Course T314 Chapter 7

AC 800M Hardware

Extended Automation System 800xA

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 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
 3BSE036351 IndustrialIT 800xA – Control and I/O
AC 800M Controller - Hardware and Operation
 3BSE035980 IndustrialIT 800xA – Control and I/O
Basic Control Software – Introduction and Configuration
 3BSE020923 IndustrialIT 800xA – Control and I/O
S800 I/O – General Information and Installation
 3BSE020924 IndustrialIT 800xA – Control and I/O
S800 I/O – Modules and Termination Units
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 Overview
AC 800M Controller Hardware

Optional up to CPU S800 I/O

12 Communication
modules

RS-232 channels
Redundant Ethernet
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 AC 800M
Hardware AC 800M Hardware

 CPU
 Communication Interfaces
 I/O Connections
 Hardware Redundancy
 Hardware Configuration
 Application Download
 Online Functions
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 CPU
CPU PM8xx

Compact Flash Card

Fuses for Modulebus

and CEX-bus

CPU Baseplate
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 CPU
Choosing the Right CPU
Choice of speed, memory and availability

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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 CPU
Different Processor Units
Unit Description On-line Redundancy
replacement
PM851 48 MHz / 8 Mbytes RAM No No
1 Ethernet port, 1 Serial port and 1 tool port. Application speed is half
of PM860. Maximum one CEX bus module.

PM856 48 MHz / 8 Mbytes RAM No No

2 Ethernet ports, 1 Serial port and 1 tool port. Application speed is
half of PM860.

PM860 48 MHz / 8 Mbytes RAM No No

2 Ethernet ports, 1 Serial port and 1 tool port.

PM861 48 Mhz / 16 Mbytes RAM Yes Yes

2 Ethernet ports, 1 Serial port and 1 tool port. Singular or redundant.

PM861A Same as PM861 but can use redundant communication unit CI854A, Yes Yes
CI860 and BC810.

PM864 96 Mhz / 32 Mbytes RAM Yes Yes

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, Yes Yes
CI860 and BC810.

PM865 (PA/HI) 96 Mhz / 32 Mbytes RAM Yes Yes

2 Ethernet ports, 1 Serial port and 1 tool port. PM865 can be used in
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an AC 800M High Integrity system.

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 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 !!!
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 CPU
Battery
Compact Flash card available for non-volatile storage (application and data)
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Internal External
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 CPU
AC 800M Ports
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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 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
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 AC 800M
Hardware AC 800M Hardware

 CPU
 Communication Interfaces
 I/O Connections
 Hardware Redundancy
 Hardware Configuration
 Application Download
 Online Functions
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Interface Units
Communication

Modbus TCP CI867

Satt I/O CI865
Overview

TRIO I/O CI862

FF HSE CI860
DriveBus CI858

INSUM CI857
S100 I/O CI856
MB300 CI855

PROFIBUS DP CI854A
RS232 CI853

PM8xx
 Communication
Interface Units Refer to Manuals for Details
Unit Description On-line Redundancy
replacement
CI851 PROFIBUS DP-V0 communication interface unit. No No
Only to use with S200 I/O.

CI853 RS-232C serial No No

CI854 PROFIBUS DP-V1 communication interface unit. No No

Redundant Profibus cabling possible.

CI854A PROFIBUS DP-V1 communication interface unit. Yes Yes

Redundant Profibus cabling and redundant interface cards.

CI855 MasterBus 300 communication interface unit for the AC 800M. Yes No

CI856 S100 I/O system communication interface unit. Yes No

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. Yes No

CI858 Communication interface for ABB Drives using DriveBus No No

CI860 Fieldbus Foundation HSE communication interface unit. Yes No

Not possible to use in AC800M HI.

CI865 Communication interface unit for older Satt I/O systems. Yes No

CI867 Provides communication with Modbus TCP via Ethernet. Yes No

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 Communication
Interfaces Communication Exchange Bus - CEX Bus

TB850

TK850 with DB25P and TB851

or
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 AC 800M
Hardware AC 800M Hardware

 CPU
 Communication Interfaces
 I/O Connections
 Hardware Redundancy
 Hardware Configuration
 Application Download
 Online Functions
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 I/O
Connections Range of ABB I/O Units
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 I/O
Connections I/O Connection Possibilities
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 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

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Duplex
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Simplex max. 15 or 200m

max. 15 or 200m
 I/O
Connections S800 I/O Connected with Profibus
CI801
Profibus slave

with CI854
TB810 Profibus
master

Base cluster

Max. 2.5 meters

TB820 I/O cluster 1
Optical modem

I/O cluster 2 I/O cluster 3 I/O cluster 4

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Duplex
Simplex max 15 or 200m
max 15 or 200m
 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.
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 I/O
Connections Module Termination Units

Compact Extended
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 AC 800M
Hardware AC 800M Hardware

 CPU
 Communication Interfaces
 I/O Connections
 Hardware Redundancy
 Hardware Configuration
 Application Download
 Online Functions
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 Hardware
Redundancy Redundant Processor Unit
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 Hardware
Redundancy Controller and I/O Redundancy

CEX -bus splitter

BC810

Redundancy Redundant S800

Redundant I/O as direct I/O
Link Cable
PROFIBUS CI
CI854A

Redundant or Singular
S800 I/O
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Optical ModuleBus
Cable
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 Hardware
Redundancy ModuleBus I/O Redundancy
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 Hardware
Redundancy PROFIBUS I/O Redundancy

TU846 or TU847
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 AC 800M
Hardware AC 800M Hardware

 CPU
 Communication Interfaces
 I/O Connections
 Hardware Redundancy
 Hardware Configuration
 Application Download
 Online Functions
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 Hardware
Configuration Adding a CPU

ModuleBus Scan Cycle Time

 can be set in the range 0...100 ms

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 default setting is 0 (as fast as possible) and can load the CPU significantly
 minimum scan time in practice will be 6 ms
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 Hardware
Configuration Adding Communication Interface
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 Hardware
Configuration Hardware Libraries
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 Hardware
Configuration Adding S800 I/O on ModuleBus
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 Hardware
Configuration Adding S800 I/O on PROFIBUS
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 Hardware
Configuration Hierarchical Dot Notation

Controller_1.0.11.3.1

Channel 1

 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)
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 Hardware
Configuration Settings of I/O Units
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 Hardware
Configuration Adding Compact Flash
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 Hardware
Configuration Changing the IP address
System identity should normally correspond to the setting for Ethernet 1
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 AC 800M
Hardware AC 800M Hardware

 CPU
 Communication Interfaces
 I/O Connections
 Hardware Redundancy
 Hardware Configuration
 Application Download
 Online Functions
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Download
Application
Download
 Application
Download Difference Report
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 Application
Download Re-Authentication
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 AC 800M
Hardware AC 800M Hardware

 CPU
 Communication Interfaces
 I/O Connections
 Hardware Redundancy
 Hardware Configuration
 Application Download
 Online Functions
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 Online
Functions Status of I/O-Signals
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Functions
Forcing
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Functions
SoftController
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