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Control IT Hardware

(AC800 M/C) & SoftController

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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

AC 800 M

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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

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AC 800M Controller with a S800 I/O Module

Communication Interface Processor Module

AC 800M I/O System

S800 I/O

Module

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Processor Module

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Processor Module

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Hardware mapped to Control Builder

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Base components for AC 800M

Processor Module PM860 - Processor TP830 - Baseplate

Communication Interfaces CI851 – Profibus CI852 – Foundation Fieldbus CI853 – RS232-C

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

Battery Backup SB821- External Backup

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Processor Module

MPC860/48MHZ Motorola Power PC

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

2 MB System FLASH PROM For non-volatile storage of

firmware and license key Mounted on the module

Optical Modulebus to connect clusters of S800 I/O modules

A connector for Compact Flash (not included in this release)

Two Ethernet ports for connection to the control network CN1, CN2

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

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. 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 CPU module does has no requirement for a UPS It has a 5 ms reservoir to safely

shutdown 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

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Battery Backup

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

External battery

Internal battery External battery Connection

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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 Remote I/O via Profibus

Foundation Fieldbus and Advant Fieldbus to come

Recommened to use ABB I/O S900, S800 and S200

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 application sets the limit

The hardware is relatively cheap

Buy an extra controller

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I/O System

Local I/O Up to 96 modules

Remote I/O via Profibus

CI851CI851ProfibusProfibus

PM860PM860CPUCPU

CI830CI830FCIFCI 12 I/O modules12 I/O modules

CI830CI830FCIFCI 12 I/O modules12 I/O modules

12 I/O Modules12 I/O ModulesPM860PM860CPUCPU

12 I/O modules12 I/O modules

12 I/O modules12 I/O modules

OpticalOptical

TB820TB820OpticalOpticalModemModem

TB820TB820OpticalOpticalModemModem

Up to 7 clusters and 200m between clustersUp to 7 clusters and 200m between clusters

OpticalOptical

Up to 5 PROFIBUS segmentsUp to 5 PROFIBUS segmentsUp to 32 stations per segmentUp to 32 stations per segmentUp to 24 modules per stationsUp to 24 modules per stationsUp to 384 DI/DO and 192AI/AO per stationUp to 384 DI/DO and 192AI/AO per station

12 I/O modules12 I/O modulesTB820TB820OpticalOpticalModemModem

Up to 24 modules per stationsUp to 24 modules per stations

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AC 800M / S800 I/O Interconnection

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CI851 PM810 AI810 AI810 AO810 AO810

TB820 DI810 DI810 DO810 DO810

AO810 AO810

TB805

TB806

TK801V003/6/12

CI851

TK811V015/050/150

TB850V007

TB851

CI830 DI810 DI810 DO810 DO810

TB820 DI810 DI810 DO810 DO810

TB810

See note 4

AC 800M / S800 I/O Interconnection

See note 3

See note 2

See note 1

AI810 AI810 AO810 AO810 AO810 AO810

To addition module clusters

See note 5

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Modulebus Extension & Termination

DIN-Rail

TB805 TB806

TK801V003/006/012

Note 3

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I/O Module on Compact & Extended MTUsI/O Modules

CI830

Compact MTU

Extended MTU

Typical Compact MTU with I/O Module

Typical Extended MTU with I/O Module

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AC 800M Connectors for Optical Modulebus

Duplex Fiber Optic Cable Connector

Simplex Fiber Optic Cable Connector

Rx

Tx

Front View

TK811V015/050/150

TK812V015/050/150

For connection from PM810 to TB820 Note 1

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TB820 Optical Modulebus Connection

Duplex Fiber Optic Cable Connector

Simplex Fiber Optic Cable Connector

Optical ModuleBusInterface Connectors(X4, X5)

Rx

Tx

Rx

Tx

X4

X5

Front View

TK811V015/050/150

TK812V015/050/150

Note 5

TB820

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CEX Extension & Termination

Note 2

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CEX Extension & Termination

Note 2

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Supported S800 I/O Modules (Local & Remote)

S800 I/O ModulesS800 I/O ModulesS800 I/O I.S. ModulesS800 I/O I.S. Modules

S800L I/O ModulesS800L I/O Modules

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Supported S200 I/O Modules (Remote I/O)Via 200-APB12 PROFIBUS Adapter

S200L I/O ModulesS200L I/O Modules

S200 I/O ModulesS200 I/O Modules

S200L I/O ModulesS200L I/O Modules

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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

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PROFIBUS Connection - CI830 & TB820

Connector for TB810

Profibus-DP Connector

Power Supply

Connections

TB820

Modulebus Optical Port

Note 4

CI830

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AC 800M, Profibus integration

Profibus-DP

Profibus-PA via standard segmentcoupler

S800 I/O

S900 I/O

DP/PA Converter

Profibus-PA

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Foundation Fieldbus (In future release)

CI852 – Foundation Fieldbus H1 Interface Power from the processor

module TP852 – Baseplate

Up to 32 Foundation Fieldbus Devices

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AC 800M ,FF integration

FF H1

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

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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 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

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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

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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

Example of Wall mountedExample of Wall mounted

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Environmental Specifications

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CE Compliance

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Electromagnetic Compatibility and Main Voltage Conditions

AC 800 C

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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

Two on-board RJ-45 jacks for RS-232 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)

Battery back-up module - SB210

1 slot for an optional battery plug-in board with a real-time clock and a lithium battery

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AC 800C Hardware Layout

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Hardware mapped to Control Builder88 77

112233445566

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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

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

Programming Terminal

Central I/O Remote I/O

S800 I/O

S200/S200L I/O

AC 800C

S200/S200L I/OProfibus-DP

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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

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

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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

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Supported S200 I/O (Local & Remote)

S200L I/O ModulesS200L I/O Modules

S200 I/O ModulesS200 I/O Modules

S200C I/O ModulesS200C I/O Modules

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AC 800C Communication Possibilities

To Control Builder Via a serial port using the PPP

protocol, or alternatively via Ethernet

Serial Interfaces Available protocols are

Siemens 3964R (as master), COMLI, MODBUS RTU (as

master) and MMS. User-defined protocols may also be used

Fieldbus Support PROFIBUS FOUNDATION Fieldbus

On-board serial Communication COM 0 can receive and

transmit signals COM 0 is the default channel

for the programming station tool port

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

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Communication Extensions

Ethernet Communication Board CI272

Profibus Communication Board CI274

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)

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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)

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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

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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

one or more I/O adapters, 200-APB12, 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

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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

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Power Supply

Note The controller and the I/O

systems should, if possible, have separate 24 V DC supplies

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Technical Data

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Environmental Specification - Climate

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Environmental Specification - Mechanical

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CE - Compliance

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Electro Magnetic Compatibility

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Electro Magnetic Compatibility

SoftController

For future release

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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 Allen-Bradley)

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Hardware mapped to Control Builder

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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

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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

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Supported S200 I/O (Local & Remote)

S200L I/O ModulesS200L I/O Modules

S200 I/O ModulesS200 I/O Modules

S200C I/O ModulesS200C I/O Modules

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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

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PROFIBUS-DP Communication

A plug-in board a PROFIBUS-DP 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

S800 I/O Modules via PROFIBUSS800 I/O Modules via PROFIBUS

S200 I/O Modules via PROFIBUSS200 I/O Modules via PROFIBUS

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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

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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

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DataHighway Plus

DataHighway Plus is a multi-master 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.

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Hardware Requirements

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