Product Guide (3BSE026021R201)

ControlIT
AC 800M
Version 2.1
Controller Hardware
Product Guide
ControlIT
AC 800M
Version 2.1
Controller Hardware
Product Guide
NOTICE
The information in this document is subject to change without notice and should not be
construed as a commitment by ABB Automation Technology Products. ABB Automation
Technology Products. assumes no responsibility for any errors that may appear in this
document.
In no event shall ABB Automation Technology Products be liable for direct, indirect, spe-
cial, incidental or consequential damages of any nature or kind arising from the use of
this document, nor shall ABB Automation Technology Products be liable for incidental or
consequential damages arising from use of any software or hardware described in this
document.
This document and parts thereof must not be reproduced or copied without written per-
mission from ABB Automation Technology Products, 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 89/336/EEC and in Low
Voltage Directive 72/23/EEC.
Copyright © 1999-2003 ABB Automation Technology Products.

All rights reserved.
Release: March 2003

Document number: 3BSE 026 021 R201
TRADEMARKS
Registrations and trademarks used in this document include:
IndustrialIT Registered trademark of ABB Ltd, Switzerland.

IT
Control Registered trademark of ABB Ltd, Switzerland.
OperateIT Registered trademark of ABB Ltd, Switzerland.
CompactFlash Trademark of SanDisk Corporation, U.S.A.
Foundation Fieldbus Trademark of Fieldbus Foundation, U.S.A.
Modbus Trademark of Gould Electronics Inc., U.S.A.
PROFIBUS DP Registered Trademark of PROFIBUS International (P.I.).
INSUM Registered Trademark of ABB Schaltanlagentechnik GmbH,

Germany.
Siemens and all Siemens-products mentioned in this publication are trademarks

of Siemens AG, Germany.
TABLE OF CONTENTS
About This Book

Intended Use of This Book................................................................................................9
Use of Caution, Information, and Tip Icons ......................................................................9
Related Documentation ...................................................................................................10
Section 1 - Overview
Introduction .....................................................................................................................15
Product Benefits ..............................................................................................................17
Features............................................................................................................................18
Section 2 - Functional Description

Processor Unit - General .................................................................................................19
Processor Unit - Redundancy ..........................................................................................20
Communication ...............................................................................................................22
Battery Back-up...............................................................................................................22
Power Supply...................................................................................................................24
I/O System .......................................................................................................................26
Drive System ...................................................................................................................30
Installation .......................................................................................................................32
Configuration...................................................................................................................33
Section 3 - Software Components

General ............................................................................................................................35
3BSE 026 021 R201 5

Table of Contents
Section 4 - Hardware Components

Processor unit - Single Configuration ............................................................................. 37
Processor Unit - Redundant Configuration ..................................................................... 39
Communication Interfaces .............................................................................................. 40
PROFIBUS DP Interface - CI851 and TP851 ..................................................... 40
FOUNDATION Fieldbus H1 Interface - CI852 and TP852 ................................ 42
RS232-C Interface - CI853 and TP853................................................................ 44
PROFIBUS DP-V1 Interface - CI854 and TP854 ............................................... 46
MasterBus 300 Interface - CI855 and TP853 ...................................................... 48
S100 I/O Interface - CI856 and TP856 ................................................................ 50
INSUM Interface - CI857 and TP853.................................................................. 52
Battery Back-up .............................................................................................................. 54
Power Supply Components - SD821, SD822, SD823, SS822 ........................................ 56
Mounting Rails................................................................................................................ 59
CEX-bus Extension and Termination.............................................................................. 60
Modulebus Extension and Termination........................................................................... 62
RCU Link Cable and Termination .................................................................................. 62
Section 5 - Mechanical Design

Cabinet Design ................................................................................................................ 63
Mounting Dimensions for proper Ventilation ................................................................. 67
Section 6 - Technical Data and Performance

Technical Data................................................................................................................. 69
Processor Unit - PM8xx and TP830 .................................................................... 69
PROFIBUS DP Interface - CI851 and TP851 ..................................................... 75
FOUNDATION Fieldbus H1 Interface - CI852 and TP852 ................................ 76
RS232-C Interface - CI853 and TP853................................................................ 77
PROFIBUS DP-V1 Interface - CI854 and TP854 ............................................... 78
MasterBus 300 Interface - CI855 and TP853 ...................................................... 79
S100 I/O Interface - CI856 and TP856 ................................................................ 80
INSUM Interface - CI857 and TP853.................................................................. 81
External Battery Back-up Unit - SB821 .............................................................. 82
6 3BSE 026 021 R201

Table of Contents
Power Supply Components - SD821,SD822,SD823,SS822 ...............................82

DIN Rail and Al-profile .......................................................................................83
Section 7 - Ordering
Ordering Procedure .........................................................................................................85
Licenses ......................................................................................85
Price List Structure ..........................................................................................................85
Appendix A - Power Consumption

General ............................................................................................................................89
Current Consumption and Power Dissipation .................................................................90
Appendix B - Recommended Components

Recommended Components............................................................................................93
Appendix C - Environmental Data

Environmental Data for AC 800M Products ...................................................................99
Climatic and Mechanical Environmental Conditions ........................................100
CE Compliance ..................................................................................................102
Electromagnetic Compatibility and Main Voltage Conditions ..........................103
Installation Requirements...................................................................................105
The Laying of Field Cables................................................................................105
Types of Field Cables.........................................................................................105
Lightning Strike Protection ................................................................................106
Inductive Load Suppression ...............................................................................106
INDEX ........................................................................................................................107
3BSE 026 021 R201 7

Table of Contents
8 3BSE 026 021 R201

About This Book
Intended Use of This Book
This Product guide does not contain last-minute product information and updates
which might affect functionality and/or performance. For information on late
changes and restrictions, please refer to the Release Notes.
Use of Caution, Information, and Tip Icons

This publication includes 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:
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
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 Caution notices.
3BSE 026 021 R201 9

Related Documentation About This Book
Related Documentation
Table 1 on page 10 details the documentation and media applicable to the AC 800M
Controller. Table 2 on page 13 details the media associated with the AC 800M
Controller.
Table 1. Related Documentation
Category Title Description

Product AC 800M/C Connect, Product Guide Description of the AC 800M/C Connect
Guides product (integration with Process Portal
A and other IndustrialIT suites).
Control Software and The product guide is intended to be
Control Builder M, Product Guide used as an introduction to the new
Control Software and Control Builder M
versions, as well as a reference when
discussing technical solutions with
customers.
S800 I/O, Product Guide Description of the S800 I/O family.
Hardware AC 800M Controller Hardware Describes how to install, configure and
Hardware and Operation perform maintenance on the AC 800M
Controller Hardware.
AC 800M/C PROFIBUS DP Describes how to install and wire a
User’s Guide PROFIBUS DP I/O System.
Wiring and Installation
Terminal Diagrams Gives information about the
AC 800M inputs/outputs of the AC 800M units.
The diagrams can be used as templates
for a connection diagram.
S800 I/O General Information and Describes the general installation and
Installation configuration for the S800 I/O system.
User’s Guide
10 3BSE 026 021 R201

About This Book Related Documentation

Hardware S800 I/O units and Termination Units Describes the standard I/O units and
(cont.) User’s Guide termination units in the S800 I/O
system.
S800 I/O units and Termination Describes I/O units and termination
Units, with Intrinsic Safety Interface units with I.S. interface within the S800
User’s Guide I/O system.
S800 I/O Fieldbus Communication, Describes the PROFIBUS DP FCI within

Interface for PROFIBUS DP the S800 I/O system.
User’s Guide
FOUNDATION Fieldbus, Wiring and Describes how to install and wire
Installation a FOUNDATION Fieldbus H1.
Terminal Diagrams S800 I/O Gives information about the
inputs/outputs of the S800 I/O units. The
diagrams can be used as templates for
an I/O connection diagram.
Software Control IT for Gives release-related information about
AC 800M/C Release Notes Control IT 3.1, including new/changed
features and how to upgrade from
previous versions.
AC 800M/C Installation and start-up of the various
Control Builder M Getting Started, software packages that are contained
Introduction and Installation on the Control Software for AC 800M/C
CD.
This manual also provides a tutorial
on how to create applications.
3BSE 026 021 R201 11


Software AC 800M/C Communication, Describes design principles and
(cont.) Protocols and Design protocols used in the Control Network.
The focus is on planning and design
issues and the manual does not deal
with wiring or installation issues.
AC 800M/C Application A handbook for technicians who intend
Programming, Strategy and Design to program ControlIT for AC 800M/C
products using the programming tool,
Control Builder M. It gives strategic hints
and directions in project design,
different programming languages,
organizing code, and practical hints
when programming and commissioning.
AC 800M/C FOUNDATION Fieldbus Details how the FOUNDATION Fieldbus
I/O system is integrated with controllers.
AC 800M PROFIBUS DP Details how the PROFIBUS I/O system
User’s Guide is integrated with controllers.
Functional Description
12 3BSE 026 021 R201

About This Book Related Documentation
Table 2. Related Media

Internet PROFIBUS Web Site Standard, commercially available
PROFIBUS DP documentation.
FOUNDATION Fieldbus Web Standard, commercially available
Site FOUNDATION Fieldbus
(Fieldbus Online) documentation.
Media ControlIT for AC 800M/C Control Builder, Functions &

Products Firmware on a CD.
ControlIT for AC 800M/C User documentation manuals and
Documentation on-line help.
Control Builder On-Line Help User documentation and information
on-line.
3BSE 026 021 R201 13

14 3BSE 026 021 R201

Section 1 Overview
Introduction
AC 800M can be defined as a hardware platform consisting of individual hardware
units. AC 800M hardware platform can be programmed to perform multiple
functions, depending on the specific unit configuration and operating system
selected.
The hardware units which form the AC 800M Controller are:
• Processor units (including baseplate)
• Communication interfaces for different protocols (including baseplates)
• Power supply units, providing various power output levels
• Battery back-up unit
Once configured, the AC 800M hardware platform effectively becomes
the AC 800M Controller.
Equipped with the specified Control Software, the AC 800M Controller can be used
for all kinds of process and industrial automation applications. With Control
Software, the controller can act either as a stand alone process controller or as a
controller, performing local control tasks, in a control network consisting of many
interconnected computers.
The AC 800M Controller is delivered without firmware. To provide the controller
with Control Software, it will first be necessary to load the firmware and create
the application separately by using the Control Builder M engineering tool.
3BSE 026 021 R201 15

Introduction Section 1 Overview
The AC 800M Controller consists of a selection of units mounted on horizontal DIN

rails, as shown in Figure 1 on page 16, which can, if required, be housed within
an enclosure.
The majority of units consist of a base mounting plate and a removable cover, which
are attached to each other by means of screws. The baseplate, which is always
mounted on the DIN rail, carries the majority of the connections to the processor,
power supplies and communication interfaces, as well as to the external buses and
systems.
AC 800M I/O-System
Communication Processor S800 I/O

interface unit unit
Figure 1. Example of an AC 800M Controller with a S800 I/O Unit
16 3BSE 026 021 R201

Section 1 Overview Product Benefits
Product Benefits
Some of the benefits of the AC 800M Controller are:
• Flexibility, the AC 800M Controller can be ordered as individual units which
may be mounted in accordance with the customers own requirements.
• Extremely small footprint.
• Simple DIN rail attachment / detachment procedures, using the unique slide
& lock mechanism.
• Modularity, allowing for step-by-step expansion. You only pay for what you
require at the present time.
• Reliability and simple fault diagnosis procedures.
• CPU redundancy for higher availability.
• Built-in redundant Ethernet Communication ports.
• Built-in RS232-C communication ports.
• Low power consumption, thus no external fans required.
• Flexible process connection, using either local I/O or standard fieldbuses.
3BSE 026 021 R201 17

Features Section 1 Overview
Features
The major features of the AC 800M are:
• Support for FOUNDATION Fieldbus H1.
• Support for PROFIBUS DP and DP-V1fieldbus.
• Support for connection to S100 I/O.
• Support for connection to INSUM via Gateway (Ethernet/LON).
• Support for connection to MasterBus 300.
• Support for Field Device Tool (FDT) and Device Type Manager (DTM)
concept for tool routing of HART instruments.
• Support for ABB Drives.
• Extensive availability.
• CPU redundancy (PM861/PM864).
• Quick and simple fault-finding with the aid of LEDs on each unit / channel.
• Use of industry standard power supply voltage - 24V d.c.
• Incorporation of a wide variety of communication possibilities.
• Hardware based on standards for optimum communication connectivity
(Ethernet, PROFIBUS DP).
• High performance and large application memory.
• Built-in redundant Ethernet channels.
• Built-in RS232-C channels.
• Full EMC certification.
• Easy mounting on standard DIN rail.
• IP20 Class protection without the requirement for enclosures.
• Built-in battery back-up of memory.
• External battery back-up option available.
18 3BSE 026 021 R201

Section 2 Functional Description
Processor Unit - General

The processor unit consists of two parts:
• Processor unit, PM856/PM860/PM861/PM864, equipped with power supply
and CPU-boards
• Baseplate, TP830, with a unit termination board.
The CPU board contains the microprocessor and the RAM-memory. The memory
holds an executable version of the firmware, the controller system configuration and
an application program.
The processor unit also has an optical Modulebus used for connecting additional
clusters of S800 I/O, and a connector housing for a plug-in CompactFlash card,
(not included is this release and intended for future use).
The baseplate has two RJ45 Ethernet ports, (CN1, CN2), for connection to the
Control Network, and two RJ45 serial ports, (COM3, COM4). One of the serial
ports, (COM3), is an RS232-C port with modem control signals whereas the other,
(COM4), is isolated and used for the connection of a configuration tool.
Both the electrical Modulebus and the communication expansion bus (CEX-bus)
connectors are mounted on the baseplate. The built-in electrical Modulebus can be
used in single CPU configuration for connecting one cluster of S800 I/O units
directly to the baseplate. The CEX-bus is used for extending the on-board
communication ports with communication interface units.
All baseplates are provided with a unique Ethernet address which provides every
CPU with a hardware identity. The address can be found on the Ethernet address
label attached to the TP830 baseplate, as shown in Figure 2 on page 21.
3BSE 026 021 R201 19

Processor Unit - Redundancy Section 2 Functional Description
Processor Unit - Redundancy

Processor unit redundancy is available. In this case, the controller contains two
processor units, each including memory for system and application software. One
unit is acting as primary, the other is backup (hot stand-by). The primary processor
unit controls the process. The backup stands by to take over in case of a fault in the
primary. The changeover is done bumplessly and in less than 10 ms. During the
changeover, the process outputs are frozen.
Following a changeover, the system operates as a system without redundancy with
only one processor unit in operation. You can replace the malfunctioning processor
unit while the system is running. After the replacement is carried out, the system
once again has a redundant processor unit.
If an error arises in the backup unit, you can also replace the backup unit while the
system is running.
Errors which occur in the backup unit can never affect the primary unit’s operation.
The primary unit and the backup unit are logically separated from one another.
Hardware errors in the primary processor unit cause the system to perform a correct
changeover. These hardware errors are "single errors."
The application programming and the communication are totally unaffected by the
redundancy.
The serial port COM3, can not be used in redundant CPU configuration.
S800 I/O units are connected to the two CPUs by the optical Modulebus. The built-
in electrical Modulebus on the baseplates can not be used for connection of
S800 I/O in redundant CPU configuration.
20 3BSE 026 021 R201

Section 2 Functional Description Processor Unit - Redundancy
LED
Status
Indicators
INIT
Push button
RCU Link
Connector
(PM861/PM864)
Rx/Tx
Optic Ports
Tx / Rx
Status
Indicators External Battery
Supply Socket
Communication
Ports
Serial Number
Base Plate
SE00263650
(TP830)
ETHERNET: 0000230A008E
Ethernet Address
Figure 2. Processor Unit - General View (here shown with PM861 and TP830)
3BSE 026 021 R201 21

Communication Section 2 Functional Description
Communication
The number of ports and protocols, provided by the processor unit, can be expanded
by adding communication units to the CEX-bus.
Examples of unit types that may be connected to the CEX-bus are as follows:
• FOUNDATION Fieldbus
• PROFIBUS DP and DP-V1
• Dual RS232-C ports
• S100 I/O
• INSUM
• MasterBus 300
This expansion provides the means of connecting remote I/O, fieldbus instruments
and additional RS232-C ports.
Battery Back-up
A battery is used to power the back-up for both the RAM and the real time clock in
the case of a power failure. Battery back-up can be provided in two ways:
• using the internal battery, (as shown in Figure 3 on page 23).
• using an external battery unit, (SB821), for longer back-up times.
The external battery unit is mounted on the DIN rail and connected to the CPU via a
cable.
22 3BSE 026 021 R201

Section 2 Functional Description Battery Back-up
Captive Screw
Cover
Internal
Battery
Holder
External Battery
Supply Socket
Figure 3. Back-up Battery - Connection
3BSE 026 021 R201 23

Power Supply Section 2 Functional Description
Power Supply
The power supply units are switch-mode power converters, that convert a.c. mains
supply voltage to a regulated 24V d.c. The mains input supply voltage can be either
115V a.c. or 230V a.c. and is selected using a switch, mounted on the front panel of
the unit. The three power supply units have rated output capacities as follows:
• SD823 = 24 Volts d.c. regulated @ 10A
• SD822 = 24 Volts d.c. regulated @ 5A
• SD821 = 24 Volts d.c. regulated @ 2.5A
The power supply units can be used in both redundant and non-redundant
applications. When redundant power supply units are connected to a common load,
a voting device, (SS822), must be used to combine the two outputs to a single
output, via diodes. The redundant power supply units may be connected to
completely separate mains supplies or to the same mains supply, depending on the
configuration selected.
The L- output (0V) of the power supply units can be used without being grounded.
If grounding is required, the power supply unit L- output (0V) can be grounded
directly or via a suitable resistor.
The processor unit has no requirement for an uninterruptible power supply in order
to shut down safely. The processor unit has an internal power reservoir that lasts for
5ms, which is sufficient for it to make a controlled power down. The power supply
units easily handle short power interruptions (<20ms) that can normally occur
within any industrial environment. Despite this, it is sometimes necessary to protect
certain applications, from brief voltage failures, by installing an Uninterruptible
Power Supply (UPS) device.
24 3BSE 026 021 R201

Section 2 Functional Description Power Supply
SA Supervision
Signals to
SB CPU module
via TP830
L+ L+ L- L- L+ L+ L- L- OK+ F OK+ F
OK OK A B
SD821 SD821 SS822

N L PE N L PE A+B+L+ L+ L-
L+
+24V
Mains
Input
L-
Protective Earth 0V
Figure 4. Example of a Redundant Power Supply Configuration
3BSE 026 021 R201 25

I/O System Section 2 Functional Description
I/O System
There are several methods of connecting I/O systems to the AC 800M Controller:
• Via the Modulebus (for connection of S800 I/O only).
• Via CI856 (for connection of S100 I/O only).
• PROFIBUS DP and DP-V1 for all I/O systems and units that are equipped with
an adapter suitable for PROFIBUS DP connections.
Please note that S800 I/O units can also be connected to PROFIBUS DP using the
Fieldbus Communication Interface, CI830.
For further information, refer to the documentation for the specific I/O-system.
For information about supported I/O-units refer to AC 800M/C Application
Programming, Strategy and Design, see Related Documentation on page 10.
S800 I/O
S800 I/O are connected to AC 800M, via Modulebus or PROFIBUS DP / DP-V1.
See Figure 5 on page 28 for examples of AC 800M / S800 I/O interconnection.
The top right area of Figure 5 on page 28 shows one cluster (or group) of units,
connected to the built-in electrical Modulebus of an AC 800M Controller. The
maximum number of units per cluster is 12. However, a further seven clusters, each
comprising of up to 12 units, can be added to the optical Modulebus. This results in
a total count of 96 units for the local Modulebus.
In redundant CPU configuration, connection of S800 I/O is done only with the
optical Modulebus. See Figure 6 on page 29. Each cluster of I/O units is connected
to two TB840s. Each processor unit is connected to one of the TB840s. Note that the
built-in electrical Modulebus can not be used in redundant CPU configuration.
26 3BSE 026 021 R201

Section 2 Functional Description I/O System
S100 I/O
S100 I/O are connected to the AC 800M, via the communication unit CI856. A bus
extension cable TK575/TK580, together with DSBC174/DSBC176 or DSBC173A,
connects the S100 I/O units to the baseplate, TP856, of CI856. Up to five S100 I/O
racks can be connected to the CI856.
Redundant S100 I/O bus extension can not be connected to CI856.
Other I/O Systems

A PROFIBUS DP segment (or node), shown on the top left-hand side of Figure 5 on
page 28, allows for a large increase in the numbers of units connected to each
AC 800M Controller. The segment is shown here with a Fieldbus Communications
Interface (FCI) unit (type CI830), connected to the PROFIBUS DP network.
The use of FCI units, or other types of adapters, allows the selection of units from
several I/O families.
3BSE 026 021 R201 27

I/O System Section 2 Functional Description
Max 12 Modules Max 12 Modules per Cluster
CI851 CI852 PM8xx DI810 AI810 DO810

PROFIBUS DP FOUNDATION CPU
Fieldbus H1
Electrical Modulebus Cluster
Max 12 Modules per Cluster

Optical See
Note 2
TB820 DI810 AI810 AO820 See

Note 1
To 6 Additional Optical
1 Segment of Modulebus Clusters
Optical
PROFIBUS DP
CI830 DI810 AI810 AO820
See Note 3
Optical TB820 DI810 AI810 AO820
Additional stations
up to maximum of
32 stations per Segment
Repeater Unit
Note 1 - Maximum 7 clusters. Max 200 m between clusters.
Note 2 - Central S800 I/O. Maximum 96 modules.
R Note 3 - Remote S800 I/O. Maximum 24 modules/station,
24 x 32 =768 modules per segment.
Figure 5. Example of AC 800M / S800 I/O Interconnection in Single CPU

Configuration
28 3BSE 026 021 R201

Section 2 Functional Description I/O System
CEX-bus extension cable
CI851 CI852 PM8xx

PM8xx
PROFIBUS DP FOUNDATION CPU
CPU
Fieldbus H1
RCU Link Cable
Optical
See
Note 1
TB840 TB840 DI810 AI810 AO820
1 Segment of To 6 Additional Optical

Optical
PROFIBUS DP Modulebus Clusters
CI830 DI810 AI810 AO820
See Note 2
Optical TB820 DI810 AI810 AO820
Additional stations
up to maximum of
32 stations per Segment
Repeater Unit
Note1 - Maximum 7 clusters x 12 = 84 modules. Max 200 m between clusters.
R Note 2 - Remote S800 I/O. Maximum 24 modules/station,
24 x 32 =768 modules per segment.
Figure 6. Example of AC 800M / S800 I/O Interconnection in Redundant CPU

Configuration
3BSE 026 021 R201 29

Drive System Section 2 Functional Description
Drive System
ABB Standard (Std) and Engineered (Eng) Drives can be connected to AC 800M
via the optical Modulebus or via PROFIBUS DP and CI830.
Modulebus
In single CPU configuration, ABB Drives can be connected to the processor unit via
the optical Modulebus. See Figure 7 on page 31. The number of ABB Drives which
can be connected to the optical Modulebus, can be described by the following
equation:
(No. of ABB Drives) < 84 - (12 x (No. of TB820s))
PROFIBUS DP and CI830

In single and redundant CPU configuration, ABB Drives can be connected via
PROFIBUS DP and CI830. See Figure 7 on page 31. Only Standard Drives can be
connected to CI830. Fourteen (14) Standard Drives can be connected to each CI830
if there are no I/O units connected. For the number of Drives that can be connected
to the same CI830, when both I/O units (TB820) and Standard Drives are
connected, refer to documentation about FCI for PROFIBUS DP. See Related
Documentation on page 10.
For more information about ABB Drives and its types (Std and Eng) refer to
S800 I/O documentation, see Related Documentation on page 10.
For information about Branching Unit (Figure 7 on page 31) see ABB Drive System
documentation.
30 3BSE 026 021 R201

Section 2 Functional Description Drive System
CI851 PM8XX
CPU DI810
PROFIBUS DP
Optical
TB820 DI810 AI810 AO820
Optical ABB Std Drive Branching Unit
Optical
ABB Std Drive ABB Eng Drive

ABB Std Drive
1 Segment of
PROFIBUS DP
CI830 DI810 AI810 AO820

Optical
TB820 DI810 AI810 AO820
ABB Std Drive Branching Unit

Optical
Optical
ABB Std Drive ABB Std Drive

ABB Std Drive
Figure 7. Example of Connection of ABB Drives in Single CPU Configuration
3BSE 026 021 R201 31

Installation Section 2 Functional Description
Installation
The AC 800M Controller consists of units that are mounted on a horizontal DIN rail
as shown in Figure 8 on page 32. Each baseplate has a locking device that ensures
contact between the metal back plate and the DIN rail, providing an effective
ground connection.The locking device can be set to any of the following three
positions, OPEN, SLIDE or LOCKED, which makes installation and removal of the
baseplates very simple.
The AC 800M and S800 I/O-units have protection class IP 20. A protection class
higher than IP 20 is recommended, however, due to the conditions in normal
industrial environments.
Lugs for extra screws to provide secure

mounting in locations subject to vibration
Figure 8. DIN Rail Mounting of AC 800M / S800 I/O Units
32 3BSE 026 021 R201

Section 2 Functional Description Configuration
Configuration
Using the engineering tool, Control Builder M, it is possible to download controller
firmware, configure hardware (I/O and communication units), make application
programs with IEC61131-3, compile and run programs off-line, as an aid to process
simulation before finally downloading an application to the controller.
The Control Builder M offers a set of library options. Simply select the option that
corresponds most closely to the system requirements. The Control Builder Online
Help facility provides detailed step-by-step information on the procedures to be
taken when creating an application, for the AC 800M Controller.
The Control Builder M, installed in a PC, is connected to the RS232-C port, COM 4
by means of a programming cable. Alternatively, the Control Builder M can be
connected, via the Control Network, to port CN1 or CN2 on the AC 800M
controller, using the MMS protocol on Ethernet (TCP/IP).
3BSE 026 021 R201 33

Configuration Section 2 Functional Description
34 3BSE 026 021 R201

Section 3 Software Components
General
The software used by the AC 800M Controller is named Control Software. This is a
generic name for the scope of functions used in a controller, and does not stand for a
specific software package.
These functions are:
• the hardware functions (supervision, communication buses, I/O buses, etc.)
• the firmware functions loaded into the controller (real time executive system,
real time clock, redundant communication, etc.)
• the application program loaded into the controller (library functions,
communication protocols, etc.)
To produce an application, it is necessary to use the engineering tool Control
Builder M. This tool is extremely versatile, with many useful functions in addition
to system configuration.
The AC 800M is delivered without Control Software. To provide the Controller
with Control Software it is necessary to first load the firmware, and then download
the application separately, using the Control Builder M engineering tool.
However, the processor unit is provided, at delivery, with firmware which enables
the use of the CN1 or CN2 ports. The released firmware (from the CD) must always
be downloaded to the CPU before any application program is downloaded. If there
is no firmware preloaded into the CPU, the COM 4 port must be used.
For information about the application program, firmware, downloading and types of
different licenses refer to AC 800M/C Application Programming, Strategy and
Design. See Related Documentation on page 10.
3BSE 026 021 R201 35

General Section 3 Software Components
36 3BSE 026 021 R201

Section 4 Hardware Components
Processor unit - Single Configuration

The processor unit consists of two parts:
• Processor unit (PM856/PM860/PM861/PM864), with CPU and Power Supply
boards
• Baseplate (TP830), housing the unit termination board
The CPU board contains the microprocessor and RAM memory, a real-time clock,
LED indicators, INIT push button, and a CompactFlash interface.
The main function of the power supply board is to generate isolated, short circuit
proof +5V and +3.3V supplies, for the CPU and I/O units. The board also contains
opto-isolated RS232-C drivers / receivers for the service port, together with a back-
up battery holder for memory / real time clock, (RTC).
The termination board, housed in the TP830 baseplate, is where the majority of the
external connections are attached. It is grounded to the DIN rail by means of the
metallic components of the housing. The termination board is provided with: screw
terminals for power supply (L+, L-); redundant power supply monitoring
(supervision signals SA, SB); RJ45 connectors for the control network, serial port
and service port; connectors for the electrical Modulebus and the CEX-Bus. All
units on the CEX-bus and the electrical Modulebus are powered by the 24V d.c.
connected to the baseplate.
The CN1 and CN2 ports are used for connection of Control Network. CN1 should
be used in a single network. Both ports should be used for a redundant network. The
COM3 is a RS232-C port with modem signals. The following are protocol
examples: MODBUS, COMLI, Siemens 3964R or custom designed protocols. The
COM4 port is used for connection to the Control Builder with the TK212 cable.
3BSE 026 021 R201 37

Processor unit - Single Configuration Section 4 Hardware Components
The processor unit has a communication expansion bus connector located on

the left-hand side of the TP830 baseplate. This CEX-bus provides extension of the
on-board communication ports with additional communication units.
Internal battery cover
CPU module
Baseplate
CEX-bus (TP830)
Socket
Modulebus
Socket
Power Supply
and Signal
Supervision Socket
(for connection cable
SS822)
Figure 9. Processor Unit Assembly - General View (shown here with PM860 /
TP830)
38 3BSE 026 021 R201

Section 4 Hardware Components Processor Unit - Redundant Configuration
Processor Unit - Redundant Configuration

Processor unit redundancy is available. In this case, the controller contains two
processor units, each including memory for system and application software. The
primary processor unit controls the process. The backup stands by to take over in
case of a fault in the primary. The changeover is done bumplessly and in less than
10 ms. During the changeover, the process outputs are frozen.
The PM861/PM864 has an RCU Link Connector for connection of the RCU Link
Cable TK851, see Figure 2 on page 21. In a redundant system, the two processor
units are linked together with the RCU Link Cable. Both processor units are also
connected to the same CEX-bus, with the TK850 CEX-bus extension cable. Any
one of the two can control the expansion units, see Figure 10 on page 39.
S800 I/O units are connected to the two processor units with the optical Modulebus
and two TB840s. The built-in electrical Modulebus on the baseplates can not be
used for connection of S800 I/O in redundant CPU configuration.
CEX-bus ext.
cable TK850
RCU Link cable

TK851
Figure 10. Connection of CPU Redundancy
3BSE 026 021 R201 39

Communication Interfaces Section 4 Hardware Components
Communication Interfaces
A communication interface unit comprises of two main assemblies:
• Communication Extension baseplate which provides the CEX-bus logic
together with the necessary DIN rail mounting facilities.
• Communication Extension unit which contains an appropriate communication
unit together with a d.c./d.c. converter to supply the appropriate voltages from
the +24V d.c., supplied from the CEX-bus.
PROFIBUS DP Interface - CI851 and TP851

The CI851 and TP851 assemblies, shown in Figure 11 on page 41, are used for
connecting remote I/O and fieldbus instruments via PROFIBUS DP. The TP851
baseplate has one female DB9 connector for connecting PROFIBUS DP. The
baseplate has a preset, two letter Alpha code lock to prevent the installation of an
incorrect type of unit onto the TP851 baseplate.
The CI851 is powered by the processor unit, via the CEX-bus, and therefore does
not require any additional external power source.
The PROFIBUS DP must be terminated at the two outermost nodes. ABB
recommend the use of connectors with built-in termination, since the fieldbus will
then always be terminated, even if it is disconnected from the unit.
It is also possible to connect PROFIBUS PA to the CI851, via a gateway.
40 3BSE 026 021 R201

Section 4 Hardware Components PROFIBUS DP Interface - CI851 and TP851
F
R
Rx/Tx
RTS
CI851
Front View
CI851 / TP851
Figure 11. PROFIBUS DP Communication Interface
3BSE 026 021 R201 41

FOUNDATION Fieldbus H1 Interface - CI852 and TP852 Section 4 Hardware Components
FOUNDATION Fieldbus H1 Interface - CI852 and TP852

The CI852 / TP852 assemblies, shown in Figure 12 on page 43, are used for
connecting FOUNDATION Fieldbus H1 (FF H1) to the AC 800M. The FF H1 has a
communication speed of 31.25kbit/s and is intended for remote connection and
configuration of field devices.
The TP852 baseplate has one female DB9 connector, used for connecting the FF H1
to the AC 800M. The baseplate also incorporates a preset, two letter Alpha code
lock, to prevent the installation of an incorrect type of unit onto the TP851
baseplate.
The CI852 is connected, via a transformer, to the FF H1 bus and thus neither
supplies nor consumes electrical power from the FF H1 bus. The number of field
devices that can be connected via CI852 depends on physical limitations in the FF
H1 network.
The FF H1 bus enables reuse of the existing cabling for 4-20mA analog signals.
This means that the cables often become the dominant dimensioning factor.
Connection of an FF configuration tool can be made directly to the FF H1 bus.
42 3BSE 026 021 R201

Section 4 Hardware Components FOUNDATION Fieldbus H1 Interface - CI852 and TP852
F
R
Rx/Tx
&,
)URQW9LHZ
&,73
Figure 12. FOUNDATION Fieldbus H1 Communication Interface
3BSE 026 021 R201 43

RS232-C Interface - CI853 and TP853 Section 4 Hardware Components
RS232-C Interface - CI853 and TP853

The CI853/TP853 assemblies, shown in Figure 13 on page 45, should be used when
an extension of the processor unit, onboard RS232-C ports, is required.
An RS232-C channel, with full modem support, can be connected to each of the
COM1 and COM2 ports. The two ports on a C1853/TP853, can be configured for
different protocols.
If the cable lengths are required to be extended beyond 15 meters, a short distance
modem, TC562, must be used. The TC562 is connected to the TP852 baseplate or
the TP830 baseplate, using TK853 cable.
TC562 short distance modem allows cable lengths to be extended (depending on the
modem transmission speed selected) to a distance of 18000 m (19700 yds) at 600
bit/s.
Table 3. TC562 Short Distance Modem - Technical Data
Item Value
Type TC562 - Short Distance Modem
Manufacturer - Westermo - MD-12DC
Transfer Asynchronous, full/half duplex/simplex
Power Supply 24V d.c. (Min. 12V d.c.- Max 36V d.c.)
Power Consumption 3W
44 3BSE 026 021 R201

Section 4 Hardware Components RS232-C Interface - CI853 and TP853
F
R
Tx1
Rx1
Tx2
Rx2
&,
COM1 COM2
Front View
CI853 / TP853
Figure 13. RS232-C Communication Interface
3BSE 026 021 R201 45

PROFIBUS DP-V1 Interface - CI854 and TP854 Section 4 Hardware Components
PROFIBUS DP-V1 Interface - CI854 and TP854

connecting remote I/O and fieldbus instruments via PROFIBUS DP-V1. The TP854
baseplate has two female DB9 connectors for connecting PROFIBUS DP-V1 with
support of Line Redundancy. The baseplate has a preset, two letter Alpha code lock,
to prevent the installation of an incorrect type of unit onto the TP854 baseplate.
The PROFIBUS DP-V1 must be terminated at the two outermost nodes. ABB
recommend the use of connectors with built-in termination, since the fieldbus will
then always be terminated, even if it is disconnected from the unit.
It is also possible to connect PROFIBUS PA to the CI854, via a gateway.
46 3BSE 026 021 R201

Section 4 Hardware Components PROFIBUS DP-V1 Interface - CI854 and TP854
F
R
RxA
RxB
CI854
PROFIBUS A
PROFIBUS B
Figure 14. 352),%86'39&RPPXQLFDWLRQ,QWHUIDFH
3BSE 026 021 R201 47

MasterBus 300 Interface - CI855 and TP853 Section 4 Hardware Components
MasterBus 300 Interface - CI855 and TP853

connection of an AC 800M to single or redundant MasterBus 300 Networks. This
allows DataSet communication and transmission of time between
Advant Controller 410/450 and AC 800M.
The TP853 baseplate has two RJ45 connectors for connecting MasterBus 300. The
baseplate has a preset, two letter Alpha code lock, to prevent the installation of an
incorrect type of unit onto the TP853 baseplate.
The connection to ethernet is made according to the general rules for connecting an
ethernet node.
If the Ethernet cable has a transceiver, the connector from the transceiver must be
converted to RJ45. The communication unit, CI855, can not provide power to the
transceiver, therefore a separate power source must be used.
48 3BSE 026 021 R201

Section 4 Hardware Components MasterBus 300 Interface - CI855 and TP853
F
R
Tx1
Rx1
Tx2
Rx2
&,
COM1 COM2
Front View
CI855 / TP853
Figure 15. MasterBus 300 Communication Interface
3BSE 026 021 R201 49

S100 I/O Interface - CI856 and TP856 Section 4 Hardware Components
S100 I/O Interface - CI856 and TP856

connecting S100 I/O to AC 800M. The TP856 baseplate has one female 36 pin
center line miniature ribbon connector, for connecting the TK575/TK580 bus
extension cable from S100 I/O. A bus extender, DSBC174/DSBC176 or
DSBC173A, must also be used. The baseplate has a preset, two letter Alpha code
lock to prevent the installation of an incorrect type of unit onto the TP856 baseplate.
50 3BSE 026 021 R201

Section 4 Hardware Components S100 I/O Interface - CI856 and TP856
F
R
TO
CI856
I/O
Front View
CI856 / TP856
Figure 16. S100 I/O Communication Interface
3BSE 026 021 R201 51

INSUM Interface - CI857 and TP853 Section 4 Hardware Components
INSUM Interface - CI857 and TP853

connection of an AC 800M controller with INSUM through TCP/IP over Ethernet
and an INSUM TCP/IP Gateway which has a LON interface communicating with
the underlying INSUM system.
The TP853 baseplate has one RJ45 Ethernet connector (only COM1 is used for
INSUM). The baseplate has a preset, two letter Alpha code lock, to prevent the
installation of an incorrect type of unit onto the TP853 baseplate.
52 3BSE 026 021 R201

Section 4 Hardware Components INSUM Interface - CI857 and TP853
F
R
Tx1
Rx1
Tx2
Rx2
&,
COM1 COM2
Front View
CI857 / TP853
Figure 17. ,1680&RPPXQLFDWLRQ,QWHUIDFH
3BSE 026 021 R201 53

Battery Back-up Section 4 Hardware Components
Battery Back-up
Internal Battery
The internal battery is located under a removable cover on the processor unit, see
Figure 3 on page 23.
External Battery
If a longer memory back-up time is required, an external battery unit (SB821) must
be used. The external battery unit is mounted on the DIN rail and connected to the
CPU, via a cable.
Both batteries are of the non-rechargeable type, and it is therefore recommended
that the battery is replaced after any system commissioning phase, several system
power-downs or after any lengthy continuous power failure. This should be done in
order to sustain the specified battery back-up time.
54 3BSE 026 021 R201

Section 4 Hardware Components Battery Back-up
SB821 3.6V Lithium Battery Unit

Note the warning
! text on the battery.
X1
B- B+ SH
Figure 18. SB821 External Battery Unit - Cover Removed
3BSE 026 021 R201 55

Power Supply Components - SD821, SD822, SD823, SS822 Section 4 Hardware Components
Power Supply Components - SD821, SD822, SD823,SS822
Power Supply Units - SD821 / SD822 / SD823

The SD82x series Power Supply Units (PSU’s) are used to provide power to the
AC 800M Controller, when connected to an industrial mains network of installation
category III. All three PSUs can be used for both redundant and non-redundant
applications, as well as load sharing functions.
The three PSUs are designed as switch mode power converters, that is, converting
a.c. mains supply voltage to a regulated 24V d.c. output. The three converters have
rated output capacities as follows:
SD823 = 24 Volts d.c. regulated @ 10A
SD822 = 24 Volts d.c. regulated @ 5A
SD821 = 24 Volts d.c. regulated @ 2.5A
The mains input voltage is set to either 115V or 230V by means of a switch
mounted on the front face of the unit. The factory default for this switch is in
the 230V position.
The output voltage of all three PSUs is, as stated, a regulated, low noise, 24V d.c.
A green LED, mounted on the PSU front panel, indicates that the output circuit is
providing the correct output voltage level. The double connectors, provided on
the 24V d.c. output terminals, allow for the connection of more than one piece of
equipment.
All three PSUs are designed to maintain the output voltage within an acceptable
range for 20ms, in the event of a total mains power failure.
SD821 is shown in Figure 19 on page 57. For measurements for all power supply
units, see Table 12 on page 82.
56 3BSE 026 021 R201

Section 4 Hardware Components Power Supply Components - SD821, SD822, SD823, SS822
110mm (4.3")
50mm (2.0") 103mm (4.1")
97mm (3.8")
L+ L+ L- L-
OK
125mm
(4.9")
SD821
44mm
(1.7")
N L PE
230
Mains Voltage
Selection Switch
(115 / 230)
Figure 19. Connections for SD821 Power Supply Unit (2.5A)
3BSE 026 021 R201 57

Power Supply Components - SD821, SD822, SD823, SS822 Section 4 Hardware Components
SS822 Voting Unit

When designing a redundant power supply, the output connections from two
identical Power Supply Units (PSUs) are connected to the SS822 voting unit,
see Figure 20 on page 58. The voting unit separates the redundant power converters,
supervises the voltage supplied, and generates supervision signals to be connected
to the processor unit.
Green LED’s, mounted on the front panel of the SS822, provide a visual indication
that the correct output voltage is being delivered. Simultaneously with the green
LED illuminating, a voltage free contact closes the path to the corresponding
“OK connector”.
The SS822 Voting Unit trip levels (2 off) are factory preset.
110mm (4.3")
50mm (2.0") 103mm (4.1")

97mm (3.8")
OK+ F OK+ F
A B
125mm
(4.9")
SS822
44mm
(1.7")
A+B+L+L+L-
Figure 20. SS822 Voting Unit Connections
58 3BSE 026 021 R201

Section 4 Hardware Components Mounting Rails
Mounting Rails
All units, comprising the AC 800M Controller, are mounted onto DIN rails
(type: TS 35/7.5). However, the DIN rail itself is not rigid enough to support the
units on its own. Therefore, a support, such as an Al-profile, which has been
specifically designed for supporting DIN rails, is recommended, (see Figure 21 on
page 59). Refer to price list for additional information.
The key features of the Al-profile are:
• Simple mounting features.
• No drilling required, profile incorporates pre-formed channels suitable for
self-tapping screws.
• Provides secure mounting in locations subject to extreme vibration,
see Figure 8 on page 32.
• Rigid, non-flexible construction.
• Easy fit, press-in cable retaining duct.
Pre-formed Al-profile
channels
DIN rail
Cable Duct
Figure 21. DIN Rail Mounted on an Al-Profile
3BSE 026 021 R201 59

CEX-bus Extension and Termination Section 4 Hardware Components
CEX-bus Extension and Termination

A TB850 CEX-bus terminator must always be installed on the last unit on
the CEX bus, as shown in Figure 22 on page 60. A CEX-bus terminator is supplied
with each PM8xx single configuration processor unit.
Terminator F F
R R
TB850 Rx/Tx Rx/Tx
RTS RTS
CPU module
CI851 CI851
Figure 22. TB850 Terminator for CEX-bus (Male)
When Communication Interface units are mounted on adjacent DIN rails, they are
connected by means of a CEX-bus extension cable (TK850) and terminated using a
TB851 CEX-bus terminator, as shown in Figure 23 on page 61. However, only one
TK850 CEX-bus extension cable may be used in any one CEX-bus.
The CEX-bus extension cable, TK850, is also used in redundant CPU configuration,
see Figure 10 on page 39.
The length of the cable is 0.7m (2.3’).
60 3BSE 026 021 R201

Section 4 Hardware Components CEX-bus Extension and Termination
F F F
R R R
Tx1 Rx/Tx Rx/Tx
Rx1 RTS
Tx2
Rx2
CPU module
CI853 CI852 CI851
COM1 COM2
TK850 Cable
Terminator
F F F TB851
R R R
Tx1 Tx1 Rx/Tx
Rx1 Rx1
Tx2 Tx2
Rx2 Rx2
CI853 CI853 CI852
COM1 COM2 COM1 COM2
Figure 23. TB851 Terminator for CEX-bus (Female)
3BSE 026 021 R201 61

Modulebus Extension and Termination Section 4 Hardware Components
Modulebus Extension and Termination

A terminator, TB807, must always be mounted on the last I/O-unit on the
Modulebus. A Modulebus terminator is delivered with the PM8xx processor unit.
For additional information about the Modulebus, refer to the Product Guide for
S800 I/O.
RCU Link Cable and Termination

The Redundant Control Unit Link Cable, TK851, is used to transfer log data from
the Primary CPU to the Backup CPU and to exchange status and control
information between the Primary and the Backup CPUs, see Figure 10 on page 39.
The RCU Link uses 68-pole connectors. One of the connectors has a label marked
“UPPER”. The CPU connected to this connector will be defined as the upper CPU
in the Control Builder and Operator Station.
The RCU Link Terminator Plug, TB852, is required when the processor unit
PM861/PM864 operates in single configuration.
62 3BSE 026 021 R201

Section 5 Mechanical Design
Cabinet Design
The figures listed below are examples of how the AC 800M Controllers, Power
Supply units, Voting units and S800 I/O units can be configured and mounted within
cabinets:
• Figure 24 on page 64, Wall Cabinet - Single Power Supply Arrangement
• Figure 25 on page 65, Wall Cabinet - Dual Power Supply (Local/Field)
Arrangement
• Figure 26 on page 66, Floor Mounted Cabinet - Unit Arrangement (Redundant
PSU)
The DIN-rails are using the supporting Al-profile to ensure rigidness. See Figure 21
on page 59.
The cabinets shown in the figures are ABB manufactured cabinets:
• RE820 Wall Cabinet
• RM550 Floor Cabinet
3BSE 026 021 R201 63

Cabinet Design Section 5 Mechanical Design
Modulebus
Expansion
Cable
Aluminium
Profile
Cable
Duct
Mains Breaker SD821 PSU 24V d.c. Distribution

Unit Terminals
Figure 24. Wall Cabinet - Single Power Supply Arrangement
64 3BSE 026 021 R201

Section 5 Mechanical Design Cabinet Design
Mains Breaker SD821 PSU SD821 PSU

Unit (Modules) (Field)
24V d.c. Distribution 24V d.c. Distribution

(Modules in Cabinet) (Field Equipment)
Figure 25. Wall Cabinet - Dual Power Supply (Local/Field) Arrangement
3BSE 026 021 R201 65

Cabinet Design Section 5 Mechanical Design
SD822
Redundant
Power
Supply Units
(Field
Equipment)
Mains
Breakers
SS822
Voting
Units
SD822 Redundant
Power Supply Units
Figure 26. Floor Mounted Cabinet - Unit Arrangement (Redundant PSU)
66 3BSE 026 021 R201

Section 5 Mechanical Design Mounting Dimensions for proper Ventilation
Mounting Dimensions for proper Ventilation

To maintain cooling airflow through the AC 800M Controller units, no obstructions
must be placed within 50mm (2") above and 25mm (1") below the units, as shown
in Figure 27 on page 67. Note that the CPU and communication interfaces must be
mounted on a horizontal DIN rail.
>50mm (2.0")
Unobstructed areas
>240mm
(9.4")
>25mm (1.0")
>50mm (2.0")
Unobstructed areas
>25mm (1.0")
Figure 27. Ventilation Requirements - Minimum Mounting Dimensions
3BSE 026 021 R201 67

Mounting Dimensions for proper Ventilation Section 5 Mechanical Design
68 3BSE 026 021 R201

Section 6 Technical Data and Performance
Technical Data
Processor Unit - PM8xxand TP830
Performance Data for PM856/PM860

The processor units PM856 and PM860 have the same internal design. They differ
only in performance when executing an application program.
Using the same application program in PM856 and PM860, the difference in
execution time can be expressed as:
Execution time in PM856 = 2 *Execution time in PM860
Example: If a certain application program has an execution time of 100ms in
PM860, the same application program will have an execution time of 200ms in
PM856.
Performance Data for PM861/PM864

The processor unit PM861/PM864 has the same performance data as the PM860.
Switch over time from Primary CPU to Backup CPU, in redundant CPU
configuration, is less than 10ms.
3BSE 026 021 R201 69

Processor Unit - PM8xx and TP830 Section 6 Technical Data and Performance
Table 4. Processor Unit - PM8xx and TP830
Item Value
CPU • PM856/PM860/PM861
MPC860 Microprocessor running at 48MHz.
• PM864
MPC862 Microprocessor running at 96MHz.
Memory • PM856/PM860
2MBytes flash PROM (firmware storage).
8MBytes SDRAM (5MB available for
application program and 3MB used for
executable firmware).
• PM861
executable firmware)
• PM864
executable firmware)
Internal Battery Lithium Battery 3.6V, 950mAh.
Battery memory back-up time is:
• PM856/PM860
a minimum of 48 hours.
• PM861/PM864
a minimum of 36 hours.
External Battery Unit Lithium battery, 3.6V 16Ah.
(SB821) Battery memory back-up time is:
• PM856/PM860
a minimum of 1 month.
• PM861/PM864
a minimum of 3 weeks.
70 3BSE 026 021 R201

Section 6 Technical Data and Performance Processor Unit - PM8xx and TP830
Table 4. Processor Unit - PM8xx and TP830 (Continued)
Item Value
Unit Size and Weight Width (measured along DIN rail).
• 119mm (4.7") (Note: When not mounted,
CEX bus contact protrudes an additional
4mm (0.16")
Depth (measured from wall).
• 135mm (5.3")
Height (measured vertically, inclusive of locking
device).
• 186mm (7.3")
Weight
• 1100g (2.4lb) (package PM856K01)
• 1100g (2.4lb) (package PM860K01)
• 1200g (2.6lb) (package PM861K01)
• 2800g (6.1lb) (package PM861K02)
• 1200g (2.6lb) (package PM864K01)
• 2800g (6.1lb) (package PM864K02)
All packages incl. TP830 and bus terminations
Protective Rating IP20 according to EN60529, IEC 529.
Port CN1, CN2 Ethernet Communication:
Contact type: RJ45 Communication speed, 10Mbit/s (half duplex)
Signal levels, IEEE802.3, 10 Base T
3BSE 026 021 R201 71

Item Value
Port COM3 COM3, Serial Communication:
Contact type: RJ45 Communication speed selectable in steps from 75
to 115200 baud. 75, 110, 134.5, 150, 300, 600,
1200, 1800, 2000, 2400, 9600, 19200, 38400,
115200 baud.
This range of transmission rates can be
limited by the communication protocol used,
please refer to documentation for the
communication protocol.
Signal levels, RS232-C
Full modem support
Port COM4 COM4, Serial Communication to Control Builder
Contact type: RJ45 Communication speed 9600 baud
Signal levels, RS232-C
Electrical Modulebus I/O capacity
1 S800 I/O base cluster with up to
12 S800 I/O-units with a total of up to
192 S800 I/O-signals.
Optical Modulebus I/O capacity
7 S800 I/O clusters each with 12 units totaling up
to 1344 I/O-signals.
CEX-bus 12 communication interfaces can be connected.
Supply Current and Fuses for Modulebus
Buses Maximum supply current 1A.
Fuse 2A (fast).
CEX-bus
Maximum supply current 2.4A.
Fuse 3.15 A (fast).
See Figure 28 on page 74
72 3BSE 026 021 R201

Section 6 Technical Data and Performance Processor Unit - PM8xx and TP830
Item Value
Redundant Power Supply Inputs designated SA, SB
Status Max input voltage 30V d.c.
Min. input voltage for high level 15V d.c.
Max input voltage for low level 8V d.c.
Supply Requirements Supply voltage (L+, L-), 24V d.c.
Allowed variation, 19.2 - 30V d.c.
Internal power reservoir for making a controlled
power down: 5ms
Current Consumption 24V (1) • PM856/PM860
(excl. Modulebus and CEX- typical 180mA.
bus). • PM861
typical 250mA.
• PM864
typical 287mA.
Power Loss (Heat) (1) • PM856/PM860
(with full load of I/O and CEX- typical 10W, Max.13W.
bus units). • PM861
typical 11W, Max. 15.3W.
• PM864
typical 11.9W, Max. 16.4W.
(1) See also Appendix A, Power Consumption.
3BSE 026 021 R201 73

Mounting Socket for Mounting Socket for

CPU Board Power Supply Board
Mounting Socket for Modulebus Fuse

Redundancy Board
(PM861only)
CEX-bus Fuse

Figure 28. TP830 Baseplate - Mounting Sockets and Fuses
74 3BSE 026 021 R201

Section 6 Technical Data and Performance PROFIBUS DP Interface - CI851 and TP851
PROFIBUS DP Interface - CI851 and TP851

Table 5. PROFIBUS DP Interface - CI851 and TP851
Item Value
Type DP Master Class I
Protocol PROFIBUS DP
Communication speed 9.6, 19.2, 93.75, 187.5, 500, 1500, 3000,
6000, or 12000 kbit/s
Bus Capacity (one segment) Max 32 nodes
Galvanic Isolation Yes
Status Indicators Red LED for error
Green LED for run
Yellow LED for traffic
Connector DB9, female on TP851
Current Consumption from CEX-bus Typical 150mA
24V d.c.
Power Dissipation 3.6W typical
Weight 700g (1.5lb) (package CI851K01)
Dimensions W 59 x H 185 x D 127.5mm
(W 2.3 x H 7.3 x D 5.0 inches)
3BSE 026 021 R201 75

FOUNDATION Fieldbus H1 Interface - CI852 and TP852 Section 6 Technical Data and
FOUNDATION Fieldbus H1 Interface - CI852 and TP852

Table 6. CI852 FOUNDATION Fieldbus Interface Specifications
Item Description
Type FOUNDATION Fieldbus H1 master and link schedule
Number of Channels Single channel FOUNDATION Fieldbus H1
(31.25 kbit/s)
Protocols FOUNDATION Fieldbus H1 via port on CI852
Communication speed 31.25kbit/s (FF H1)
Allowed Node Address 20 - 247
Galvanic Isolation By means of transformer
Green LED for run
Connector DB9, male on TP85
Current Consumption from Typical 140mA
CEX-bus 24V d.c
(W 2.9 x H 7.3 x D 5.0 inches)
Protective Rating IP20 according to EN60529, IEC 529
76 3BSE 026 021 R201

Section 6 Technical Data and Performance RS232-C Interface - CI853 and TP853
RS232-C Interface - CI853 and TP853

Table 7. CI853 - RS232-C Communication Interface Specifications
Item Description
Type Double unisolated RS232-C ports with Hayes
modem signals.
Number of Channels 2 channels
Protocol Determined by software, application and licenses.
Intended for Modbus, Siemens 3964R, COMLI
and custom designed protocols.
Communication speed Selectable in steps from 75 to 115200 baud.
75, 110, 134.5, 150, 300, 600, 1200, 1800, 2000,
2400, 9600, 19200, 38400, 115200 baud.
This range of transmission rates can be limited
by the communication protocol used, please refer
to documentation of the communication protocol.
Galvanic Isolation Non-isolated
Green LED for run
Connector Two RJ45 connectors on TP853
Current Consumption Typical 100mA
(W 2.9 x H 7.3 x D 5.0 inches)
3BSE 026 021 R201 77

PROFIBUS DP-V1 Interface - CI854 and TP854 Section 6 Technical Data and Performance
PROFIBUS DP-V1 Interface - CI854 and TP854
7DEOH 352),%86'39,QWHUIDFH&,DQG73
Item Value
Type DP Master Class 1and 2 for DP-V0 Services
DP Master Class II for DP-V1 Services
Protocol PROFIBUS DP-V0 and DP-V1
Communication speed 9.6, 19.2, 93.75, 187.5, 500, 1500, 3000, 6000,
or 12000 kbit/s
Bus Capacity (one segment) Max 32 nodes
Galvanic Isolation Yes
Green LED for run
Connector two DB9, female on TP854
Current Consumption from Typical 190mA (max. 240mA)
CEX-bus 24V d.c.
(W 2.3 x H 7.3 x D 5.0 inches)
78 3BSE 026 021 R201

Section 6 Technical Data and Performance MasterBus 300 Interface - CI855 and TP853
MasterBus 300 Interface - CI855 and TP853
Table 8. MasterBus 300 Interface - CI855 and TP853
Item Value
Type Ethernet unit
Protocol MasterBus 300, dataset
Communication speed 10Mbit/s (half duplex)
Green LED for run
Connector 2 RJ45 connectors on TP853
24V d.c.
(W 2.3 x H 7.3 x D 5.0 inches)
3BSE 026 021 R201 79

S100 I/O Interface - CI856 and TP856 Section 6 Technical Data and Performance
S100 I/O Interface - CI856 and TP856

Table 9. S100 I/O Interface - CI856 and TP856
Item Value
Type S100 I/O Communication Interface
Bus Capacity (one segment) Max 5 I/O racks with 20 I/O units each
Galvanic Isolation No
Green LED for run
Yellow LED for access time-out
Connector 36 pin center line miniature ribbon
connector, female on TP856, for bus
extension cable TK575/TK580.
24 V d.c.
(W 2.3 x H 7.3 x D 5.0 inches)
80 3BSE 026 021 R201

Section 6 Technical Data and Performance INSUM Interface - CI857 and TP853
INSUM Interface - CI857 and TP853
Table 10. INSUM Interface - CI857 and TP853
Item Value
Type Ethernet unit
Protocol TCP/IP
Communication speed 10Mbit/s (half duplex)
Green LED for run
Connector 2 RJ45 connectors on TP853
(only one connector, COM1, can be uesd)
24V d.c.
(W 2.3 x H 7.3 x D 5.0 inches)
3BSE 026 021 R201 81

External Battery Back-up Unit - SB821 Section 6 Technical Data and Performance
External Battery Back-up Unit - SB821

Table 11. External Battery Back-up Unit - SB821
Item Description
Battery Lithium battery, 3.6V 16Ah
Dimensions W 85.6 x H 136 x D 51mm
(W 3.4 x H 5.4 x D 2.0 inches)
Weight 600g (1.3lb) incl. TK821V020
Protective rating IP20 according to EN60529, IEC 529
Power Supply Components - SD821,SD822,SD823,SS822

Table 12. SD82x and SS822 - Individual Technical Data
SD821 SD822 SD823 SS822

Parameter
Converter Converter Converter Voter
Rated Output Current (A) 2.5A 5A 10A 20A
Rated Output Power 60W 120W 240W -
Rated Output Voltage 24V 24V 24V 23.5V
Rated Input Power 160VA 280VA 690VA 500W
(at full load) 70W 135W 265W
Efficiency Factor 87% typ 90% typ 90% typ -
Mains/Input Voltage, (nominal) 115/230V 115/230V 115/230V 2 x 24V
a.c. a.c. a.c. d.c.
Mains Voltage Variation 85 - 110% 85 - 110% 85 - 110% -
Primary Peak Current at 25A 15A 30A
Power On
Heat Dissipation 8.6W 13.3W 26.7W 10W
Secondary Voltage Holdup >20ms >20ms >20ms -
Time at Mains Blackout
82 3BSE 026 021 R201

Section 6 Technical Data and Performance DIN Rail and Al-profile
Table 12. SD82x and SS822 - Individual Technical Data (Continued)
SD821 SD822 SD823 SS822

Parameter
Converter Converter Converter Voter
Dimensions, Width 50mm 65mm 120mm 50mm
HxD = 125 x 110mm (2.0") (2.6") (4.7") (2.0")
(4.9 x 4.3 inches)
Mounting Spacing W mm 10mm 15mm 15mm 10mm
(along DIN rail) (0.4") (0.6") (0.6") (0.4")
Mounting Spacing H mm 25mm 25mm 25mm 25mm
(above each other) (1.0") (1.0") (1.0") (1.0")
Weight 600g 700g 1100g 800g
(lb) (1.3lb) (1.5lb) (2.4lb) (1.8lb)
Protective Rating IP20 according to EN60529, IEC 529
DIN Rail and Al-profile

Table 13. DIN Rail and Al-profile - Required Dimensions
Al-Profile DIN rail

Cabinet / Application
(length) (length)
For RE820 Cabinet 719mm (28.3") 683mm (26.9")
For RM550 Cabinet 592mm (24") 556mm (21.9")
For Standard Use 465mm (19") 429mm (16.9")
3BSE 026 021 R201 83

DIN Rail and Al-profile Section 6 Technical Data and Performance
84 3BSE 026 021 R201

Section 7 Ordering
Ordering Procedure
The product guide is aimed to assist ABB sales representatives in ordering
AC 800M Hardware products.
This section describes the price lists required when ordering and provides an
example of an order. However, it is outside the scope of this product guide to give a
complete description of all ordering procedures and tools. It is assumed that each
ABB sales representative is familiar with price lists, CAST and other tools to order.
Licenses
In addition to AC 800M Controller Hardware, it is necessary to have licenses for
Control Software and other software that are integrated with it.
Please refer to the corresponding Price List and Supporting Product Guide for
detailed ordering information.
Price List Structure
Price List: AC 800M, version 2.1, 3BSE 025 496

Price Book: Control IT - AC 800M/C for SB2, 3BSE 027 811
Contains only the AC 800M units (processor, communication units and power
supplies) for ordering parts.
Supporting Product Guides: This Product Guide
3BSE 026 021 R201 85

Price List Structure Section 7 Ordering
Price List: AC 800M/C Product Box and Manuals, 3BSE 025 501
The CD in the Product Box contains all software packages for controllers
(firmware), Control Builder, OPC Server and utilities. All manuals are included as
.pdf-files to be viewed online or printed. To make use of the software on the CD,
appropriate licenses must be purchased.
Price List: Control Software Base Licenses, 3BSE 025 497

The Control Software Base License for an AC 800M Controller. This is the first
license to order for a controller and gives the customer the right to use certain
functions and libraries in an application program.
Supporting Product Guide: Control Software and Control Builder M
3BSE 026 333 R201
Price List: Control Software Expansion Licenses, 3BSE 025 498

Control Software licenses to expand an existing Base License for an AC 800M
Controller. To be used for expansion of the I/O unit support or the license level.
3BSE 026 333 R201
Price List: Control Builder M, Base Licenses, 3BSE 028 325

This license gives the customer the right to use the engineering tool,
Control Builder M, for the AC 800M Controller.
3BSE 026 333 R201
86 3BSE 026 021 R201

Section 7 Ordering Price List Structure
Price List: Control Builder M, Expansion Licenses, 3BSE 028 326

License to expand an existing Control Builder M Base License to a higher license
level.
3BSE 026 333 R201
Price List: OPC Server for AC 800M/C Licenses, 3BSE 025 500
This license gives the customer the right to use the OPC server to connect
the AC 800M Controller to other products, for example an operator station.
3BSE 026 333 R201
Price List: AC 800M/C Connect Base Licenses, 3BSE 025 691

Price Book: Operate IT - Process Portal A and Related Products for SB2,
3BSE 026 490
Connect base licenses for the connection between the AC 800M Controller and the
Operate IT Process Portal A platform. License for both first workplace and
additional workplaces are available. The licenses is scaled by means of tags.
Supporting Product Guide: AC 800M/C Connect
3BSE 026 332 R201
3BSE 026 021 R201 87

Price List Structure Section 7 Ordering
Price List: AC 800M/C Connect Expansion Licenses, 3BSE 025 692

Price Book: Operate IT - Process Portal A and Related Products for SB2,
3BSE 026 490
Connect expansion licenses for tag expansion of the connection between the AC
800M Controller and the Operate IT Process Portal A platform. License for both
first workplace and additional workplaces are available.
Supporting Product Guide: AC 800M/C Connect
3BSE 026 332 R201
88 3BSE 026 021 R201

Appendix A Power Consumption General
Appendix A Power Consumption
General
At 40°C (104°F) ambient, it is considered unnecessary to calculate the heat
dissipation requirements for a standard AC 800M Controller with S800 I/O
configuration, mounted within ABB floor or wall mounted cabinets.
For a standard AC 800M Controller configuration, housed within an ABB floor or
wall mounted cabinet, the recommended fuse rating for the external mains supply is
as follows:
Table 14. AC 800M Mounted in ABB Cabinet - Fuse Requirements
Fuse Rating Fuse Type

10A Slow to Rupture
Should the configuration be other than that stated, detailed instructions for
calculating current consumptions can be found in the following text.
The tables below present the current consumption and power dissipation of all
relevant hardware units included in AC 800M Controller.
Use this information:
• When dimensioning the supply requirements of an AC 800M and S800 I/O
configuration.
• When calculating the power loss generated in a cabinet.
The values given in the tables are typical and adapted to these kinds of applications.
It is assumed that 70 percent of the channels on a unit are active simultaneously.
3BSE 026 021 R201 89

Current Consumption and Power Dissipation Appendix A Power Consumption
Current Consumption and Power Dissipation
Current Consumption and Power Dissipation

Refer to Table 15 on page 90 for typical current consumption and power dissipation
data for AC 800M units.
Table 15. Current Consumption and Power Dissipation Data for

AC 800M Units
Current at 24 V Power Dissipation

Unit Remarks
Typical Max Typical Max
PM856 180mA 300mA 5.0W 8.0W (1)
PM860 180mA 300mA 5.0W 8.0W (1)
PM861 250mA 430mA 6.0W 10.3W (1)
PM864 287mA 487mA 6.9W 11.4W (1)
CI851 150mA 200mA 3.6W 5.0W
CI852 140mA 200mA 3.4W 5.0W
CI853 100mA 150mA 2.4W 3.6W
CI854 190mA 240mA 4.6W 5.8W
CI855 150mA 200mA 3.6W 5.0W
CI856 120mA 200mA 2.9W 5.0W
CI857 150mA 200mA 3.6W 5.0W
(1) These figures are for the PM8xx alone. For current consumption data relating to the CEX-bus and
the Modulebus units, see Table 16 on page 91.
The CPU, via TP830, supplies the following currents to units on the CEX-bus and
the Modulebus, see Table 16 on page 91.
90 3BSE 026 021 R201

Appendix A Power Consumption Current Consumption and Power Dissipation
Table 16. CPU Current Supply to CEX-bus and Modulebus
Bus +5V +24V

Modulebus max. 1.5A (1) max. 1.0A
CEX-bus Not Applicable max. 2.4A
(1) Corresponds to additional 0.5A on +24V.
Maximum current on +24V supplied to the CPU (incl. supply of Modulebus and
CEX-bus) is shown in Table 17 on page 91:
Table 17. Maximum Current Supply to CPU incl. Modulebus and CEX-bus (24V)
CPU Maximum Supply Current

PM856 4.2A
PM860 4.2A
PM861 (single) 4.3A
PM861(redundant pair) 3.3A (no Modulebus)
PM864 (single) 4.4A
PM864 (redundant pair) 3.4A (no Modulebus)
Due to transfer/conversion losses in the CPU, when full current supply to

Modulebus and CEX-bus is used, the power dissipation of the CPU increases with
5W, in addition to the values in Table 15 on page 90.
Calculations
1. Calculate the current requirements on each bus, (Modulebus and CEX-bus).
Ensure that the limits detailed in Table 16 on page 91 are not exceeded. Data
relating to TB820, TB840 and CI830 can be located in the S800 I/O
documentation. See Related Documentation on page 10.
3BSE 026 021 R201 91

Current Consumption and Power Dissipation Appendix A Power Consumption
2. Calculate the current consumption at 24V, for each electrical Modulebus,

by adding:
Im = I (24V) + I (5V) x 0.3
3. To calculate the requirement for a specific power supply unit, add all the 24V
current consumptions, as follows:
Itot = Im1 + Im2 + .... + Iunits Table 15 + ICI830s + ITB820s + ITB840s
If redundant CPUs are used, current for both CPUs, must be included.
92 3BSE 026 021 R201

Appendix B Recommended Components Recommended Components
Appendix B Recommended Components
Recommended Components
All of the recommended components, listed below, were successfully used during
ABB’s exhaustive testing phase, prior to the launch of the AC 800M Controller.
Table 18. Recommended Components - PROFIBUS DP
Component Description
PROFIBUS DP No specific PROFIBUS DP components are recommended,
due to the large selection of commercially available
equipment manufactured to the PROFIBUS DP Standard.
For further details refer to PROFIBUS DP Web Site, see
Related Documentation on page 10.
PROFIBUS DP-V1 No specific PROFIBUS DP-V1 components are
recommended, see PROFIBUS DP above.
Table 19. Recommended Components - FOUNDATION Fieldbus
FOUNDATION No specific FOUNDATION Fieldbus components are
Fieldbus recommended, due to the large selection of commercially
available equipments available, manufactured to the
FOUNDATION Fieldbus Standard (IEC 1158-2).
This statement covers all FOUNDATION Fieldbus equipments,
including:
• FOUNDATION Fieldbus filters.
• FOUNDATION Fieldbus bus spur distribution terminals.
• FOUNDATION Fieldbus termination.
For further details refer to FOUNDATION Fieldbus
documentation and the FOUNDATION Fieldbus Web Site, see
Related Documentation on page 10.
3BSE 026 021 R201 93

Recommended Components Appendix B Recommended Components
Table 20. Recommended Components for Control Networks
HUBS 3Com Hub, 8/TPO - (8 ports, RJ45)
(For Non- Suitable for smaller systems
Industrial No supervision required.
Environments)
No configuration required.
Plug and play capability.
BayStack, 350/24 - (24 port, Star topology, RJ45)
Suitable for larger systems
Supervision required.
Fibre optic capabilities
No plug and play capability.
HUBS Hirschmann Rail Hub RH1-TP- (4 ports, RJ45)
(Industrial Suitable for small to medium systems
Environments) No supervision required.
High Mean Time Between Failures (MTBF)
Rugged Design for high temp use
Plug and play capability.
94 3BSE 026 021 R201

Table 20. Recommended Components for Control Networks (Continued)
SWITCHES Hirschmann Rail Switch RS2 (8 ports, Ring, Bus or Star
(Industrial topology RJ45)
Environments Suitable for larger systems
Supervision required.
High Mean Time Between Failures (MTBF)
Rugged Design for high temp use
No plug and play capability.
CABLES Electrical - Class 5, STP
Optical - As recommended by Manufacturer of HUBS and
SWITCHES
3BSE 026 021 R201 95

Table 21. Recommended Components - Miscellaneous
DIN rail Phoenix:
• TS 35/7.5
• Steel, yellow chromated with holes
• DIN 46 277, EN 50 022
DIN rail DIN-rail end support device
Accessories Phoenix: UK 4-TG+ST-BE
(Standard commercially available components)
Cabinets ABB Automation Technology Products, LV systems
Wall cabinet RE820
• for 3 DIN rails
• W 800 x H 1200 x D 330mm (31.5 x 40.1 x 13.0 inches)
• IP54
Floor cabinet RM550

• for 6 DIN rails
• W 840 x H 2125 x D 512mm (33.1 x 83.7 x 20.2 inches)
• IP54
See Figure 24 on page 64, Figure 25 on page 65 and
Figure 26 on page 66.
96 3BSE 026 021 R201

Table 22. Recommended Components - Process Cables
Mains Various Manufacturers, to Standard;
• RKFK 3x1.5mm2
RS232-C Unitronic
• CY 3 x 0.25mm2
• CY 7x 0.25mm2
Belden
• Belden 8723 2 pair (0.34mm2)
FOUNDATION Fieldbus Unitronic
• Suitable Commercially Available Cable.
Belden
• Suitable Commercially Available Cable.
PROFIBUS DP Unitronic
• Twisted pair, 0.34mm2
• Unitronic-Bus L2/F.I.P
Belden
• Twisted pair, 0.34mm2
• Belden 3079A
3BSE 026 021 R201 97

98 3BSE 026 021 R201

Appendix C Environmental Data Environmental Data for AC 800M Products
Appendix C Environmental Data
Environmental Data for AC 800M Products

The immunity of products to environmental factors during operation, transportation,
and storage, is summarized in this section.
Industrial environment has a power network supplied from a high or medium
voltage transformer, dedicated for the supply of an installation feeding
manufacturing or similar plants. The Industrial environment is characterized
by the existence of industrial apparatus, heavy frequently switched inductive or
capacitive loads, and the associated magnetic fields are high.
Control products incl. I/O-systems are normally intended for Industrial
environment.
The products, manufactured by ABB or others, are normally type tested or
evaluated to ensure compliance with the environmental standards specified below.
The environmental specifications applicable to peripheral equipment, for example
printers, may differ. Please refer to the data sheets of the products concerned.
The degree to which the units withstand environmental influence, depends on their
components and their design. The system enclosures, the types of cable, and how
these are routed, determines the environmental specification of the complete
system.
3BSE 026 021 R201 99

Climatic and Mechanical Environmental Conditions Appendix C Environmental Data
Climatic and Mechanical Environmental Conditions
Industrial Environment
Table 23. Industrial Environment
Environmental Specification
Compliance
Environment Transportation Operative with Standard
Factor and Storage Range
Temperature -25 to +70°C Cabinets (1): EN 61131-2
+5 to +40°C
-25 to +60°C (3) Units (2):
+5 to +55°C
+10 to +40°C (3)
Temp. change Min. 3min within 3°C/min. EN 61131-2
Climatic Conditions
temp. range
Humidity RH=5-95% RH=5-95% EN 61131-2
RH=20-80% (3) RH=20-80% (3)
non- max 29g/m3
condensation non-
condensation
Altitude 3000m 2000m EN 61131-2
Pollution degree Degree 2 IEC 60664
Corrosion Copper corrosion Copper corrosion ISA 71.04 class
of 300 Angstrom of 300 Angstrom G1
(4) (4)
over 28 days over 28 days ITF SSG 4251G1
100 3BSE 026 021 R201

Appendix C Environmental Data Climatic and Mechanical Environmental Conditions
Table 23. Industrial Environment (Continued)
Compliance
Environment Transportation Operative with Standard
Factor and Storage Range
Vibration 10< f <50Hz, Continuous: 0.0375mm EN 61131-2
amplitude
(Occasional: 0.075mm amplitude)
50< f <150Hz, Continuous: 0.5g
acceleration
Mechanical Conditions
(Occasional: 1.0g acceleration)

5< f <500Hz, Continuous: 0.2g
acceleration (3)
Emitted noise - <55dB (A)
Shock, no 150m/s 2
, 11ms 150m/s2, 11ms EN 61131-2
package 20g, 3ms (3)
20g, 3ms (3)
DAT drives; 5g, DAT drives; 5g,

3ms 3ms
Fall in package <10kg: 1m EN 61131-2
10-40kg: 0.5m
>40kg: 0.25m
>100kg: 0.025m
(1) Cabinets = Enclosures, Cases, Consoles
(2) Units = Subracks, plug-in units, printed circuit boards
(3) Workstation, PC computers and peripherals, for example printers
(4) 1000 Angstrom for S800 I/O-family
3BSE 026 021 R201 101

CE Compliance Appendix C Environmental Data
CE Compliance
All products comply with EMC Directive 89/336/EEC and Low Voltage
Directive 73/23/EEC (relevant products also fulfill the Teleterminal Directive).
The products are provided with a CE marking. Some products require enclosure,
as specified in User Guides, to meet the EMC Directives.
Compliance to the Directives is verified by the practice of the following standards
at the minimum:
• EMC Directive 89/336/EEC.
• EN 61131-2 Product standard, Programmable controllers.
• EN 50081-2 Generic emission standard.
• EN 61000-6-2 Generic immunity standard.
• Low Voltage Directive 73/23/EEC.
• EN 50178 for all new products, e.g. S100 and S800 family, or good electrical
safety practice based on EN 60950, EN 61010, EN 50178, EN60439,
IEC60255 depending on the product.
• Teleterminal Directive 91/263/EE.
102 3BSE 026 021 R201

Appendix C Environmental Data Electromagnetic Compatibility and Main Voltage Conditions
Electromagnetic Compatibility and Main Voltage Conditions
Table 24. Electromagnetic Compatibility and Main Voltage Conditions
Compliance with
Industrial Standard
Environment Factor
Environment
Emission Class A EN 55011
-Radiated
-Conducted
Immunity 10V/m EN 61000-4-3
Electromagnetic Compatibility Conditions
-Radiated RF field ENV 50 204

Immunity 10V EN 61000-4-3
-Conducted RF field
Immunity 4kV contact discharge EN 61000-4-2
-ESD (Electrical 8kV air discharge
Discharge)
Immunity 2kV, power ports EN 61000-4-4
-EFT/B (Electrical Fast 1kV, other lines
Transient/Burst)
Immunity - IEC 60255-22-1
-Damped oscillatory
wave
Immunity 30A/m, cont. EN 61000-4-8
-Power frequency 3A/m for CRTs
magnetic field
Immunity 2kV, common EN 61000-4-5
-Surge 1kV, differential
3BSE 026 021 R201 103

Electromagnetic Compatibility and Main Voltage Conditions Appendix C Environmental Data
Table 24. Electromagnetic Compatibility and Main Voltage Conditions (Continued)
Compliance with
Industrial Standard
Environment Factor
Environment
Main voltage a.c Unom: -15% to +10%
Electromagnetic Compatibility Conditions
Main voltage d.c. -15% to 20% of rated

value
Main frequency a.c. 47 - 63Hz, ± 5% IEC 60255-6
Main voltage Max 10ms EN 61000-4-11
interruption, a.c.
Overvoltage
Category Class III
-Permanently
connected equipment
Overvoltage
Category Class II
-Non-permanently
connected equipment
104 3BSE 026 021 R201

Appendix C Environmental Data Installation Requirements
Installation Requirements
Installation rules for all products are included in relevant product documentation.
Some general installation rules and applications are described below.
The Laying of Field Cables

There are no special requirements for the laying of field and communication cables
connected to products, except:
• Cables for short-distance communication without modems should always be
routed 10cm (4 inches) away from other cables.
All cables, connected to products, should be run 30cm (12 inches) away from power
cables (heavy current cables) not belonging to products, and 10cm (4 inches) away
from cables belonging to class 4 of relevant international immunity standards.
Types of Field Cables

Shielded cables are always required for:
• Communications (see product documentation for the type of cable)
• High-frequency pulse transmission (see product documentation
for the type of cable)
• Low level analog signals e.g. Pt100 and thermocouples
• Analog application with a system accuracy > 12 bits
For other applications, it is possible to use unshielded cables.
Digital and analog signals of the same type can be run in the same cable.
Signal and return conductor are always to be located in the same cable.
3BSE 026 021 R201 105

Lightning Strike Protection Appendix C Environmental Data
Lightning Strike Protection

Industries and power plants are normally equipped with well integrated earthing
networks which are installed as part of the power distribution system.
In such installations it is not necessary to install additional protection against
lightning strike.
Additional protection against lightning strike is always necessary when:
• Cables extend beyond the area covered by the earth line network
• Cables are located above ground
• Overhead cables are used.
Inductive Load Suppression

Inductive load, such as relays and contactors directly connected to products, do not
have to be suppressed. The necessary suppression components (varistors or
snubbers - RC units) are installed on the circuit boards.
106 3BSE 026 021 R201

INDEX
A COM4 37, 72
ABB Drives 30 Communication 22, 40, 71, 77
AC 800M 26, 32 to 33, 35, 42 Control Builder 35, 37
Al-profile 59, 83 Control Network 37
CPU 35, 37, 70
B Current consumption 90
Base plate 19 PM856/860/861/864 73
Battery 37, 82
Battery Back-up 22, 54 D
External 82 DIN rail 16, 22, 32, 54, 59, 83
External Battery 54 DSBC173A 27
Internal Battery 54 DSBC174/DSBC176 27
Battery back-up
External battery 70 E
Internal battery 70 Ethernet ports 19
Branching Unit 30 External battery 22
C F
Cabinet Design 63 Fieldbus Communications Interface 27
CAST 85 FOUNDATION Fieldbus 22, 42, 76
CEX-Bus 37 Fuse Requirement 89
CEX-bus 19, 22, 72
Extension 60 G
Termination 60 Grounding 24
CI830 26, 30
CI851 40, 75 I
CI852 42, 76 I/O-system 26
CI853 44, 77 I/O-systems 99
CI854 46, 78 INSUM 22, 52, 81
CI855 48, 79 internal battery 22
CI856 26, 50, 80
CI857 52, 81
CN1 35, 37, 71
CN2 35, 37, 71
COM3 37, 72
3BSE 026 021 R201 107

Index
M T
MasterBus 300 22, 48, 79 TB820 28, 30
Modulebus 19, 26, 30, 37, 72 TB840 26, 39
Extension 62 TK212 37
Termination 62 TK575/TK580 27
Mounting Rails TK850 39
Al-profile 59 TK851 39
TP830 19, 21, 37, 44, 69
P TP851 40, 75
PM856/860 37 TP852 42, 76
PM860 21 TP853 44, 48, 52, 77, 79, 81
PM861 37 TP854 46, 78
PM864 37 TP856 27, 50, 80
PM8xx 69
Power Supply 24, 56, 73
Processor Module 37, 58, 69
Redundancy 20
Processor Unit 19
Processor unit 19
PROFIBUS DP 22, 26, 40, 75
PROFIBUS DP-V1 22, 26, 46, 78
R
RAM 19, 22, 70
RCU Link Cable 39, 62
Termination 62
RCU Link Connector 39
RJ45 77
RS232 22, 37, 44, 72, 77
RS232-C 77
S
S100 27
S100 I/O 22, 27, 50, 80
S800 26
S800 I/O 26
SD821 24, 56, 82
SD822 24, 56, 82
SD823 24, 56, 82
SS822 24, 58, 82
108 3BSE 026 021 R201

3BSE 026 021 R201. Printed in Sweden March 2003
Copyright © 1999-2003 by ABB. All Rights Reserved
® Registered Trademark of ABB.
™ Trademark of ABB.
http://www.abb.com/control
Automation Technology Products Automation Technology Products Automation Technology Products

Västerås, Sweden Wickliffe, Ohio, USA Mannheim, Germany
www.abb.com/processautomation www.abb.com/processautomation www.abb.de/processautomation
email: [email protected] email: [email protected] email: [email protected]

Product Guide (3BSE026021R201)

Uploaded by

Copyright:

Available Formats

Product Guide (3BSE026021R201)

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Product Guide (3BSE026021R201)

Uploaded by

Copyright:

Available Formats

ControlIT

Copyright © 1999-2003 ABB Automation Technology Products.

Release: March 2003

IndustrialIT Registered trademark of ABB Ltd, Switzerland.

OperateIT Registered trademark of ABB Ltd, Switzerland.

CompactFlash Trademark of SanDisk Corporation, U.S.A.

Foundation Fieldbus Trademark of Fieldbus Foundation, U.S.A.

Modbus Trademark of Gould Electronics Inc., U.S.A.

PROFIBUS DP Registered Trademark of PROFIBUS International (P.I.).

INSUM Registered Trademark of ABB Schaltanlagentechnik GmbH,

Siemens and all Siemens-products mentioned in this publication are trademarks

About This Book

Section 2 - Functional Description

Section 3 - Software Components

3BSE 026 021 R201 5

Section 4 - Hardware Components

Section 5 - Mechanical Design

Section 6 - Technical Data and Performance

6 3BSE 026 021 R201

Power Supply Components - SD821,SD822,SD823,SS822 ...............................82

Appendix A - Power Consumption

Appendix B - Recommended Components

Appendix C - Environmental Data

3BSE 026 021 R201 7

8 3BSE 026 021 R201

Intended Use of This Book

Use of Caution, Information, and Tip Icons

Caution icon indicates important information or warning related to the concept

Information icon alerts the reader to pertinent facts and conditions.

Caution hazards are associated with equipment or property damage, it should be

3BSE 026 021 R201 9

Table 1. Related Documentation

Category Title Description

10 3BSE 026 021 R201

Table 1. Related Documentation

Category Title Description

S800 I/O Fieldbus Communication, Describes the PROFIBUS DP FCI within

3BSE 026 021 R201 11

Table 1. Related Documentation

Category Title Description

12 3BSE 026 021 R201

Table 2. Related Media

Category Title Description

Media ControlIT for AC 800M/C Control Builder, Functions &

3BSE 026 021 R201 13

14 3BSE 026 021 R201

3BSE 026 021 R201 15

The AC 800M Controller consists of a selection of units mounted on horizontal DIN

Communication Processor S800 I/O

Figure 1. Example of an AC 800M Controller with a S800 I/O Unit

16 3BSE 026 021 R201

3BSE 026 021 R201 17

18 3BSE 026 021 R201

Processor Unit - General

3BSE 026 021 R201 19

Processor Unit - Redundancy

20 3BSE 026 021 R201

3BSE 026 021 R201 21

22 3BSE 026 021 R201

Figure 3. Back-up Battery - Connection

Figure 14. 352),%86'39&RPPXQLFDWLRQ,QWHUIDFH