Course T314
© ABB University - 1
Revision C
Extended Automation System 800xA
Chapter 7
AC 800M Hardware
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
© ABB University - 2
Revision C

Reference Documentation

3BSE036351

3BSE035980

3BSE020923

3BSE020924
IndustrialIT 800xA – Control and I/O
AC 800M Controller - Hardware and Operation
IndustrialIT 800xA – Control and I/O
Basic Control Software – Introduction and Configuration
IndustrialIT 800xA – Control and I/O
S800 I/O – General Information and Installation
IndustrialIT 800xA – Control and I/O
S800 I/O – Modules and Termination Units
Overview
AC 800M Controller Hardware
Optional up to
12 Communication
modules
CPU
S800 I/O
RS-232 channels
© ABB University - 3
Revision C
Redundant Ethernet
AC 800M
Hardware
AC 800M Hardware






© ABB University - 4
Revision C

CPU
Communication Interfaces
I/O Connections
Hardware Redundancy
Hardware Configuration
Application Download
Online Functions
CPU
CPU PM8xx
Compact Flash Card
Fuses for Modulebus
and CEX-bus
© ABB University - 5
Revision C
CPU
Baseplate
CPU
Choosing the Right CPU
Choice of speed, memory and availability
Redundant
PM864
Redundant
PM865
32MB
96 MHz
32MB
96 MHz
SIL2
Redundant
PM861
PM860
PM856
PM851
16MB
48 MHz
© ABB University - 6
Revision C
8MB
24 MHz
8MB
24 MHz
8MB
48 MHz
CPU
Different Processor Units
© ABB University - 7
Revision C
Unit
Description
On-line
replacement
Redundancy
PM851
48 MHz / 8 Mbytes RAM
1 Ethernet port, 1 Serial port and 1 tool port. Application speed is half
of PM860. Maximum one CEX bus module.
No
No
PM856
48 MHz / 8 Mbytes RAM
2 Ethernet ports, 1 Serial port and 1 tool port. Application speed is half
of PM860.
No
No
PM860
48 MHz / 8 Mbytes RAM
2 Ethernet ports, 1 Serial port and 1 tool port.
No
No
PM861
48 Mhz / 16 Mbytes RAM
2 Ethernet ports, 1 Serial port and 1 tool port. Singular or redundant.
Yes
Yes
PM861A
Same as PM861 but can use redundant communication unit CI854A,
CI860 and BC810.
Yes
Yes
PM864
96 Mhz / 32 Mbytes RAM
2 Ethernet ports, 1 Serial port and 1 tool port. Singular or redundant.
PM864 is 50% faster than PM861 in executing an application.
Yes
Yes
PM864A
Same as PM864 but can use redundant communication unit CI854A,
CI860 and BC810.
Yes
Yes
PM865 (PA/HI)
96 Mhz / 32 Mbytes RAM
2 Ethernet ports, 1 Serial port and 1 tool port. PM865 can be used in
an AC 800M High Integrity system.
Yes
Yes
CPU
Start Modes


© ABB University - 8
Revision C

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 !!!
CPU
Battery
© ABB University - 9
Revision C
Compact Flash card available for non-volatile storage (application and data)
Internal
External
CPU
AC 800M Ports
Communication
Expansion CEX-bus
CPU
S800I/O’s on the
Electrical ModuleBus
RCU link
connection
© ABB University - 10
Revision C
Ethernet ports
COM 3-4 ports
Fiber opticale
ModuleBus
CPU
AC 800M High Integrity Controller

Added functionality on PM865 includes:





© ABB University - 11
Revision C

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
AC 800M
Hardware
AC 800M Hardware






© ABB University - 12
Revision C

CPU
Communication Interfaces
I/O Connections
Hardware Redundancy
Hardware Configuration
Application Download
Online Functions
© ABB University - 13
Revision C
CI865
CI862
CI860
CI858
CI857
CI856
CI855
CI854A
CI853
Satt I/O
TRIO I/O
FF HSE
DriveBus
INSUM
S100 I/O
MB300
PROFIBUS DP
RS232
PM8xx
CI867
Modbus TCP
Communication
Interface Units
Overview
Communication
Interface Units
Refer to Manuals for Details
© ABB University - 14
Revision C
Unit
Description
On-line
replacement
Redundancy
CI851
PROFIBUS DP-V0 communication interface unit.
Only to use with S200 I/O.
No
No
CI853
RS-232C serial
No
No
CI854
PROFIBUS DP-V1 communication interface unit.
Redundant Profibus cabling possible.
No
No
CI854A
PROFIBUS DP-V1 communication interface unit.
Redundant Profibus cabling and redundant interface cards.
Yes
Yes
CI855
MasterBus 300 communication interface unit for the AC 800M.
Yes
No
CI856
S100 I/O system communication interface unit.
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.
Yes
No
CI857
INSUM communication interface unit.
Yes
No
CI858
Communication interface for ABB Drives using DriveBus
No
No
CI860
Fieldbus Foundation HSE communication interface unit.
Not possible to use in AC800M HI.
Yes
No
CI865
Communication interface unit for older Satt I/O systems.
Yes
No
CI867
Provides communication with Modbus TCP via Ethernet.
Yes
No
Communication
Interfaces
Communication Exchange Bus - CEX Bus
TB850
© ABB University - 15
Revision C
or
TK850 with DB25P
and TB851
AC 800M
Hardware
AC 800M Hardware






© ABB University - 16
Revision C

CPU
Communication Interfaces
I/O Connections
Hardware Redundancy
Hardware Configuration
Application Download
Online Functions
© ABB University - 17
Revision C
I/O
Connections
Range of ABB I/O Units
© ABB University - 18
Revision C
I/O
Connections
I/O Connection Possibilities
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
© ABB University - 19
Revision C
I/O cluster 2
I/O cluster 3
Duplex
Simplex
max. 15 or 200m
max. 15 or 200m
I/O cluster 4
I/O
Connections
S800 I/O Connected with Profibus
CI801
Profibus slave
with
TB810
CI854
Profibus
master
Base cluster
Max. 2.5 meters
TB820
Optical modem
I/O cluster 1
© ABB University - 20
Revision C
I/O cluster 2
I/O cluster 3
I/O cluster 4
Duplex
Simplex
max 15 or 200m
max 15 or 200m
© ABB University - 21
Revision C
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.
I/O
Connections
Module Termination Units
© ABB University - 22
Revision C
Compact
Extended
AC 800M
Hardware
AC 800M Hardware






© ABB University - 23
Revision C

CPU
Communication Interfaces
I/O Connections
Hardware Redundancy
Hardware Configuration
Application Download
Online Functions
© ABB University - 24
Revision C
Hardware
Redundancy
Redundant Processor Unit
Hardware
Redundancy
Controller and I/O Redundancy
CEX -bus splitter
BC810
Redundant
PROFIBUS CI
CI854A
Redundancy
Link Cable
Redundant S800
I/O as direct I/O
© ABB University - 25
Revision C
Redundant or Singular
S800 I/O
Optical ModuleBus
Cable
© ABB University - 26
Revision C
Hardware
Redundancy
ModuleBus I/O Redundancy
Hardware
Redundancy
PROFIBUS I/O Redundancy
© ABB University - 27
Revision C
TU846 or TU847
AC 800M
Hardware
AC 800M Hardware






© ABB University - 28
Revision C

CPU
Communication Interfaces
I/O Connections
Hardware Redundancy
Hardware Configuration
Application Download
Online Functions
Hardware
Configuration
Adding a CPU
© ABB University - 29
Revision C
ModuleBus Scan Cycle Time



can be set in the range 0...100 ms
default setting is 0 (as fast as possible) and can load the CPU significantly
minimum scan time in practice will be 6 ms
© ABB University - 30
Revision C
Hardware
Configuration
Adding Communication Interface
© ABB University - 31
Revision C
Hardware
Configuration
Hardware Libraries
© ABB University - 32
Revision C
Hardware
Configuration
Adding S800 I/O on ModuleBus
© ABB University - 33
Revision C
Hardware
Configuration
Adding S800 I/O on PROFIBUS
Hardware
Configuration
Hierarchical Dot Notation
Controller_1.0.11.3.1
Channel 1
© ABB University - 34
Revision C

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)
© ABB University - 35
Revision C
Hardware
Configuration
Settings of I/O Units
© ABB University - 36
Revision C
Hardware
Configuration
Adding Compact Flash
Hardware
Configuration
Changing the IP address
© ABB University - 37
Revision C
System identity should normally correspond to the setting for Ethernet 1
AC 800M
Hardware
AC 800M Hardware






© ABB University - 38
Revision C

CPU
Communication Interfaces
I/O Connections
Hardware Redundancy
Hardware Configuration
Application Download
Online Functions
© ABB University - 39
Revision C
Application
Download
Download
© ABB University - 40
Revision C
Application
Download
Difference Report
© ABB University - 41
Revision C
Application
Download
Re-Authentication
AC 800M
Hardware
AC 800M Hardware






© ABB University - 42
Revision C

CPU
Communication Interfaces
I/O Connections
Hardware Redundancy
Hardware Configuration
Application Download
Online Functions
© ABB University - 43
Revision C
Online
Functions
Status of I/O-Signals
© ABB University - 44
Revision C
Online
Functions
Forcing
© ABB University - 45
Revision C
Online
Functions
SoftController
© ABB University - 46
Revision C