Control IT Hardware (AC800 M/C) & SoftController

ABB Ltd - Page 1

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A suite of IEC 61131-3 compatible controllers

AC 800M the new Modular Controller
designated for binary control as well as advanced control applications

AC 800C the Compact Controller for small,

yet advanced applications

SoftControl the controller that runs

on a PC providing high performance at low cost
ABB Ltd - Page 2

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AC 800 M

ControlIT AC 800M Hardware

AC 800M
Modular and flexible concept, DIN-rail mounted Built in redundant Ethernet Very low power consumption Hot swap of communication- and I/O modules Local and remote I/O options Industry quality hardware with excellent EMC and MTBF properties

ABB Ltd - Page 4

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AC 800M Controller with a S800 I/O Module

AC 800M Communication Interface Processor Module I/O System S800 I/O Module

ABB Ltd - Page 5

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Processor Module

ABB Ltd - Page 6

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Processor Module

ABB Ltd - Page 7

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Hardware mapped to Control Builder

1 2 3 4 5

6
7 8

3 2 8
ABB Ltd - Page 8

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Base components for AC 800M

Processor Module
PM860 - Processor TP830 - Baseplate

Power Supply
SD821 - 24 V d.c. regulated @ 2.5 A SD822 - 24 V d.c. regulated @ 5 A SD823 - 24 V d.c. regulated @ 10 A

Communication Interfaces
CI851 Profibus CI852 Foundation Fieldbus CI853 RS232-C

Battery Backup
SB821- External Backup

ABB Ltd - Page 9

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Processor Module
MPC860/48MHZ
Motorola Power PC

Two Ethernet ports for connection to the control network

CN1, CN2

8 MB RAM
5 MB for application program 3 MB for executable firmware Mounted on the module

Two serial ports (COM3, COM4)

COM3 is an RS232-C port with modem control signals COM4 is isolated and used for the connection of the configuration tool

2 MB System FLASH PROM

For non-volatile storage of firmware and license key Mounted on the module

ABB Ltd - Page 10

Optical Modulebus to connect clusters of S800 I/O modules A connector for Compact Flash (not included in this release)

Electrical Modulebus is used for connection clusters of S800 I/O directly to the baseplate CEX-bus is used for extending the on-board communication ports with communication interface modules

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Power Supply
Switch-mode power converters
Converting a.c. Mains supply voltage to a regulated 24 V d.c.

The CPU module does has no requirement for a UPS

It has a 5 ms reservoir to safely shutdown

Input can be either 115 V a.c. or 230 V a.c Redundant or non redundant
When a redundant power supply is connected to a common load, you need a voting device, SS822, to combine two outputs into one via diodes

The power supply handles short power interruptions (<20 ms) Available modules
SD 823
24 V d.c. regulated @ 10 A

SD 822
24 V d.c. regulated @ 5 A

SD 821
24 V d.c. regulated @ 2.5 A
ABB Ltd - Page 11

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Battery Backup
External battery Internal battery
Up to one month (720 hours) Lithium Battery 3.6 V, 950 mAh.

External battery module SB821

Lithium battery, 3.6 V 16 Ah A minimum of 18 months Mounted on the DIN rail and connected to the CPU via cable

Internal battery

External battery Connection

ABB Ltd - Page 12

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I/O System
Local I/O S800
12 local I/O modules per cluster
24 with optical modem

7 clusters x 12 I/O modules of local on the Modulebus Up to 96 local I/O Modules

Field Communication Interface (FCI) is used to connect the I/O modules to the PROFIBUS There is no physical limit for the number of I/Os that can be connected to AC 800M Recommendation
~600-700 I/O per controller
The memory for the

Remote I/O via Profibus

Foundation Fieldbus and Advant Fieldbus to come Recommened to use ABB I/O S900, S800 and S200

application sets the limit

The hardware is relatively cheap

Buy an extra controller

ABB Ltd - Page 13

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I/O System
Local I/O
Up to 96 modules

Remote I/O via Profibus CI851 PM860 Profibus CPU

PM860 12 I/O Modules CPU

Optical
TB820
Optical Modem

12 I/O modules

CI830 12 I/O modules FCI

Up to 24 modules per stations

Optical TB820
Optical Modem
ABB Ltd - Page 14

CI830 12 I/O modules FCI 12 I/O modules TB820

Optical Modem

12 I/O modules

Up to 7 clusters and 200m between clusters

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Up to 5 PROFIBUS segments Up to 32 stations per segment Up to 24 modules per stations Up to 384 DI/DO and 192AI/AO per station

AC 800M / S800 I/O Interconnection

ABB Ltd - Page 15

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AC 800M / S800 I/O Interconnection

TB805 CI851 PM810 AI810 AI810 AO810 AO810 AO810 AO810 See note 1 TB806 TB850V007 TB851

TK801V003/6/12

CI851 See note 2

AI810 AI810 AO810 AO810 AO810 AO810

See note 3

TK811V015/050/150

TB820 DI810 DI810 DO810 DO810 See note 5 To addition module clusters

CI830 DI810 DI810 DO810 DO810 TB810

ABB Ltd - Page 16

See note 4 TB820 DI810 DI810 DO810 DO810

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Modulebus Extension & Termination

TB805 TB806

DIN-Rail

TK801V003/006/012
ABB Ltd - Page 17

Note 3
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I/O Module on Compact & Extended MTUs

I/O Modules

Extended MTU

Typical Compact MTU with I/O Module

CI830 Compact MTU

ABB Ltd - Page 18

Typical Extended MTU with I/O Module

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AC 800M Connectors for Optical Modulebus

Duplex Fiber Optic Cable Connector TK811V015/050/150

Rx Tx

TK812V015/050/150
Simplex Fiber Optic Cable Connector
Front View

ABB Ltd - Page 19

For connection from PM810 to TB820

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Note 1

TB820 Optical Modulebus Connection

TB820

Optical ModuleBus Interface Connectors (X4, X5)

TK811V015/050/150 Rx X4 Tx Duplex Fiber Optic Cable Connector Rx X5 Tx Simplex Fiber Optic Cable Connector
ABB Ltd - Page 20

TK812V015/050/150

Front View

Note 5
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CEX Extension & Termination

ABB Ltd - Page 21

Note 2
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CEX Extension & Termination

ABB Ltd - Page 22

Note 2
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Supported S800 I/O Modules (Local & Remote)

S800 I/O Modules S800 I/O I.S. Modules

S800L I/O Modules

ABB Ltd - Page 23

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Supported S200 I/O Modules (Remote I/O)

Via 200-APB12 PROFIBUS Adapter S200L I/O Modules S200 I/O Modules

S200L I/O Modules

ABB Ltd - Page 24

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PROFIBUS Support
CI851 Profibus Interface
Power from the processor module

TP851 Baseplate Profibus DP must be terminated on both sides It is possible to connect any standard PROFIBUS I/O via CI851
For example S800 I/O or S200 I/O

ABB Ltd - Page 25

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PROFIBUS Connection - CI830 & TB820

Connector for TB810 Power Supply Connections

ABB Ltd - Page 26

TB820

Modulebus Optical Port

Profibus-DP Connector

Note 4
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CI830

AC 800M, Profibus integration

S800 I/O

Profibus-PA via standard segmentcoupler

Profibus-DP S900 I/O

Profibus-PA
ABB Ltd - Page 27

DP/PA Converter
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Foundation Fieldbus (In future release)

CI852 Foundation Fieldbus H1 Interface
Power from the processor module

Up to 32 Foundation Fieldbus Devices

TP852 Baseplate

ABB Ltd - Page 28

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AC 800M ,FF integration

Communication with FF-instruments is easily performed via IEC 61131-3 function blocks

FF H1

ABB Ltd - Page 29

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Serial Interface RS232-C

CI853 RS232-C
Two serial ports Power from the processor module

TP853 Baseplate A RS232-C channel, with full modem support, can be connect to COM1 or COM2 For cables longer than 15m a short distances modem, TC562, must be used
Up to 12 km, depending on the transmission speed

ABB Ltd - Page 30

Available Protocols
Please see screen dump to the right

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CEX Extension and Termination

CEX Bus in the communication bus TB 850 CEX-bus termination shall always be installed on the last unit CEX extension cable TK850 (0.7m) to mount the modules on another DIN-rail

ABB Ltd - Page 31

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Modulebus Extension and Termination

The Modulebus connects the local I/O A terminator, TB807, must always be mounted on the last I/O module on the Modulebus Will support direct connection to Drives in the future

ABB Ltd - Page 32

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Installation
Mounted on a horizontal DIN rail
Locking device to connect to the DIN rail to get grounding The locking device can be in OPEN, SLIDE or LOCKED

AC800M & S800I/O has protection class IP20 To get higher protection we recommend the following cabinets with protection class IP54
RM550 Floor mounted RE820 Wall mounted

ABB Ltd - Page 33

Example of Wall mounted

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Environmental Specifications

ABB Ltd - Page 34

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CE Compliance

ABB Ltd - Page 35

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Electromagnetic Compatibility and Main Voltage Conditions

ABB Ltd - Page 36

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AC 800 C

AC 800C Main Module

Processor Module PM210
18,432 MHz 2 Mb RAM and 2 Mb Flash PROM

On board I/O Modules

10 DI, 6 DO

Battery back-up module SB210 1 slot for an optional battery plug-in board with a real-time clock and a lithium battery

Two on-board RJ-45 jacks for RS232 channels

COM 0 The port for the Control Builder COM 1- full set of modem control signals

Two slots for optional communication plug-in boards are provided

Serial Links Ethernet PROFIBUS-DP master of class 1 FOUNDATION Fieldbus link master (future)

ABB Ltd - Page 38

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AC 800C Hardware Layout

ABB Ltd - Page 39

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Hardware mapped to Control Builder

8
7 1

1 2 3 4 5 6 7 8

ABB Ltd - Page 40

5 2 3
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Installation
Horizontally and vertically mounted on the DIN rail The AC 800C, S200, S200L and S800 I/O-unit have all protection class IP 20

ABB Ltd - Page 41

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AC 800C / S200/S200L/ S800 I/O Modules Interconnection

Programming Terminal

Central I/O

Remote I/O

AC 800C S800 I/O

S200/S200L I/O

ABB Ltd - Page 42

Profibus-DP
S200/S200L I/O
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How to connect I/O Modules

On-board I/O
10 DI and 6 DO on board
24 V DC

The inputs and outputs are filtered and galvanically isolated by optocouplers

Local Input/Output (I/O) units

8 S200 Local I/O Modules
two rows by means of the

extension cables CE1 or CE3.

8 Extra via a TK210 cable and a 200 AIO adapter

ABB Ltd - Page 43

Remote I/O Modules

PROFIBUS-DP can be used for connection of remote I/O units, for instance S200/S200L and S800 I/O units

The total number of I/O units connected (central and remote) to the controller are 32 I/O units

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On board I/O
On-board I/O
10 DI and 6 DO on board
24 V DC

The inputs and outputs are filtered and galvanically isolated by optocouplers A separate two-pole plug-in screw connector for the external +24 V DC power supply
The unit is not damaged if the

polarity is reversed

ABB Ltd - Page 44

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Local I/O
Local Input/Output (I/O) units
8 S200 Local I/O Modules
two rows by means of the

extension cables CE1 or CE3 0.3 and 0.9 m respectively

8 Extra via a TK210 cable and a 200 AIO adapter

(length 0.5, 1.0, or 2.5 m)

Note that a TK210 cable longer than 0.9 m is not allowed in hazardous locations according to UL1604

ABB Ltd - Page 45

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Supported S200 I/O (Local & Remote)

S200C I/O Modules S200 I/O Modules

S200L I/O Modules

ABB Ltd - Page 46

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AC 800C Communication Possibilities

To Control Builder
Via a serial port using the PPP protocol, or alternatively via Ethernet

On-board serial Communication

COM 0 can receive and transmit signals
COM 0 is the default channel

Serial Interfaces
Available protocols are Siemens 3964R (as master), COMLI, MODBUS RTU (as master) and MMS. User-defined protocols may also be used

for the programming station tool port

Fieldbus Support
PROFIBUS FOUNDATION Fieldbus

COM 1 has a full set of modem control signals Each channel has LEDs indicating the status of transmit and receive activities RS-232 is a point-to-point communication standard with a maximum cable length of 15 meters

ABB Ltd - Page 47

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Communication Extensions

Ethernet Communication Board CI272

Profibus Communication Board CI274

ABB Ltd - Page 48

RS-232 Communication Board CI271

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Communication Extensions - Serial

RS-232 Communication Board CI271 (Option)
There are two RJ-45 jacks for RS-232 channels Full set of modem control signals This gives a multiple RS-232 point-to-point communication with e.g. printers, scales, bar codes, controllers, and for multiple protocols (COMLI, Modbus, etc)

ABB Ltd - Page 49

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Communication Extensions - Ethernet

Ethernet Communication Board CI272 (Option)
Enables a network consisting of many interconnected controllers, operator stations and servers Communication via MMS It has one RJ-45 jack for Ethernet 10BASE-T (twisted pair, max. cable length 100 m)

ABB Ltd - Page 50

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PROFIBUS Board CI274

PROFIBUS Board - CI274
A fast (12 Mb/s) PROFIBUS-DP master

A PROFIBUS-PA can also be used, via a segment coupler 1, in heavy industries with intrinsically safe I/Os The CI274 board acts as a PROFIBUS-DP master of class 1 and up to two of them can be installed on the AC 800C controller

ABB Ltd - Page 51

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PROFIBUS Board CI274

Can be used to connect remotely installed S800 I/O, S200 I/O, S200L I/O and third party I/O units
Maximum length of 100 to 1200 meters, depending on the transmission rate S800/S800L I/O
The S800 I/O units are connected to

one or more I/O adapters, CI830 These I/O units are connected to one or more I/O adapters, with a maximum of twelve I/O units per adapter.

Additional units can be connected to the same adapter via optical cables and optical interface units, TB820.

S200/S200L I/O
These I/O units are connected to
ABB Ltd - Page 52

one or more I/O adapters, 200APB12, with a maximum of eight I/O units per adapter

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FOUNDATION Fieldbus CI 275 (future release)

The CI275 board is an optional interface for remote connection of 31.25 Kb/s FOUNDATION Fieldbus devices
A maximum length of 200 to 1900 meters, depending on cable type The CI275 board acts as link master device

Used to connect remotely installed I/O and third-party units and which comply with its specifications

ABB Ltd - Page 53

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Battery Backup - SB210

At least a year with the battery and 20 minutes without Low battery voltage, such as after a power failure, is indicated by flashing PWR Battery replacement can be performed during operation by lifting a small lid in the controller cover. UL-approved 3 V batteries of type CR2430 must be used

ABB Ltd - Page 54

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Power Supply
Note
The controller and the I/O systems should, if possible, have separate 24 V DC supplies

ABB Ltd - Page 55

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Technical Data

ABB Ltd - Page 56

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Environmental Specification - Climate

ABB Ltd - Page 57

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Environmental Specification - Mechanical

ABB Ltd - Page 58

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CE - Compliance

ABB Ltd - Page 59

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Electro Magnetic Compatibility

ABB Ltd - Page 60

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Electro Magnetic Compatibility

ABB Ltd - Page 61

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SoftController For future release

SoftControl An Overview
A personal computer can be turned into a controller by means of Control Builder software and communication plug-in boards Central I/O
S200 and S200L I/O units

Remote I/O
Via PROFIBUS-DP and FOUNDATION Fieldbus. SattBus (developed by ABB Automation Products) and DataHighway Plus (from AllenBradley)

ABB Ltd - Page 63

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Hardware mapped to Control Builder

ABB Ltd - Page 64

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Communications Serial Interface

S-232 Protocols
A PC is usually delivered with one or two RS-232 COM-ports (COM1 and COM2) You can add more interface boards Standard protocols such as PPP is specified by use of standard Windows installation software A range of other protocols can be defined by the Project Explorer

ABB Ltd - Page 65

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Local I/O
S200/S200L I/O units
Up to four plug-in boards can be handled by the Soft Controller
each of them capable of

connecting up to sixteen I/O units

Use the ISA CIIO Board Alternatively, the units can be connected via PROFIBUS-DP

ABB Ltd - Page 66

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Supported S200 I/O (Local & Remote)

S200C I/O Modules S200 I/O Modules

S200L I/O Modules

ABB Ltd - Page 67

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Ethernet Communication
Ethernet
A standard Ethernet PC board can be used if the controller is to be connected to Ethernet

Use standard network components to build your network

ABB Ltd - Page 68

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PROFIBUS-DP Communication
A plug-in board a PROFIBUSDP network. Up to four board per SoftController Two adapters
one for connection of up to eight S200/S200L I/O units The other for connection of up to twelve S800 I/O units

S200 I/O Modules via PROFIBUS

S800 I/O Modules via PROFIBUS

ABB Ltd - Page 69

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FOUNDATION Fieldbus
FOUNDATION Fieldbus
Up to thirty-two FOUNDATION Fieldbus devices can be connected to a plug-in board. Up to four such boards can be handled by the SoftControl

ABB Ltd - Page 70

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SattBus
SattBus is a communication protocol and a physical layer, both developed by ABB Automation Products Up to 120 nodes can be connected to a SATTBUSPC board, and up to four such boards can be handled by the SoftController COMLI can be used for communication on SattBus

ABB Ltd - Page 71

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DataHighway Plus
DataHighway Plus is a multimaster communication protocol from Allen-Bradley Up to 63 Allen-Bradley PLC-5 systems can be connected to a DataHighway Plus board, and up to four such boards can be handled by the SoftController.

ABB Ltd - Page 72

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Hardware Requirements

ABB Ltd - Page 73

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 ABB Ltd - Page 74

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