T308-04 AC800M Hardware - RevC

System 800xA training
Chapter 4 AC800M Hardware
TABLE OF CONTENTS
Chapter 4 AC800M Hardware................................................................................................................................................ 1
4.1 General Information ..................................................................................................................................................... 2
4.1.1 Objectives.............................................................................................................................................................. 2
4.1.2 Legend .................................................................................................................................................................. 2
4.1.3 Reference Documentation ...................................................................................................................................... 2
4.2 Overview AC 800M Hardware ..................................................................................................................................... 3
4.3 Central Processing Unit ................................................................................................................................................ 4
4.3.1 Components........................................................................................................................................................... 4
4.3.2 Different Processor Units ....................................................................................................................................... 5
4.3.3 Start Modes ........................................................................................................................................................... 6
4.3.4 Battery................................................................................................................................................................... 7
4.3.5 AC 800M Communication Ports............................................................................................................................. 8
4.3.6 AC 800M High Integrity Controller........................................................................................................................ 9
4.4 Communication Interface Units ...................................................................................................................................10
4.4.1 Overview..............................................................................................................................................................10
4.4.2 Communication Exchange Bus - CEX Bus ............................................................................................................11
4.5 Input / Output Modules................................................................................................................................................12
4.5.1 Range of ABB I/O modules...................................................................................................................................12
4.5.2 I/O Connection Possibilities ..................................................................................................................................13
4.5.3 S800 I/O Connected with ModuleBus....................................................................................................................14
4.5.4 S800 I/O Connected with PROFIBUS ...................................................................................................................15
4.5.5 Limitations of CI801.............................................................................................................................................16
4.5.6 Module Terminal Unit for S800I/O .......................................................................................................................16
4.6 LED indications ..........................................................................................................................................................18
4.6.1 PM8xx Controller Indications ...............................................................................................................................18
4.6.2 S800 IO Module LEDs..........................................................................................................................................21
4.6.3 S800L IO Module LEDs .......................................................................................................................................22
4.7 Hardware Redundancy.................................................................................................................................................24
4.7.1 Redundant Processor Unit - PM861/PM864/PM865 ..............................................................................................24
4.7.2 Controller and I/O Redundancy.............................................................................................................................25
4.7.3 Module Terminal Unit for S800I/O .......................................................................................................................25
4.7.4 Redundant ModuleBus I/O Connections................................................................................................................26
4.7.5 Redundant PROFIBUS I/O Connections................................................................................................................27
4.7.6 Redundant Power Supply ......................................................................................................................................29
Chapter 4 - 1
T308-04 AC800M Hardware - RevC
4.1 General Information

4.1.1 Objectives
Upon completion of this chapter, you will be able to:
Describe the AC 800M hardware components
Explain the interconnections between hardware modules
Explain the LED indications
Describe the redundant hardware
4.1.2 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
4.1.3 Reference Documentation
Chapter 4 - 2
3BSE036351
Industrial IT 800xA Control and I/O

AC 800M Controller - Hardware and Operation
3BSE035980

Basic Control Software Introduction and Configuration
3BSE020923

S800 I/O General Information and Installation
3BSE020924

S800 I/O Modules and Termination Units
4.2 Overview AC 800M Hardware

The AC 800M controller consists of a selection of units mounted on horizontal DINrails, which can be housed within an enclosure. The majority of units consist of a base
mounting plate and removable cover attached with screws.
The hardware units that form the AC 800M controller are:
Central Processor Unit (CPU)
Communication interface modules for different protocols
S800 I/O modules
Power supply modules
Optional up to
12 Communication
modules
CPU
S800 I/O
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.
Chapter 4 - 3
4.3 Central Processing Unit

4.3.1 Components
The CPU consists of a base plate TP830 and a replaceable processor module PM8xx
with various speed and memory combinations.
Compact Flash Card
Fuses for Modulebus

and CEX-bus
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.
Compact Flash Card

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.
NOTE!
Chapter 4 - 4
Compact Flash cannot be used in an AC 800M High

Integrity controller.
4.3.2 Different Processor Units

The key differences between the different CPUs are memory and frequency, also some
can only be used in stand alone mode and others can be used in redundant mode.
Redundant
PM864
Redundant
PM865
Redundant
PM861
PM860
PM856
32MB
96 MHz
PM851
32MB
96 MHz
SIL2
16MB
48 MHz
8MB
48 MHz
8MB
24 MHz
8MB
24 MHz
Unit
PM851
Description
24 MHz (48MHz for communication) / 8 Mbytes RAM
On-line
replacement
Redundancy
No
No
No
No
No
No
Yes
Yes
1 Ethernet port, 1 Serial port and 1 tool port. Application

speed is half of PM860. Maximum one CEX bus module.
PM856
24 MHz (48MHz for communication) / 8 Mbytes RAM

2 Ethernet ports, 1 Serial port and 1 tool port. Application
speed is half of PM860.
PM860
48 MHz / 8 Mbytes RAM

2 Ethernet ports, 1 Serial port and 1 tool port.
PM861

2 Ethernet ports, 1 Serial port and 1 tool port. Singular or
redundant.
PM861A
Same as PM861 but can use redundant communication unit

CI854A, CI860 and BC810.
Yes
Yes
PM864
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, CI860 and BC810.
Yes
Yes
PM865 (PA/HI)
No
Yes
2 Ethernet ports, 1 Serial port and 1 tool port. PM865 can be

used in an AC 800M High Integrity system.
Chapter 4 - 5
4.3.3 Start Modes

The controller may be started with the following start modes:
Mode
Chapter 4 - 6
Invoked by
Description
Warm Init
Power Off/On with a

battery backed up CPU
Applications restart with retain values.
Cold Init
Press Init < 2.5 s
Applications restart with cold retain values.
Reset
Press Init > 3 s or until

Run LED flashes
Applications are deleted in controller.
4.3.4 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.
Internal Battery
min time (hours)
External Battery
min time (weeks)
PM851/PM856/PM860
48
PM861
36
CPU Type
PM864
36
PM861A
118
12
PM864A
235
24
PM865 HI
235
24
PM865 PA
235
24
NOTE!
A Compact Flash card can be used for non-volatile

storage of application and data.
The battery must be exchanged whenever:
the battery LED flashes
multiple or extended power cuts have occurred
extended periods of system downtime have occurred
at least every second year (1Ah cell) or fifth year (18 Ah cell), regardless of
whether the battery has been considerably used or not
Chapter 4 - 7
4.3.5 AC 800M Communication Ports

Detailed description of the communication ports of the CPU:
Communication
Expansion CEX-bus
CPU
S800I/Os on the
Electrical ModuleBus
RCU link
connection
Ethernet ports
Fiber opticale
ModuleBus
Two built-in RS-232 serial ports:

COM3 with modem support for several protocols
COM4 intended as tool port for Control Builder
Two built-in Ethernet ports (IEEE 802.3, 10BaseT with TCP/IP):

CN2 used for redundancy or routing
Built-in ModuleBus for optical or electrical connection to I/O communication
Built-in CEX-bus (Communication Extended Bus) for external communication

modules
NOTE!
Chapter 4 - 8
COM 3-4 ports
In a configuration with redundant CPUs, COM3 and the

electrical ModuleBus cannot be used.
4.3.6 AC 800M High Integrity Controller

AC 800M can easily be configured for usage in safety critical applications. The main
components of such a system are PM865, SM810, SS823 and the S800 I/O High
Integrity system, running a High Integrity version of Control Software.
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.
Chapter 4 - 9
4.4 Communication Interface Units

4.4.1 Overview
CI857
CI856
CI855
INSUM
S100 I/O
MB300
PM8xx
CI858
DriveBus
RS232
CI860
FF HSE
CI854A
CI862
TRIO I/O
CI853
CI865
Satt I/O
PROFIBUS DP
CI867
Modbus TCP
A number of communication modules can be connected to the CEX bus.
The table below is a summary of the interfaces (for details refer to hardware manual):
Unit
CI851
Description
PROFIBUS DP-V0 communication interface unit.
On-line
replacement
Redundancy
No
No
Only to use with S200 I/O.

CI853
RS-232C serial communication interface unit.
No
No
CI854
No
No
Yes
Yes
Redundant Profibus cabling possible.

CI854A

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
Chapter 4 - 10
4.4.2 Communication Exchange Bus - CEX Bus

TB850
or
TK850 with DB25P
and TB851
Up to 12 communication units can be placed on the CEX bus
The CEX-bus must be terminated if a communication unit is connected. A CEXbus termination is delivered with the CPU: TB850 (male) or TB851 (female).
An extension cable TK850 with connector DB25P with metal housing and a
length of 0.7 meter (2.3) can be used for extending the CEX bus to a second DIN
rail.
Chapter 4 - 11
4.5 Input / Output Modules

4.5.1 Range of ABB I/O modules
The following I/O types can be connected to an AC 800M system:
Chapter 4 - 12
S800 modular I/O
S800 modular I/O with intrinsic safety (IS)
S800L I/O
This is a compact I/O with an integrated I/O and terminal unit. This I/O cannot be
replaced on-line.
S200 I/O
This I/O must be connected through communication module CI865
S900 I/O
This I/O must be connected through a CI920 PROFIBUS module. The I/O is
suitable for use in hazardous areas.
S100 I/O
This I/O must be connected through communication module CI856
4.5.2 I/O Connection Possibilities

I/O units are connected in two ways:
ModuleBus (electrical or optical)
PROFIBUS DP
An I/O cluster consists of one CI830/CI801 or TB820 and a number of I/O modules.
Max. 12 I/O modules can be included in one I/O cluster.
S900 I/O can only be connected through PROFIBUS DP.
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.
Chapter 4 - 13
4.5.3 S800 I/O Connected with ModuleBus

The ModuleBus interface is used for handling local S800 I/O on the AC 800M
controller. I/O units connected to ModuleBus are organized into clusters. The
ModuleBus in the AC 800M controller consists of:
Electrical ModuleBus (base cluster) not extensible and maximum of twelve

S800 I/O units
Optical ModuleBus maximum of seven TB820 cluster modems
Max. 96 I/O modules
1-12* S800 I/O modules per cluster
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
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.
Chapter 4 - 14
4.5.4 S800 I/O Connected with PROFIBUS

The CI854 unit is the main PROFIBUS DP-V1 communication interface and it can be
used to communicate with remote I/O or with actual PROFIBUS devices.
Max. 24 I/O modules / I/O Station
1 base cluster
1-7 I/O cluster
1-12* S800 I/O modules per cluster

*The memory size and bus load in the CI830/CI801 or TB820 limits the number
of I/O modules per cluster
Max. cluster length 2.5m (electrical ModuleBus)
CI801
Profibus slave
with
TB810
CI854
Profibus
master
Base cluster
Max. 2.5 meters
TB820
Optical modem
I/O cluster 1
I/O cluster 2
I/O cluster 3
I/O cluster 4
Duplex
Simplex
max 15 or 200m
NOTE!
max 15 or 200m
CI840 is the redundant version of CI801.
Chapter 4 - 15
4.5.5 Limitations of CI801

The maximum number of I/O modules you can connect to a station is 24 modules.
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. The table below shows the maximum
number of I/O modules that can be connected to one CI801.
NOTE!
Please refer to the manual for more information.
4.5.6 Module Terminal Unit for S800I/O

The S800 I/O unit is attached to an MTU, Module Terminal Unit. A number of MTUs
are available. They can however be divided into two major groups, depending on the
physical layout:
Compact / 1 connection per channel
Extended / 3 connections per channel
Compact
NOTE!
Chapter 4 - 16
Extended
Mechanical key protection prevents wrong I/O module

type from being inserted.
The table below gives an overview of which MTU could be used for the different I/Omodules.
Chapter 4 - 17
4.6 LED indications

All hardware units have LED indicators on the front panel. These indicators can be
used to diagnose different error conditions in the hardware. Typically after reading the
status of the unit by looking at the LED, a number of different actions should be tried
to remedy the problem.
4.6.1 PM8xx Controller Indications

On the front of the controller there are a series of LED indications as shown in the
diagram below.
Fault
Primary
Run
Power
Battery
Dual
4 x Tx and
Rx LEDs
Chapter 4 - 18
4.6.1.1 Running Conditions

Under normal running conditions the LED indications should be indicated in the
following table.
Name
F(ault)
Color
Red
Function
Normal State OFF
Self check OK
P(ower)
Green
Normal state ON
When lit, indicates that the CPU DC/DC converter is
generating valid +5 V and +3.3 V DC supply voltages. No
software control.
B(attery)
Green
Normal state ON
Lit when condition of internal or external battery is satisfactory.
The LED is controlled by a software battery voltage test
BATTOK (1)
Tx
Yellow
Data Transmission(2) for CN1,CN2 ,COM3 and COM4

Flashes in synchronization with Tx traffic
Rx
Yellow
Data Reception(2) for CN1,CN2 ,COM3 and COM4

Flashes in synchronization with Rx traffic
Valid for PM861/PM864/PM865

PRIM(ary)
Yellow
Lit in single and redundant configuration.

Indicates Primary CPU in redundant configuration. Controlled
by software
DUAL
Yellow
Lit when the CPU is running in redundant configuration and

synchronized state.
(1) The battery provides back-up power for both the application memory and the real
time clock during power down. The battery is either accessible via the PM8xx cover
panel or externally connected to the external battery connector. Battery voltage is
cyclically checked by the software. Voltage is common for both the internal and
external battery. For this reason the internal battery should be removed when using the
external battery, since having two batteries connected in parallel will result in greatly
reduced capacity.
(2) Only CN1 for PM851. Do not connect to CN2.
Chapter 4 - 19
4.6.1.2 Fault Conditions

In the event of a suspected controller malfunction, refer to the table below for LED
indications and possible corrective action.
Fault
Possible Cause & Corrective Action
F(ault) LED is ON
Controller Re-start, (INIT), in progress.
Wait for Controller restart to finalize.
If condition persists:
R(un) LED is OFF
Check that the CEX-bus fuse is serviceable.
Check for a module failure on the CEX-bus.
No application loaded on the Controller.
Load application.
Restart Controller (INIT push button).
Controller application failed.
B(attery) LED is flashing
Reload application.
Restart Controller (INIT push button).
Battery power (Internal or External) is below an acceptable level or nonexistent.
Install new battery.
External battery cable disconnected.
Rx is off
Connect external battery cable.
CN ports: Telegrams from other station cannot be received on the controller.
Check IP addresses and Network cables.
COM ports: Telegrams from slaves are not received.
DUAL LED is OFF on both

CPUs
(PM861 and PM864 only)
Check COM port and protocol settings.
Check serial cables and modems.
The CPUs are in the process of being re-started or configured. Allow time for
this to finalize.
RCU Link Cable disconnected.
Connect the RCU Link Cable.
Different Control Software in the two CPUs.
NOTE!
Chapter 4 - 20
Upgrade the CPUs with the same control software.
Refer to section Maintenance in manual 3BSE036351

Controller Hardware - Hardware and Operation!
4.6.2 S800 IO Module LEDs

The S800 modules are the most widely used for general applications due to their
ability to be replaced online.
The figure below shows examples of front panels for different types of IO modules.
On the front of each IO module there are three LEDs (F)ault, (R)un and (W)arning
indicating the module status. One additional LED (O)utput Set as Predetermined is
included on output modules.
For modules with special LED indications, refer to manual S800 IO - Modules and
Termination Units for explanation.
The FAULT LED will indicate when the IO module detects a fatal error or before first
access after power up. The RUN LED indicates when the IO module is operational.
The WARNING LED indicates when a non-fatal error is detected, for example, an out
of range analog channel, and the module continues to run.
The OSP LED indicates when the IO module is in OSP state, that is, when the module
is commanded to OSP or when automatically set to OSP state due to communication
error. The OSP value can be set on individual channels, which for a digital output can
be 0 or 1, or the last known valid value. Similarly an analog output can have an OSP
value of anything between 0 and 100% or the last known valid value.
In addition to the general LEDs, each digital channel has one amber LED indicating
current state (on/off).
Chapter 4 - 21
The table below shows the status of the LEDs during different states of the IO unit.
4.6.3 S800L IO Module LEDs

The low cost version can be distinguished by the fact that the base is integral with the
unit. S800L IO units have fewer LED indicators than S800 IO.
Chapter 4 - 22
On the front of each IO module there is one LED indicating the module status.
Some IO modules also have LED indicators that are specific for that module. Digital
IO units also have one LED for each channel.
The table below shows the LED indication during different conditions of the IO unit.
Chapter 4 - 23
4.7 Hardware Redundancy

4.7.1 Redundant Processor Unit - PM861/PM864/PM865
In a system with redundant Processors, the controller contains two processor units,
each including memory for system and application software. In a redundant system the
two processor units are linked together with the RCU Link Cable (max 1 m).
One unit is acting as primary, the other is backup (hot stand-by). The primary
processor unit controls the process. The backup stands by to take over in case of a
fault in the primary. The primary CPU is always updating the backup CPU.
You can select late in your project if you need redundancy option.
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!
Chapter 4 - 24
The changeover is done bumpless and in less than 10 ms.
4.7.2 Controller and I/O Redundancy

Use of redundancy will reduce the maximum number of S800 channels. Each cluster
may contain up to 12 single S800 I/O units or up to 6 redundant S800 I/O units.
CEX -bus splitter

BC810
Redundant
PROFIBUS CI
CI854A
Redundancy
Link Cable
Redundant S800
I/O as direct I/O
Redundant or Singular
S800 I/O
Optical ModuleBus
Cable
4.7.3 Module Terminal Unit for S800I/O

For redundant S800 DI, DO, DP and AO modules the MTU842 and MTU843 are
used. For the redundant S800 AI modules the MTU844 and MTU845 are used. On
these MTUs there is one shunt-stick for each channel for configuration of mA or
voltage input.
Use of redundancy will reduce the maximum number of S800 channels on the
ModuleBus. Each cluster may contain up to 12 single S800 I/O units or up to 6
redundant S800 I/O units.
Chapter 4 - 25
4.7.4 Redundant ModuleBus I/O Connections

When you use redundant I/O module configuration, the maximum number of I/O
modules in one cluster is 6 pairs.
Chapter 4 - 26
4.7.5 Redundant PROFIBUS I/O Connections

When you use redundant I/O module configuration, the maximum number of I/O
modules in one cluster is 6 pairs.
TU846 is used for Redundant I/O modules
TU847 is used for non redundant I/O modules
CI840 is connected to CI854 PROFIBUS master
TU846 or TU847
Chapter 4 - 27
For PROFIBUS it is possible to have different levels of redundancy:
Line redundancy
Master redundancy
CI854A
Master
For a redundant master solution the CI854A is installed in a redundant configuration.

The Profibus DP-V1 cable is connected to both primary and backup module. When a
CI854A module fails or bus communication is interrupted, the redundancy partner is
automatically activated. A CI854A pair balances the data cyclically over a fast link.
Chapter 4 - 28
4.7.6 Redundant Power Supply

In the figures below, there are two examples of redundant power solutions. The SS82x
voting unit is used to connect two redundant power supplies to a common load.
Redundant power supplies connected to the SS82x voting device with one common
main.
L+ L+ L- LOK
SD821
N L PE
L+ L+ L- LOK
SD821
N L PE
OK+ F OK+ F
A
B
L+ to +24V
L- to 0V
SA & SB to
supervision inputs
on PM860 or CI830
SS822
A+B+L+L+L-
Main
Redundant power supplies connected to the SS82x voting device with two separate
mains.
L+ L+ L- LOK
L+ L+ L- LOK
SD821
N L PE
SD821
N L PE
Mains 1
Mains 2
OK+ F OK+ F
A
B
L+ to +24V
L- to 0V
SA & SB to
supervision inputs
on PM860 or CI830
SS822
A+B+L+L+L-
Chapter 4 - 29
Chapter 4 - 30

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