Control IT Hardware (AC800 M/C) & SoftController

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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

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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
AC 800M
I/O System
Communication Interface
Processor Module
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 _at_ 2.5 A
• SD822 - 24 V d.c. regulated _at_ 5 A
• SD823 - 24 V d.c. regulated _at_ 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 (lt20 ms)
• Available modules
• SD 823
• 24 V d.c. regulated _at_ 10 A
• SD 822
• 24 V d.c. regulated _at_ 5 A
• SD 821
• 24 V d.c. regulated _at_ 2.5 A

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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
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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

CI851 Profibus
PM860 CPU
PM860 CPU
12 I/O Modules
Optical
CI830 FCI
12 I/O modules
TB820 OpticalModem
12 I/O modules
Up to 24 modules per stations
CI830 FCI
Optical
12 I/O modules
TB820 OpticalModem
12 I/O modules
TB820 OpticalModem
12 I/O modules
Up to 7 clusters and 200m between clusters
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
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AC 800M / S800 I/O Interconnection
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AC 800M / S800 I/O Interconnection
TB805
PM810
AI810
AI810
AO810
AO810
AO810
AO810
CI851
TK801V003/6/12
TB850V007
TB851
See note 1
TB806
See note 3
AI810
AI810
AO810
AO810
AO810
AO810
CI851
See note 2
DO810
TB820
DI810
DI810
DO810
TK811V015/050/150
See note 5
To addition module clusters
CI830
DI810
DI810
DO810
DO810
TB810
See note 4
TB820
DI810
DI810
DO810
DO810
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Modulebus Extension Termination
TB805
TB806
DIN-Rail
TK801V003/006/012
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
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
Note 1
For connection from PM810 to TB820
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TB820 Optical Modulebus Connection

TB820
Optical ModuleBus Interface Connectors (X4, X5)
TK811V015/050/150
Rx
X4
Tx
Duplex Fiber Optic Cable Connector
Rx
X5
TK812V015/050/150
Tx
Simplex Fiber Optic Cable Connector
Front View
Note 5
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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 Modules
S800 I/O I.S. Modules
S800L I/O Modules
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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
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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
TB820 Modulebus Optical Port
Power Supply Connections
Profibus-DP Connector
Note 4
CI830
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AC 800M, Profibus integration
S800 I/O
Profibus-PA via standard segmentcoupler
Profibus-DP
S900 I/O
Profibus-PA
DP/PA Converter
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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
Communication with FF-instruments is easily
performed via IEC 61131-3 function blocks
FF H1
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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 mounted
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Environmental Specifications
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CE Compliance
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Electromagnetic Compatibility and Main Voltage
Conditions
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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 Builder
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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
AC 800C
S800 I/O
S200/S200L I/O
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
• 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)
S200C I/O Modules
S200 I/O Modules
S200L 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
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SoftControllerFor 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)
S200C I/O Modules
S200 I/O Modules
S200L 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

S200 I/O Modules via PROFIBUS
S800 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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