages (function block diagram, struc-
tured text, ladder diagram, sequential function chart, and instruction list)
plus ABBs own high-powered Control Module language, thereby, matching
the application with the best-suited language.
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AC 800M Control and I/O
ABB ABB
Process Automation Division Process Automation Division
Vsters, Sweden Wickliffe, Ohio, USA
Phone: +46 (0)21 32 50 00 Phone: +1 440 585 8500
Fax: +46 (0)21 13 78 45 Fax: +1 440 585 8756
www.abb.com/controlsystems www.abb.com/controlsystems Produced by R&B TeknikTransfer HB, Vsters, Sweden.
e-mail: processautomation@se.abb.com e-mail: industrialitsolutions@us.abb.com
ABB ABB
Process Automation Division Process Automation Division
Singapore Mannheim, Germany
Phone: +65 6776 5711 Phone: +49 (0)1805 26 67 76
Fax: +65 6778 0222 Fax: +49 (0)1805 77 63 29
www.abb.com/controlsystems www.abb.de/controlsystems
e-mail: processautomation@sg.abb.com e-mail: marketing.control-products@de.abb.com
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Copyright 2009, ABB. All rights reserved.Specifications subject to change without notice. Pictures, schematics, and other graphics contained here in
are published for illustration purposes only and do not represent product configurations or functionality. User documentation accompanying the product
is the exclusive source for functionality descriptions. The IndustrialIT wordmark, Aspect Objects, and all abovementioned names in the
form XXXXXX IT are registered or pending trademarks of ABB. All rights to other trademarks reside with their respective owners.