Transcript Control IT - Hardware and SoftController

© ABB Ltd - Page 1
Control IT
Hardware
(AC800 M/C) &
SoftController
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A suite of IEC 61131-3 compatible controllers
 AC 800M – the new Modular Controller
designated for binary control as well as advanced
control applications
 AC 800C – the Compact Controller for small,
yet advanced applications
 SoftControl – the controller that runs
© ABB Ltd - Page 2
on a PC providing high performance at
low cost
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AC 800 M
ControlIT AC 800M Hardware
 AC 800M
© ABB Ltd - Page 4
 Modular and flexible concept,
DIN-rail mounted
 Built in redundant Ethernet
 Very low power consumption
 Hot swap of communication- and
I/O modules
 Local and remote I/O options
 Industry quality hardware with
excellent EMC and MTBF
properties
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AC 800M Controller with a S800 I/O Module
AC 800M
Communication Interface
I/O System
Processor Module
S800 I/O
© ABB Ltd - Page 5
Module
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Processor Module
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Processor Module
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Hardware mapped to Control Builder
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Base components for AC 800M

Processor Module

 SD821 - 24 V d.c. regulated @ 2.5 A
 SD822 - 24 V d.c. regulated @ 5 A
 SD823 - 24 V d.c. regulated @ 10 A
 PM860 - Processor
 TP830 - Baseplate

Communication Interfaces
© ABB Ltd - Page 9
 CI851 – Profibus
 CI852 – Foundation Fieldbus
 CI853 – RS232-C
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Power Supply

Battery Backup
 SB821- External Backup
Processor Module

MPC860/48MHZ

 Motorola Power PC

8 MB RAM
 5 MB for application program
 3 MB for executable firmware
 Mounted on the module


© ABB Ltd - Page 10

 CN1, CN2

Optical Modulebus to connect
clusters of S800 I/O modules
A connector for Compact Flash
(not included in this release)
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Two serial ports (COM3, COM4)
 COM3 is an RS232-C port with
modem control signals
 COM4 is isolated and used for
the connection of the
configuration tool
2 MB System FLASH PROM
 For non-volatile storage of
firmware and license key
 Mounted on the module
Two Ethernet ports for
connection to the control
network


Electrical Modulebus is used
for connection clusters of S800
I/O directly to the baseplate
CEX-bus is used for extending
the on-board communication
ports with communication
interface modules
Power Supply

Switch-mode power converters

 Converting a.c. Mains supply
voltage to a regulated 24 V d.c.


Input can be either 115 V a.c. or
230 V a.c
Redundant or non redundant
 When a redundant power
supply is connected to a
common load, you need a
voting device, SS822, to
combine two outputs into one
via diodes
The CPU module does has no
requirement for a UPS
 It has a 5 ms reservoir to safely
shutdown


The power supply handles
short power interruptions (<20
ms)
Available modules
 SD 823
 24 V d.c. regulated @ 10 A
 SD 822
 24 V d.c. regulated @ 5 A
 SD 821
© ABB Ltd - Page 11
 24 V d.c. regulated @ 2.5 A
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Battery Backup
External battery

Internal battery
 Up to one month (720 hours)
 Lithium Battery 3.6 V, 950 mAh.

External battery module SB821
 Lithium battery, 3.6 V 16 Ah
 A minimum of 18 months
 Mounted on the DIN rail and
connected to the CPU via cable
© ABB Ltd - Page 12
Internal battery
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External battery Connection
I/O System

Local I/O – S800

 12 local I/O modules per
cluster
 24 with optical modem
 7 clusters x 12 I/O modules of
local on the Modulebus
 Up to 96 local I/O Modules

Remote I/O via Profibus
 Foundation Fieldbus and
Advant Fieldbus to come
 Recommened to use ABB I/O
S900, S800 and S200


Field Communication Interface
(FCI) is used to connect the I/O
modules to the PROFIBUS
There is no physical limit for
the number of I/Os that can be
connected to AC 800M
Recommendation
 ~600-700 I/O per controller
 The memory for the
application sets the limit
 The hardware is relatively
cheap
© ABB Ltd - Page 13
 Buy an extra controller
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I/O System


Local I/O
Remote I/O via Profibus
 Up to 96 modules
CI851 PM860
Profibus CPU
PM860
12 I/O Modules
CPU
Optical
TB820
Optical
Modem
CI830
12 I/O modules
FCI
12 I/O modules
Up to 24 modules per stations
CI830
12 I/O modules
FCI
Optical
TB820
© ABB Ltd - Page 14
Optical
Modem
12 I/O modules
TB820
Up to 7 clusters and 200m between clusters
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Optical
Modem
12 I/O modules
Up to 5 PROFIBUS segments
Up to 32 stations per segment
Up to 24 modules per stations
Up to 384 DI/DO and 192AI/AO per station
© ABB Ltd - Page 15
AC 800M / S800 I/O Interconnection
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AC 800M / S800 I/O Interconnection
TB805
TB850V007
CI851 PM810 AI810 AI810 AO810 AO810 AO810 AO810
TB851
CI851
See note 1
AI810 AI810 AO810 AO810 AO810 AO810
See note 2
TK811V015/050/150
TB820 DI810 DI810 DO810 DO810
See note 5
To addition module clusters
CI830 DI810 DI810 DO810 DO810
© ABB Ltd - Page 16
TB810
See note 4
TB820 DI810 DI810 DO810 DO810
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TK801V003/6/12
TB806
See note 3
Modulebus Extension & Termination
TB805
TB806
DIN-Rail
© ABB Ltd - Page 17
TK801V003/006/012
Note 3
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I/O Module on Compact & Extended MTUs
I/O Modules
Extended MTU
Typical Compact MTU with I/O Module
CI830
© ABB Ltd - Page 18
Compact MTU
Typical Extended MTU with I/O Module
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AC 800M Connectors for Optical Modulebus
Duplex Fiber Optic Cable Connector
TK811V015/050/150
Rx
Tx
TK812V015/050/150
Simplex Fiber Optic Cable Connector
© ABB Ltd - Page 19
Front View
For connection from PM810 to TB820
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Note 1
TB820 Optical Modulebus Connection
TB820
Optical ModuleBus
Interface Connectors
(X4, X5)
TK811V015/050/150
Rx
X4 Tx
Duplex Fiber Optic Cable Connector
Rx
TK812V015/050/150
X5
Tx
© ABB Ltd - Page 20
Simplex Fiber Optic Cable Connector
Front View
Note 5
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CEX Extension & Termination
Note 2
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CEX Extension & Termination
Note 2
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Supported S800 I/O Modules (Local & Remote)
S800 I/O Modules
S800 I/O I.S. Modules
© ABB Ltd - Page 23
S800L I/O Modules
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Supported S200 I/O Modules (Remote I/O)
Via 200-APB12 PROFIBUS Adapter
S200L I/O Modules
S200 I/O Modules
© ABB Ltd - Page 24
S200L I/O Modules
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PROFIBUS Support

CI851 – Profibus Interface
 Power from the processor
module



TP851 – Baseplate
Profibus DP must be
terminated on both sides
It is possible to connect any
standard PROFIBUS I/O via
CI851
© ABB Ltd - Page 25
 For example S800 I/O or S200
I/O
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PROFIBUS Connection - CI830 & TB820
© ABB Ltd - Page 26
Connector for TB810
Power Supply
TB820
Connections
Modulebus Optical Port
Profibus-DP Connector
Note 4
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CI830
AC 800M, Profibus integration
S800 I/O
Profibus-PA via standard
segmentcoupler
Profibus-DP
S900 I/O
© ABB Ltd - Page 27
Profibus-PA
DP/PA Converter
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Foundation Fieldbus (In future release)

CI852 – Foundation Fieldbus
H1 Interface
 Power from the processor
module
© ABB Ltd - Page 28

TP852 – Baseplate
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Up to 32 Foundation Fieldbus
Devices
AC 800M ,FF integration
Communication with FF-instruments is
easily performed via IEC 61131-3 function
blocks
© ABB Ltd - Page 29
FF H1
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Serial Interface – RS232-C

CI853 – RS232-C
 Two serial ports
 Power from the processor
module



TP853 – Baseplate
A RS232-C channel, with full
modem support, can be
connect to COM1 or COM2
For cables longer than 15m a
short distances modem, TC562,
must be used
 Up to 12 km, depending on the
transmission speed
© ABB Ltd - Page 30

Available Protocols
 Please see screen dump to the
right
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CEX Extension and Termination


© ABB Ltd - Page 31

CEX Bus in the communication
bus
TB 850 CEX-bus termination
shall always be installed on the
last unit
CEX extension cable TK850
(0.7m) to mount the modules
on another DIN-rail
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Modulebus Extension and Termination


© ABB Ltd - Page 32

The Modulebus connects the
local I/O
A terminator, TB807, must
always be mounted on the last
I/O module on the Modulebus
Will support direct connection
to Drives in the future
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Installation

Mounted on a horizontal DIN
rail
 Locking device to connect to
the DIN rail to get grounding
 The locking device can be in
OPEN, SLIDE or LOCKED


AC800M & S800I/O has
protection class IP20
To get higher protection we
recommend the following
cabinets with protection class
IP54
© ABB Ltd - Page 33
 RM550 – Floor mounted
 RE820 – Wall mounted
Example of Wall mounted
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© ABB Ltd - Page 34
Environmental Specifications
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CE Compliance
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Electromagnetic Compatibility and Main Voltage Conditions
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AC 800 C
AC 800C Main Module

Processor Module – PM210
 18,432 MHz
 2 Mb RAM and 2 Mb Flash PROM

On board I/O Modules
 10 DI, 6 DO
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Two on-board RJ-45 jacks for RS232 channels
 COM 0 – The port for the Control
Builder
 COM 1- full set of modem control
signals
© ABB Ltd - Page 38

Two slots for optional
communication plug-in boards are
provided



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Serial Links
Ethernet
PROFIBUS-DP master of class 1
FOUNDATION Fieldbus link master
(future)
 Battery back-up module SB210
 1 slot for an optional battery
plug-in board with a real-time
clock and a lithium battery
© ABB Ltd - Page 39
AC 800C Hardware Layout
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Hardware mapped to Control Builder
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7
1
1
2
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Installation

© ABB Ltd - Page 41

Horizontally and vertically
mounted on the DIN rail
The AC 800C, S200, S200L and
S800 I/O-unit have all
protection class IP 20
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AC 800C / S200/S200L/ S800 I/O Modules Interconnection
Programming Terminal
Central I/O
Remote I/O
AC 800C
S800 I/O
© ABB Ltd - Page 42
S200/S200L I/O
Profibus-DP
S200/S200L I/O
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How to connect I/O Modules

On-board I/O
 10 DI and 6 DO on board
 24 V DC
 The inputs and outputs are
filtered and galvanically
isolated by optocouplers

Local Input/Output (I/O) units
 8 S200 Local I/O Modules
 two rows by means of the
extension cables CE1 or CE3.
 8 Extra via a TK210 cable and a
200 AIO adapter
© ABB Ltd - Page 43

Remote I/O Modules
 PROFIBUS-DP can be used for
connection of remote I/O units,
for instance S200/S200L and
S800 I/O units
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
The total number of I/O units
connected (central and remote)
to the controller are 32 I/O units
On board I/O

On-board I/O
 10 DI and 6 DO on board
 24 V DC
 The inputs and outputs are
filtered and galvanically
isolated by optocouplers
 A separate two-pole plug-in
screw connector for the
external +24 V DC power
supply
 The unit is not damaged if the
© ABB Ltd - Page 44
polarity is reversed
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Local I/O

Local Input/Output (I/O) units
 8 S200 Local I/O Modules
 two rows by means of the
extension cables CE1 or CE3
0.3 and 0.9 m respectively
 8 Extra via a TK210 cable and a
200 AIO adapter
 (length 0.5, 1.0, or 2.5 m)
© ABB Ltd - Page 45
 Note that a TK210 cable longer
than 0.9 m is not allowed in
hazardous locations according
to UL1604
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Supported S200 I/O (Local & Remote)
S200C I/O Modules
S200 I/O Modules
© ABB Ltd - Page 46
S200L I/O Modules
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AC 800C Communication Possibilities

To Control Builder
 Via a serial port using the PPP
protocol, or alternatively via
Ethernet

Serial Interfaces
 Available protocols are
Siemens 3964R (as master),
 COMLI, MODBUS RTU (as
master) and MMS. User-defined
protocols may also be used

Fieldbus Support
© ABB Ltd - Page 47
 PROFIBUS
 FOUNDATION Fieldbus
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
On-board serial
Communication
 COM 0 can receive and
transmit signals
 COM 0 is the default channel
for the programming station
tool port
 COM 1 has a full set of modem
control signals
 Each channel has LEDs
indicating the status of
transmit and receive activities
 RS-232 is a point-to-point
communication standard with
a maximum cable length of 15
meters
Communication Extensions
Ethernet Communication Board CI272
© ABB Ltd - Page 48
Profibus Communication Board CI274
RS-232 Communication Board CI271
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Communication Extensions - Serial

RS-232 Communication Board
CI271 (Option)
© ABB Ltd - Page 49
 There are two RJ-45 jacks for
RS-232 channels
 Full set of modem control
signals
 This gives a multiple RS-232
point-to-point communication
with e.g. printers, scales, bar
codes, controllers, and for
multiple protocols (COMLI,
Modbus, etc)
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Communication Extensions - Ethernet

Ethernet Communication Board
CI272 (Option)
© ABB Ltd - Page 50
 Enables a network consisting
of many interconnected
controllers, operator stations
and servers
 Communication via MMS
 It has one RJ-45 jack for
Ethernet 10BASE-T (twisted
pair, max. cable length 100 m)
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PROFIBUS Board – CI274

PROFIBUS Board - CI274
 A fast (12 Mb/s) PROFIBUS-DP
master

© ABB Ltd - Page 51

A PROFIBUS-PA can also be
used, via a segment coupler 1,
in heavy industries with
intrinsically safe I/Os
The CI274 board acts as a
PROFIBUS-DP master of class
1 and up to two of them can be
installed on the AC 800C
controller
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PROFIBUS Board – CI274

Can be used to connect remotely
installed S800 I/O, S200 I/O, S200L
I/O and third party I/O units
 Maximum length of 100 to 1200
meters, depending on the
transmission rate
 S800/S800L I/O
 The S800 I/O units are connected to
one or more I/O adapters, CI830
 These I/O units are connected to
one or more I/O adapters, with a
maximum of twelve I/O units per
adapter.

Additional units can be connected to
the same adapter via optical cables
and optical interface units, TB820.
 S200/S200L I/O
© ABB Ltd - Page 52
 These I/O units are connected to
one or more I/O adapters, 200APB12, with a maximum of eight
I/O units per adapter
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FOUNDATION Fieldbus – CI 275 (future release)

The CI275 board is an optional
interface for remote connection
of 31.25 Kb/s FOUNDATION
Fieldbus devices
 A maximum length of 200 to
1900 meters, depending on
cable type
 The CI275 board acts as link
master device
© ABB Ltd - Page 53

Used to connect remotely
installed I/O and third-party
units and which comply with its
specifications
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Battery Backup - SB210


© ABB Ltd - Page 54

At least a year with the battery
and 20 minutes without
Low battery voltage, such as
after a power failure, is
indicated by flashing PWR
Battery replacement can be
performed during operation by
lifting a small lid in the
controller cover. UL-approved 3
V batteries of type CR2430
must be used
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Power Supply

Note
© ABB Ltd - Page 55
 The controller and the I/O
systems should, if possible,
have separate 24 V DC
supplies
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© ABB Ltd - Page 56
Technical Data
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© ABB Ltd - Page 57
Environmental Specification - Climate
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© ABB Ltd - Page 58
Environmental Specification - Mechanical
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© ABB Ltd - Page 59
CE - Compliance
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© ABB Ltd - Page 60
Electro Magnetic Compatibility
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© ABB Ltd - Page 61
Electro Magnetic Compatibility
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SoftController
For future release
SoftControl – An Overview


A personal computer can be
turned into a controller by
means of Control Builder
software and communication
plug-in boards
Central I/O
 S200 and S200L I/O units

Remote I/O
© ABB Ltd - Page 63
 Via PROFIBUS-DP and
FOUNDATION Fieldbus.
SattBus (developed by ABB
Automation Products) and
DataHighway Plus (from AllenBradley)
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© ABB Ltd - Page 64
Hardware mapped to Control Builder
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Communications – Serial Interface

S-232 Protocols
© ABB Ltd - Page 65
 A PC is usually delivered with
one or two RS-232 COM-ports
(COM1 and COM2)
 You can add more interface
boards
 Standard protocols such as
PPP is specified by use of
standard Windows installation
software
 A range of other protocols can
be defined by the Project
Explorer
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Local I/O

S200/S200L I/O units
 Up to four plug-in boards can
be handled by the Soft
Controller
 each of them capable of
connecting up to sixteen I/O
units
© ABB Ltd - Page 66
 Use the ISA CIIO Board
 Alternatively, the units can be
connected via PROFIBUS-DP
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Supported S200 I/O (Local & Remote)
S200C I/O Modules
S200 I/O Modules
© ABB Ltd - Page 67
S200L I/O Modules
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Ethernet Communication

Ethernet
 A standard Ethernet PC board
can be used if the controller is
to be connected to Ethernet
© ABB Ltd - Page 68

Use standard network
components to build your
network
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PROFIBUS-DP Communication



A plug-in board a PROFIBUSDP network.
Up to four board per
SoftController
Two adapters
 one for connection of up to
eight S200/S200L I/O units
 The other for connection of up
to twelve S800 I/O units
© ABB Ltd - Page 69
S800 I/O Modules via PROFIBUS
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S200 I/O Modules via PROFIBUS
FOUNDATION Fieldbus

FOUNDATION Fieldbus
© ABB Ltd - Page 70
 Up to thirty-two FOUNDATION
Fieldbus devices can be
connected to a plug-in board.
Up to four such boards can be
handled by the SoftControl
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SattBus


© ABB Ltd - Page 71

SattBus is a communication
protocol and a physical layer,
both developed by ABB
Automation Products
Up to 120 nodes can be
connected to a SATTBUSPC
board, and up to four such
boards can be handled by the
SoftController
COMLI can be used for
communication on SattBus
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DataHighway Plus

© ABB Ltd - Page 72

DataHighway Plus is a multimaster communication
protocol from Allen-Bradley
Up to 63 Allen-Bradley PLC-5
systems can be connected to a
DataHighway Plus board, and
up to four such boards can be
handled by the SoftController.
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© ABB Ltd - Page 73
Hardware Requirements
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© ABB Ltd - Page 74
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