Process Automation

Freelance 2016
Mounting and Installation Instructions
AC 900F Controller

Power and productivity

TM
for a better world
 Freelance 2016
Mounting and Installation Instructions
AC 900F Controller
NOTICE
This document contains information about one or more ABB products and may include a
description of or a reference to one or more standards that may be generally relevant to
the ABB products. The presence of any such description of a standard or reference to a
standard is not a representation that all of the ABB products referenced in this document
support all of the features of the described or referenced standard. In order to determine
the specific features supported by a particular ABB product, the reader should consult the
product specifications for the particular ABB product.

ABB may have one or more patents or pending patent applications protecting the intel-
lectual property in the ABB products described in this document.

The information in this document is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this document.

In no event shall ABB be liable for direct, indirect, special, incidental or consequential
damages of any nature or kind arising from the use of this document, nor shall ABB be
liable for incidental or consequential damages arising from use of any software or hard-
ware described in this document.

This document and parts thereof must not be reproduced or copied without written per-
mission from ABB, and the contents thereof must not be imparted to a third party nor used
for any unauthorized purpose.

The software or hardware described in this document is furnished under a license and
may be used, copied, or disclosed only in accordance with the terms of such license. This
product meets the requirements specified in EMC Directive 2014/30/EU and in Low Volt-
age Directive 2014/35/EU.

TRADEMARKS
All rights to copyrights, registered trademarks, and trademarks reside with their respec-
tive owners.

Copyright © 2015 by ABB.

All rights reserved.

Release: September 2015

Document number: 2PAA109295R0201
 Table of Contents
About this book
Use of warning, caution, information, and tip icons .............................................................. 9
Terminology.......................................................................................................................... 10

Section 1 - Overview
AC 900F Controller .............................................................................................................. 11
Features ..................................................................................................................... 13
Communication .................................................................................................................... 14
System ....................................................................................................................... 14
Fieldbus ..................................................................................................................... 15

Section 2 - Configuration
Configuration levels.............................................................................................................. 17
Controller redundancy .......................................................................................................... 19

Section 3 - Modules
PM CPU modules ................................................................................................................. 23
CPU modules PM 902F and PM 901F...................................................................... 24
Features ..................................................................................................................... 24
Interfaces ................................................................................................................... 25
LED display and control elements ............................................................................ 30
Battery ....................................................................................................................... 33
Display unit ............................................................................................................... 33
CI/CM PROFIBUS modules ................................................................................................ 33
CI 930F PROFIBUS-DP Master Interface ................................................................ 34
CI 773F PROFIBUS-DP Master Interface ................................................................ 37
CM 772F PROFIBUS-DP Master Interface.............................................................. 39
PROFIBUS connector and cables ............................................................................. 41

M&I – AC 900F Controller 5

Table of Contents

CI CAN Bus module .............................................................................................................43

CI 910F CAN Bus interface.......................................................................................43
Connection of Freelance I/O racks ............................................................................46
CP-C switch-mode power supply units and accessories .......................................................49
Switch-mode power supply units CP-C 24/5.0 and CP-C 24/10.0 ............................49
CP-A RU redundancy unit .........................................................................................52
CP-A CM control module.........................................................................................54
CP-C MM messaging module....................................................................................56

Section 4 - Accessories
Controller accessories ...........................................................................................................59
TD 951F display unit .................................................................................................59
TA 951F battery for RAM buffering..........................................................................61
Dummy couplers TA 924F and TA 724F...................................................................63
Diagnostic cables TK 890F and TK 891F .................................................................64
TA525 inscription labels ............................................................................................64
CAN Bus accessories ............................................................................................................66
TP 910F CAN Bus termination plug .........................................................................66
TK 811F CAN cable ..................................................................................................67
TK 831F CAN cable ..................................................................................................68
TB 870F terminal block .............................................................................................69

Section 5 - Mounting
Mounting to the DIN rail.......................................................................................................72
PM 902F CPU module...............................................................................................72
TU terminal blocks ....................................................................................................73
CP-C switch-mode power supply units and CP-C RU redundancy unit....................74
Wall mounting .......................................................................................................................76
PM 902F CPU module...............................................................................................76
TU terminal blocks ....................................................................................................77
Coupler bus slots ...................................................................................................................78
PM housing front...................................................................................................................79
Dimensional drawings...........................................................................................................80

6 M&I – AC 900F Controller

 Table of Contents

Dimensional drawings of the PM CPU-module........................................................ 80

Dimensional drawings of the CP-C 24/5.0 and CP-C 24/10.0.................................. 81
Dimensional drawing of the CP-A RU...................................................................... 82
Dimensional drawings of the CP-C MM and CP-A CM .......................................... 82

Section 6 - Wiring
Safety instructions ................................................................................................................ 83
General instructions.............................................................................................................. 83
Controller earthing................................................................................................................ 84
Cable routing ........................................................................................................................ 85
Cable shields......................................................................................................................... 85
Switch cabinet ...................................................................................................................... 86
Minimum distances .............................................................................................................. 86
Reference potential ............................................................................................................... 86
Equipotential bonding .......................................................................................................... 87
Power consumption .............................................................................................................. 88
Fuse dimensions ................................................................................................................... 89
Bus termination .................................................................................................................... 90
Serial interfaces of the CPU module ......................................................................... 90

Section 7 - Commissioning
Data backup .......................................................................................................................... 95
Insertion of the TA 951F battery ............................................................................... 95
Controller configuration via terminal program .................................................................... 97
Controller configuration via display unit............................................................................ 105
Boot configuration................................................................................................... 105

Section 8 - Service
Module replacement ........................................................................................................... 109
CI communication interfaces .................................................................................. 109
I/O modules ............................................................................................................. 110
Replacement of accessories ................................................................................................ 110
TD 951F .................................................................................................................. 110

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Table of Contents

Battery change .........................................................................................................110

Online functions of the display unit ....................................................................................111
Start menu ................................................................................................................112
Main menu ...............................................................................................................113
Controller menu .......................................................................................................113
Maintenance menu ...................................................................................................116
Offline functions of the display unit ...................................................................................119
Update/Restore.........................................................................................................119

Section 9 - Technical Data

Modules and accessories .....................................................................................................124
General technical data..............................................................................................124
PM 902F, PM 901F..................................................................................................125
CI 930F ....................................................................................................................128
CI 773F ....................................................................................................................130
CM 772F ..................................................................................................................132
CI 910F ....................................................................................................................134
Certificates ...............................................................................................................135
TD 951F ...................................................................................................................136
TA 951F ...................................................................................................................137
TA 924F ...................................................................................................................138
TA 724F ...................................................................................................................139
Switch-mode power supply units and accessories ..............................................................140
General technical data..............................................................................................140
CP-C 24/5.0 .............................................................................................................141
CP-C 24/10.0 ...........................................................................................................143
CP-C RU ..................................................................................................................145
CP-C MM ................................................................................................................147
CP-A CM .................................................................................................................149

Index

8 M&I – AC 900F Controller

 About this book

Use of warning, caution, information, and tip icons

This publication includes Warning, Caution, and Information where appropriate
to point out safety related or other important information. It also includes Tip to
point out useful hints to the reader. The corresponding symbols should be
interpreted as follows:

Electrical warning icon indicates the presence of a hazard which could result in
electrical shock.

Warning icon indicates the presence of a hazard which could result in personal
injury.

Caution icon indicates important information or warning related to the concept

discussed in the text. It might indicate the presence of a hazard which could
result in corruption of software or damage to equipment/property.

Information icon alerts the reader to pertinent facts and conditions.

Tip icon indicates advice on, for example, how to design your project or how to
use a certain function
Although Warning hazards are related to personal injury, and Caution hazards are
associated with equipment or property damage, it should be understood that
operation of damaged equipment could, under certain operational conditions, result
in degraded process performance leading to personal injury or death. Therefore,
comply fully with all Warning and Caution notices.

M&I – AC 900F Controller 9

Terminology About this book

Terminology
The Glossary contains terms and abbreviations that are unique to ABB or have a
usage or definition that is different from standard industry usage. Please make
yourself familiar to that.
You will find the glossary at the end of the Engineering Manual System
Configuration.

10 M&I – AC 900F Controller

 Section 1 Overview

AC 900F Controller
The PM 902F or PM 901F CPU module is the core component of an AC 900F
controller. As there are only minor differences in appearance between both CPU
module types, the drawings and photos of the PM 902F included in the present
document also apply to the PM 901F.
The term “controller” used in this manual is equivalent to the term “process station”
in Freelance Engineering or to the precise type designation “AC 900F”.

AC 900F_ Controller.png

Unless a description refers to special features and functions of a specific module

type variant, the general type designations PM, CI, TA, TU etc. are used throughout
this document.
Depending on the application and requirements, the controller can be
complemented by additional modules. These modules are fieldbus communication
interfaces and I/O modules.

M&I – AC 900F Controller 11

AC 900F Controller Section 1 Overview

The AC 900F comprises the following components:

• PM CPU module with
– PM 902F: four Ethernet interfaces
– PM 901F: three Ethernet interfaces
– one diagnostic interface
– two serial interfaces
– one TD display unit (optional)
• up to ten S700 I/O modules with I/O terminal blocks
• max. two CI/CM fieldbus communication interfaces
The controller can be used in single or redundant configuration. It supports remote
I/Os, transmitters, actuators, drives, and other devices using PROFIBUS and other
fieldbus protocols. ABB offers a wide range of different devices and
network components for applications in standard and hazardous areas.
In the present version, the AC 900F controller supports the following fieldbus
technologies:
• PROFIBUS-DP V0/V1
• Modbus RTU (serial) and Modbus TCP
• Telecontrol protocol (serial) and Telecontrol TCP
• ABB CAN Bus protocol
Depending on type and number of process signals, input/output modules are used
either as “direct” I/O or as remote I/O. For more detailed information on assembly
and installation of I/O modules, please refer to Mounting and Installation
Instructions, I/O Modules for AC 700F / AC 900F.
Similar to the AC 700F and AC 800F, the hardware configuration of the AC 900F is
based on the hardware function block principle.
The AC 900F controller is designed for the combination with fieldbus-compliant
components like remote I/O, field devices and network components. ABB offers
equipment for applications in standard and hazardous areas.

12 M&I – AC 900F Controller

Section 1 Overview Features

Features
The AC 900F exhibits the following main features:

CPU module
– PowerPC (II Pro family)
– RISC architecture

Main memory
– Main memory for data and application

Battery
– Lithium battery for RAM buffering

Interfaces
– Four or three Ethernet interfaces depending on the CPU module. The first
interface is used for Control Net, the second as redundancy link and the
remaining interfaces three and four are available for other connections or
Control Net redundancy.

Coupler bus
– Two slots C1 and C2
– Supports fieldbus communication interfaces

I/O bus
– Ten slots L1 to L10 for up to ten I/O modules
– Supports different I/O module types

M&I – AC 900F Controller 13

Communication Section 1 Overview

Display and control elements

– SD card reader
– LEDs
– Switches/buttons
– Display unit (optional accessory)

Power supply unit

– Terminals for 24 V DC power supply

Communication
System

TCP/IP, UDP/IP
The Control Net (Ethernet) connects the individual stations with each other. It
transfers data between the controllers and between Freelance Operations, the
gateways and Freelance Engineering. The AC 900F controller supports data sending
and receiving through TCP/IP (Ethernet-based sending/receiving) and/or UDP/IP
(lateral communication). Additional application layers can be implemented by
downloading them on the controllers. Simultaneous operation of TCP/IP, UDP/IP
and application layer is also ensured.
The data distribution at the bus is based on the Ethernet switch. The max. data
transmission rate is 10 Mbit/s for 10 Base T and max. 100 Mbit/s for Fast-Ethernet.
Twisted pair cables with RJ45 connector are used as transmission medium. The
maximum cable length is 100 m at a maximum transmission speed of Mbit/s.
Detailed diagnostic messages for rapid fault localization can be retrieved via the
diagnostic interface and/or the Freelance Engineering software.

14 M&I – AC 900F Controller

Section 1 Overview Fieldbus

Fieldbus

PROFIBUS®
PROFIBUS-DP is designed for rapid data exchange in the field area. Central control
units communicate with decentralized field devices like remote I/O, transmitters or
drives etc. using a fast serial connection. The data exchange with the distributed
modules is mainly performed on a cyclic basis. PROFIBUS-DP is optimized in
terms of high speed and simple device connection. This protocol variant is
specifically designed for the communication between programmable controllers and
a distributed I/O level. The AC 900F controller supports PROFIBUS Master
redundancy.
For additional information on PROFIBUS-DP and the PROFIBUS CI/CM modules,
please refer to Section 3, Modules as well as to the Engineering Manual,
Communication and Fieldbusses.

Modbus
Numerous automation systems support the Modbus protocol by default or as an
optional feature. This ensures easy communication with the AC 900F process
station via on-board SER interfaces using the RS232/RS485 standards
(MODBUS®) or TCP/IP (MODBUS TCP®). The Modbus protocol also ensures
process data exchange with other systems via the serial or the Ethernet interfaces of
the AC 900F.
This protocol allows data to be transmitted in either master or slave mode. For the
configuration with serial interface, a specific MODM_DEV interface object must be
assigned in the hardware structure. The interface-specific parameters are defined in
this block.
For the TCP configuration (Ethernet), a specific MTCP_DEV interface object must
be assigned in the hardware structure.
Please refer to the Engineering Manual, Communication and Fieldbusses and the
Engineering manual, System Configuration, Hardware Structure for more
detailed information.

M&I – AC 900F Controller 15

Fieldbus Section 1 Overview

Telecontrol protocol
The function blocks of the telecontrol library are designed for the connection
between the Freelance Engineering tool and external systems. The link is made via
the serial interface (RS-232) or the Ethernet interface of the CPU module. The
telecontrol protocol complying to IEC 60870-5-101 (serial)/IEC 60870-5-104
(TCP/Ethernet) is used.
For the serial interface, the telecontrol protocol provides device modules for
symmetrical data transmission (FWK_DEV), asymmetrical data transmission as a
master (FWK_DEV_M) and asymmetrical data transmission as a slave
(FWK_DEV_SL). These modules are configured in the hardware structure. Please
refer to the Engineering Manual, System Configuration, Hardware Structure for
more detailed information.
For Ethernet-supported communication, the Ethernet interface and the parameters of
the IEC 60870-5-104 compliant protocol must be set in the FWK_DEV_104
function block designed for telecontrol connection in the Ethernet network. The
FWK_DEV_104 device module can be configured in the hardware structure below
the Ethernet interface of the AC 900F.

ABB CAN Bus protocol

The CAN Bus of the AC 900F controller is intended to be used for connecting rack-
based Freelance I/O modules only. With this feature, the current AC 900F controller
CPU modules of type PM 902F/901F can alternatively take over the tasks of the
CPU module types DCP 02/10 of the Freelance rack system.

16 M&I – AC 900F Controller

 Section 2 Configuration

This section provides information on the AC 900F controller configuration for

single and redundant operation.
The AC 900F controller features a modular design. The basic components are a PM
CPU module, CI/CM PROFIBUS communication interfaces and S700 I/O modules.
The external 24 VDC voltage required to operate the controller can be provided by a
CP-C power supply unit, for example.

Configuration levels
The AC 900 F controller in basic configuration comprises the PM CPU module and
two TA dummy couplers designed to protect the unused C1/C2 slots. The on-board
Ethernet interfaces and serial interfaces of the CPU module are available for field
communication.

AC 900F_only CPU.png

M&I – AC 900F Controller 17

Configuration levels Section 2 Configuration

The controller of the medium configuration level is composed of a PM CPU module

and up to two CI/CM modules for PROFIBUS communication. Alternatively, a
CAN Bus module can be plugged into one of these two slots.

Medium configuration.png

The high configuration level controller is composed of a PM CPU module and up to

two CI modules for PROFIBUS communication. Alternatively, a CAN Bus module
can be plugged into one of these two slots. S700 I/O modules are used as “direct
I/O”.

AC 900F_ Controller.png

18 M&I – AC 900F Controller

Section 2 Configuration Controller redundancy

The S700 I/O modules are connected on the right side of the I/O bus, i.e. they are
simply plugged to the TU terminal blocks that were previously added to the CPU
modules. Up to ten I/O modules can be connected to the I/O bus of the CPU module.
The configuration in the Freelance Engineering hardware structure should
correspond to the actual controller configuration (local DIN rail). Make sure that
there are no blank TU terminal blocks between the individual I/O modules. I/O
modules connected on the right side of a gap (i.e. of a blank terminal block) are not
controlled by the CPU module.

Controller redundancy
Two controllers of identical configuration - hereinafter referred to as redundant
controllers - are used for redundant operation. While the active controller has the
“Primary“ status, the “Secondary“ status is assigned to the other controller. During
normal operation, the primary is the active controller and the secondary the passive
one (hot standby).
For synchronization purposes, a point-to-point Ethernet connection (100 MBit/s)
must be established between the controllers. This connection is also referred to as
redundancy link.
A redundant configuration may be composed of two controllers of basic or medium
level configuration. Make sure to use only the CI 930F, CI 910F or CI 773F
communication interface modules for the medium configuration level as only these
module types are suitable for redundant operation.
The S700 Direct I/O and the CM 772F communication module are not supported
with redundant controller arrangement.

M&I – AC 900F Controller 19

Controller redundancy Section 2 Configuration

If the primary controller (Primary) fails, the secondary controller is activated via a
designated communication connection (redundancy link).
The cyclical adjustment ensures smooth change over from the primary to the
secondary controller, i.e.
• the outputs of fieldbus-connected I/O components are maintained.
• the internal status (component data, variables) is maintained.
• the configuration and operating data of the primary and secondary controllers
are automatically adapted.

AC 900F in redundant configuration using the on-board interfaces for Modbus and
telecontrol protocols.

Controller Redundancy us.png

20 M&I – AC 900F Controller

Section 2 Configuration Controller redundancy

Redundant AC 900F with PROFIBUS line redundancy in the field at a redundant

Control Net. The figure below shows a configuration with PROFIBUS line
redundancy using a CI 930F module.

Line redundancy_us.png

M&I – AC 900F Controller 21

Controller redundancy Section 2 Configuration

An existing PROFIBUS line in a single configuration with a CI 773F module can be

enhanced to become a PROFIBUS with redundant lines by using additional RLM 01
modules, as shown in the following figure:

Line Redundancy CI773F us.png

22 M&I – AC 900F Controller

 Section 3 Modules

This section provides information on the features and interfaces of the various AC
900F modules.
The parameter data have a direct effect on the module functionality. For more
information on module configuration and parameter setting refer to Engineering
Manual, Process Stations, and Engineering Manual, System Configuration,
Hardware Structure.

PM CPU modules
The PM CPU module is the basic component of the AC 900F controller. It comes
with a high-performance processor for multitasking and for processing tasks with
short cycle times.
The module is equipped with three or four on-board Ethernet network connections
of 100 Mbit/s and two serial interfaces. A third serial interface is provided for
diagnostic purposes and for the connection of a radio clock.
Additional modules can be added on the left and right sides of the CPU module
using the coupler bus slots and an I/O bus interface.
The TD display unit shows the system status and diagnostic data directly at the
module. The operating mode can be changed using the switches provided on the
front panel of the CPU module.

M&I – AC 900F Controller 23

CPU modules PM 902F and PM 901F Section 3 Modules

CPU modules PM 902F and PM 901F

CPU_PM902_us.png

Features
The essential features of the PM CPU module are listed below:
• Power-PC processor (RISC architecture)
• Main memory for data and application
• 2 slots for fieldbus communication interfaces
• I/O bus for direct connection of I/O modules
• On-board communication interfaces
– Ethernet
– RS 232/485
– I/O bus
– Coupler bus
• 24 V DC supply voltage
• SD card reader

24 M&I – AC 900F Controller

Section 3 Modules Interfaces

• Display and control elements

• Housing color (gray)
• Convection cooling without temperature derating
• Main memory with error detection/correction
• Display (dot matrix LCD display) as an optional accessory

Interfaces
The PM CPU module features the following on-board interfaces:

Ethernet interfaces
– ETH1, Control Net
– ETH2, redundancy link / depending on application
– ETH3, Control Net / depending on application
– ETH4, (only PM 902F) depending on application

Serial interfaces
– SER1, depending on application
– SER2, depending on application
– DIAG, diagnostics, settings and radio clock

Power supply unit

– DC-IN +/-24 V DC

Coupler bus
– C1, C2

I/O bus
– Connection on the right

M&I – AC 900F Controller 25

Interfaces Section 3 Modules

For more detailed information refer to the Mounting and Installation Instructions,
I/O Modules for AC 700F / AC 900F.

Power supply
An external 24 V DC voltage supply of sufficient power is required for operating the
CPU module, the modules on the C1/C2 slots and for the I/O bus. The DC-IN
connection is used for power supply. The corresponding supply lines must be
connected to the removable 5-pin terminal block.

Power supply_us.png

L+ and M are provided twice, which allows also I/O modules or external sensors to
be supplied using these terminals.

Number of conductors per terminal Conductor type Cross-section

1 -- solid 0.08 - 1.5 mm²
1 -- flexible 0.08 - 1.5 mm²
1 with wire end ferrule (without plas- flexible 0.25 - 1.5 mm²
tic sleeve)
1 with wire end ferrule (with plastic flexible 0.25 - 0.5 mm²
sleeve)
1 TWIN wire end ferrule flexible 0.5 mm²
2 identical cross-section solid 0.08 - 0.5 mm²
2 identical cross-section flexible 0.08 - 0.75 mm²
2 identical cross-section in wire end flexible 0.25 - 0.34 mm²
ferrule, without plastic sleeve

26 M&I – AC 900F Controller

Section 3 Modules Interfaces

The following instructions must be thoroughly read and observed to ensure safe
operation.
• Make sure that the maximum supply voltage (see Section 9, Technical Data)
for modules, sensors and other devices is not exceeded. A module supply
voltage of more than 30 V DC may lead to irreversible damage and destruction
of the system.
• Incorrect wiring (e.g. +/- of the power supply is connected to both L+/L+ or
M/M) will cause a short circuit. This may trip the fuse of the power supply unit
or damage the switch-mode power supply unit.
For general information on safety and precautionary measures, please refer to
the Safety Instructions for the AC 700F/AC 900F.

Ethernet interfaces
The on-board Ethernet network interfaces of 100 Mbit/s can be used for
communication between the controllers, gateways, control station and engineering
stations as well as for Ethernet-based field devices to support Modbus TCP or
telecontrol protocol as per IEC-104.
ETH

Ethernet interface_Pin assignment_us.png

For more detailed information on the wiring of the Ethernet interface, please refer to
Section 6, Wiring.

Serial interfaces
A removable 9-pin terminal block is used for the connection to both SER1 and
SER2 serial interfaces of the CPU module. The SER1 and SER2 interfaces can be

M&I – AC 900F Controller 27

Interfaces Section 3 Modules

configured (and provided with termination resistors) for RS-232 or RS-485 and
used for Modbus RTU and telecontrol protocol as per IEC 60870-5-101 (depending
on the terminals used). For more detailed information on the wiring of the series
interfaces, please refer to Section 6, Wiring.
SER

Serial interface_ser1_ser2_us.png

Diagnostic interface
The third DIAG interface is provided to connect a PC for diagnostics/setting
purposes. In addition, a radio clock for time synchronization can be permanently
connected to this interface.
DIAG

Diag_interface_us.png

A TK 890F/891F diagnostic cable is required to connect the DIAG serial interface

with the serial interfaces of the PC. The default transmission rate is 19.2 kBit/s but
can be changed to 9.6 kBit/s (see Controller configuration via terminal program on
page 97).

Coupler bus
The PM CPU module features two C1/C2 coupler bus slots for the connection of
additional communication interfaces, e.g. CI/CM PROFIBUS modules.

28 M&I – AC 900F Controller

Section 3 Modules Interfaces

Coupler bus C1-C2_us.png

Unused slots must be covered with TA dummy couplers to comply with the ISA
74.01 G3 requirements.

I/O bus
The I/O bus on the right side of the PM CPU module is provided for communication
with I/O modules that are directly connected to the CPU module. This bus serves for
exchanging I/O data and diagnostic data between the CPU module and the I/O
modules.

IO_Bus_us.png

M&I – AC 900F Controller 29

LED display and control elements Section 3 Modules

Up to 10 TU I/O terminal blocks (one block per I/O module) can be added to the
CPU module. For this purpose, the I/O terminal blocks are equipped with a male
connector on the left and a female connector on the right side.

LED display and control elements

LEDs and switches

The LEDs on the front panel show essential status information and diagnostic data.
The operating mode can be changed using the switches.

LED Color Status Meaning

PWR Green ON Power supply correctly connected, 24V DC voltage
is applied
OFF No supply voltage
Power supply not correctly connected
ERR Red ON Hardware error during self-test
Flashing Error occurred, LED continues to flash until the sys-
tem is stopped or started again
OFF No error
RUN Green ON AC 900F is operating RUN
Red ON AC 900F was stopped STOP

30 M&I – AC 900F Controller

Section 3 Modules LED display and control elements

LED Color Status Meaning

P/S Green on ON In redundant configurations, the active AC 900F is
Primary referred to as Primary.
Synchronous operation as normal state
Flashing Non synchronous operation as transition state; oc-
curs when the data are not aligned with the Sec-
ondary
Orange ON Synchronization mode
on Sec-
Flashing Synchronization on
ondary
Red on ON Redundancy synchronization failed
Second-
ary
OFF No redundancy configured
BATT Green ON Sufficient battery capacity for the indicated buffer-
ing time
Red ON Battery test during power-up
Empty battery
Battery not connected
Orange ON The battery must be replaced.

Three switches are provided for the following functions:

– RUN/STOP
– TOGGLE (Primary/ Secondary)
– RESET

RUN/STOP switch
This switch is used to start and stop the program sequence. In redundant mode, the
position of the RUN/STOP switch on the active AC 900F is used.

M&I – AC 900F Controller 31

LED display and control elements Section 3 Modules

Both controllers perform the command (Run or Stop). The LED display on the
Primary shows the current status. In the case of a redundancy change-over, the last
status is retained irrespective of the RUN/STOP switch position.
Change-over to Run
Normal operation. The program sequence is started. If the module is
reset and a self-test is subsequently started, no configuration menu
appears at the diagnostic interface.
Change-over to Stop
The program sequence is stopped. If the module is reset and a self-
test is subsequently started, the configuration menu appears at the
diagnostic interface.

TOGGLE switch
With a redundant AC 900 F configuration in synchronized state, a change-over of
the TOGGLE switch on the Primary produces the following effect: The previous
Secondary changes immediately to Primary and the previous Primary to Secondary
without requiring any system rebooting. Any actuation of the TOGGLE switch on
the Secondary will be ignored.

RESET switch
The RESET switch is used to reset the AC 900F. Depending on the system status,
either a warm or a cold start is initiated. A “tool“ (e.g. a ball pen or similar) is
required to actuate the RESET switch.
When the RESET switch is pressed for a specified time, the following functions will
be released:
Single controller
< 4 s = Warm start
> 4 s = Cold start
Redundant controller
< 4 s = no function
> 4 s = redundancy change-over and cold start of the controller with actuated
RESET switch

32 M&I – AC 900F Controller

Section 3 Modules Battery

SD card reader
The SD card reader is used for data backup, for restoring the application as well as
for updating the firmware. All high-quality SD cards with up to 32 GB are
supported. With an appropriate adapter, micro SD cards can be used as well.

Battery
The optional battery serves for saving the SRAM contents (e.g. process and
configuration data) in the event of power failure and to supply the real time clock.
The CPU module monitors the battery status (capacity). A low battery capacity
warning is displayed before data storage is at risk (about 2 weeks in advance). Upon
this warning message, the battery should be replaced as soon as possible. For more
detailed information, please refer to Section 4, Accessories.

Display unit
The PM CPU module supports the TD 951F display as an optional accessory.
Remove the front panel to install the display unit to the PM CPU module. For more
detailed information, please refer to Section 4, Accessories.

CI/CM PROFIBUS modules

The AC 900F is designed for operation with different PROFIBUS communication
interfaces like the CI 930F, CI 773F and CM 772F that can be connected on the left
side of the PM CPU module.
PROFIBUS communication interfaces ensure communication via the PROFIBUS-
DP fieldbus. The internal coupler bus connects the CI/CM with the CPU module.
This applies to data and power supply. A dual-port RAM is used for data exchange.

M&I – AC 900F Controller 33

CI/CM PROFIBUS modules Section 3 Modules

CI 930F PROFIBUS-DP Master Interface

The CI 930F provides two on-board PROFIBUS interfaces A/B for increased
availability regarding PROFIBUS communication.

CI 930F_us.png

Data arriving at CI 930F via the coupler bus are routed in parallel to both A and B
connections.
Data arriving to CI 930F via the controller coupler bus are routed in parallel to the
two PROFIBUS terminals A and B.
The first data coming in over line A or line B with a correct telegram start are
routed to the coupler bus. With simultaneity, either line A or line B is selected at
random. Testing and selection is always based on the first character. In the case of a
telegram start with error on A, the control logic in CI 930F switches to the
redundant line B. The same procedure applies vice-versa for line B.

34 M&I – AC 900F Controller

Section 3 Modules CI/CM PROFIBUS modules

Features

Protocol PROFIBUS-DP master V0/V1

Fieldbus connection D-SUB, 9-pin, female connector

Internal power supply Via coupler bus

LEDs Five LEDs for status display

Use AC 900F

Form factor Similar to AC 900F with PM

902F/901F

Housing color Gray

Number of slaves 125

Controller redundancy support Yes

Hot plug Yes

HCIR Yes

Line redundancy Yes

LED status displays

After having been switched on, the CI 930 PROFIBUS module performs a self-test
during power-up. During initialization, with newly configured modules or after a
change of the operating mode, all LEDs may light up briefly before reaching the
defined status.

M&I – AC 900F Controller 35

CI/CM PROFIBUS modules Section 3 Modules

LED Color Status Meaning

PWR Green ON Module in operation and must not be removed
OFF Module not in operation and may be removed, if re-
quired
STA Green ON Active module operating properly
OFF Module start-up
Orange ON Module identified by the CPU module, but inactive
Red ON Module error
RUN Green ON Module has taken over the master function
OFF Module inactive relative to the PROFIBUS
Green 200 ms Module ready to take over the master function
pulse
Line redundancy OFF
LED A Green ON Bus traffic
(line A)
OFF No bus traffic

Line redundancy ON
LED A (line A) LED B (line B) LED A and B must be considered as a pair
Color Status Color Status
Green ON Green ON Data reception on both lines, A and B
OFF OFF No data reception on lines A and B
Red ON Green ON No data reception on line A, but data recep-
tion on line B
Green ON Red ON No data reception on line B, but data recep-
tion on line A

36 M&I – AC 900F Controller

Section 3 Modules CI 773F PROFIBUS-DP Master Interface

CI 773F PROFIBUS-DP Master Interface

The CI 773F is the CM 772F successor model. It provides additional features and
sufficient memory (I/O bytes) for the maximum number of PROFIBUS slaves.

CI 773F_us.png

Features

Protocol PROFIBUS-DP master V0/V1

Fieldbus connection D-SUB, 9-pin, female connector

Internal power supply Via coupler bus

LEDs Four for status display

Use AC 700F, AC 900F

Form factor Similar to AC 700F with PM 783F

Housing color Gray

M&I – AC 900F Controller 37

CI 773F PROFIBUS-DP Master Interface Section 3 Modules

Number of slaves 125

Controller redundancy support Yes

Hot plug Yes

HCIR Yes

LED status displays

After having been switched on, the CI 773 PROFIBUS module performs a self-test
during power-up. During initialization, with newly configured modules or after a
change of the operating mode, all LEDs may light up briefly before reaching the
defined status.

LED Color Status Meaning

PWR Green ON Module in operation and must not be removed
OFF Module not in operation and may be removed, if re-
quired
STA Green ON Active module operating properly
OFF Module start-up
Orange ON Module identified by the CPU module, but not active
Red ON Module error
RUN Green ON Module has taken over the PROFIBUS master func-
tion
OFF Module inactive relative to the PROFIBUS
Green 200 ms Module ready to take over the master function
pulse
LED L Green ON Bus traffic
OFF No bus traffic

38 M&I – AC 900F Controller

Section 3 Modules CM 772F PROFIBUS-DP Master Interface

CM 772F PROFIBUS-DP Master Interface

CM 772_us.png

The number of possible slaves is determined by the total number of input and output
bytes. As a rule, many PROFIBUS PA devices (few I/O bytes) or a limited number
of remote I/O (many I/O bytes) can be connected to the bus.

Features

Protocol PROFIBUS-DP master V0/V1

Fieldbus connection D-SUB, 9-pin, female connector

Internal power supply Via coupler bus

LEDs Five LEDs for status display

Use AC 700F, AC 900F

Form factor Similar to AC 700F with PM 783F

Housing color White

M&I – AC 900F Controller 39

CM 772F PROFIBUS-DP Master Interface Section 3 Modules

Controller redundancy support No

Hot plug No

HCIR No

LED status displays

After having been switched on, the CI 772 PROFIBUS module performs a self-test
during power-up. If the test is successfully performed, the yellow LED RDY lights
up, if not, the LED starts to flash and the initialization is aborted. If the LED RDY
does not light up at all, the PROFIBUS module is probably defective. During
initialization, with newly configured modules or after a change of the operating
mode, all LEDs may light up briefly before reaching the defined status.

LED Color Status Meaning

PWR Green ON Voltage is applied
OFF No voltage is applied
RDY Yellow ON Coupler ready for operation
Cyclic flashing Boot loader is active
Non-cyclic flashing Hardware or system error
OFF Defective hardware
RUN Green ON Communication on
Cyclic flashing Ready for communication
Non-cyclic flashing Parameterization error
OFF No communication
STA Yellow ON DP master: data or token are transmit-
ted via the network
OFF DP master: No token

40 M&I – AC 900F Controller

Section 3 Modules PROFIBUS connector and cables

LED Color Status Meaning

ERR Red ON PROFIBUS error
OFF No error

PROFIBUS connector and cables

Fieldbus interface
The PROFIBUS DP connector features the following pin assignment:

PROFIBUS DP_Pin assignment_us.png

Bus link

Type Twisted pair wire (shielded)

Impedance level 135…165 Ω
Cable capacity < 30 pF/m
Cable core diameter ≥ 0.64 mm

Cable core cross-section ≥ 0.34 mm2

Resistance per cable core < 55 Ω/km

Loop resistance (resistance of two cable < 110 Ω/km
cores)

M&I – AC 900F Controller 41

PROFIBUS connector and cables Section 3 Modules

Cable length
The maximum cable length of a PROFIBUS subnet within one segment depends on
the baud rate (transmission rate).

Transmission rate in kBit/s Maximum cable length

9.6;19.2; 45.45; 93.75 1200 m
187.5 1000 m
500 400 m
1500 200 m
3000, 6000, 12000 100 m

Bus termination
Both bus segment ends must be provided with a termination resistor. These resistors
are usually integrated into the PROFIBUS connector. As the bus termination is
active, it must be ensured that both terminations are supplied with +5 V by a module
or an external power supply.

CM 772_Bus termination_us.png

42 M&I – AC 900F Controller

Section 3 Modules CI CAN Bus module

CI CAN Bus module

An AC 900F controller with CI 910F CAN Bus module allows for connecting rack-
based I/O modules.

CI 910F CAN Bus interface

The CI 910F CAN Bus interface comprises three CAN Bus lines, CAN 1 to CAN 3.
The lines are electrically isolated from the system and designed for redundant
operation with a second AC 900F controller.
The internal coupler bus connects the CI 910 F to the CPU module. This is valid for
both data transmission and power supply. A dual port RAM is used for data
exchange.

CI910F_R5_us.png

M&I – AC 900F Controller 43

CI 910F CAN Bus interface Section 3 Modules

Features
Protocol ABB CAN Bus protocol

CAN interfaces Acc. to ISO/DIN 11898, CAN 2.0

Channels / lines CAN 1, CAN 2 and CAN 3

Transmission rate for rack- 100 kBit/s or 500 kBit/s

based I/O
Number of CI 910F modules Max. one module, optionally in slot
per controller C1 or C2

Fieldbus connector D-SUB, 9-pole, female

Power supply Via coupler bus

LEDs Five LEDs for status display

Used with AC 900F

Form factor Similar to AC 900F with PM

902F/901F

Housing color Gray

Controller redundancy Yes

support
Hot plug Yes

44 M&I – AC 900F Controller

Section 3 Modules CI 910F CAN Bus interface

LED status displays

After having been switched on, the CI 910F CAN Bus module performs a self-test
during power-up. During initialization, with newly configured modules or after a
change of the operating mode, all LEDs may light up briefly before reaching the
defined status.

LED Color Status Meaning

PWR Green ON Module in operation and must not be removed
OFF Module not in operation and may be removed,
if required
STA Green ON Active module operating properly
OFF Module start-up
Orange ON Module identified by the CPU module, but inactive
Red OFF Module under power, but not yet identified or module
failure
L1 Green Flashing Communication on CAN 1 channel
OFF No communication
Yellow Flashing Sporadic transmission error
Red Flashing Transmission interrupted (bus off mode)
L2 Green Flashing Communication on CAN 2 channel
OFF No communication
Yellow Flashing Sporadic transmission error
Red Flashing Transmission interrupted (bus off mode)
L3 Green Flashing Communication on CAN 3 channel
OFF No communication
Yellow Flashing Sporadic transmission error
Red Flashing Transmission interrupted (bus off mode)

M&I – AC 900F Controller 45

Connection of Freelance I/O racks Section 3 Modules

CAN Bus connector

The CAN Bus connector of CI 910F features the following pin assignment:

CAN_Bus_Pin assignment_us.png

Connection of Freelance I/O racks

When connecting the AC 900F controller to a Freelance rack, you have to remove
the DCP 02/10 CPU modules.
For detailed information about the accessories, e.g.regarding their function, pin
assignment, wire color, cable length etc. please refer to Section 4, Accessories.

AC 900F controller at the beginning (end) of the CAN Bus

The TP 910F CAN Bus termination plug is used for terminating the three CAN
busses directly at the controller at the beginning (end) of the bus lines. The open end
of the TK 811F CAN cable is connected to the screw terminals of the TP 910F plug.

46 M&I – AC 900F Controller

Section 3 Modules Connection of Freelance I/O racks

CAN single AC 900F at the beginning of the bus_us.png

Redundant AC 900F controller at the beginning (end) of the CAN Bus

The terminating resistors integrated into the TP 910F termination plug ensure that
the termination and, thus, the function of the three CAN Bus lines is preserved even
if a CAN bus module or controller is replaced. TB 870F is used for connecting the
CAN bus between controllers and to the I/O rack.
The TK 831F cable contains feed and return lines. When replacing a CI 910F
module or controller, only disconnect the 9-pole connector. Disconnecting the
25-pole connector will interrupt the CAN Bus.

M&I – AC 900F Controller 47

Connection of Freelance I/O racks Section 3 Modules

CAN redundant AC 900F at the beginning of the bus us.png

48 M&I – AC 900F Controller

Section 3 Modules CP-C switch-mode power supply units and accessories

CP-C switch-mode power supply units and accessories

Switch-mode power supply units CP-C 24/5.0 and CP-C 24/10.0

CP-C 24.png

General description

Operating status display

The green “OUTPUT OK“ LED lights up during operation.

Adjustment of the output voltage

Using the “OUTPUT adjust“ potentiometer, the output voltage can be adjusted
within the range of 22 to 28 V.

Parallel operation
In order to increase capacity or to ensure redundancy, devices of the same type can
be connected in parallel. To ensure symmetric current distribution, the line
connections should feature identical cross-section and length.

M&I – AC 900F Controller 49

Switch-mode power supply units CP-C 24/5.0 and CP-C 24/10.0 Section 3 Modules

Parallel operation, increase in capacity

For “n” number of power supply units connected in parallel the output current can
be increased to “n x Ir”. A parallel connection is recommended if the power supply
unit is not rated to provide the power required for the most powerful consumer load.
In this case, the consumer load should be supplied by several independent power
supply units. Up to max. 5 devices of identical type can be connected in parallel.

CP_C24_parallel_operation_capacity.png

Parallel operation, redundancy

Redundant circuits are used to increase the operational reliability of the system in
case of errors (e.g. incorrect wiring, fuse trip in primary circuit, failure of individual
devices). If a fault occurs in the first power supply circuit (referred to as initial
fault), all loads are supplied by the second redundant circuit. For this purpose, the
power supply units connected in parallel are rated such as to ensure that the total
power requirements of all loads can be entirely covered by a single power supply
unit.

CP_C24_parallel_operation_redundancy.png

50 M&I – AC 900F Controller

Section 3 Modules Switch-mode power supply units CP-C 24/5.0 and CP-C 24/10.0

Electrical connection

Input side [L, N, protective earth conductor]

Connect the input terminals L, N and the protective earth conductor. The protective
conductor must permanently be connected (protection class I).
Do not plug or unplug the connectors when the unit is energized. The installation
must be in compliance with EN 60950, the supply lines must be equipped with
appropriate disconnecting devices (e.g. line safety switches).
For detailed information on stripping length, cable cross-section, torque and input
side protection, please refer to Section 9, Technical Data.

Output side [L+, L+, L-, L-]

Rate the lines for the maximum output current or provide separate fuse protection.
For details on the output side fuse protection, please refer to Section 9, Technical
Data of the power supply units. To minimize voltage drops, a maximum cable cross-
section should be selected.
Do not plug or unplug the connectors when the unit is energized. The power supply
units are overload proof, short-circuit proof and no-load proof. The secondary
power supply unit side is galvanically isolated from the input and not internally
earthed (SELV). It can be earthed by the user (either L+ or L-), if required (PELV).

M&I – AC 900F Controller 51

CP-A RU redundancy unit Section 3 Modules

CP-A RU redundancy unit

If a fault occurs in the first power supply circuit, the secondary supply circuit covers
the total current requirements of all consumer loads and the output circuits are
uncoupled by the CP-A RU redundancy unit.

CP-A RU_primary switch-mode power supplies.png

Operation/Function

Parallel operation, true redundancy

Redundant circuits are used to increase the operational reliability of the system in
case of errors (e.g. incorrect wiring, fuse trip, failure of individual devices). If a fault
occurs in the first power supply circuit (referred to as initial fault), all loads are
supplied by the second redundant circuit. For this purpose, the power supply units
connected in parallel are rated such as to ensure that the total power requirements of
all loads can be entirely covered by a single power supply unit. The output circuits
are uncoupled by the CP-A RU redundancy unit as shown in the figure below.

52 M&I – AC 900F Controller

Section 3 Modules CP-A RU redundancy unit

CP-A RU_Parallel operation_real redundancy.png

Electrical connection

Input side [INPUT 1 + - / INPUT 2 + -]

Connect the input terminals as shown in the figure below:

CP-A RU_Circuit diagram.png

M&I – AC 900F Controller 53

CP-A CM control module Section 3 Modules

For detailed information on the wire stripping length, please refer to Section 9,
Technical Data. Left input terminal + - for channel 1, right input terminal + - for
channel 2.

Output side [OUTPUT + + - -]

Rate the lines for the maximum output current or provide separate fuse protection.
To minimize voltage drops, a maximum cable cross-section should be selected.
Observe the polarity!

CP-A CM control module

The CP-A CM control module can be plugged to the CP-A RU redundancy unit.
This module features threshold values adjustable within a range of 14 to 28 Volt and
two relay outputs and is designed for monitoring both channels of the energized
redundancy unit.

CP-A CM control module for CP-A RU.png

Function
The CP-A CM control module indicates the supply of both input voltages at the CP-
A RU by means of LEDs and energized output relays.
The output relay threshold values can be set between 14 und 28 V for each channel
separately. If the voltage in one of the channels falls below the set threshold value

54 M&I – AC 900F Controller

Section 3 Modules CP-A CM control module

due to a fault (e.g. power supply unit failure, tripped fuse), the corresponding relay
is de-energized. The green “IN 1“ and “IN 2“ LEDs light up when the voltage
exceeds the set threshold value. The green “OUT“ LED lights up when the output
voltage is > 3 V.

Electrical connection
Terminal assignment

Terminals Designation Function

SENSE OUT The SENSE OUT + + - terminals are arranged
at the + and - potential on the output side and
can be used for signaling purposes.

INPUT 1 (IN 1) Potential-free change-over contact

OK message 11-14 closed and 11-12 opened when the
voltage in channel 1 (IN 1) of the CP-A RU
exceeds the threshold value set at “IN 1 <V“.
11-12 closed and 11-14 opened when the
voltage in channel 1 (IN 1) of the CP-A RU is
lower than the threshold value set at “IN 1 <V“.
INPUT 2 (IN 2) Potential-free change-over contact
OK message 21-24 closed and 21-22 opened when the
voltage in channel 2 (IN 2) of the CP-A RU
exceeds the threshold value set at “IN 2 <V“.
21-22 closed and 21-24 opened when the
voltage in channel 2 (IN 2) of the CP-A RU is
lower than the threshold value set at “IN 2 <V“.

M&I – AC 900F Controller 55

CP-C MM messaging module Section 3 Modules

CP-C MM messaging module

The CP-C-MM messaging module can be connected to the primary CP-C switch-
mode power supply units. This module monitors the input/output voltage of the
switch-mode power supply unit and signals when the corresponding limit value is
not reached.

CP-C MM messaging module for primary switch-mode power supply.png

Function
The CP-C MM messaging module indicates the correct power supply unit function
by means of LEDs and energized output relays. In addition, the power supply unit
can be switched off by closing of a potential-free contact at the “REMOTE OFF”
input.
If the supply voltage at the “INPUT” of the power supply unit falls below
82 V AC (70 V DC), the corresponding “INPUT OK” output relay (contacts 11-
12/14) is de-energized and the “INPUT OK“ LED goes off.
If the “OUTPUT“ voltage of the power supply unit falls below 19.8 V DC, the
“OUTPUT OK“ relay (contacts 21-22/24) is de-energized and the “OUTPUT OK“
LED goes off. The output voltage can only be monitored in uncoupled parallel
operation.

56 M&I – AC 900F Controller

Section 3 Modules CP-C MM messaging module

Electrical connection

CP-C MM_electrical connection.png

Terminal assignment

Terminals Designation Function

REMOTE OFF If the terminals are short circuited by a normally
open contact (R < 1 kΩ), for instance, the power
supply unit is switched off remotely.
If the resistance R between the terminals is
> 10 kΩ, the power supply unit is switched on.
Attention:
Terminal potential = Input voltage
INPUT OK Potential-free change-over contact
message 11-14 closed and 11-12 opened, when the power
supply unit input voltage is > 85 V AC / 90 V DC.
11-12 closed and 11-14 opened, when the power
supply unit input voltage is 82 V AC / 70 V DC.
11-14 also closed with REMOTE OFF.

OUTPUT OK Potential-free change-over contact

message 21-24 closed and 21-22 opened, when the power
supply unit output voltage is 20.2 V AC / V DC.
21-22 closed and 21-24 opened, when the power
supply unit output voltage is 19.8 V AC / V DC.

M&I – AC 900F Controller 57

CP-C MM messaging module Section 3 Modules

58 M&I – AC 900F Controller

 Section 4 Accessories

The following section provides information on the AC 900F accessories and their
application. In addition, the features and the handling are described. The technical
data of the accessories are included in Section 9, Technical Data.

Controller accessories
The components listed below are accessories for the controller. Some are optional,
others are required to ensure the intended controller operation.

TD 951F display unit

The TD 951F display unit is an optional AC 900F accessory. It features a dot-matrix
LCD display with 128 x 64 pixel resolution as well as keys with fixed and variable
functions.

Display elements.png

M&I – AC 900F Controller 59

TD 951F display unit Section 4 Accessories

Use
The display unit is used for the following functions:
• Network settings
• Status display
• Display of process and diagnostic data
• Module change
• Application backup/restoring
• Firmware updating
• Safety settings
• Memory image

Functions

Key Description

Function keys F1 to F4. Select a menu or enable a function. For de-

tails about menus and functions refer to Section 7 and 8.

Move right or select next

Move left or select previous

60 M&I – AC 900F Controller

Section 4 Accessories TA 951F battery for RAM buffering

Key Description

Move up (selection) or increase value by 1

Move down (selection) or decrease value by 1

Quit menu without data saving or acknowledging

Quit menu upon data saving or acknowledging

TA 951F battery for RAM buffering

Battery_TA 951F.png

The accessory TA 951F comprises a 2/3A lithium battery with connecting cable.
The battery is provided with a plastic sheathing. This battery can be replaced while
the AC 900F is in operation.
• Cylindrical lithium cell
• 3 V, 1200 mAh
• Primary cell, non-rechargeable
• Mechanical plug coding to prevent reverse polarity

M&I – AC 900F Controller 61

TA 951F battery for RAM buffering Section 4 Accessories

Use
The TA 951F lithium battery serves to supply the real time clock and the SRAM in
order to save the memory contents (e.g. process and configuration data) in the event
of power failure.
The CPU module is delivered without lithium battery. A new TA 951F battery must
always be inserted during initial start-up of the CPU module.
After longer voltage supply interruptions at the CPU module (maintenance
operations, shut-down, transport or similar), a new battery must be installed as well
in order to ensure the specified buffering times.
Although the CPU module can also be operated without battery its use is strictly
recommended in order to avoid data loss.
The CPU module monitors the battery voltage and thus indirectly also the battery
capacity (charging status). The “Low CPU module battery capacity” message is
issued when the capacity has reached a level that is sufficient for 14 days buffering.
The battery should be replaced at regular intervals and as soon as possible after the
low battery warning has been displayed.
The TA 951F lithium battery is the only battery type that is compatible with the PM
CPU module. It is a non-rechargeable primary cell.
The battery must only be replaced with the controller supply voltage ON in order
to avoid any data loss.
Data buffering is not possible without a battery when the supply voltage is
switched off.

Safety instructions
Risk of overheating and subsequent explosion!
Batteries must not be short-circuited, recharged, opened or thrown
into fire!
B

Store the batteries in a dry place.

Strictly observe the applicable local recycling and environmental
regulations during disposal of used batteries.

62 M&I – AC 900F Controller

Section 4 Accessories Dummy couplers TA 924F and TA 724F

Battery lifetime
The battery lifetime is the time the battery will retain data while the power supply to
the CPU module is switched off. As long as the CPU module is powered, the battery
will be discharged by a very low test current and its self-discharge.

Dummy couplers TA 924F and TA 724F

The dummy couplers are designed to protect unused slots against contact (ESD),
corrosion and other effects.

TA_724F.png

Features

TA 924F
Form factor Similar to AC 900F with PM 902F/901F
Height 152 mm
TA 724F
Form factor Similar to AC 700F with PM 783F
Height 135 mm

M&I – AC 900F Controller 63

Diagnostic cables TK 890F and TK 891F Section 4 Accessories

Use
Unused C1 and C2 coupler bus slots must be covered by dummy couplers. This is of
essential importance in order to comply with the ISA 74.01 G3 requirements.

Diagnostic cables TK 890F and TK 891F

• PC side: D-SUB, 9-pin, female connector
• AC 900F side: D-SUB, 9-pin, male connector
The diagnostic cable is available in two different lengths:
• TK 890F with 10 m length
• TK 891F with 5 m length

Use
The TK 890F or TK 891F cable connects the AC 900F to the 9-pin port of the PC
provided for diagnostic purposes. For interfaces with a 25-pin connector, a
commercial adapter is additionally required. The energized diagnostic PC can be
connected to the running AC 900F.

TA525 inscription labels

TA525_us.png

64 M&I – AC 900F Controller

Section 4 Accessories TA525 inscription labels

Use
The labels are provided to mark the various AC 900F modules (CPU module,
communication interfaces and I/O modules). Waterproof felt pins can be used for
labelling.

Handling instructions
Insert the label with slight pressure. To remove the label, a small screwdriver is
inserted at the lower edge of the label.
While slight pressure is required for installation, a small screwdriver is used as a
lever for removing the label.

M&I – AC 900F Controller 65

CAN Bus accessories Section 4 Accessories

CAN Bus accessories

Different accessories are needed, depending on the controller configuration
(single/redundant) an the location where the controller is connected to the CAN bus
of the Freelance I/O racks. Refer to Section 3, Modules for details about the
connection variants.

TP 910F CAN Bus termination plug

CAN TP 910F_us.png

Features
• CAN Bus termination, triple
• Integrated terminating resistors (cannot be deactivated)
• D-SUB connector, 9-pin, male (M)
• 6 screw terminals
• Connection area for cable shield and strain relief

Use
The TP 910F termination plug serves for terminating (with correct impedance level)
three CAN bus lines directly at the CI 910F CAN Bus interface module.
The screw terminals in the plug allow to connect either the TK 811F open-end CAN
cable or a commercial twisted-pair cable.

66 M&I – AC 900F Controller

Section 4 Accessories TK 811F CAN cable

TK 811F CAN cable

CAN TK 811F_us.png

Features
• Shielded twisted-pair cable
• D-SUB connector, 9-pin, male (M)
• Open-end wires with wire-end sleeves
• Cable length 3 m

Use
The TK 811F cable connects the Freelance I/O racks to the CI 910F module. The six
wires and the cable shield are connected to the TP 910F terminal plug or a preceding
TB 870F terminal block.

M&I – AC 900F Controller 67

TK 831F CAN cable Section 4 Accessories

TK 831F CAN cable

CAN TK 831F_us.png

Features
• Shielded twisted-pair cable
• Two connectors, D-SUB 9-pin male (M) and D-SUB 25-pin female (F)
• Cable length 0.5 m

Use
The TK 831F cable connects the CI 910F CAN module to the TB 870F terminal
block. The cable is provided with a feed line and a return line for each signal in
order to avoid using spurs. For example, the pins 1 and 14 of the 25-pin connector
are electrically connected to pin 2 of the 9-pin connector via one wire, each.
When replacing the CI 910F module or the controller, disconnect the 9-pin
connector only. Disconnecting the 25-pin connector will interrupt the CAN bus.

Connector pin assignment

Channel Signal Pins D-SUB 25 Pins D-SUB 9

1 CAN 1H 1, 14 2
CAN 1L 2, 15 3
2 CAN 2H 4, 17 6
CAN 2L 5, 18 7
3 CAN 3H 7, 20 8
CAN 3L 8, 21 4

68 M&I – AC 900F Controller

Section 4 Accessories TB 870F terminal block

TB 870F terminal block

CAN TB 870F_us.png

Features
• 25-pin D-SUB plug for connecting TK 831F
• Two terminal strips with 14 screw terminals, each
• DIN rail mounting

Use
The TB 870F terminal block connects the CAN bus of the primary controller to that
of the secondary controller. It is also used to connect a controller in the middle of a
CAN bus line between two I/O racks.

Terminal strips

Channel Signal Input terminals Output terminals

1 CAN 1H 1 14
CAN 1L 2 15
2 CAN 2H 4 17
CAN 2L 5 18
3 CAN 3H 7 20
CAN 3L 8 21

M&I – AC 900F Controller 69

TB 870F terminal block Section 4 Accessories

70 M&I – AC 900F Controller

 Section 5 Mounting

This section provides information on initial mounting and removal of the modules
and accessories of an AC 900F controller. These operations must be performed
while all components are de-energized.
Prior to performing any mounting or demounting operations, switch off the
controller and associated devices and secure the equipment against unintentional
start-up.

Observe appropriate distances to adjacent devices (see dimensional drawings) to

ensure sufficient cooling of the equipment.

M&I – AC 900F Controller 71

Mounting to the DIN rail Section 5 Mounting

Mounting to the DIN rail

PM 902F CPU module
Snap the PM CPU module onto the DIN rail. For this purpose, the module must be
placed on top of the rail and pushed downwards until it locks in place.

Mounting_1.png

To remove the module from the DIN rail, press it down and pull it off the rail.

SYSDAT32.png

72 M&I – AC 900F Controller

Section 5 Mounting TU terminal blocks

TU terminal blocks
Place the terminal block onto the DIN rail and press it down until it locks in place.
Move the terminal block to the left to ensure a solid mechanical and safe electrical
connection. Up to ten terminal blocks can be connected successively to the PM
902F module.

SYSDAT34.png

To remove the terminal blocks, carefully insert a screwdriver between both elements
and slide them apart, as shown in the figure. For this purpose, the elements are
provided with a recess designed for the insertion of a screwdriver tip.

SYSDAT35.png

M&I – AC 900F Controller 73

CP-C switch-mode power supply units and CP-C RU redundancy unit Section 5 Mounting

CP-C switch-mode power supply units and CP-C RU redundancy unit

The CP-C 24/5.0, CP-C 24/10.0 and CP-C RU modules are installed in four steps:
1. Slightly tilt the module and place it on the DIN rail (horizontal mounting
position, input terminals at the top).
2. Move the module downwards up to the stop.
3. Press against the front side to lock the module in place.
4. Slightly shake the module to check whether it is correctly locked.

PS_Mount_us.png

To remove the CP-C or CP-C RU, proceed as follows:

1. Unlock the module using a screwdriver.
2. Tilt the module and remove it to the top.

PS_Dismount.png

74 M&I – AC 900F Controller

Section 5 Mounting CP-C switch-mode power supply units and CP-C RU redundancy unit

CP-C MM messaging module and CP-A CM control module

While the CP-C MM messaging module is plugged on a CP-C switch-mode power
supply unit, the CP-A CM control module must be mounted to a CP-C RU
redundancy unit.
The modules are attached to the front side of the power supply unit or the
redundancy unit. The embossed front film at the power supply unit or the
redundancy unit is thus penetrated by the locking latches and the plug contacts.

CP-C MM_CM_Mount.png

To remove the CP-C MM and CP-A CM modules, carefully press and tilt them
upwards. Pull the module downwards to unlock the locking latch and remove the
CP-C MM or the CP-A CM module from the power supply unit or the redundancy
unit, respectively.

CP-C MM_CM_Dismount.png

M&I – AC 900F Controller 75

Wall mounting Section 5 Mounting

Wall mounting
Wall mounting is an alternative to DIN rail mounting of the AC 900F controller. The
description below generally also applies for installation on a mounting panel inside
a cabinet.

PM 902F CPU module

The 902F PM CPU module features four bores for screws on the rear side of the
housing (see arrows).

Ac 900F_wall accessory_1.png

Suitable dowels and screws (e.g. 4 x 50 mm) must be selected depending on the wall
material at the place of installation.

AC 900F_wall accessory_3.png

The enclosed mounting set (red parts) is intended for both upper screws. Both
plastic tubes are designed to bridge the gap between the plastic housing and the
wall. Insert the nose of these tubes into the bore provided in the plastic housing.

76 M&I – AC 900F Controller

Section 5 Mounting TU terminal blocks

TU terminal blocks
When using a direct I/O, the corresponding number of I/O terminal blocks must be
connected on the right side of the CPU module using the previously attached
accessory part. The TA526 accessory part for wall mounting prevents any
deformation of the terminal block during fixing to the wall. It is recommended to
mount the terminal blocks in small groups of up to three units. After having marked
the correct position and drilled the bores, the terminal blocks can be fixed by means
of screws. Use two M4 screws per terminal block for this purpose. The screws must
be inserted at the terminal block front.

TA526 wall mounting.png

M&I – AC 900F Controller 77

Coupler bus slots Section 5 Mounting

Coupler bus slots

The C1 and C2 coupler bus slots serve for connecting the CI/CM communication
interfaces to the CPU module. When configuring the AC 900F controller and
integrating a CI/CM module, the bottom module part must be plugged in first. Then
press the module backwards until it locks in place at the top of the slot.

Coupler bus C1-C2_us.png

A TA dummy coupler is installed and removed from the C1/C2 slots as described
for a communication interface.
The module change during operation is described in Section 8, Service.

78 M&I – AC 900F Controller

Section 5 Mounting PM housing front

PM housing front
The central area of the housing front of the CPU module is equipped with a
removable cover. This cover can be taken off without any tools and be replaced by a
TD display unit.

display.png

M&I – AC 900F Controller 79

Dimensional drawings Section 5 Mounting

Dimensional drawings
Note: All dimensions are indicated in mm.

Dimensional drawings of the PM CPU-module

Front view

AC 900F_dimensions.png

Lateral view

AC 900F_depth.png

80 M&I – AC 900F Controller

Section 5 Mounting Dimensional drawings of the CP-C 24/5.0 and CP-C 24/10.0

Dimensional drawings of the CP-C 24/5.0 and CP-C 24/10.0

CP_C24_dimensional_drawing.png

Install the devices in upright position with the input terminals being arranged at the
bottom. In order to ensure sufficient convection cooling, the minimum distance to
other modules must not be less than 80 mm in vertical and 10 mm in horizontal
direction.

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Dimensional drawing of the CP-A RU Section 5 Mounting

Dimensional drawing of the CP-A RU

CP_A_RU_dimensional_drawing.png

Install the devices in upright position with the input terminals being arranged at the
bottom. In order to ensure sufficient convection cooling, the minimum distance to
other modules must not be less than (A) 10 mm in horizontal direction and (B)
50 mm in vertical direction.

Dimensional drawings of the CP-C MM and CP-A CM

CP-C MM_CP-A CM.png

The CP-C MM and CP-A CM modules have identical dimensions.

82 M&I – AC 900F Controller

 Section 6 Wiring

This section provides information on wiring the AC 900F controller exclusive of the
CI/CM communication interface module. It contains safety instructions, general
guidelines and information on cable routing.

Safety instructions

Make sure to strictly observe the following safety instructions when wiring the
controller. This requirement is essential to exclude personal injury and equipment
damage.

Please refer to the safety instructions for the AC 700F/AC 900F for general
information on safety and precautionary measures.

The L+ and M terminals are assigned twice. Incorrect wiring may cause short
circuits and damage the power supply unit or the fuse protection of the power supply
unit. If no suitable protection is provided (suitable module), the CPU module may
be damaged as well. For this reason, the CPU module must be wired in compliance
with the following instructions and an adequately dimensioned fuse must be used.

General instructions
Strictly observe the following basic principles and instructions when installing and
wiring the controller.
The specified earthing and shielding measures must be implemented in order to
ensure reliable controller operation.

M&I – AC 900F Controller 83

Controller earthing Section 6 Wiring

• Keep all connecting lines as short as possible. This is particularly important for
the earthing conductors.
• Make sure to select sufficiently dimensioned wire cross-sections. This is
particularly important for earthing conductors.
• To achieve low-impedance, i.e. optimum contacts over a large surface, proceed
as follows:
– establish vibration-resistant connections,
– use bare contact areas (remove paint, clean surface),
– avoid the use of aluminum parts (oxidize easily),
– select solid plug and screw connections,
– directly earth the cable shields with clips to a well-grounded metallic
surface,
– do not use drain wires (pig-tails),
– do not use toothed washers to lock the screw unions.

Contact_us.png

Controller earthing
Proper earthing of the controller requires an earthed mounting plate or metal frame.
Additional earthing measures are only required if the mounting surface or frame
material cannot be earthed. In this case, a short earthing conductor must be
connected to the lower left/right fastening screw of the CPU module. l
The controller is earthed through the DIN rail or both lower fastening screws. Use
yellow chromated steel DIN rails to ensure proper earthing.

84 M&I – AC 900F Controller

Section 6 Wiring Cable routing

Cable routing
• Ensure proper cable routing during wiring.
• Sort the cables in different cable groups (power current cables, power supply
cables, signal cables and data cables).
• Make sure to lay signal and data cables separately from power current cables,
i.e. in separate conduits or cable bundles. The distance should be at least 20
cm.
• Signal and data cables should be installed close to earthed surfaces.

Cable shields
• Use only shielded data cables. The shield must be earthed on both sides. Make
sure that no compensating currents pass through the cable shield. A current-
carrying equipotential bonding line can be used for this purpose.
• If a cable shield is earthed on one side, it only provides protection against
capacitive coupling and low-frequency interference (50/60 Hz ripple voltage).
• Only use braided-shield cables. Foil shields exhibit low mechanical stability as
well as poor contact and HF properties.
• Only metallic or metal-coated connectors must be used for shielded data
cables.
• Use only shielded cables for analog signals. Earth the shield on one end only
for the transmission of small signals.
• Earth the cable shield using a clamp directly at the entry into the switch
cabinet. Guide the shield up to the module without any interruption.
• There must be a low-impedance connection between the PE bar and the shield
bar.

M&I – AC 900F Controller 85

Switch cabinet Section 6 Wiring

Switch cabinet
• Low-impedance connections between the switch cabinet, mounting plate,
earthing bar (PE) and shield bar must be provided.
• Earth the switch cabinet doors on the sides using short and highly flexible
conductors.
• To protect the control system against interferences, only bulbs or interference-
suppressed fluorescent/LED lamps should be used in the direct vicinity of the
control system for switch cabinet lighting.
• If an interference immunity of 6 kV instead of 4 kV is required, the controller
must be installed in a switch cabinet and operated exclusively with the door
being closed.

Minimum distances
• Provide for adequate distances to the switch cabinet walls, cable conduits,
adjacent devices, etc. There should be a distance of 20 mm around the
controller to all sides in order to ensure proper ventilation and electrical
insulation.
• Horizontal installation is highly recommended. Vertical mounting is also
possible, but involves restrictions in terms of performance due to insufficient
air circulation, which causes heating of the devices.
• When mounting the system in vertical position, mechanical stops must be
provided at the top and the bottom to protect the modules against vibrations.
For applications with high levels of vibration, the installation of mechanical
stops on the left and right sides is also recommended for horizontal mounting
in order to efficiently protect the modules against vibrations.

Reference potential
• Ensure a uniform reference potential throughout the line and earth the complete
electrical equipment, as far as possible.
• Install the earth conductors in star configuration to avoid the formation of
ground loops.

86 M&I – AC 900F Controller

Section 6 Wiring Equipotential bonding

Equipotential bonding

SYSD24.png

Item No. Description

1 Power supply unit for the CPU module *)
2 Fuse for the CPU module
3 Power supply unit for the I/O modules *)
4 Fuse for the I/O modules *
5 Fuses for the relay output contacts
see module description
6 0V rail (signal reference potential)
7 Earthing of the 0V rail

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Power consumption Section 6 Wiring

Item No. Description

8 Switch cabinet earthing
9 Equipotential bonding line between the switch cabinets, if applicable, at
least 16 mm2
10 Cable shield earthing
*) The use of a common power supply unit is also possible.

• Install sufficiently dimensioned equipotential bonding lines if high potential

differences between the system components are present or expected to occur
with your specific application.
• The impedance of the equipotential bonding line should amount to maximum
10% of the shield impedance of shielded signal lines between the same points.
• The cross-section of the equipotential bonding line must be rated for the
maximum compensating current. Experience has shown that a cross-section of
16 mm² is usually sufficient.
• Equipotential bonding and shielded signal cables should be laid as close as
possible to each other to prevent the formation of inductive loops and the risk
of interference coupling.
• Ensure low-impedance connection between equipotential bonding lines and
PE.

Power consumption
The total power consumption of the controller corresponds to the sum of all
individual consumption values. The following values must be taken into
consideration:
• the power consumption of the CPU module through the L+ and M terminals.
After voltage conversion within the CPU module, the communication
interfaces and the bus-connected I/O modules are supplied from here as well.
• the power consumption for the process supply voltage at the ZP and UP
terminals of the terminal blocks. The power for the consumers at the
digital/analog outputs and the electronics inside the I/O module is also supplied
from here.

88 M&I – AC 900F Controller

Section 6 Wiring Fuse dimensions

A single power supply unit can be used for both supply voltages. The CPU module
and the I/O modules should, however, be provided with separate fuse protection. As
a matter of course, separate power supply units can also be used.

Module type PM 902F and PM 901F

Power supply L+ and M terminals
Voltage 24 V DC
Current consumption 1A
Power consumption 24 W (entire station)

Make sure that the power supply unit used is rated for the required inrush current.

Fuse dimensions
To select the appropriate fuses for the station, the power consumption and the inrush
currents (melting integral of the upstream fuse) must be taken into account.

Module type PM 902F and PM 901F

Total melting integrals 22 A2s
Rated current 4.0 A
Characteristic AT high breaking capacity
Recommended fuse protection Type IEC/EN60127-2/V
Dimensions Glass tube fuse, 5x20 mm

M&I – AC 900F Controller 89

Bus termination Section 6 Wiring

Bus termination
Serial interfaces of the CPU module

Interface standards
Serial interfaces comply with the EIA RS-232 and EIA RS-485 standards.

Serial interfaces (SER1 and SER2) for the CPU module

Serial interface_ser1_ser2_us.png

The SER1, SER2 serial interfaces are connected by means of a removable 9-pin
terminal block. They can be configured for RS-232 or RS-485 and used e.g. for
Modbus (master / slave).
If the RS-485-bus is used, each connected bus line (each bus segment) must be
electrically terminated. This includes:
• one 120 Ohm bus terminating resistor on both wire ends (to avoid signal
reflections).
• one additional 470 Ohm pull-up resistor on RxD/TxD-P and one 470 Ohm
pull-down resistor on RxD/TxD-N per bus. These two resistors are designed to
ensure a defined high level on the bus when no data are transmitted.
• shielded twisted-pair cables with an impedance level of 100 to 120 Ohm.

90 M&I – AC 900F Controller

Section 6 Wiring Serial interfaces of the CPU module

The two 470 Ohm resistors are integrated into the CPU module and can be activated
by a short wire link between the terminals 1-2 and 3-4. The following drawing
shows an RS485 bus with a bus master at the line end.

RS 485 bus_us.png

If the master is located within the bus line, a terminating resistor is not provided.
The pull-up resistor and the pull-down resistor, however, need to be activated (see
drawing below). The cable shields of the bus line must be earthed.

RS-485 Bus_bus line_us.png

The external 120 ohm resistor (line termination) must be protected against
electrostatic discharge. It is recommended to provide the complete resistor
(except for the wire ends) with a heat shrink tube for this purpose.

Ethernet_Connect_us.png

M&I – AC 900F Controller 91

Serial interfaces of the CPU module Section 6 Wiring

Redundant controller
The RS232/485 bus lines of a redundant controller should first be connected to
terminal strips and then be guided to the field. The terminal strips must be arranged
as close as possible to the controller. In this configuration, the pull up/down resistors
of the CPU module are not required.
RS232

RS 232 redundant PM.png

92 M&I – AC 900F Controller

Section 6 Wiring Serial interfaces of the CPU module

RS485

RS485 redundant PM.png

A regulated power supply with output voltage 5 V DC +/- 10% is needed to provide
for a defined quiescent level on the RS484 bus. .
The 5 V DC power supply unit must have a safe electrical isolation. As described
earlier in this section, the external resistors must be protected against electrostatic
discharge.

M&I – AC 900F Controller 93

Serial interfaces of the CPU module Section 6 Wiring

Ethernet
The CPU module features several on-board Ethernet interfaces. As far as the
maximum line lengths in Ethernet networks are concerned, various factors must be
taken into consideration. With twisted pair cables (transmission rate of 10 Mbit/s
and 100 Mbit/s) for instance, the maximum length of one segment, i.e. the
maximum distance between two network components is limited to 100 m due to the
electric properties of the cable.
In addition, the length limitation for one collision domain must be observed. A
collision domain is the area within a network that may be affected by a potential
collision. However, this must only be taken into consideration if the components are
operated in half duplex mode, as the CSMA/CD access process is only used in this
case. If all components work in full duplex mode, no collisions will be caused.

94 M&I – AC 900F Controller

 Section 7 Commissioning

This section provides information on the basic operations required for first
commissioning of the controller.

Data backup
Data backup is not possible without a battery when the supply voltage is switched
off.
.

The use of unsuitable batteries leads to explosion or fire hazards. This is why
exclusively TA 951F lithium batteries must be used for the PM CPU module.

As soon as the battery is connected and the controller is not supplied with
operating voltage, buffering and battery unloading are started.

To insert the battery, proceed as described below.

Insertion of the TA 951F battery

Remove the detachable front panel of the CPU module or the display unit installed
in this position. The following drawing shows the mounting position of the battery
behind the fixed housing front part.
The new CPU module housing has been equipped with a battery compartment that
replaces the previously used battery holder.
Module with battery compartment (new)
Push the battery to the left into the battery compartment. It will be locked
in place by the front panel or the display unit.

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Insertion of the TA 951F battery Section 7 Commissioning

Module with battery holder

Place the battery in inclined position onto the lower holder. Press the
battery downwards and then to the left until it locks in the upper holder.
Both holders are provided for locking purposes only; they are not
electrically connected to the battery.
To connect the battery to the power supply, plug in the battery connector into the
mating socket. The connector is keyed to ensure reverse polarity protection. Close
the housing with the previously removed front panel or display unit.

Battery_04_us.png

96 M&I – AC 900F Controller

Section 7 Commissioning Controller configuration via terminal program

Controller configuration via terminal program

When used for the first time, no valid IP parameters (IP address, subnet mask and
gateway) are assigned to the controller. For this reason, the controller waits for the
entry of valid IP parameters when it is started for the first time.
Connect the TK 890F/891F cable to the diagnostic interface of the controller and to
the serial interface of the Engineering Station.
Establish the communication between the Engineering Station and the controller
using a terminal program. A terminal program can be found in the Freelance
installation directory <InstallationDirectory\exe\Terminal.EXE
Make the following settings for the serial interface:
Baud rate: 19200 (default)
Parity: none
Flow control: none
Data bits: 8
Stop bits: 1

Hardware self-test
A hardware self-test is performed with every start of the AC 900F. The controller
system messages are indicated via the diagnostic interface (DIAG).
Boot loader configuration
When the AC 900F is started, the boot loader displays a configuration message
showing the Firmware version number in the header.

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Controller configuration via terminal program Section 7 Commissioning

98 M&I – AC 900F Controller

Section 7 Commissioning Controller configuration via terminal program

The configuration data of the boot loader can be retrieved at any time by pressing
the space bar during the waiting time of 2 seconds. The following message will be
displayed:

Enter PIN code: ****

<C>hange, set <T>ime or <P>in, <L>oad config, <S>ave or continue

<B>oot?

The PIN prompt is not displayed during first commissioning, but only after this
safety function has been activated using the terminal program or the display unit.

Configuration data
Select the <C>hange menu item to change the controller configuration data. After
having selected C, the following instruction is displayed.

For each of the following questions, hit <RET> to keep the value in
braces or enter a new value.

The default values for the different configuration items appear in braces. Press the
ENTER key to confirm the displayed value or change the values as required.
IP addresses
The IP addresses of the Ethernet interfaces can be set using the terminal program.
For each on-board Ethernet interface, a prompt that requests the entry in
DDD.DDD.DDD.DDD format is displayed. The address is entered as decimal
number (DDD = 0...255). Leading zeros can be omitted.
For example: 172.16.1.22 <ENTER>

Enter IP address: [172.16.1.22]

An IP address must be assigned to each Ethernet interface in the various subnets.

It is recommended to set an IP address within the range of 172.16.[0 - 15].[0 -
255] for the Control Net.

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Controller configuration via terminal program Section 7 Commissioning

The 255.255.255.255 broadcast address and the 0.0.0.0 address are special cases
and cannot be set. In case of an invalid entry, the boot loader repeats this
configuration item.
Subnet mask
There is a subnet mask for each Internet address. Contact your network
administrator for the mask that corresponds to your Internet address.

Enter subnet mask: [255.255.240.0]

The subnet mask is entered as described for the Internet address.

Default router
If a default router for communication with remote operator stations is installed in
your network, the corresponding Internet address can be entered here.

Enter default router IP address: [0.0.0.0]

Data transmission rate, duplex mode and redundancy

The controller supports 10 MBit/s (10BASE-T) and 100 MBit/s (100BASE-TX) in
half duplex and full duplex mode. Upon selection of Auto negotiation, the controller
independently negotiates the data transmission rate and the duplex mode with the
remote station.
ETH1.

Set Ethernet link 1 configuration:

0. Auto negotiation
1. 100 MBit full duplex
2. 100 MBit half duplex
3. 10 MBit full duplex
4. 10 MBit half duplex
Select: [0]

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Section 7 Commissioning Controller configuration via terminal program

ETH2

Set Ethernet link 2 configuration:

0. Auto negotiation
1. 100 MBit full duplex
2. 100 MBit half duplex
3. 10 MBit full duplex
4. 10 MBit half duplex
5. Redundancy Link
7. Offline
Select: [5]

Enter [5] to enable the redundancy link at ETH2 for operation of a redundant
controller. The IP address, baud rate and mode for the application are defined as
default settings.
ETH3

Set Ethernet link 3 configuration:

0. 10/100 MBit auto
6. Redundant ControlNet
7. Offline
Select: [7]

Select [6] to configure the controller for the connection to a redundant Control Net.
ETH3 will then operate with the setting 10/100 MBit auto.
ETH4

Set Ethernet link 4 configuration:

0. 10/100 MBit auto
7. Offline
Select: [7]

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Controller configuration via terminal program Section 7 Commissioning

Auto restore

Auto restore from SD card [n]

The controller can be configured to automatically restore the configuration data

saved on the SD card (Backup config) when a cold start is initiated. For more
information on this function refer to Section 8, Service.

Diagnostic interface transmission rate

Enter baudrate of console port: [19200]

The Diagnostic interface transmission rate can be set to 9600 Bit/s or 19200 Bit/s.
Default value is 19200 Bit/s.

Waiting time for the configuration block start-up

Enter CPU delay (in seconds) before starting up: [2]

Any value between 2 and 60 seconds can be entered for the waiting time. In case of
an invalid entry, the boot loader repeats this configuration item. It is recommended
not to change the default setting.
The boot loader then displays the current configuration data that are still to be saved.
The default setting for all other parameters must not be changed!

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Section 7 Commissioning Controller configuration via terminal program

Select the <S>ave menu item in order to save the configuration data in the non-
volatile memory. The following message will be displayed:

Parameters saved

As soon as the following prompt is displayed, further settings can be made.

<C>hange, set <T>ime or <P>in, <L>oad config, <S>ave or continue

<B>oot?

Date and time

Select the <T>ime menu item, which will allow you to set the time and date of the
battery buffered real-time clock of the AC 900F.
The order of the date format is day, month, year.

Enter date <dd.mm.yy>: 22.07.12

The order of the time format is hour, minute, second.

Enter local time (hh:mm:ss):00:17:00

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Controller configuration via terminal program Section 7 Commissioning

In case of an invalid entry, the boot loader repeats this configuration item. When the
entry is correct, the real-time clock is started.

RTC time: 22.07.08, 00:17:02 local

Date and time must be precisely set during first commissioning of the AC 900F.

Identification PIN
Select the <P>in menu item in order to define an identification PIN.
Enter a four-digit PIN. Confirm the PIN by entering it once again. The PIN prompt
is deactivated when 0000 is entered.
The PIN-protected menus and functions are listed in section 8 (Security).

Change PIN (ESC for no change, 0000 to clear)

Enter new PIN: 1234

Confirm PIN: 1234

PIN changed

Starting the operating system

When the above configuration is completed (or upon expiry of the waiting time),
select the <B>ooting menu item. The boot loader attempts to start an existing
operating system or project configuration, if any, or waits for bootstrapping by the
Engineering Station.

104 M&I – AC 900F Controller

Section 7 Commissioning Controller configuration via display unit

Controller configuration via display unit

During the first controller start, the TD 951F display shows the Boot Configuration
menu and a prompt for entering the basis settings.

Boot configuration
In order to activate the configuration mode of a controller during operation, the
controller supply voltage must be switched off and on again with the ESC key being
pressed and held during restart.

Boot configuration
F1:IP addresses
Control Net
Gateway
Redundancy
F1: ETH1
F2: ETH2
F3: ETH3
F4: ETH4
F2: Update/Restore
Please refer to section 8 “Service”
F3: Display settings
Backlight
Contrast

The Boot Configuration menu features three submenus.

Boot_Config.png

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Boot configuration Section 7 Commissioning

Before using the display unit for additional settings, access the F3 Display Settings
menu to perfectly adjust the brightness and the contrast of the display.

F1 - IP Address
IP Address setting is mandatory to communicate with the AC 900F via Ethernet.
Press F1 to access the Network submenu.
The IP address of the Gwy:000.000.000.000 default gateway is displayed in
the first line (read only). The gateway address can only be changed using the
terminal program.
Specify in the second line whether the controller is used in redundant configuration
or not. This setting must correspond to the hardware structure in Freelance
Engineering. The AC 900FR hardware object requires the Redundancy enabled
setting. Press the arrow key on the right to select the function and the top arrow key
to enable the redundancy mode.

Network_settings.png

To configure an Ethernet interface, press the function key assigned to the relevant
interface. When pressing the F1 key, for instance, the settings of the Eth1 interface
are displayed.
The configuration of [Eth4] is not provided for the PM 901F CPU module.
Change the IP address using the arrow keys. If required, proceed in the same way to
change the subnet mask. Make sure that the interface is enabled, if required. This
process can be interrupted at any time by pressing the ESC key. Press OK to apply
the changed settings.

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Section 7 Commissioning Boot configuration

It is recommended to set IP addresses within the range specified below for the
Control Net.
IP address 172.16.[0 - 15].[0 - 255]
Subnet mask: 255.255.240.0
The 255.255.255.255 broadcast address and the 0.0.0.0 address are special cases
and cannot be set.
Eth1 is designed to connect the controller with the Control Net. For this reason, this
interface must be enabled in any case and be provided with addresses.

Ethernet enabled.png

Eth2 can be freely used. However, if the controller is defined as redundant in the
Network menu, Eth2 is reserved for the redundancy link. The information
Redundancy Link will appear at the top of the display. In this case, the IP address
and the subnet mask cannot be set.

Ethernet_enabled-02.png

Eth3 can be freely used. If the controller will be connected to a Redundant Network
(redundant Control Net), Eth3 (line B) is required in addition to Eth1 (line A).

M&I – AC 900F Controller 107

Boot configuration Section 7 Commissioning

Ethernet_enabled-03.png

Eth4 can be freely used, e.g. for Modbus communication via TCP/IP Ethernet.

Ethernet_enabled-04.png

F2 - Update/Restore
The Update/Restore functions are generally not required for controller
commissioning. For more detailed information on these functions, please refer to
Update/Restore in Section 8, Service.

F3 - Display Settings
Adjust the Backlight and the Contrast using the arrow keys provided for both menu
items.

Display_Settings.png

Press the OK key to apply the settings.

108 M&I – AC 900F Controller

 Section 8 Service

This section provides information on maintenance and service operations. As far as

the display unit is required for this purpose, its operation is also described.

Module replacement
Unless otherwise specified, the modules must be de-energized prior to connection or
disconnection. Make sure to switch off the DC-IN operating voltage, the UP process
voltage and additional voltage supply sources, if any.

CI communication interfaces
There are several possibilities to connect or disconnect a communication interface
to/from a C1/C2 slot without disturbing the CPU module.

AC 900F in de-energized state

After having de-energized the controller, press on the lock at the top of the CI/CM
communication interface and disconnect the module from the slot.

AC 900F in energized state

The CI 930F and CI 773F PROFIBUS communication interfaces are designed for
hot plug (connection/disconnection when energized). Make sure that the
communication interface concerned is deactivated prior to
connection/disconnection. There are two different methods available for this
purpose:
• using the TD 951 display unit. For more detailed information on the menu
operation, please refer to F1 - Module exchange on page 117
• using a PC (terminal program) via the DIAG diagnostic interface.

M&I – AC 900F Controller 109

I/O modules Section 8 Service

I/O modules
The I/O bus of the CPU module is not designed for the connection and
disconnection of I/O modules during operation.
Connect or disconnect I/O modules only when the controller is de-energized.

If an I/O module is connected or disconnected while the system is operating, an

unintentional reset or lock up of the controller may be caused.

Replacement of accessories
TD 951F
If only one display unit is provided, for instance, this unit can be removed from a
controller and connected to another controller during operation. A previous
deactivation of the TD 951F is not required for this purpose. Press the upper and
lower snap-in noses simultaneously to remove or install the TD 951F.

Battery change
Replace the battery with the controller supply voltage ON in order to avoid any data
loss.
Remove the detachable front panel of the CPU module or the display unit installed
in this position. For electrical disconnection, carefully unplug the small connector
from the battery socket. The used battery can then be removed from the battery
compartment or the battery holder by carefully pulling the battery cable. Insert the
new battery as described under Insertion of the TA 951F battery on page 95.
Lithium batteries must not be recharged, opened or thrown into fire. Store the
batteries in a dry place. Strictly observe the applicable local environmental
regulations during disposal of used batteries.

110 M&I – AC 900F Controller

Section 8 Service Online functions of the display unit

Online functions of the display unit

The online functions are available after having loaded the configuration
(application). The display unit serves for displaying the controller status and process
parameters as well as for supporting the module replacement and data storing on an
SD card.

Start menu (online)

F1: Process data
F2: Controller status
F3: Diagnostic data
Main menu (online)
F1: Controller
F2: Security
F1: PIN
F2: Download
F3: RUN/STOP
F3: Restart
F1: Warm start
F2: Cold start
F3: Initialization
F2: Maintenance
F1: Module exchange
C1 slot
C2 slot
F2: Backup configuration
on SD card
F3: Save memory image
on SD card
Boot configuration (offline)
F2: Update/Restore
F1: Restore configuration
from SD card
F2: Firmware update
from SD card
F3: Enable autorestore

M&I – AC 900F Controller 111

Start menu Section 8 Service

Start menu
The start menu of the AC 900F display is generally the starting point for performing
the functions described in this section. Press the ESC key to quit the start menu or to
return to the start menu.
The start menu provides three functions with the basic setting being the first
function (display of process data). The basic setting and the name of the start menu
can be changed. These changes cannot be made on the display unit, but only by
modifying the controller parameters in Freelance Engineering.

F1 - Process data
Press F1 to display the freely selectable parameters (max. 12 variables
Var1...Var12). The process data selection as well as the indication of name and unit
must be made in Freelance Engineering.

Process values.png

F2 - Controller status
Press F2 to display the current controller status.

CPU state.png

112 M&I – AC 900F Controller

Section 8 Service Main menu

F3 - Diagnostic data
Press F3 to display the diagnostic data.

Diagnosis report.png

Main menu
When the ESC key is pressed, the Main menu is displayed. This menu provides
access to the Controller menu via F1 and to the Maintenance menu via F2.

Main menu.png

Controller menu
The Controller menu provides access to the Security and Restart submenus.

Controller_restart.png

M&I – AC 900F Controller 113

Controller menu Section 8 Service

F2 - Security
Select the desired function using the F1 or F2 function key.

Controller security.png

Access to the controller Webserver and Telnet can be blocked by the configuration.
This setting can only be entered in Freelance Engineering and not on the display
unit.
AC 900F Parameters > CPU/Security > Security > Webserver disabled or Telnet
disabled

F1 function: Change PIN

By entering a PIN, access to the Controller menu and the use of the functions
included in this menu by unauthorized persons is excluded. The same applies to the
functions of the Boot Configuration menu.
Enter a four-digit PIN using the arrow keys. Enter the PIN once again to confirm it.

Enter PIN.png

The lock symbol at the right top of the start menu indicates an activated PIN, i.e. a
protected controller.

114 M&I – AC 900F Controller

Section 8 Service Controller menu

Locked.png

Enter 0000 to deactivate the PIN prompt. The previously mentioned menus and
functions will be available again.

F2 function: Download enabled/disabled

Press F2 to block (disable) downloads. It is thus no longer possible to download a
configuration (application) from the Engineering Station to the controller. The same
applies to firmware updates or the performance of “correctly” modified parameters.
Interventions from Freelance Operations are not disabled.

Display: Run/Stop enabled/disabled

The Run/Stop switch can only be disabled in Freelance Engineering and not on the
display unit.
AC 900F Parameters > CPU/Security > Security > Run/Stop switch

F3 - Restart
The functions provided in the Restart submenu allow the controller to be started in
different ways.

The Restart functions can only be activated from a single controller. In the case of
controller redundancy, pressing F1...F3 will only produce a redundancy change
(Toggle).
With controller redundancy, the warm/cold start or initialization functions in
Freelance Engineering should be used

Select the restart type by pressing the corresponding function key. Regardless of the
function key selected, the Restart now? prompt will be displayed. Press the OK
key to release the function.

M&I – AC 900F Controller 115

Maintenance menu Section 8 Service

Restart type.png

F1 function: Warm start

All controller data and variables are retained. Output modules indicate the set
security values.
F2 function: Cold start
All controller data are initialized. During cold start, output modules indicate first the
set security values and then the initialization values.
F3 function: Initialize
The entire user configuration is cancelled. Output modules indicate the set security
values. Restart the controller to load a new configuration.

Maintenance menu
Select the Maintenance menu to access the Module exchange, Backup config and
Save memory image functions.

Maintenance screen.png

116 M&I – AC 900F Controller

Section 8 Service Maintenance menu

F1 - Module exchange
This function supports the CI module change with the controller being in operation.
The current ON/OFF status of both C1 and C2 slots is displayed.
Press the F3 (C2) or F4 (C1) function key to change the status. Change back to ON
after a module change has been performed in OFF state.

Module exchange.png

F2 - Backup config
The controller writes a copy of the loaded configuration (application) on the SD
card. This function is only activated on condition that an application is running on
the controller and an SD card is inserted.

Save application.png

As soon as the process is completed, an OK message appears on the display.

The parameter/variable values that were temporarily changed by Write or Force
in the application and thus on the controller will not be saved on the SD card.

The file with the backup copy has the name <IP Address>.CFI, with the IP address
being indicated in hexadecimal format. During the saving process, the controller
remains in operation, but downloads are rejected.

M&I – AC 900F Controller 117

Maintenance menu Section 8 Service

F3 - Save memory image

The controller writes a copy of its memory contents on the SD card. This function is
only activated on condition that an application is running on the controller and an
SD card is inserted.

Write memory image.png

As soon as the process is completed, an OK message appears on the display.

The file with the memory contents has the name <IP Address>.MEM, with the IP
address being indicated in hexadecimal format. During the saving process, the
controller remains in operation, but downloads are rejected.

118 M&I – AC 900F Controller

Section 8 Service Offline functions of the display unit

Offline functions of the display unit

The following information refers to functions that can only be performed offline.
For this reason, the controller must be in Boot Configuration mode.
In order to activate the configuration mode of a controller during operation, the
controller supply voltage must be switched off and on again with the ESC key being
pressed and held during restart.

Boot Config.png

Update/Restore
The menu (Update/Restore) provides three F1 - F3 functions.

Restore.png

F1 - Restore config
The controller searches the configuration (application/project) on the SD card under
the file name that corresponds to the IP address in hexadecimal format.

M&I – AC 900F Controller 119

Update/Restore Section 8 Service

F2 - Firmware update
The controller searches a valid firmware file on the SD card and loads it into the
flash memory of the CPU module. Upon restoring or updating, the controller is
automatically rebooted. Depending on the file size, this process can take several
seconds (loading..... is displayed). As soon as the ABB logo appears, you can
remove the SD card from the slot.
Make sure that the SD card is not removed and the power supply is not switched
off during firmware updating!

F3 - Enable autorestore
The controller can be configured to automatically restore the configuration data
saved on the SD card (Backup config) when a cold start is initiated.
The Autorestore function can only be properly performed on condition that the SD
card with the configuration remains installed. The controller features a monitoring
function to check whether this is the case. This monitoring function can be activated
using the AC 900F parameter dialog in Freelance Engineering, only:
CPU/Security > SD card > SD card monitoring
If the SD card is removed while the monitoring function is activated, the controller
displays a “SD card removed” message. This message appears in the Freelance
Operations message list.
In the Freelance Engineering Commissioning mode the AC 900F parameter dialog
shows the following:
[...] SD card available: [ ] = no card, [v]= card available
As to the use of the Autorestore function, please observe the following information.
CPU module with battery
In the case of a cold start and an empty memory, the data will be automatically
transferred from the memory card to the controller memory. If the controller already
contains data, the data from the memory card will not be stored.

120 M&I – AC 900F Controller

Section 8 Service Update/Restore

CPU module without battery

This AC 900F operating mode is recommended with regular supply voltage failures
for a longer period of time, e.g. with solar energy supply. As no energy is supplied at
night (buffering mode), the battery would be discharged within less than two years.
In order to ensure that after a control start the controller operates with the data from
the memory card and not with “partly” still available data in the memory, a
minimum turn-off time of the controller must be observed. The turn-off time
(discharge of the buffer capacitors in the CPU module) must be > 60 s.

M&I – AC 900F Controller 121

Update/Restore Section 8 Service

122 M&I – AC 900F Controller

 Section 9 Technical Data

The modules and accessories described in the following section are designed in
compliance with the requirements specified in EN/IEC 61131-2.
Unless otherwise stated in the technical data, modules and accessories are compliant
to UL 61010-1, CAN/CSA-C22.2 and certified for installation in hazardous
locations according to UL Class I, Division 2 (Groups A, B, C, and D).
The supply voltage 24 V DC for the system must be separated at least by reinforced
insulation from all hazardous voltages. This requirement is specified in the UL
61010-1 standard, third edition.
The system is not intended for direct connection to telecommunication circuits. The
system is designed for indoor use only.

EXPLOSION HAZARD
This equipment is suitable for use in Class I, Division 2 (Groups A, B, C, D) or
non-hazardous locations only.
Do not disconnect while circuit is live unless area is known to be non-hazardous.
Substitution of any components may impair suitability for class 1, division 2.
Batteries must only be changed in an area known to be non-hazardous.

M&I – AC 900F Controller 123

Modules and accessories Section 9 Technical Data

Modules and accessories

General technical data

Ambient conditions
Shock IEC/EN 60068-2-27
Free fall IEC/EN 60068-2-32
Vibrations IEC/EN 60068-2-6
Temperature changes IEC/EN 60068-2-14
Damp heat IEC/EN 60068-2-30
95% at +55 °C, no condensation
Degree of pollution 2
Operating altitude max. 2000 m above sea level
higher altitudes upon request
EMC
Emitted interference IEC/EN 61000-6-4
Electromagnetic fields IEC/EN 61000-4-3

The currently available UL approvals (cULus, UL Class 1 Div 2) for modules and
accessories are only valid for operation in environments with an ambient temper-
ature of 0 to 60 °C.
An adaptation of the approval to an extended temperature range of -20 to +70 °C
has been applied for at UL. The application does not include the CM 772F and TA
724F modules.

124 M&I – AC 900F Controller

Section 9 Technical Data PM 902F, PM 901F

PM 902F, PM 901F

Application
PM 902F, Standard CPU module (8 MB, 4x ETH, 800 MHz)
PM 901F, Lite CPU module (3 MB, 3x ETH, 400 MHz)

Electrical data
Rated input voltage 24 V DC
Input voltage range 19.2 - 32.5 V AC
Rated input current 1A
Power dissipation in module < 18 W
External fuse, recommended 4 AT as per IEC/EN 60127-2/V
Fuse breaking capacity high
DC-IN connector 5-pin, pluggable, spring connection
Power supply cable, recommended 0.75 mm2, L > 1 m

Mechanical data
Dimensions W x H x D 227 x 152 x 95 mm
Weight 1.07 kg
Type of protection IP 20

Power
CPU pulse frequency 800 MHz, PM 902F
400 MHz, PM 901F

Program memory
Application and data, battery- 8 MB, PM 902F
buffered 3 MB, PM 901F
Application and data 16 MB

RAM buffering
Buffer time at Ta +40 °C > 2 years
Residual buffer time 14 days, after warning
Real-time clock with buffer battery Yes

M&I – AC 900F Controller 125

PM 902F, PM 901F Section 9 Technical Data

Ethernet
Number of ports 4, PM 902F
3, PM 901F
Transmission rate 10/100 MBit/s
Auto-Negotiation Yes
Auto MDI-X Yes
Connection RJ45 female connector

Serial interface
Number of ports 2
Physical interface RS 232/485
Transmission rate 0.6 - 38.4 kBit/s
Connector 9-pin, pluggable, spring connection

Diagnostic interface (radio clock)

Physical interface RS 232
Transmission rate 19.2 kBit/s (default); 9.6 kBit/s
Connector D-SUB, 9-pin, male connector

I/O bus
Number of I/O modules 10
Supported I/O S700 I/O modules

Coupler bus
Number of slots 2
Hot-plug function Yes
Currently supported modules CI 930F, CI 773F, CM 772F

SD card reader/writer
Supported SD cards
Standard size SD, 32 x 24 mm
with adapter miniSD, microSD
Capacity max. 32 GB
Specification SD, SDHC
Supported file system FAT, FAT32

126 M&I – AC 900F Controller

Section 9 Technical Data PM 902F, PM 901F

Control and display elements

Switches and buttons RUN/STOP, TOGGLE, RESET
Status indicators, multi-colored LEDs PWR, ERR, RUN, P/S, BATT
TD 951F display unit Accessory, optional

Ambient temperature
Operation
PM 902F, 3BDH...R0005 - 20 ... +70 °C, HW-Rev. ≥ 06.00
PM 902F, 3BDH...R0001 - 20 ... +70 °C, HW-Rev. ≥ 03.00
PM 901F - 20 ... +70 °C
Storage - 40 ... +85 °C
Storage (installed TD 951F) - 25 ... +85 °C

Certificates
Declaration of conformity CE
ANSI/ISA 71.04-1985 G3
Approvals
PM 902F cULus
UL Class 1 Div 2 (groups A, B, C, D)
EAC
PM 901F In preparation

M&I – AC 900F Controller 127

CI 930F Section 9 Technical Data

CI 930F

Application
CI 930F PROFIBUS DP Master module

Fieldbus
Transmission protocol PROFIBUS-DP Master V0/V1
Transmission rate 9.6 kBit/s to 12 MBit/s
Transmission standard EIA RS-485 as per EN 50170, potential-
free
Number of slaves max. 126
Dual-port memory 64 kB

Line redundancy
Field bus connector (line A and B)
CI 930F 3BDH...R0005 two D-SUB female connectors, 9-pin
CI 930F 3BDH...R0001 D-SUB and RJ45 (TU 951F required)

Electrical data
Current consumption 80 mA, via DC-IN of the CPU module
Power dissipation 1.8 W

Mechanical data
Dimensions W x H x D
CI 930F 3BDH...R0005 28 x 152 x 75 mm
CI 930F 3BDH...R0001 28 x 135 x 75 mm
Weight 117 g
Type of protection IP 20

Status indicators
LEDs PWR, STA, RUN, A, B

128 M&I – AC 900F Controller

Section 9 Technical Data CI 930F

Ambient temperature
Operation - 20 ... +70 °C
Storage - 40 ... +85 °C

Certificates
Declaration of conformity CE
ANSI/ISA 71.04-1985 G3
Approvals cULus
UL Class 1 Div 2 (Groups A, B, C, D)
EAC

M&I – AC 900F Controller 129

CI 773F Section 9 Technical Data

CI 773F

Application
CI 773F PROFIBUS DP Master module

Fieldbus
Transmission protocol PROFIBUS-DP Master V0/V1
Transmission rate 9.6 kBit/s to 12 MBit/s
Transmission standard EIA RS-485 as per EN 50170, potential-
free
Number of slaves max. 126
Dual-port memory 16/64 kB, use depending on CPU module
Fieldbus connection D-SUB, 9-pin, female connector (F)

Electrical data
Current consumption 80 mA, via DC-IN of the CPU module
Power dissipation 1.8 W

Mechanical data
Dimensions W x H x D 28 x 135 x 75 mm
Weight 102 g
Type of protection IP 20

Status indicators
LEDs PWR, STA, RUN, L

Ambient temperature
Operation - 20 ... +70 °C
Storage - 40 ... +70 °C

Certificates
Declaration of conformity CE
ANSI/ISA 71.04-1985 G3

130 M&I – AC 900F Controller

Section 9 Technical Data CI 773F

Approvals cULus
UL Class 1 Div 2 (Groups A, B, C, D)
EAC

M&I – AC 900F Controller 131

CM 772F Section 9 Technical Data

CM 772F

Application
CM 772F PROFIBUS DP Master module

Fieldbus
Transmission protocol PROFIBUS-DP Master V0/V1
Transmission rate 9.6 kBit/s to 12 MBit/s
Transmission standard EIA RS-485 as per EN 50170, potential-
free
Number of slaves max. 126, depending on the number of
I/O data
Dual-port memory 8 kB
Fieldbus connection D-SUB, 9-pin, female connector

Electrical data
Current consumption 50 mA, via DC-IN of the CPU module
Power dissipation 1.2 W

Mechanical data
Dimensions W x H x D 28 x 135 x 75 mm
Weight 96 g
Type of protection IP 20

Status indicators
LEDs PWR, RDY, RUN, STA, ERR

Ambient temperature
Operation 0 ... +60 °C
Storage - 25 ... +75 °C

132 M&I – AC 900F Controller

Section 9 Technical Data CM 772F

Certificates
Declaration of conformity CE
Approvals cULus
UL Class 1 Div 2 (Groups A, B, C, D)
EAC, GL

M&I – AC 900F Controller 133

CI 910F Section 9 Technical Data

CI 910F

Applications
CI 910F CAN Bus module

Fieldbus
Transmission protocol ABB CAN Bus protocol
Transmission rate max. 1 MBit/s
Settings for rack-based I/O modules 100 kBit/s or 500 kBit/s, depending on
bus length
CAN interface acc. to ISO/DIS 11898 and CAN 2.0
Electrical isolation CAN channels to system
Number of I/O racks max. 5
Dual-port memory 256 kB
Fieldbus connection D-SUB, 9-pin, female connector (F)

Electrical data
Current consumption 90 mA, via DC-IN of the CPU module
Power dissipation 1.9 W

Mechanical data
Dimensions W x H x D 28 x 152 x 75 mm
Weight 178 g
Type of protection IP 20

Status indicators
LEDs PWR, STA, L1, L2 , L3

Ambient temperature
Operation - 20 ... +70 °C
Storage - 40 ... +85 °C

134 M&I – AC 900F Controller

Section 9 Technical Data Certificates

Certificates
Declaration of conformity CE
Approvals (pending) ANSI/ISA 71.04-1985 G3
cULus
UL Class 1 Div 2 (Groups A, B, C, D),
EAC

M&I – AC 900F Controller 135

TD 951F Section 9 Technical Data

TD 951F

Application
TD 951F Display unit (dot-matrix)

Display
Design Dot-matrix LCD display
Resolution 128 x 64 dots

Mechanical data
Dimensions W x H x D 58 x 110 x 22 mm
Weight 88 g
Type of protection IP 20

Electrical data
Current consumption 15 mA
Power dissipation 0.35 W

Ambient temperature
Operation - 20 ... +70 °C
Storage - 25 ... +70 °C

Certificates
Declaration of conformity CE
ANSI/ISA 71.04-1985 G3
Approvals cULus
UL Class 1 Div 2 (Groups A, B, C, D)
EAC

136 M&I – AC 900F Controller

Section 9 Technical Data TA 951F

TA 951F

Application
TA 951F Battery for RAM buffering

Mechanical data
Design Lithium
Size 2/3 A
Weight 15 g

Electrical data
Rated voltage 3V
Capacity 1200 mAh
Battery type Non-rechargeable

Ambient temperature
Operation - 40 ... +70 °C
Storage - 40 ... +70 °C

Certificates
Declaration of conformity CE
ANSI/ISA 71.04-1985 G3
Approvals cULus
UL Class 1 Div 2 (Groups A, B, C, D)
EAC

M&I – AC 900F Controller 137

TA 924F Section 9 Technical Data

TA 924F

Application
TA 924F Coupler bus dummy

Mechanical data
Dimensions W x H x D 28 x 152 x 75 mm
Weight 78 g
Type of protection IP 20

Ambient temperature
Operation - 20 ... +70 °C
Storage - 40 ... +85 °C

Certificates
Declaration of conformity CE
Approvals cULus
UL Class 1 Div 2 (Groups A, B, C, D)
EAC

138 M&I – AC 900F Controller

Section 9 Technical Data TA 724F

TA 724F

Application
TA 724F Coupler bus dummy

Mechanical data
Dimensions W x H x D 28 x 135 x 75 mm
Weight 50 g
Type of protection IP 20

Ambient temperature
Operation 0 ... +60 °C
Storage - 25 ... +75 °C

Certificates
Declaration of conformity CE
Approvals cULus
UL Class 1 Div 2 (groups A, B, C, D)
EAC

M&I – AC 900F Controller 139

Switch-mode power supply units and accessories Section 9 Technical Data

Switch-mode power supply units and accessories

General technical data

Ambient conditions
Vibrations IEC/EN 60068-2-6
Shock IEC/EN 60068-2-27
Damp heat IEC/EN 60068-2-3
93% at 40 °C, no condensation
Installation altitude max. 2000 m above sea level
Climate class 3K3 IEC/EN 60721
Degree of pollution 2

Standards and directives

Product standard IEC/EN 61204
Low voltage directive 2006/95/EC
EMC directive 2004/108/EC
Electrical safety EN 50178, EN 60950, UL 60950,
UL 508
Safety extra low voltage SELV (EN 60950)

EMC
Interference immunity IEC/EN 61000-6-2
Emitted interference IEC/EN 61000-6-3, class B

140 M&I – AC 900F Controller

Section 9 Technical Data CP-C 24/5.0

CP-C 24/5.0

Application
CP-C 24/5.0 Switch-mode power supply unit

L and N inputs
Rated voltage 110 - 240 V AC
AC voltage range 85 - 264 V AC
Rated current 1.3 - 0.6 A
DC voltage range 100 - 350 V DC (external fuse)
Frequency range 47 - 63 Hz
Power consumption typ. 135 W
Efficiency factor max. 88%
Hold-up time > 100 ms
Internal fuse (equipment protection) 4 A, delayed-action
Inrush current < 23 A
l2t at cold start 0.9 A2s
Parallel connection max. 5 devices, no symmetrical current
Protection against transient overvoltage Varistors
Reactive power compensation (PFC) Yes

L+ and L- outputs
Rated voltage 24 V DC +/- 0.5%
Output voltage adjustment range 22 - 28 V
Rated current at Ta < 60 °C 5A
Current derating at 60 °C < Ta ≤ 70 °C - 2.5% per K temperature increase
Peak current (power reserve) < 7.25 A at Ta < 40 °C
Rated power 120 W
Power dissipation < 15 W
Short-circuit current limiting 11 A
Starting of capacitive loads Unlimited
Resistance to Short-circuit, no load and overload

Status indicators
OUTPUT OK, green LED Output voltage OK

M&I – AC 900F Controller 141

CP-C 24/5.0 Section 9 Technical Data

Mechanical data
Dimensions W x H x D 60 x 130 mm x 137 mm
Weight approx. 0.96 kg
Installation DIN rail
Mounting position Horizontal
Minimum distance between devices > 10 mm horizontal, > 80 mm vertical
Type of protection IP 20

Electrical connection
Wire size 0.2 - 2.5 mm2
Wire type Rigid, finely stranded with/without wire
end ferrule
Protection class I

Ambient temperature
Operation with derating - 25 ... +70 °C
Operation at rated current 0 ... +60 °C
Storage - 40 ... +85 °C

Certificates
Declaration of conformity CE
Approvals cULus
UL Class 1 Div 2 (Groups A, B, C, D)
EAC

The voltage as well as the input and output wiring must comply with the
requirements specified for Class I, Div. 2 - Article 501-10(B) (1) NEC.

142 M&I – AC 900F Controller

Section 9 Technical Data CP-C 24/10.0

CP-C 24/10.0

Application
CP-C 24/10.0 Switch-mode power supply unit

L and N inputs
Rated voltage 110 - 240 V AC
AC voltage range 85 - 264 V AC
Rated current 2.6 - 1.2 A
Frequency range 47 - 63 Hz
DC voltage range 100 - 350 V DC (external fuse)
Power consumption typ. 269 W
Efficiency factor max. 88%
Hold-up time > 40 ms
Internal fuse (equipment protection) 6.3 A, delayed-action
Inrush current < 33 A
l2t at cold start 0.2 A2s
Parallel connection max. 5 devices, no symmetrical current
Protection against transient overvoltage Varistors
Reactive power compensation (PFC) Active

L+ and L- outputs
Rated voltage 24 V DC +/- 0.5%
Adjustment range 22 - 28 V
Rated current at Ta < 60 °C 10 A
Current derating at 60 °C < Ta ≤ 70 °C - 2.5% per K temperature increase
Peak current (power reserve) < 12.25 A at Ta < 40 °C
Rated power 240 W
Power dissipation < 29 W
Short-circuit current limiting 19 A
Starting of capacitive loads Unlimited
Resistance to Short-circuit, no load and overload

Status indicators
OUTPUT OK, green LED Output voltage OK

M&I – AC 900F Controller 143

CP-C 24/10.0 Section 9 Technical Data

Mechanical data
Dimensions W x H x D 90 x 130 x 137 mm
Weight approx. 1.34 kg
Installation DIN rail
Mounting position Horizontal
Minimum distance between devices > 10 mm horizontal, > 80 mm vertical
Type of protection IP 20

Electrical connection
Wire size 0.2 - 2.5 mm2
Wire type Rigid, finely stranded with/without wire
end ferrule
Protection class I

Ambient temperature
Operation with derating - 25 ... +70 °C
Operation at rated current 0 ... +60 °C
Storage - 40 ... +85 °C

Certificates
Declaration of conformity CE
Approvals cULus
UL Class 1 Div 2 (Groups A, B, C, D)
EAC

The voltage as well as the input and output wiring must comply with the
requirements specified for Class I, Div. 2 - Article 501-10(B) (1) NEC.

144 M&I – AC 900F Controller

Section 9 Technical Data CP-C RU

CP-C RU

Application
CP-A RU Redundancy unit

Input (+) and (-)

Rated voltage 24 V DC
Voltage range 10 - 40 V AC
Rated current per channel 1 - 20 A
Peak current per channel 30 A for 300 s
Protection against transient overvoltage Yes

L+ and L- outputs
Rated voltage 24 V DC
Rated current at Ta < 60 °C 1 - 40 A
Current derating at 60 °C < Ta ≤ 70 °C - 2.5% per K temperature increase
Peak current 60 A for 300 s
Energy recovery resistance < 40 V
Voltage drop typ. 0.6 W

Mechanical data
Dimensions W x H x D 60 x 130 x 137 mm
Weight 0.89 kg
Installation DIN rail
Mounting position Horizontal
Minimum distance between devices > 10 mm horizontal, > 50 mm vertical
Type of protection IP 20

Electrical connection
Wire size
Finely stranded with wire end 2.5 - 10 mm2
errule
Finely stranded without wire 0.5 - 10 mm2
end ferrule

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CP-C RU Section 9 Technical Data

Rigid 0.5 - 16 mm2

Protection class III

This device is rated for the connection to safety extra low voltage. If no
safety extra low voltage is applied at the input side, the screw at the
housing side can be used for earthing the housing
(Protection class I).

Ambient temperature
Operation with derating - 25 ... +70 °C
Operation at rated current - 25 ... +60 °C
Storage - 40 ... +85 °C

Certificates
Declaration of conformity CE
Approvals cULus,
EAC

146 M&I – AC 900F Controller

Section 9 Technical Data CP-C MM

CP-C MM

Application
CP-C MM Messaging module for CP-C

Input - supply circuits

Rated voltage 110 - 240 V AC / 100 - 350 V DC
Voltage range 70 - 264 V AC / 80 - 350 V DC
Power consumption typ. 2.5 VA / 1.5 W

Input - control circuit

Type of triggering Volt-free triggering
Control input, REMOTE OFF control Remote OFF
function
Switching-off threshold R ≤ 1 kΩ
Switching-on threshold R ≥ 10 kΩ
Input current Typ. 1 mA (200 mA for 200 µs)

Output
Relay with change-over contacts 11-12/14, 21-22/24
Functional principle Closed-circuit principle
Max. switching voltage / current 250 V / 1 A
Min. switching voltage / current 24 V / 10 mA
Rated current at 24 V / 230 V 1 A, ohmic and inductive load
Switching cycle 0.1 x 106

Monitoring function
Monitoring Low voltage detection
Input threshold value(s) 85 V AC / 90 V DC
Output threshold value(s) 20 V DC

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CP-C MM Section 9 Technical Data

Status indicators
REMOTE OFF, green LED Input ≤ 1kΩ
INPUT OK, green LED Supply voltage OK
OUTPUT OK, green LED Output voltage OK

Mechanical data
Dimensions (W x H x D ) 56.5 x 54 x 24 mm
Weight 65 g
Type of protection IP 20

Electrical connection
Wire size
Finely stranded with wire end 0.2 - 2.5 mm2
ferrule
Finely stranded without wire end 0.2 - 2.5 mm2
ferrule
Rigid 0.2 - 4 mm2
Protection class ||

Ambient temperature
Operation - 25 ... +70 °C
Storage - 40 ... +85 °C

Certificates
Declaration of conformity CE
Approvals cULus
EAC

148 M&I – AC 900F Controller

Section 9 Technical Data CP-A CM

CP-A CM

Application
CP-A CM Control module for CP-A RU

Inputs
Rated voltage 24 V DC
Voltage range 13 - 30 V AC
Power consumption approx. 1 W

Output
Relay with change-over contact 11 - 12/14, 21 - 22/24
Functional principle Closed-circuit principle
Max. switching voltage / current 250 V / 1 A
Min. switching voltage / current 24 V / 10 mA
Rated current at 24 V / 230 V 1 A, ohmic and inductive load
Switching cycle 0.1 x 106

Monitoring function
Monitoring Low voltage detection
Measured voltage Rated operating voltage
Threshold values 14 - 24 V

Operating status displays

IN1, green LED Input voltage > threshold values = OK
IN2, green LED Input voltage > threshold values = OK
Value of channel 2 = no error Output voltage > 3 V = OK

Mechanical data
Dimensions (W x H x D ) 56.5 x 54 x 24 mm
Weight 63 g
Type of protection IP 20

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CP-A CM Section 9 Technical Data

Electrical connection

Wire sizes
Finely stranded with wire end 0.2 - 2.5 mm2
ferrule
Finely stranded without wire end 0.2 - 2.5 mm2
ferrule
Rigid 0.2 - 4 mm2
Protection class ||

Ambient temperature
Operation - 25 ... +70 °C
Storage - 40 ... +85 °C

Certificates
Declaration of conformity CE
Approvals cULus
EAC

150 M&I – AC 900F Controller

Section 9 Technical Data CP-A CM

The following modules and accessories are designed according to EN/IEC

61131-2 standards.
Unless otherwise stated in the article description, modules and accessories are
compliant to UL 61010-1, CAN/CSA-C22.2 and certified for installation in
hazardous locations according to UL Class I, Division 2 (Groups A, B, C and D).
The supply voltage 24 V DC for the system must be separated at least by reinforced
insulation from all hazardous voltages. This is according to the Standard UL 61010-
1 third edition. The system is not intended for direct connection to
Telecommunication circuits. The system is for indoor use only.

EXPLOSION HAZARD
This equipment is suitable for use in Class I, Division 2 (Groups A, B, C, D) or
non-hazardous locations only.
Do not disconnect while circuit is live unless area is known to be non-hazardous.
Substitution of any components may impair suitability for class 1, division 2.
Batteries must only be changed in an area known to be non-hazardous.

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CP-A CM Section 9 Technical Data

152 M&I – AC 900F Controller

 Index
B N
Battery ............................................................. 13 Network interfaces ......................................... 25
Bus systems ..................................................... 14
O
C Overview ........................................................ 11
Communication interface ................................ 19
Control module R
Electrical connection ............................... 55 Redundancy .................................................... 16
Controller - Overview ..................................... 11 Redundancy unit
Coupler bus ..................................................... 13 Electrical connection ............................... 53
CP-A CM ........................................................ 57
Electrical connection ............................... 55 S
CP-C MM SER1, SER2 ................................................... 26
Electrical connection ........................ 54, 57
CPU module .................................................... 13

D
Diagnostic interface (DIAG) ........................... 28
Diagnostic interface transmission rate .......... 102
Display and control elements .......................... 30
Dummy coupler .............................................. 17

E
Ethernet ........................................................... 94

I
I/O bus ...................................................... 13, 25
Interfaces ......................................................... 13

M
Main memory .................................................. 13
Messaging module
Electrical connection ............................... 57

M&I – AC 900F Controller 153

Index

154 M&I – AC 900F Controller

Contact us

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