S800 I/O

General Information and Installation

Users Guide

S800 I/O
General Information and Installation

Users Guide
3BSE 020 923R201

NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by
Automation Products AB. Automation Products AB assumes no responsibility for any errors that may appear in this
document.
In no event shall Automation Products AB be liable for direct, indirect, special, incidental, or consequential damages of
any nature or kind arising from the use of this document, nor shall Automation Products AB 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 Automation Products ABs written permission,
and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
The software 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.

CE MARKING
This product meets the requirements specified in EMC Directive 89/336/EEC and in Low Voltage Directive 73/23/EEC.

TRADEMARKS
ABB Master, MasterFieldbus, and MasterBus are registered trademarks of ABB Asea Brown Boveri Ltd., Switzerland
Advant is a registered trademark of ABB Asea Brown Boveri Ltd., Switzerland.
Advant Controller is a trademark of ABB Asea Brown Boveri Ltd., Switzerland
PROFIBUS and PROFIBUS-DP are registered trademarks of Profibus International (P.I.).
HART is a registered trademark of HART Communication Foundation.

Copyright Automation Products AB 2000.

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TABLE OF CONTENTS
Chapter 1 - Introduction
1.1

About This Book ....................................................................................................2

1.2

Product Overview...................................................................................................4
1.2.1

Product Scope........................................................................................7
1.2.1.1

CI810 Fieldbus Communication Interface ...................10

1.2.1.2

CI820 Fieldbus Communication Interface ...................10

1.2.1.3

CI830 Fieldbus Communication Interface ...................10

1.2.1.4

TB815 Interconnection Unit.........................................11

1.2.1.5

TB810/TB811 ModuleBus Optical Port.......................11

1.2.1.6

TB820 ModuleBus Modem ..........................................12

1.2.1.7

Module Termination Units ...........................................14

1.2.1.8

I/O Modules..................................................................14

1.2.1.9

Power Supply................................................................15

1.2.1.10

Example of Enclosure Configurations..........................17

1.2.1.11

Support for External Intrinsic Safety System ...............18

1.2.1.12

Support for HART ........................................................19

1.3

Related Documentation ........................................................................................19

1.4

Terminology .........................................................................................................21

Chapter 2 - Installation
2.1

Site Planning ........................................................................................................23

2.1.1

Site Selection and Preparation ............................................................23

2.1.2

Environmental Considerations ............................................................24

2.1.3

Electromagnetic Compatibility and CE Marking................................26

2.1.4

Layout of I/O Stations .........................................................................26

2.1.4.1

2.1.5

Grounding ...........................................................................................41

2.1.6

Signal Cable Considerations ...............................................................43

2.1.6.1

3BSE 020 923R201

I/O Station with S800 I/O.............................................26

Recommendations for Signal and Process Cable .........44

2.1.7

Power Requirements ...........................................................................46

2.1.8

Hazardous Applications ......................................................................47

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CONTENTS (continued)

2.2

2.1.9

High Voltage Switch-gear Applications.............................................. 47

2.1.10

Lightning Strike Protection................................................................. 47

2.1.11

Mounting Dimensions......................................................................... 47

Installation Procedures......................................................................................... 50
2.2.1

Personnel Safety........................................................... 51

2.2.1.2

Equipment Safety ......................................................... 51

Grounding in Enclosures .................................................................... 52

2.2.3

Cable Routing in Enclosures............................................................... 54

2.2.4

Power Connection............................................................................... 55

2.2.5

I/O Station with S800 I/O ................................................................... 56

2.2.6

Checklists............................................................................................ 59
2.2.6.1

Grounding Philosophy, Ground Plane System ............ 59

2.2.6.2

Process Cabling, Shielding, Grounding,

Max. Length ................................................................. 60

2.2.6.3

Power Supply ............................................................... 61

2.2.6.4

Lightning Protection..................................................... 62

2.2.6.5

MTU, I/O Module ........................................................ 62

2.2.6.6

Cabinet, Internal Cables ............................................... 63

2.2.6.7

Environmental Data ..................................................... 64

2.2.6.8

Airborne Contaminants ................................................ 64

2.2.6.9

Miscellaneous............................................................... 65

2.2.6.10

External Cables ............................................................ 65

Final Procedure Before Start-up ......................................................... 65

Start-up and Shut-down Procedures..................................................................... 66

2.3.1

2.3.2

ii

2.2.1.1
2.2.2

2.2.7
2.3

Safety Regulations .............................................................................. 50

Start-up Procedures ............................................................................. 66

2.3.1.1

Safety Regulations ....................................................... 66

2.3.1.2

Controller and I/O ........................................................ 66

Shut-down Procedures ........................................................................ 67

2.3.2.1

Safety Regulations ....................................................... 67

2.3.2.2

I/O Station .................................................................... 67

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7DEOHRI&RQWHQWV

CONTENTS (continued)
2.4

Product Verification .............................................................................................69

2.4.1

General ................................................................................................69
2.4.1.1

2.4.2

Check of Process Input/Output Systems ......................70

Final Check .........................................................................................74

Chapter 3 - Configuration
3.1

Before You Start ...................................................................................................75

3.1.1

Design Considerations ........................................................................75

3.1.1.1

I/O Station Layout Hardware Configuration

Guidelines.....................................................................75

3.1.1.2

CI810/CI820/CI830 FCI...............................................82

3.1.1.3

TB820 ModuleBus Modem ..........................................82

3.1.2

SD811 and SD812 Power Supply Configurations ..............................88

3.1.3

Power Supply Load Calculation..........................................................91

3.1.4

Heat Dissipation ..................................................................................92

3.1.4.1

Cabinet Ventilation .......................................................92

3.1.4.2

Heat Dissipation Permitted in Cabinets........................92

3.1.4.3

Calculation of Heat Generated in a Cabinet .................92

3.1.5

Maintenance and Repair......................................................................93

3.1.6

Expansion Considerations ...................................................................93

3.1.7

Power Supply Requirements ...............................................................94

3.1.8

Power and Cooling ..............................................................................95

Chapter 4 - Operation
4.1

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Operating Overview .............................................................................................99

iii

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CONTENTS (continued)
Chapter 5 - Maintenance
5.1

Preventive Maintenance..................................................................................... 101

5.2

Hardware Indicators........................................................................................... 101

5.2.1

Color ................................................................................................. 101

5.2.2

Location ............................................................................................ 102

5.2.3

Identification ..................................................................................... 103

5.3

Error Messages .................................................................................................. 103

5.4

Fault Finding and User Repair........................................................................... 103

5.4.1

Introduction....................................................................................... 103

5.4.2

Diagnostics and Fault Indications..................................................... 104

5.4.3

List of General Fault Finding Procedures and Hints ........................ 104

5.4.4

5.4.3.1

Location of Malfunction ............................................ 104

5.4.3.2

External Factors ......................................................... 104

5.4.3.3

Safety at Start/Stop..................................................... 105

5.4.3.4

Check of Power Supply.............................................. 105

User Repair ....................................................................................... 106

5.4.4.1

I/O Module Replacement ........................................... 106

5.4.4.2

Power Supply Module Replacement.......................... 106

5.4.4.3

Communication Module Replacement....................... 108

Appendix A - Specifications
A.1

SD811/SD812 Power Supply Module, 24V d.c................................................. 111

A.2

TB805/TB806 ModuleBus Cable Adapter-Out/In............................................. 119

A.3

TB807 ModuleBus Terminator .......................................................................... 122

A.4

TB810/TB811 ModuleBus Optical Port ............................................................ 125

A.5

TB820 ModuleBus Modem ............................................................................... 129

Appendix B - Power Up
B.1

iv

Power Up on S800 I/O....................................................................................... 135

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General Information and Installation Users Guide

Section

Chapter 1 Introduction
The S800 I/O is distributed modular I/O which communicates with numerous
controllers over a Advant Fieldbus 100 (AF 100), PROFIBUS-DP or directly.
The S800 I/O provides easy installation of the I/O modules and process cabling. It is
highly modularized and flexible so that I/O modules can be combined to suit many
applications.The S800 I/O can be mounted in many configurations to fit most
requirements.

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3BSE 020 923R201

General Information and Installation Users Guide

Chapter 1 Introduction

1.1 About This Book

This book provides a general description of the S800 I/O and reference information
about equipment common to all types of installations, for example power supplies
and Modulebus components. It provides overall instructions for site planning and
installation, start-up and shutdown procedures, and information regarding capacity
and performance. This book is not intended to be the sole source of instruction for
the S800 I/O system.
This chapter provides introductory and background information including
guidelines how to find information in the manual related documentation and a
product and functional overview of the S800 I/O.
Chapter 2 guides in installation of the I/O system including:

Guidelines for planning the installation of the product.

Information how to set up the equipment. It includes safety regulations,

handling and unpacking instructions, inspection and assembly procedures,
cable routing and connections, setup procedures, etc. Common instructions as
well as instructions directed to specific subsystem are given. Activities prior to
power up are described.

Shut-down procedures. In addition to safety regulations, the basic shut down

procedures are given. You should know how to shut-down the product if initial
power up has problems.

Start-up procedures. In the set-up section the conditions and the preparation for
start are discussed, and here you can find basic power up procedures, such as,
how to apply power to and initialize the I/O system.

Product Verification. Initial determination that the I/O is functional.

Chapter 3 will give you the information needed to obtain the desired function.
The main information is structured as follow:

Design considerations and guidelines are given.

Capacity and performance.

Chapter 4 discusses the different start modes and operating modes of the I/O.
Chapter 5 focus is on fault finding supported by built in diagnostics and use of
system status displays in operator station and LEDs on I/O hardware units.

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General Information and Installation Users Guide

Section 1.1 About This Book

Those people involved in system engineering should attend the applicable system
engineering or maintenance courses offered by ABB Automation University.

Use of Warning, Caution, Information, and Tip Symbols

This publication includes :DUQLQJ, &DXWLRQ, and ,QIRUPDWLRQ symbols where

appropriate to draw the readers attention to safety related or other important
information. It also includes a symbol for 7LS to provide useful hints to the reader.
The symbols should be interpreted as follows:
Warning indicates the presence of a hazard which could result in SHUVRQDOLQMXU\.

Caution indicates the presence of a hazard which could result in HTXLSPHQWRU

SURSHUW\GDPDJH.
Information alerts the reader to pertinent facts and conditions.

Tip indicates advice on, for example, how to design your project or how to use a
certain function.
Although :DUQLQJ hazards are related to personal injury, and &DXWLRQ 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, it is
important to comply fully with all :DUQLQJ and &DXWLRQ notices.

3BSE 020 923R201

General Information and Installation Users Guide

Chapter 1 Introduction

1.2 Product Overview

The S800 I/O provides easy installation of the I/O modules and process cabling. It is
highly modularized and flexible so that the I/O modules can be combined to suit
many applications including Intrinsic Safety Interface. The S800 I/O modules and a
Fieldbus Communication Interface (FCI) are combined to form an I/O Station.
The equipment that is used as part of the I/O Station with S800 I/O is presented in
Table 1-1.
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Device Type
Designator

Function

AI801

8 AI channels (1x8), 0...20mA

AI810

8 AI channels (1x8), 0...20mA, 0...10V

AI820

4 AI channels (differential), -20...+20mA, -10...+10V, -5...+5V

AI830

8 AI channel for Resistance Measurements (e.g. Pt 100 sensors)

AI835

7+1 AI channels for Thermocouples or mV Inputs

AI890

8 AI channels (1x8), 0...20mA, I.S. interface

AO801

8 AO channels (1x8), 0...20mA

AO810

8 AO channels (1x8), 0...20mA

AO820

4 AO channels galv. isolated (bipolar), -20...+20mA, -10...+10V

AO890

8 AO channels (1x8), 0...20mA, I.S. interface

CI810

Fieldbus Communication Interface (FCI) for Advant Fieldbus 100

CI820

Redundant Fieldbus Communication Interface (FCI) for Advant

Fieldbus 100

CI830

Fieldbus Communication Interface (FCI) for PROFIBUS-DP

DI801

16 DI channels (1x16), 24V d.c., current sink

DI810

16 DI channels (2x8), 24V d.c., current sink

DI811

16 DI channels (2x8), 48V d.c., current sink

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General Information and Installation Users Guide

Section 1.2 Product Overview

7DEOH  ,26WDWLRQZLWK6,2&RPSRQHQWV&RQWLQXHG

Device Type
Designator

Function

DI814

16 DI channels (2x8), 24V d.c. current source

DI820

8 DI channels (8x1), 120V a.c./d.c., current sink

DI821

8 DI channels, (8x1) 230V a.c./d.c., current sink

DI830

16 DI channels (2x8) 24V d.c. with sequence of event (SOE)

handling, current sink

DI831

16 DI channels (2x8) 48V d.c. with sequence of event (SOE)

handling, current sink

DI885

8 DI channels, (1x8) 24/48V d.c. with sequence of event (SOE)

handling, current sink

DI890

8 DI channels (8x1), I.S. interface

DO801

16 DO channels (1x16), 24Vd.c., 0.5A, current sourcing

DO810

16 DO channels (2x8), 24Vd.c., 0.5A, current sourcing

DO814

16 DO channels (2x8), 24Vd.c., 0.5A, current sinking

DO815

8 DO channels (2x4), 24V d.c., 2A, current sourcing

DO820

8 DO channels (8x1), Relay, 250V, 3A a.c. normally open

DO821

8 DO channels (8x1), Relay, 250V, 3A a.c. normally closed

DO890

4 channels (4x1), 12V 40 mA, I.S. interface

DP820

2 channels, pulse count and frequency measurement

TB805

Cable adaptor out module (electrical ModuleBus)

TB806

Cable adaptor in module (electrical ModuleBus)

TB807

Terminator module for electrical ModuleBus

TB810

ModuleBus Optical Port Module 10 Mbit driver, fiber optic

connection.

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General Information and Installation Users Guide

Chapter 1 Introduction

7DEOH  ,26WDWLRQZLWK6,2&RPSRQHQWV&RQWLQXHG

Device Type
Designator

Function

TB811

ModuleBus Optical Port Module 5 Mbit driver, fiber optic

connection.

TB815

ModuleBus Interconnection Unit to redundant FCIs (CI820)

TB820

ModuleBus Modem, fiber optic ModuleBus interface of an I/O

cluster. 10 Mbit driver.

TC501V150

Cable terminator for AF 100 twisted pairs, 150 ohms

TC505

Connector: AF 100 Trunk Tap to FCI

TK801V003

Cable, ModuleBus Extension, 300 mm (11.8")

TK801V006

Cable, ModuleBus Extension, 600 mm (23.6")

TK801V012

Cable, ModuleBus Extension, 1.2 m (47.25")

TK811V015

Cable, Optical ModuleBus Extension, 1.5 m (59"), duplex, plastic

TK811V050

Cable, Optical ModuleBus Extension, 5 m (16), duplex, plastic

TK811V150

Cable, Optical ModuleBus Extension, 15 m (50), duplex, plastic

TK812V015

Cable, Optical ModuleBus Extension, 1.5 m simplex, plastic

TK812V050

Cable, Optical ModuleBus Extension, 5 m simplex, plastic

TK812V150

Cable, Optical ModuleBus Extension, 15 m simplex, plastic

TU810

Compact MTU, 3*8 + 2*3 terminals, 50V

TU811

Compact MTU, 2*8 terminals, 250V

TU812

Compact MTU, 25 pin D-sub Connector for field connection, 50V

TU814

Compact MTU, Crimp Snap-in Connector for field connection,

50V

TU830

Extended MTU, 3*16 + 2*4 terminals, 50V

TU831

Extended MTU, 8*2 terminals, 250V

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General Information and Installation Users Guide

Section 1.2.1 Product Scope

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Device Type
Designator

Function

TU835

Extended MTU, 4*2 groups + 2*4 power terminals, 50V,

individually fused per channel

TU836

Extended MTU, 2*4 groups + 2*6 power terminals, 250V,

individually fused per channel

TU837

Extended MTU, 2*4 groups + 2*6 power return terminals, 250V,

fused

TU838

Extended MTU, 2*4 groups + 2*4 power return terminals, 50V,

fused

TU890

Compact MTU, I.S. applications, 50V

SD811

Power supply, 120/230V a.c. to 24V d.c. @ 2.5A

SD812

Power supply, 120/230V a.c. to 24V d.c. @ 5.0A

RE810

Wall Cabinet, IP65, 800 x 1000 x 300 mm (31.5 x 39.4 x 11.8)

1.2.1 Product Scope

The S800 I/O is a modular I/O system. The modular system allows for easy
configuration of the I/O type and size.
An S800 I/O Station can consist of a base cluster and up to 7 additional I/O clusters.
The base cluster, consists of a Fieldbus Communication Interface module (FCI) and
up to 12 I/O modules. I/O clusters 1 to 7 consist of a ModuleBus Modem and up to
12 I/O modules. I/O clusters 1 to 7 are connected to the FCI though a fiber optic
expansion of the ModuleBus. An S800 I/O Station can have up to 24 I/O modules.
This means that an I/O Station can have a maximum of 384 digital channels or a
maximum of 192 analog channels.
An S800 I/O Station base cluster can also consist of redundant FCIs to provide
greater availability of communications between the Advant Controller and the
ModuleBus.

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General Information and Installation Users Guide

Chapter 1 Introduction

Each I/O cluster can be divided in groups using ModuleBus extension cables
between the groups. The maximum length of the electrical ModuleBus of an I/O
cluster is 2.5 meters (8.2 ft.) including extension cables. The factory made extension
cables which plug into the cable adaptors are available in lengths of 0.3, 0.6 and
1.2 m (1, 2 and 4 ft.). The maximum length of the optical ModuleBus expansion is
dependent on the number of ModuleBus Modems. The maximum length between
any two clusters is 15m (50ft.) with plastic fiber and 200m (667ft) with HCS glass
fiber. Factory made optical duplex cables (plastic fiber) are available in lengths of
1.5, 5 and 15 m (5, 16.7 or 50 ft.).
ModuleBus

Each S800M I/O module is installed on a Module Termination Unit (MTU). The
first MTU with its I/O module or S800L module connects to the FCI or a clusters
ModuleBus Modem and then each of the remaining MTUs or S800L modules
connect to the previous MTU or S800L module. With redundant FCIs, the
ModuleBus connects to the ModuleBus Interconnection Unit.
An FCI communicates with its I/O modules over the ModuleBus. The ModuleBus
can be divided into 8 clusters, one base cluster and up to 7 I/O cluster. The base
cluster consists of the FCI and I/O modules. Additional I/O clusters (1 to 7) consist
of a ModuleBus Modem and I/O modules. The ModuleBus Modems are connected
via optical cables to an optional ModuleBus Optical Port module on the FCI.
Within a cluster the ModuleBus is made up of increments that are integrated into
each MTU or S800L module. The FCI and ModuleBus Modems have a ModuleBus
outlet connector to connect to an MTU or a S800L module. An MTU and S800L
module have a bus inlet and a bus outlet connector. By adding, on the DIN rail, an
MTU or a S800L module to a FCI or a ModuleBus Modem, the bus is automatically
expanded up to a maximum of 12 MTUs or S800L modules. Unique position codes
are automatically assigned to each MTU or S800L module as the bus is expanded.
An inserted S800M module is assigned the unique position identity of its MTU.
Through the incremental bus design the physical size of an S800 I/O installation is
directly proportional to the number of installed MTUs or S800L modules.

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General Information and Installation Users Guide

Section 1.2.1 Product Scope

The S800M I/O modules can be inserted and removed from MTUs without
disturbing system operation. The physical lock, which locks an I/O module to its
MTU, allows I/O module removal only when the lock is in its unlock position. The
locking mechanism also acts as a logic lock so that an I/O module is only
operational when the lock is in the locked position. If the lock is in its unlocked
position, output channels are de-energized and I/O modules can be
inserted/removed without need to remove system or field power.
The MTUs are totally passive units with all active circuitry allocated to the I/O
module. The ModuleBus requires a terminator to be installed after the last MTU or
S800L module of a cluster.

2.5 meters (8.2 feet) maximum

Status

S1 23 456 78 910 11121314 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

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2.5 meters (8.2 feet) maximum

Status

S1 23 456 789 10 1112 13 14 1516

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

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3BSE 020 923R201

General Information and Installation Users Guide

Chapter 1 Introduction

1.2.1.1 CI810 Fieldbus Communication Interface

The CI810 Fieldbus Communication Interface (FCI) module is a configurable
communication interface which performs operations such as signal processing,
gathering of various supervision information, OSP handling and configuration of reinserted I/O modules. The FCI connects to the controller by way of the Advant
Fieldbus 100 (AF 100) twisted pair segment. The FCI supports redundant media
configurations.
Please refer to specifications in 6,2)LHOGEXV&RPPXQLFDWLRQ,QWHUIDFHIRU
$GYDQW)LHOGEXVfor more information.

1.2.1.2 CI820 Fieldbus Communication Interface

The CI820 Fieldbus Communication Interface (FCI) module is a configurable
communication interface which performs operations such as signal processing,
gathering of various supervision information, OSP handling and configuration of reinserted I/O modules. The FCI connects to the controller by way of the Advant
Fieldbus 100 (AF 100) twisted pair segment. The FCI supports redundant fieldbus
communication interface.
Please refer to specifications in 6,2)LHOGEXV&RPPXQLFDWLRQ,QWHUIDFHIRU
$GYDQW)LHOGEXV8VHUV*XLGHfor more information.

1.2.1.3 CI830 Fieldbus Communication Interface

The CI830 Fieldbus Communication Interface (FCI) module is a configurable
communication interface which performs operations such as signal processing,
gathering of various supervision information, OSP handling and configuration of reinserted I/O modules. The FCI connects to the controller by way of the PROFIBUSDP fieldbus.
Please refer to specifications in 6,2)LHOGEXV&RPPXQLFDWLRQ,QWHUIDFHIRU
352),%86'38VHUV*XLGHfor more information.

10

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General Information and Installation Users Guide

Section 1.2.1 Product Scope

1.2.1.4 TB815 Interconnection Unit

The TB815 Interconnection Unit is used with redundant CI820 FCIs to provide an
interface to the ModuleBus (electrical and optical) and service port connections.
All signals between the redundant FCIs such as AF 100 signals and control signals
are routed through the TB815 and it also provides the termination of the electrical
ModuleBus.
Please refer to specifications in 6,2)LHOGEXV&RPPXQLFDWLRQ,QWHUIDFHIRU
$GYDQW)LHOGEXV8VHUV*XLGHfor more information.

1.2.1.5 TB810/TB811 ModuleBus Optical Port

The TB810/TB811 Optical ModuleBus Port is used with the CI810 or CI830 FCI or
the TB815 Interconnection Unit to provide an interface for the Optical ModuleBus
expansion. The TB810/TB811 has two connectors for fiber optic connections and a
connection to the communication interface module. TB810/TB811 Optical
ModuleBus Port
TB810 is used with TB820 and ABB-Drives equipment with 10 Mbit driver.
TB811 is used with ABB-Drives equipment with 5 Mbit driver. Figure 1-4 shows
the TB810/TB811 installed in the CI810 FCI.
4 6
3
7 x 10
8
2
109
4 56
3
7x1
8
2
109

CI810
SWX.X/Y
L+ L+ SA
L- L- SB

AF100
1

TB810/TB811
Optical ModuleBus Port

Tx Rx
2

SH
SH

SH
SH

LED Status
Indicators

Tx

Rx

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3BSE 020 923R201

11

General Information and Installation Users Guide

Chapter 1 Introduction

1.2.1.6 TB820 ModuleBus Modem

The TB820 ModuleBus Modem is a fiber optic interface to the ModuleBus.
The ModuleBus Modem has an electrical and an optical interface which are
logically the same bus. A maximum of 12 I/O modules can be connected to the
electrical ModuleBus and up to seven clusters can be connected to the fiber optic
ModuleBus. The fiber optic interface is intended for local distribution of I/O
clusters and where more then 12 I/O modules are required in an I/O Station.
The TB820 ModuleBus Modem has a rotary switch that selects its cluster number, 1
to 7, on the optical ModuleBus. Figure 1-5 shows the layout of TB820.

LED Status
Indicators

P
ORx1

ORx2
ERx

Electrical ModuleBus
Interface Connector

DIN Rail

CLUSTER
4 56
3
7
2
1

Cluster Address
Switch
(Address 4 shown)

TB820

L+ L+ SA
L- L- SB
X5
X4
Rx Rx
Tx
Tx

Power Supply
Connections

Optical ModuleBus
Interface Connector

Redundant Power
Supervision

)LJXUH  7%0RGXOH%XV0RGHP

12

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General Information and Installation Users Guide

Section 1.2.1 Product Scope

The ModuleBus Modem communicates with the CI810 FCI via a TB810, or
theTB815 Interconnection Unit via a TB810, and to the I/O modules. The FCI
handles the I/O-modules operations such as read and write data, read status and
configuration of modules and channels.
The TB820 ModuleBus Modem provides 24V d.c. short circuit proof (from the
source) and an isolated, short circuit proof 5 V dc power to the clusters I/O
modules by way of the electrical ModuleBus connection. One power source (single
or redundant 24V d.c.) can be connected to the power terminals (L+ & L-).
Redundant power supply can be supervised via inputs SA and SB.
58 mm (2.3)

122 mm (4.8)

R
P

ORx1

ORx2

170 mm (6.7)

ERx

CLUSTER
4 5 6
3
7
2

TB820

L+ L+ SA
L- L- SB

)LJXUH  7%0RGXOH%XV0RGHP'LPHQVLRQV

Please refer to specifications in Appendix A, Specificationsfor more information.

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General Information and Installation Users Guide

Chapter 1 Introduction

1.2.1.7 Module Termination Units

The Module Termination Units (MTU) are passive base units used to house the
S800M I/O modules. They contain the process wiring terminals and a section of the
ModuleBus.
Please refer to specifications in 6,20RGXOHVDQG7HUPLQDWLRQ8QLWVand 6
,20RGXOHVDQG7HUPLQDWLRQ8QLWVZLWK,QWULQVLF6DIHW\,QWHUIDFH8VHUV*XLGH for
more information.

1.2.1.8 I/O Modules

There are two different types of I/O modules; S800M modules and S800L modules.
S800M modules are designed to be put into a MTU.
S800L modules are designed to be put direct on a standard DIN rail and contain also
process connections and part of the ModuleBus.
S800M I/O Modules

The I/O modules have open ventilated plastic enclosures. On the front of each I/O
module there are three LEDs (FAULT, RUN and WARNING) indicating the module
status and digital I/O modules have a status LED for each channel, some even two.
One additional LED (OSP) is included on analog output and digital output modules.
I/O modules may be replaced in a fully operational I/O station. Mechanical keying
on modules and MTUs protect I/O modules from being inserted in positions where
they could be damaged by excessive voltage or current. An electronic type
designation ID in each module keeps the I/O module from being taken into
operation by the FCI, if a modules ID does not match the configured module type
definition in the data base.
S800L I/O Modules

The I/O modules have open vertical plastic enclosures and a bottom of sheet-metal.
On the front of each I/O modules there is a LED (STATUS) indicating the module
status (run or fault) and digital I/O modules have a status LED for each channel.

14

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General Information and Installation Users Guide

Section 1.2.1 Product Scope

Please refer to specifications in 6,20RGXOHVDQG7HUPLQDWLRQ8QLWVand 6

,20RGXOHVDQG7HUPLQDWLRQ8QLWVZLWK,QWULQVLF6DIHW\,QWHUIDFH8VHUV*XLGH for
more information.

1.2.1.9 Power Supply

The SD811 and SD812 are switch-mode power supply units which convert the
mains voltage to 24 volts d.c. These power supplies can be utilized for nonredundant and redundant applications and do not require additional load-sharing
control equipment or diode voting units.
Please refer to specifications in Section A.1, SD811/SD812 Power Supply Module,
24V d.c.for more information.
The S800 I/O station can be powered by a single or redundant supply voltage of
24V d.c., see Figure 1-7, Figure 1-8. Two power supplies with 120/230V inputs and
24V d.c. outputs are available to supply the I/O station and its field circuits.
The SD811 Power Supply provides 2.5A at 24V d.c. and the SD812 Power Supply
provides 5A at 24V d.c. See Power Supply Connections for details.

Power
Supply

24V
A
B
FCI
or ModuleBus Modem

I/O station

24V power supply

I/O modules

)LJXUH  ,QVWDOODWLRQ8VLQJ6LQJOH3RZHU6XSSO\8QLW

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General Information and Installation Users Guide

Chapter 1 Introduction

The FCI and ModuleBus Modem are able to supervise the redundant voltage supply.
The supervision function is individually configurable for power supervision of each
I/O station.
FCI
or ModuleBus Modem
Power
Supply
A

24V
A
B

Power
Supply
B

I/O station
24V d.c. power supply
Supervision 24V A, 24V B
I/O modules

)LJXUH  ,QVWDOODWLRQ8VLQJ5HGXQGDQW3RZHU6XSSO\8QLWV

16

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General Information and Installation Users Guide

Section 1.2.1 Product Scope

1.2.1.10 Example of Enclosure Configurations

In Figure 1-9 a layout example are shown for an I/O station in an RE810 cabinet
which could house the I/O station with power supplies for the I/O system as well as
for the field powering, and space for marshalling terminals.

POW POW

1000 mm (39.4")

FCI

800 mm (31.5")

)LJXUH  5(&DELQHWZLWK,20RGXOHVDQG5HGXQGDQW6WDWLRQ3RZHU

6XSSOLHV

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General Information and Installation Users Guide

Chapter 1 Introduction

1.2.1.11 Support for External Intrinsic Safety System

Beside S800 I/O modules with Intrinsic Safety Interfaces, Intrinsic Safety Systems
can be connected to the S800 I/O.
Intrinsic Safety System from ELCON Instruments (manufacturer outside ABB) is
supported via S800 I/O module and a special MTU.
Supported Intrinsic Safety System is the HiD Series 2000.
The S800 I/O modules are connected via MTU TU812, a standard cable and a
specific adapter board, one for each I/O module types.
For further information refer to (OFRQ,QVWUXPHQWVPDQXDOV and ,QWULQVLF6DIHW\
6XSSRUW6,2ZLWK6HULHV.
The following I/O modules are supported:
AI810, AO810, DI810 and DO810.
See Figure 1-10 for an example of a connection between S800 I/O and Intrinsic
Safety System.
S800 I/0

Intrinsic Safety System

)LJXUH  ([DPSOHRI&RQQHFWLRQEHWZHHQ6,2DQG,QWULQVLF6DIHW\6\VWHP

IURP(/&21

18

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General Information and Installation Users Guide

Section 1.3 Related Documentation

1.2.1.12 Support for HART

ELCON Instruments provides a HART protocol connection to I/O modules
integrated with the Intrinsic Safety System, see Figure 1-11.
For further information refer to (OFRQ,QVWUXPHQWVPDQXDOVand ,QWULQVLF6DIHW\
6XSSRUW6,2ZLWK6HULHV.
To PC
RS485

S800 I/O

HART Multiplexer Connection

Intrinsic Safety System

)LJXUH  ([DPSOHRI&RQQHFWLRQEHWZHHQ6,2DQG,QWULQVLF6DIHW\6\VWHP

IURP(/&21DQG+$570XOWLSOH[HU,QWHUIDFHIURP+$57

1.3 Related Documentation

Table 1-2 lists all documentation related to the S800 I/O system.

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General Information and Installation Users Guide

Chapter 1 Introduction

7DEOH  5HODWHG'RFXPHQWDWLRQ

Title

Description

S800 I/O Modules and Termination Units Describes the I/O modules and
Users Guide
termination units in the S800 I/O
system
S800 I/O Modules and Termination Units Describes I/O modules and termination
with Intrinsic Safety Interface
units with I.S. interface in the S800 I/O
Users Guide
system

20

S800 I/O Fieldbus Communication

Interface for Advant Fieldbus 100
Users Guide

Describes the AF100 FCI in the S800

I/O system

S800 I/O Fieldbus Communication

Interface for PROFIBUS-DP
Users Guide

Describes the PROFIBUS-DP FCI in

the S800 I/O system

S800 I/O PROFIBUS-DP Fieldbus

Communication Interface
Reference Manual

Describes the memory mapping on

PROFIBUS for the S800 I/O system

Interference-free Electronics

Describes the rule for the installation of

equipment to ensure the correct
operation of equipment in environments
where disturbance are present

Environmental Data for ABB Products

This manual contains a summary of the

ABB product environmental factors

Advant Fieldbus 100 Users Guide

Describes the equipment and contains

information required to install and
commission AF100

Intrinsic Safety Support S800 I/O with

Series 2000 Users Guide

Describes how S800 I/O connects to

Series 2000 from Elcon Instruments.

ABB Installation Rules

Describes the equipment and contains

information required to install and
commission.

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General Information and Installation Users Guide

Section 1.4 Terminology

1.4 Terminology
The following is a list of terms associated with S800 that you should be familiar
with.
Term

Description

AF 100

Advant Fieldbus 100 is the communications bus

between the I/O stations and the Advant Controllers.
(FCI to CI52x)

FCI

The Fieldbus Communication Interface (FCI) device

contains the interface to the fieldbus (e.g. AF 100),
ModuleBus interface and power regulators. The FCI
module can manage 24 I/O devices (up to 12 directly
and to the others in 1 to 7 I/O clusters).

Base cluster

Advant Fieldbus 100 is the communications bus

between the I/O stations and the Advant Controllers.
(FCI to CI52x)

I/O cluster

An extension of the I/O Stations ModuleBus connected

to the FCI by fiber optic connections. Up to 12 I/O
devices per cluster.

I/O device

A complete I/O device consists of one MTU and one I/O

module.

I/O module

Is an active, electronic and signal conditioning unit. Can

be a part of an I/O device or a S800L I/O module.

I/O station

An I/O station consists of one or two FCI(s), 1-7 I/O

clusters and up to 24 I/O devices.

ModuleBus

Is an incremental, electrical or optical, bus for

interconnection of I/O devices.

(ModuleBus) Extension
cable

Is used when extending the electrical ModuleBus (within

the max. 2 meters).

MTU

The Module Termination Unit is a passive base unit

containing process terminals and a part of the
ModuleBus.

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General Information and Installation Users Guide

Chapter 1 Introduction

22

Term

Description

OSP

Outputs Set as Predetermined. A user configurable

action on an output module when communications is lost
to the FCI or Controller.

PROFIBUS-DP

PROFIBUS-DP is a fieldbus standard.

RTD

Resistance Temperature Detector.

SOE

Sequence of events. Time stamping of status changes

for digital inputs.

TC

Thermocouples

I.S.

Intrinsic Safety is a protection technique to prevent

explosion in hazardous areas of a process plant.

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General Information and Installation Users Guide

Section 2.1 Site Planning

Chapter 2 Installation
This chapter contains guidelines for planning the installation of the S800 I/O
equipment.
This chapter does not give the complete list of measures to be taken with respect to
environment and other conditions on site. The equipment should be adapted to the
actual application by thorough system definition and design.
Since each system is designed to meet a specific requirement, there is no standard
configuration that describes every system. Therefore, certain areas of the following
instructions are meant only as a guide for planning a specific installation. However,
some of the information covers specific requirements for proper system and
equipment operation, and is not subject to modification.
All information given in this chapter relates to standard equipment.
For installation of Advant Fieldbus 100 and Advant Fieldbus 100 modems, see the
$GYDQW)LHOGEXV8VHUV*XLGH.
For installation of PROFIBUS see relevant documentation.

2.1 Site Planning

2.1.1 Site Selection and Preparation
When planning an S800 I/O installation, please consider the following:

Surrounding environment and atmosphere.

The temperature in the room where the equipment is to be located. This should
include an estimation of the resulting temperature rise with respect to the
power dissipation from the planned equipment.

Proximity of the equipment to the process.

Size of the cabinets to accommodate all the required equipment.

Minimum distances from a cabinet to walls and ceiling to obtain satisfactory

results from different aspects.

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General Information and Installation Users Guide

Chapter 2 Installation

Ease of access for moving equipment in and out of area.

Free space in front of cabinets. Also consider the need of space to fully open a
cabinet door either left hand or right hand hinged.

Spare area for future expansion of the system.

Grounding by an effective plane of copper bars.

Cable routing with respect to installation rules.

Availability of power and other utilities.

The following sections examine some of these factors in detail and provide
recommendations and requirements as necessary.

2.1.2 Environmental Considerations

General

S800 I/O equipment can be installed in a designated control room, or located in the
process area when housed in a suitable enclosure. The S800 I/O is designed for a
demanding industrial environment.
Temperature

,20RGXOH)DFWRUV
The maximum ambient air temperature around S800M modules is 55C (131F) for
I/O modules mounted on Extended MTUs on vertical or horizontal orientated DINrails. I/O modules mounted in Compact MTUs or S800L modules on a vertical
DIN-rail allows opera-tion at 40C (104F) and horizontal DIN-rail allows
operation at 55C (131F).
The ambient temperature de rating which applies for vertical DIN rail and Compact
MTUs is due to the reduced air flow through an I/O module due to the orientation.

24

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General Information and Installation Users Guide

Section 2.1.2 Environmental Considerations

The different hardware modules in the S800 I/O have different outputs of heat.
Accurate calculation of the heat produced by the system requires knowledge of the
modules and the work cycle. Power supplies with regulated outputs are highly
recommended to minimize heat in cabinets. Use of such devices will reduce the
power loss of resistive loads and current outputs, for example, digital inputs and
analog outputs. Please refer to Section 3.1.8, Power and Cooling for more
information.
&DELQHWV)DFWRUV
The temperature within cabinets and in the surrounding environment and
atmosphere must be considered, especially when using sealed cabinets (IP65/IP54)
or tropicalized cabinets (IP41) with considerable equipment and outside ambient
temperatures at levels approaching 40C (104F). The frequency of faults is
estimated to double for each 20 C (36F) increase in temperature. Thus, it is
important to maintain as low ambient temperature outside the cabinets (typical
operating range 10 - 40C (50 - 104F)) as possible where the equipment is
installed.Design considerations are given in Section 3.1.4.2, Heat Dissipation
Permitted in Cabinets.
Vibration

The cabinets are to be located on a stable floor, wall, deck or supporting structure,
free from vibrations.
If the system equipment is installed in a control room adjacent to large machinery
such as shakers or large presses, where frequent major vibrations occur, shock
absorbers or an isolation pad may be required to protect the system equipment.
Shock absorbers normally protect the equipment from sustained low level vibrations
(vibrations that are perceptible, but not excessive). If vibrations or shock is a major
problem, more extreme measures must be considered to alleviate the problem, such
as fasten the MTUs with extra screws.

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General Information and Installation Users Guide

Chapter 2 Installation

2.1.3 Electromagnetic Compatibility and CE Marking

Grounding, cable selection and cable routing must be considered for
electromagnetic interference-free operation. Planning considerations are discussed
in the following sections. Instructions for implementing these plans are provided in
Section 2.2, Installation Procedures.
The S800 I/O meets requirements specified in EMC Directive 89/336/EEC.
You should request CE marking and compliance when ordering the equipment.
For more information about environmental immunity, including EMC qualities with
or without CE marking, refer to the (QYLURQPHQWDO'DWDIRU$%%3URGXFWVdata
sheet.

2.1.4 Layout of I/O Stations

2.1.4.1 I/O Station with S800 I/O
The S800 I/O is mounted on a DIN-rail. The DIN-rail is mounted in a cabinet or on
an enclosure wall to a metal sheet with fastening screws every 100 mm to ensure a
good chassis ground connection in the cabinet or an open rack. The FCI,
ModuleBus Modem, MTUs and S800L I/O modules are mounted to the
DIN-rail. The FCI, ModuleBus Modem and MTUs have a snap locking device that
attaches it to the mounting rail.
It is possible to mount the FCI, ModuleBus Modem, MTUs and S800L I/O modules
both vertically and horizontally.
To mount the FCI, ModuleBus Modem or MTU, place it on the top edge of the
DIN rail, release the rail latch with a flat blade screw driver and snap the bottom
mechanism into place. When the unit is in place on the DIN rail and in position, take
away the screw driver and the rail latch will fix the unit in position on the DIN rail.
Release the unit from the DIN rail in a similar way.
S800L module has screw locking device that attaches it to the mounting rail.

26

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General Information and Installation Users Guide

Section 2.1.4 Layout of I/O Stations

0RXQWLQJ3URFHGXUHV6/,2
Use a screwdriver with a 1 mm (0.03 inch) tick flate blade that fits the locking
screw. This is the only tool you need for the mounting. See Figure 2-1.
1.

Turn the locking device to RSHQ position (1) and hook the lip at the rear of the
unit onto the DIN rail and snap the unit into position.

2.

Turn the screw to the VOLGHposition (2). Now you can slide the unit along the
rail to desired position and join it to another unit. Make sure that the connector
pins and sockets are in line. Do not use excessive force!

3.

Turn the screw clockwise to ORFNHGposition (3). The unit is now locked and
has good earth connection to the DIN rail.It is essential that the locking device
is in locked position to avoid problems due to vibration and inadequate
grounding.

1. Open

2. Slide

3. Locked

)LJXUH  0RXQWLQJ3URFHGXUHV

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General Information and Installation Users Guide

Chapter 2 Installation

DO801

Turn the screw counterclockwise to

release the locking device

)LJXUH  8QORFNLQJWKH6/,20RGXOH

28

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General Information and Installation Users Guide

Section 2.1.4 Layout of I/O Stations

A flat blade screw driver can be used to release the latch to allow easier movement
along the DIN rail or removal of the unit (Figure 2-3).

DIN-rail

I/O Module
Lock/Switch

To

E
F

Lock

A
E
F

B
C

Ground
Clip Spring
D

A
B
C

L1+ C1 2

Move up to
release rail
latch

L1+ B1 2
L1- A1 2

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

A8 L2-

Pry down to
release rail
latch

)LJXUH  078/DWFKLQJ6\VWHP

Snapping the FCI, ModuleBus Modem or MTU to the DIN-rail makes contact by a
grounding spring with the chassis.

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General Information and Installation Users Guide

Chapter 2 Installation

Connection of the MTU, or S800L module, ModuleBus connector to the FCI,

ModuleBus Modem, next MTU or S800L module is made by sliding the MTU or
the S800Lmodule along the mounting rail and then locking it in place (Figure 2-4).

T1

T2

E
F

E
F

A
B
C

AF100
1

A
B
C

SWX.X/Y
L+ L+ SA
L- L- SB

A
B
C

STN. ADDR.
4 56
3
7 x 10
8
2
109
4 56
3
7 x1
2
8
109

CI810

A
B
C

SERVICE

E
F

E
F

Tx Rx
2

SH
SH

SH

Tx

L1+ C1 2
L1+ B1 2

SH

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

L1+ C1 2
L1+ B1 2

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

Rx
L1- A1 2

A8 L2-

L1- A1 2

A8 L2-

)LJXUH  ,26WDWLRQ,QVWDOODWLRQ'LDJUDP

30

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General Information and Installation Users Guide

Section 2.1.4 Layout of I/O Stations

The MTU and S800L module (locking screw in position) can be disconnected from
the FCI, ModuleBus Modem, another MTU or S800Lmodule by using a screw
driver and pressing it between the two items.

R
P

T1

E
F

T2

D
D

AF100
1

A
B
C

SWX.X/Y
L+ L+ SA
L- L- SB

DO801

E
F

STN. ADDR.
4 56
3
7 x 10
2
8
109
4 56
3
7x1
2
8
109

CI810

A
B
C

SERVICE

Tx Rx
2

SH
SH

Tx

SH
SH

L1+ C1 2
L1+ B1 2

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

Rx
L1- A1 2

A8 L2-

)LJXUH  0RGXOH5HOHDVH

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General Information and Installation Users Guide

Chapter 2 Installation

Redundant FCI Installation

Installation of an I/O Station with redundant FCIs requires two CI820 FCIs and a
TB815 Interconnection Unit (Figure 2-6). They are connected to the I/O modules of
the base cluster by an electrical ModuleBus extension cable. From the TB815
ModuleBus connector, a TK801V0xx cable is connected to the first MTU via a
TB806 Cable Adapter-in module.

T1

T2

PR

DU

M
O
D
U
L
E
B
U
S

SERVICE

CI820

P
DU

SERVICE

STN. ADDR

CI820

TB815

4 56
3
7 x 10
2
8
109
5
4 6
3
7x1
2
8
109

SWX.X/Y

SWX.X/Y

L+L+ SA
L- L- SB

R
T2

PR

STN. ADDR

4 56
3
7 x 10
2
8
109
5
4 6
3
7x1
2
8
109

F
T1

L+ L+ SA
L- L- SB

AF100
+
SH
SH

Tx

Rx

AF100
+
SH
SH

)LJXUH  5HGXQGDQW&,)&,VDQG7%,QWHUFRQQHFWLRQ8QLW/D\RXW

The redundant FCIs can either be mounted on a separate DIN rail or the same one as
the I/O modules. Room must be allowed to the left and right of the FCIs for
disconnection from the TB815 for removal (Figure 2-7).
The total length of the ModuleBus extension, from the TB815, and ModuleBus
segments of the I/O modules must not exceed 2.5 meters (8.2 feet).

32

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Section 2.1.4 Layout of I/O Stations

Optical ModuleBus Extension can be connected to the TB815 via the TB810
ModuleBus Optical Port unit for connection of 1 to 7 additional I/O clusters.

DU

E
E

14

13
A

14

15

16

A
C

15

16

16

DI810

DI810

DI810

24V

24V

24V

AF100

+
-

SH

12

13

15

14

TB806

SH
Rx

11

13

Tx

10

SH

L+ L+ SA
L- L- SB

AF100

9
A

12

CI820

12

L+ L+ SA
L- L- SB

TB815

11

CI820

STN. ADDR
4 5 6
3
7
2
8 x 10
1 0 9
4 5 6
3
7
2
8 x1
1 0 9

A
C

11
STN. ADDR
4 5 6
3
7
2
8 x 10
1 0 9
4 5 6
3
7
2
8 x1
1 0 9

10

10

SERVICE

SERVICE

T2

T1
PR

T2

M
O
D
U
L
E
B
U
S

DU

T1
PR

L1+ C1 2
L1+ B1 2

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

L1+ C1 2
L1+ B1 2

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

L1+ C1 2
L1+ B1 2

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

SH
L1- A1 2

A8 L2-

L1- A1 2

A8 L2-

L1- A1 2

A8 L2-

TK801V003
(300 mm)
(1 ft.)

)LJXUH  &RQQHFWLRQRI5HGXQGDQW)&,VWR,20RGXOHV

ModuleBus Extension (Electrical)

When the next MTU or S800L module is located away from the previous MTU,
S800L module or from the TB815 Interconnection Unit, then a TK801V0xx
ModuleBus Extension cable must be used. The previous MTU or S800L module
will require a TB805 Cable Adapter-out to be plugged into the ModuleBus-out
connector. The TK801V0xx cable is then connected to the TB805 adapter. The next
MTU will have a TB806 Cable Adapter-in plugged into the ModuleBus-in
connector and then connected to the other end of the ModuleBus Extension cable
(see Figure 2-8).
The TB805/TB806 ModuleBus Cable Adapter-Out/In adapters mount on the DINrail. Each has a latch that locks it to the rail. There is also a grounding spring that
connects it to the DIN-rail. The latch can be released with a screw driver and the
adaptor moved toward or away (for removal) from the MTU or S800L module.

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Chapter 2 Installation

The ModuleBus Extension cable comes in three standard lengths:

TK801V003 - 300 mm (1 ft.)

TK801V006 - 600 mm (2 ft.)

TK801V012 - 1.2 meters (4 ft.).

ModuleBus length must not exceed 2.5 meters (8.2 feet) from FCI, TB815
Interconnection Unit, or ModuleBus Modem to the last MTUor S800L module
including extension cables.

TB805

D
E
F

E
F

DI810
24V

Male Cable
Connector

Female Cable
Connector

L1+C12 3 4 5 6 7 C8L2+

L1+C12 3 4 5 6 7 C8L2+

L1+B12 3 4 5 6 7 B8L2+
L1-A12 3 4 5 6 7 A8L2-

B
C

B
C

DI810
24V

B
C

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

E
F

E
F

Latch Release

B
C

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

F
R
W

TB806

F
R
W

L1+B12 3 4 5 6 7 B8L2+

TK801V003
(300 mm)
(1 ft.)

L1-A12 3 4 5 6 7 A8L2-

)LJXUH  0RGXOH%XV([WHQVLRQ&DEOH&RQQHFWLRQV

34

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General Information and Installation Users Guide

Section 2.1.4 Layout of I/O Stations

Optical ModuleBus Expansion

The FCI provides fiber optic expansion of the ModuleBus for up to 7 additional I/O
clusters or to drive equipment. The TB810/TB811 ModuleBus Optical Port must be
inserted in to the CI810 or CI830 FCI and TR815 Interconnect unit FCI to provide
optical ModuleBus expansion. See Figure 2-9 for location of the TB810/TB811on
the CI810/CI830 FCI and Figure 2-10 for location in the TB815 Interconnection
Unit.
TB810 has 10 Mbit drivers and is used with the TB820 (S800 I/O) and ABB drives
equipment. TB811 has 5Mbit drivers and is used with ABB variable drives
ACS 600 equipment. The TB811 can only use up to 10 meters (33 ft) plastic optic
fiber. A Modulebus must have the same type of drivers on each node.
4
3
2
1
4
3
2
1

CI810

AF100
L+ L+ SA
L- L- SB

56
09
56
09

7 x 10
8
7x1
8

TB810

Tx Rx
2

SH
SH

SH
SH

Tx

Rx

)LJXUH  /RFDWLRQRI7%7%0RGXOH%XV2SWLFDO3RUWLQ&,)&,

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General Information and Installation Users Guide

Chapter 2 Installation

SERVICE

SERVICE

STN. ADDR

STN. ADDR

CI820

L+ L+ SA
L- L- SB

4 56
3
7 x 10
2
8
109
4 56
3
7 x1
2
8
109

TB815

CI820

L+ L+ SA
L- L- SB

AF100
+
SH
SH

4 56
3
7 x 10
2
8
109
4 56
3
7 x1
2
8
109

AF100
+
-

Tx

SH
SH

Rx

TB810

)LJXUH  /RFDWLRQRI7%7%0RGXOH%XV2SWLFDO3RUWRQWKH7%

Each I/O cluster can have a maximum of 12 S800 I/O modules. The maximum
number of S800 I/O modules or other units connected to one FCI is 24. The optical
ring connection or duplex connection allows for a maximum distribution of 15m
(49 ft.) (plastic fiber) or 200m (667 ft.) (HCS fiber) between each I/O cluster, see
example in Figure 2-11.

36

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Section 2.1.4 Layout of I/O Stations

FCI

FCI

Simplex optical cable (TK812Vxxx)

15m (49 ft.)Max. (plastic fiber)

Duplex optical cable (TK811Vxxx)

15m (49 ft.) Max. (plastic fiber

ModuleBus Optical Port TB810

ModuleBus Modem TB820

TB807 ModuleBus Terminator

Fiber Optic Simplex Configuration

Fiber Optic Duplex Configuration

)LJXUH  2SWLFDO0RGXOH%XV([SDQVLRQ6LPSOH[DQG'XSOH[&RQILJXUDWLRQV

The TB820 can be used in both a simplex optical configuration as well as in a
duplex optical configuration. In a simplex optical configuration, the optical
ModuleBus nodes are connected in a ring. In a duplex optical configuration,
the optical ModuleBus nodes are connected in a row.

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General Information and Installation Users Guide

Chapter 2 Installation

The optical ModuleBus Extension fiber optic (plastic fiber) cable comes in three
standard lengths:

TK811V015 (duplex), TK812V015 (simplex) - 1.5 meters (5 ft.)

TK811V050 (duplex), TK812V050 (simplex) - 5 meters (16 ft.)

TK811V150 (duplex), TK812V150 (simplex) - 15 meters (49 ft.)

As with the FCI (base cluster), the electrical ModuleBus length must not exceed 2.5
meters from the ModuleBus Modem to the last MTU or S800L module of each
cluster. Each cluster requires a TB807 ModuleBus Terminator plugged into the last
MTU or S800L module.
I/O Module Installation

Connection of the I/O module to the MTU is made by setting the I/O Module Keys
#1 and #2 to the correct setting, place the I/O Module Lock/Switch to the unlock
position and then push the I/O module straight onto the MTU. The I/O module is
locked and electrically connected to the MTU by the I/O Module Lock/Switch.
R
W

I/O Module Lock/Switch

(shown unlocked)

E
F

E
F

Turn clockwise
to lock I/O Module
D

I/O Module
Key #1

E
F

E
F

A
B
C

B
C

DI810
24V

A
B
C

B
C

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

I/O Module Lock/Switch

(shown locked)

I/O Module
Key #2

)LJXUH  0780HFKDQLFDO.H\VIRU,20RGXOHDQG0RGXOH/RFN

Do QRW turn the I/O Module Lock/Switch counter-clockwise from the unlocked
position. This will cause it to break and will make the MTU and the I/O module
inoperative.

38

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General Information and Installation Users Guide

Section 2.1.4 Layout of I/O Stations

After all the MTUs or S800L module are connected, the TB807 ModuleBus
Terminator connects to the ModuleBus connector of the last MTU or S800L module
of the I/O Station. The TB807 has a snap latch (Figure 2-13) that holds it in place.
To release the terminator, the latch has to be squeezed to allow removal.

Top View
F
R
W
TB807
1
2
3
4
5
6
7
8

ModuleBus
Terminator
Latch
)LJXUH  7%0RGXOH%XV7HUPLQDWRU,QVWDOODWLRQ

The I/O Station configuration can be as shown in Figure 2-14 and/or as presented in
6,20RGXOHVDQG7HUPLQDWLRQ8QLWVand Section 1.2.1.10, Example of
Enclosure Configurations.

816 mm (32.1")

End Stop

End Stop

DIN-rail
mm
(inches)

10 84 58.5
(0.4) (3.3) (2.3)

20
(0.8)

)LJXUH  ,26WDWLRQ/D\RXWZLWK)&,DQG6,20RGXOHV

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General Information and Installation Users Guide

Chapter 2 Installation

439 mm (17.2")
ModuleBus Modem TB820
Fiber Optic
ModuleBus Cables
10 58
(0.4)(2.2)

mm
20
(0.8) (inches)

58.5
(2.3)

)LJXUH  ,26WDWLRQ/D\RXWZLWK0RGXOH%XV0RGHPDQG6,20RGXOHV

In all installations, two end stops must be mounted on the DIN-rail, one at each end
of the station, to prevent the modules from moving along the rail, see Figure 2-14
The installation rules should be followed as much as possible. The flexibility of the
system allows both horizontal and vertical mounting of the rail and mixing of MTU
types as shown in Figure 2-16.

Status

S 1 234 56 789 1011 12 13141516

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

S 1 234 56 789 10 111213 14 1516

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Status

)LJXUH  &RPSDFW([WHQGHG078DQG6/0RGXOHVVKRZLQJ+RUL]RQWDODQG

9HUWLFDO0RXQWLQJ

40

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General Information and Installation Users Guide

Section 2.1.5 Grounding

2.1.5 Grounding
General

The interference suppression for external signals, are normally directly grounded to
chassis and/or plant ground. The plant ground potential must be stable and well
defined, even in the event of a low ground fault caused by high voltage equipment
or a lightning strike.
Each I/O modules grounding spring connects to the metallic DIN-rail which serves
as the module electronics ground conductor between the inter-connected devices.
This is to ensure a good ground connection both for the internal logic and for the
EMI immunity and RF emission of the modules. The DIN mounting rail must have
a good bond to the PE of the cabinet.
If S800 I/O-modules are configured as two or more groups interconnected with
extension cables, special care should be taken to ensure that the DIN-rails of all
groups have a good connection to ground. If the DIN-rails are mounted on a
common metal sheet, no extra means need be taken except to make sure that each
rail has a reliable low ohmic path to the metal plate. Protective earth connection can
be made at a single point on the common metal plate.

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General Information and Installation Users Guide

Chapter 2 Installation

The ground wire which joins the grounding systems should be 35 mm2 (2 AWG)
copper (Cu), Figure 2-17.
Cabinets
or enclosure

Shield bar

Protective
Ground
Ground Plane
> 35 mm2
(> 2 AWG)

)LJXUH  *URXQGLQJRI(OHFWURQLF(TXLSPHQW

Protective Earth (PE)

Cabinets supplied with 120/220V a.c. always must be connected tp protective earth
(PE) grounding. The equipment PE-conductor should be of 35 mm2 (2 AWG) cross
section if copper lead.
Grounding of Signals and Voltage Supply

For minimum interference and maximum accuracy, it is normally most effective to

ground the signals from transmitters or transducers directly at a grounding point
within the cabinet. It is also advantageous to ground supply voltages for transducers,
sensing voltage for contacts, load supply voltage and so on at the same location.
All modules have galvanic isolation from the chassis; this means that group-wise
isolated modules can be grounded in different equipment as for long as all channels
have a common ground reference at the same location.

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Section 2.1.6 Signal Cable Considerations

In the event that the above recommendations (because of measurement techniques

or safety regulations) cannot be complied with, be sure to use these methods:

Signal isolation for analog input signals.

Digital inputs and outputs are divided into groups at the MTUs and I/O
modules, with supply voltage distribution and grounding common for each
single groups.

Local grounding of a signal at the transducer location may be a requirement for

individual voltage supply to each transducer. This normally hinders the use of
MTUs for voltage distribution. A ground bar with the terminal block and fuse
equipment required by the application can be used in such cases.
If the transmitter/transducer has galvanic isolation of the supply, its signal zero can
be grounded where most suitable for measurement accuracy.

2.1.6 Signal Cable Considerations

When planning for the cable routing in the plant and when selecting suitable cables
to be used, the following should be considered:

Routing of communication cables with regard to a.c. power wiring.

Mixing of signals and signal types within cables.

Need of shielded or un-shielded cables.

Cable entry into cabinets is generally from the bottom. Alternative cable entrances
can be accommodated if required. Refer to $%%,QVWDOODWLRQ5XOHV for details.

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General Information and Installation Users Guide

Chapter 2 Installation

2.1.6.1 Recommendations for Signal and Process Cable

For use in a typical industrial environment according to the basic protection:
1.

Unshielded lines are adequate for binary signals and high level (0...20mA,
10V...) analog signals.

2.

Shielded cables should be used for low level (RTDs, TC...) analog signals and
pulse transducer signals.

3.

Minimize the loop area formed between the cable and earth (environment
ground), for example by laying the cable on metallic trays that are earthed at
several points. Closed cable conduits provide an additional attenuation of up to
30 dB.

4.

Use separate cables for analog, binary and heavy current lines. Lay the cables
separately sorted according to type. The signal cables and heavy current cables
should be in separate conduits or at least 30cm apart from each other.

5.

The return-conductor should be in the same cable as the signal.

6.

The field cables must be wired according to the recommendations of

Figure 2-18.

7.

Advant Fieldbus cable installed per the $GYDQW)LHOGEXV8VHUV*XLGH.

8.

PROFIBUS-DP cable installed according to PROFIBUS.

For modules with special LED indications see respectively modules in 6,2
0RGXOHVDQG7HUPLQDWLRQ8QLWV 8VHUV*XLGH

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General Information and Installation Users Guide

Section 2.1.6 Signal Cable Considerations

I/O device
Power supply cables >600V
Distance 30 cm

Own power supply cables

process I/O cables
Field
Zone

Cables for communication with

modems = long distance bus
(isolated)
Video cables
Pulse transmission

Distance 10 cm

Cables for communicating without

modems = short distance bus
(RS232, RS422)

P
R
O
T
E
C
T
I
O
N

Electronic
Zone

B
A
R

Distance 30 cm
Power supply cables >600V

)LJXUH  5HFRPPHQGHG)LHOG&DEOH:LULQJ'LVWDQFHV

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General Information and Installation Users Guide

Chapter 2 Installation

2.1.7 Power Requirements

General

Power supplied to ABB systems power supply units and for external supply to I/O
can normally be obtained from the plant a.c. or d.c. supply sources.
A.C. Supply

A power source can be rated as Installation Category II or III with respect to level of
disturbances, voltage variations and so on, according to IEC standards. Standard
voltage range is 110 - 240V a.c. Installation Category II denotes a higher quality
than III mains. The S800 I/O power supplies SD811 and SD812 are rated for
Overvoltage Category II for Installation Category III mains.
D.C. Supply

7DEOH  5HTXLUHPHQWVIRUGF6XSSO\6RXUFHV

Device

Voltage Range

FCI/ModuleBus
Modem

19.2 - 30

SD811/SD812

185 - 250

When using a d.c. source, only floating battery or recitified d.c. systems can be used
for powering of ABB systems without galvanic isolation between the system and
the current source. With this type of supply, the power supply source is grounded in
the ABB equipment.
Externally grounded power supply requires an isolating d.c./d.c. converter for the
system.

46

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Section 2.1.8 Hazardous Applications

2.1.8 Hazardous Applications

I/O modules with Intrinsic Interfaces or standard process I/O modules and MTUs
together with isolators or barriers should be used when interfacing towards
equipment installed in hazardous locations.

2.1.9 High Voltage Switch-gear Applications

The I/O modules are not designed for direct connection to high voltage switch-gear.
Interposing relays are used for digital input and output signals as a connecting link.
For analog signals, special transmitters/converters are used.

2.1.10 Lightning Strike Protection

Industrial installations and power plants are normally provided with well-integrated
grounding networks installed together with the power distribution system.
In installations with such grounding systems, it is not necessary to install lightning
strike protection unless overhead wiring or suspended cables are used outdoors.
Large plants (water supply installations, refineries and so on) can however have an
inadequate grounding system and signal cables can be routed above ground. In such
cases lightning strike protection must be used.
Cables outside the grounding system (even for short distances such as 10 m) always
require lightning strike protection.

2.1.11 Mounting Dimensions

When placing a control cabinet, specified minimum distances to walls and ceiling
must be kept to ensure satisfactory performance.

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General Information and Installation Users Guide

Chapter 2 Installation

(6)

Min 150 mm

Overhead Clearances

)LJXUH  0LQLPXP'LVWDQFHWR&DELQHWV

To ensure adequate ventilation, there should be a free space, 150 mm (6") high,
between the top of the cabinet and the ceiling, the underside of any beam, duct or
similar object over the cabinet. When cables enter the cabinet from above, the space
available should be at least 1000 mm (40") high to provide working space, see
Figure 2-19.

Standoffs for Wall

Mounted Enclosures

Min 40 mm
(1.6 inches)

Rear and Side Clearance

Min 40 mm
(1.6 inches)

)LJXUH  0LQLPXP'LVWDQFHIURP5HDUDQG6LGHRI&DELQHWWRD:DOO

The distance between the rear and the sides of the cabinet and an adjacent wall
should be no less than 40 mm (1.6 inches), see Figure 2-20. This will ensure good
ventilation.
The free space in front of the cabinet should be the width of the door plus aisle
width.
Wall mounted enclosures should use standoffs equal to the clearance requirements.

48

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Section 2.1.11 Mounting Dimensions

Clearances within an Enclosure

Clearances within an enclosure are described in Figure 2-21.

800 mm (31.5")
Min
100 mm (3.9)

Min
8 mm (0,03)

FCI

Min
8 mm (0,03)

Min
100 mm (3,9)

Min
50 mm (2)
Min
8 mm
(0,03)

Min
8 mm (0,03) Min
100 mm (3,9)

1000 mm (39.4")

Min
50 mm (2)

SD SD
811 811

I/O

Min 40 mm (1.6)
Cable channel
Min 25 mm (1) if the cable channel is higher than 40 mm (1.6)
I/O

)LJXUH  (QFORVXUHZLWK0RGXOHVDQG5HGXQGDQW6WDWLRQ3RZHU6XSSOLHV

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General Information and Installation Users Guide

Chapter 2 Installation

2.2 Installation Procedures

After some general information in the following section, you will find individual
setup descriptions for different parts of the system. The information is given under
the following headings if relevant

Assembly

Electric Installation (including Power Supply)

Functional Measures

Preparation for Start Up.

Standard installation drawings, terminal diagram forms, and connection documents

for site preparation and installation of electrical equipment may apply also.
Equipment Required

The following is a minimum requirement:

Ordinary hand tools

Universal instrument, for example, digital multimeter.

Necessary parts of the documentation listed in Section 1.3, Related

Documentation.

Specific documentation enclosed with the equipment, drawings and so on.

2.2.1 Safety Regulations

The following instructions are to be followed when installing and operating an S800
I/O system to minimize the risks of injury to personnel and damage to the
equipment. Local statutory regulations, to the degree that they are more strict than
the following are to take precedence.

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General Information and Installation Users Guide

Section 2.2.1 Safety Regulations

2.2.1.1 Personnel Safety

The following are to be observed:

Voltage supply of a cabinet shall never be switched on during installation work.

Work with care when supply voltage is applied to the system. Voltages within the
cabinet can cause serious injury or death

All who work on the installation must know the location of the main power
supply switch to the equipment and how it is operated.

When the subsections of the process are checked and a test run has been
performed, interlocking links are to be checked by a responsible engineer.
All assembly personnel must be informed about test runs to be performed.

Process technicians are to be present when testing and operating the process
device.

2.2.1.2 Equipment Safety

Observe the following safety rules:

Avoid direct contact with the bus connector of the I/O modules.

Always switch off the voltage before extracting a module which can not to be
exchanged with power applied, for example, processor units, extension cable
adaptors and extension cables, see Chapter 5, Maintenance. Wait a sufficient
time for the capacitors to discharge before removing a power sensitive module.

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General Information and Installation Users Guide

Chapter 2 Installation

2.2.2 Grounding in Enclosures

This section describes where and how grounding is to be done in a cabinet or small
enclosures. You should be aware of the common $%%,QVWDOODWLRQ5XOHV manual
which establishes the principals of grounding, knowing when an equipment,
a circuit or a cable shield should be grounded. It also gives alternative solutions
adapted to specific plant requirements.
General

When cabinets are connected together, it forms a stable ground plane for all
equipment installed. The signal processing electronics in the modules as well as all
interference suppression for external signals is normally directly grounded to
chassis and plant ground.
Protective Earth

The main power source distribution normally includes a protective ground wire.
This shall be connected to the protected earth (PE) terminal block on a primary
power switch unit. Use cable lug connectors when connecting on the ground screw.
Ground Line

The cabinet is to be grounded with a copper lead (35 mm, 2 AWG) to the plant
ground line. Cabinets in a row shall be individually connected to the plant ground
plane as required.
Grounding of Process Cable Shields

Process cable shields are, as applicable, attached directly to the cabinet ground.
Grounding of Communication Cable Shields

The shields of communication cables are to be connected directly to the modem or

FCI module in an I/O station. This pertains to conventional shielded multi-lead
cable. Please refer to the $GYDQW)LHOGEXV8VHUV*XLGH and relevant
PROFIBUS documentation for more information.

52

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Section 2.2.2 Grounding in Enclosures

*URXQGLQJRI3URFHVV6LJQDOV
There are three applications of signal grounding directly to chassis. (High frequency
grounding by capacitors is always provided and not discussed in this context).

Refer to 6,20RGXOHVDQG7HUPLQDWLRQ8QLWV8VHUV*XLGH for the

grounding requirements of each I/O module.

Signals can be commonly grounded by earthing the reference 0V of centralized

power supply for loads and sensing. Such a power supply system must be
grounded to the same earth line as the system.

Individual grounding of a signal in the I/O cabinet is possible (if applicable

with respect to I/O module type). The requirement for such an application, is
when the signal is not grounded elsewhere, for example, not locally grounded
at load/sensor or not grounded via a power supply grounding.

Do not ground the same circuit at different points in the plant.

Grounding of Additional Equipment

Additional power supply units of different types used by loads or sensor, and
modems and so on, and are located in the controller or I/O cabinet, shall be treated
in the following way with respect to grounding:

The apparatus chassis (PE terminal) shall be connected to the installation

protective earth terminal or directly to cabinet chassis if the apparatus chassis
and bounding are accepted for protective bounding.

No circuitry of an equipment shall be completely electrically floating but

referenced to a suitable potential.

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Chapter 2 Installation

2.2.3 Cable Routing in Enclosures

There are some restrictions in mixing cables within a cabinet due to the risk of
interference.To describe the simple rules applicable at site installation, cables are
divided in categories. See Table 2-2 and the following rules for custom cabinet
installations:

Within a category cables can be arbitrary mixed.

The distance between cables belonging to different categories shall be kept >
50 mm (2").

Cabinet internal junctions have their own defined spaces for routing.
Distance to other cables should always be > 50 mm (2").
7DEOH  &DEOH&DWHJRULHVLQD&DELQHW
Cable / Application

54

Category

Power supply (a.c. / d.c.)

Process I/O, shielded and unshielded cables

Communication

ModuleBus extension to S800 I/O

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General Information and Installation Users Guide

Section 2.2.4 Power Connection

2.2.4 Power Connection

General

Cabinets erected side by side including a controller and I/O configuration are
regarded as a unit, and are connected to the a.c. (d.c.) power in one single
connection point, the centralized Power Switch unit. The switch unit is normally
located in the controller cabinet bay.
The power can be distributed to the I/O cabinets as required by the installed
equipment (Figure 2-22).

Cabinet 2
S800 I/O
Power Supp.

Cabinet 1
Controller

Power
Supp.

Power
Supp.
Power
Switch

Power
Switch
Phase
Neutral
Ground

3-wire cables

Phase
Neutral
Ground

Cabinet

Enclosure

)LJXUH  3RZHU6XSSO\&RQQHFWLRQDQG'LVWULEXWLRQ

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Chapter 2 Installation

2.2.5 I/O Station with S800 I/O

Assembly

Information regarding location of equipment may be found in the documentation

delivered with the equipment. Some general I/O Station information is presented
below.

56

Install a DIN-rail sized to allow installation of the FCI, ModuleBus Modem,

MTUs, and S800L modules, terminator and power supplies. Some extra DINrail should be allowed for expansion or the moving of the FCI, ModuleBus
Modem, MTUs or S800L modules during maintenance.

Install the FCI, ModuleBus Modem on the left end of the DIN-rail leaving
some room to the left to allow removable from the first MTU or S800L
modules. If vertical mounting is used, leave room to the top of the FCI for
removal.

Install the first MTU or S800L modules to the right (below) of the FCI or
ModuleBus Modem and all other MTUs or S800L modules to the right (below)
of the preceding MTU or S800L module.

The last MTU or S800L module (12 max.) connected to the FCI or ModuleBus
Modem will have the TB807 Terminator installed in the ModuleBus connector.

Set each MTU mechanical keys to the correct setting for the I/O module that
will be located there.

The power supply modules may be located on the same DIN-rail as the FCI or
ModuleBus Modem and the I/O modules, but should be always located on a
horizontal DIN-rail because of its weight.

Install an end stop before the first module and after the last one on the DIN-rail.

Then proceed with the electrical connections as necessary.

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General Information and Installation Users Guide

Section 2.2.5 I/O Station with S800 I/O

Electric Installation

$GYDQW)LHOGEXV )LHOGEXV&RQQHFWLRQ
The AF100 Fieldbus is connected to the terminals of a CI810 or a CI820.
The incoming fieldbus twisted pair cable is connected to a plug connector with four
terminals, two for the signal wires and two for the shield. The incoming and out
going fieldbus signal + conductors are terminated in the + terminal.
The - conductors are both terminated in the - terminal. The cable shield drain wires
are terminated in the two SH terminals and they must be bridged to ensure a
continuous shield connection in case the fieldbus plug is removed from the FCI.
Keep the drain wires as short as possible (< 50mm). If the unit is at the end of the
bus, a terminator (TK501Vxxx) must be connected. Please refer to the $GYDQW
)LHOGEXV8VHUV*XLGH for complete details.
352),%86'3)LHOGEXV&RQQHFWLRQ
The PROFIBUS-DP fieldbus is connected to the terminals of a CI830. The
incoming fieldbus cable is connected to a 9 pin D-way connector. If the unit is at the
end of the bus, a connector with termination must be used. Please refer to relevant
PROFIBUS documentation.
,2&OXVWHUV
The TB820 ModuleBus Modem of an I/O cluster is connected to the CI810/CI830
FCI or TB815 Interconnection Unit by Optical Expansion cables. The optical
ModuleBus can be a simplex, duplex or mixed design.
Optical cable length between each cluster must not exceed 15 meters with plastic
fiber cable and 200 meters with glass fiber cable.
Refer to Section 3.1.1.3, TB820 ModuleBus Modem for optical ModuleBus
configurations.
'LVWULEXWHG078VDQG6/0RGXOHV
An MTU or a S800L module can be extended to another MTU or S800L module by
using a ModuleBus extension cable. The following instructions apply:
Cable length and ModuleBus length must not exceed 2.5 meters.
Cable routing in cabinets, see Section 2.2.3, Cable Routing in Enclosures.

3BSE 020 923R201

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General Information and Installation Users Guide

Chapter 2 Installation

3URFHVV6LJQDOV
Process signals are connected to the MTUs or S800L modules according to site
installation drawings.
The following instructions also should apply:

Cable routing in cabinets, see Section 2.2.3, Cable Routing in Enclosures.

Grounding of cable shields and Process signals, see Section 2.2.2, Grounding
in Enclosures.

A carefully done electrical installation is the basis for future interference-free

operation.
Functional Measures

$GGUHVV-XPSHULQJ
All S800 I/O modules are automatically set to the correct addresses by the
ModuleBus interconnection scheme.
The FCI module station address should be set to the assigned PROFIBUS-DP or
Advant Fieldbus 100 station number set by the station address switches. Refer to
6,2)LHOGEXV&RPPXQLFDWLRQ,QWHUIDFHIRU352),%86'3 or 6,2
)LHOGEXV&RPPXQLFDWLRQ,QWHUIDFHIRU$GYDQW)LHOGEXV manual as to location
of address switches.
The ModuleBus Modem cluster address should be set to the assigned cluster
number by the cluster address switch. Refer to Section 1.2.1.6, TB820 ModuleBus
Modem.

58

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General Information and Installation Users Guide

Section 2.2.6 Checklists

Preparation for Start-up

&KHFNRIWKH([WHUQDO:LULQJ
The level of workmanship must be judged case by case, and the results will
determine the need for a check of all connections before the system is powered up.
It is possible to check, with a buzzer, that the external wiring to the process
equipment is correct and that all conductors are intact. The check of the field wiring
should be done before the I/O modules are installed. It is also possible, without
activating the control equipment, to check that transmitters, transducers and
actuators (including all process wiring) to see if they function correctly. This makes
it necessary to connect voltage to these units and develop suitable checking
methods.
An alternative method, is to make an integrated check of the process equipment,
wiring and the corresponding controller functions. This should be done on a point
by point basis. Preferably the controller should be loaded with the application data
base. The data base is then used as one check-point. Status / values can be read and
control signals to process devices can be simulated by an operator station.
Be aware of the risk of accidents. Short-circuit and over-voltage can damage the
equipment, for example, a process I/O board or field element

2.2.6 Checklists
The following checklists, Table 2-3 to Table 2-10, are a summary of important
information that should be checked for the installation.

2.2.6.1 Grounding Philosophy, Ground Plane System

7DEOH  *URXQGLQJ3KLORVRSK\*URXQGLQJ6\VWHP
Item

Concerning

Check

Grounding
philosophy

Ground
system

Grounding to PE network only. Only one

ground system. No exceptions.

Ground plane
system

Design

The ground line system of the installation

must be carefully installed and must
incorporate the switchgear.

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General Information and Installation Users Guide

Chapter 2 Installation

2.2.6.2 Process Cabling, Shielding, Grounding, Max. Length

7DEOH  3URFHVV&DEOLQJ6KLHOGLQJ*URXQGLQJ0D[/HQJWK
Item
Cables

Concerning
Prescribed type

Check
Communication cables
Pulse transducer cables
Shielded for low level AI (RTD, Pt,
thermocouple, and so on).
Signal wire and return wire in same cable

Shielding: Single
shield

Cable without
shield

Grounding:
AI, AO, DI, DO,

Should be made directly as it comes into the

cabinet

Grounding:
For AF 100, see the Advant Fieldbus 100
Communications Users Guide.
pulse transducers For PROFIBUS see relevant documentation.
Grounding

All signal circuits grounded at the same end

A.C. digital inputs Max. cable length Approximately 200 m (656 ft.)
110V and 220V

60

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General Information and Installation Users Guide

Section 2.2.6 Checklists

2.2.6.3 Power Supply

7DEOH  6XSSO\
Item

Concerning
Connection in
cabinet

Check
Phase
Return
Protective ground (if distributed)
Note: There must be no breaks in the
protective ground conductor to the PE
terminal.

A.C. Power Mains

Fuse

Incorporated in conductors

Connection of
network

No unsuppressed load on same finale circuit

from distribution box

Use of interferencesensitive power

supply units

Special isolation transformer for electronics

supply must be used

Internal distribution

Incoming power supply (110, 230V) must be

separated from other cables by 50 mm (2") or
more

D.C. (floating
battery)

Grounding, supply

Negative pole to neutral ground terminal of

cabinet directly at entry to cabinet. If
grounding of the battery is not permitted then
an isolating d.c./d.c. converter is required

D.C. (grounded
battery)

Connection

Via isolated d.c./d.c. converter unless the

main d.c. power supply is grounded at the I/O
terminals

I/O Station Supply Max. power output

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< 90% of regulator capacity

61

General Information and Installation Users Guide

Chapter 2 Installation

2.2.6.4 Lightning Protection

7DEOH  /LJKWQLQJ3URWHFWLRQ
Item

Concerning

Lightning
protection

Check
Protections are compulsory for all circuits in:
Overhead lines
Cables that leave the general ground line
network

2.2.6.5 MTU, I/O Module

7DEOH  078,20RGXOH
Item
Mounting rail

62

Concerning

Check

(for MTUs)

Ground connection to
cabinet chassis via
mounting screws

If problems, check R < 100 m,

measured with equipment switched off
and cables disconnected

MTU

Ground connection

DIN rail mounting screws (100 mm

pitch) fully tightened

Connections

Quality

Only correctly made, screwed or

clamped connections are approved

3BSE 020 923R201

General Information and Installation Users Guide

Section 2.2.6 Checklists

2.2.6.6 Cabinet, Internal Cables

7DEOH  &DELQHWV,QWHUQDO&DEOHV
Item

Concerning

Check
Through short 35 mm 2 (2 AWG) copper
conductors joining the PE terminals in
each cabinet.

Row of cabinets

Electrical connection
(grounding)

Cabinet parts
(plates)

All parts electrically

R < 100 m
connected to each other
and to the PE bar

Grounding in
cabinet

Design

Only one single grounding system for

ABB Advant equipment. NO
EXCEPTIONS

Temperature in
cabinet

Max. permitted
temperature for
continued operation.

Max. permitted temperature for

continued operation in cabinet is +5 to
+55C
(41 to 131F).
Measured just below the I/O module.
Modules on compact MTUs or S800L
modules on a vertical DIN rail allow +5
to +40C (41 to 104F) ambient
temperature.

Radio emission

Emission

S800 equipment does not require radio

proof enclosures.

Shielded cable

Design

Communication, pulse transducers and

analog circuits for Low Level (RTD Pt,
thermocouples) must be shielded up to
the S800 I/O modules

Internal cables

Routing

See Section 2.2.3, Cable Routing in

Enclosures.
Check that there is no tension in the
wiring.

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General Information and Installation Users Guide

Chapter 2 Installation

2.2.6.7 Environmental Data

Please referee to (QYLURQPHQWDO'DWDIRU$%%3URGXFWV.
7DEOH  ,PPXQLW\5HTXLUHPHQWV
Environmental
Phenomenon

Standard

Severity Level

Test
Class

Test Signal

Application

Lightning

IEC 1000-4-5

4kV CMV, 2kV NMV

2kV CMV, 1kV NMV

4
3

1,2/50 - 8/20 us

Power supply,
PI/O, Com.

Damped
Oscillation

IEC 1000-4-12

1kV CMV, 0.5kV NMV

0,1; 1 MHz

Power supply,
PI/O, Com.

Fast transient

IEC 1000-4-4

4 kV
2 kV

Power supply,
PI/O, Com.

Continuous signal IEC 1000-4-6

10V

PI/O, Com.,
Power supply

Voltage
interruption

IEC 255-11

20 ms

ESD

IEC 1000-4-2

6 kV
8 kV

Electromagnetic
field

IEC 1000-4-3

10V/m

Emission

EN 55022

10-3000 ms

Power supply

Contact
discharge
Air discharge

2.2.6.8 Airborne Contaminants

Operation, Storage and Transportation
ISA 71.04-1985 class G2 and ITF SSG 4251 G2
Copper corrosion maximum 1000 ngstrm, 28 days (1 month)

64

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General Information and Installation Users Guide

Section 2.2.7 Final Procedure Before Start-up

2.2.6.9 Miscellaneous
7DEOH  0LVFHOODQHRXV
Item

Concerning

Action

Relays and contacts Suppression

in cabinets

Cabling to non-suppressed inductive

loads in ABB cabinets must be kept
more than 100 mm (4") away from
internal cables

Thermocouples

Position of AI835
CJC RTD Cold
Junction
Compensation)

CJC RTD should be placed where the

TCs compensation cable is terminated.

Analog inputs /
outputs

Type

For externally grounded transmitters /

receivers inputs/outputs must be
differential or isolated

2.2.6.10 External Cables

When selecting cables that are to be used in the plant environment, you should
know that there are some restrictions and rules to follow:

Routing of communication cables.

Mixing of signals and signal types within cables.

Need of shielded cables.

Refer to $%%,QVWDOODWLRQ5XOHV for details.

2.2.7 Final Procedure Before Start-up

Remove all debris from the work performed and clean off all grease and dirt. Check
that no tools or assembly material are left in the cabinets. Vacuum clean the
cabinets.

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Chapter 2 Installation

2.3 Start-up and Shut-down Procedures

2.3.1 Start-up Procedures
This section includes power up for the very first definition/configuration of the
system resources. A visible result of the start-up procedures, are that all red LED on
module fronts are turned off and all green LED are turned on.

2.3.1.1 Safety Regulations

The instructions given in Section 2.2.1, Safety Regulations are applicable in all
situations when working with S800 I/O and associated equipment. Please read the
instructions carefully.
Work with care when supply voltage is applied in the system. The voltage in the
cabinet can cause serious injury or death.

2.3.1.2 Controller and I/O

When the set-up activities are finished and after using Section 2.2.6, Checklists,
the equipment will be ready for start-up, but first read the following security
guidelines before proceeding.
Security Guidelines

During the power up of S800 I/O there is always a risk of spurious output signals to
the process due to a faulty hardware module.
Critical process devices should always be identified and isolated in some way if the
process is energized. Examples of different methods are:

Disconnected output power supply.

Disconnect the process cables from outputs.

Remove output S800 I/O modules.

Succeeding operations after power up, including necessary tests, must be performed
carefully.

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General Information and Installation Users Guide

Section 2.3.2 Shut-down Procedures

2.3.2 Shut-down Procedures

Before power is switched on, and start-up of the equipment, it is important to know
how to shut-down in different situations. This is described below.

2.3.2.1 Safety Regulations

The instructions given in Section 2.2.1, Safety Regulations are applicable in all
situations when working with an Advant Controller and associated equipment.
Please read the instructions carefully.
Work with care when supply voltage is applied in the system. The voltage in the
cabinet can cause serious injury or death.

2.3.2.2 I/O Station

Emergency Shut Down

An emergency stop should always be available. It shall be controlled by local

regulations. This is a responsibility of the plant design and construction. The
controller system does not supply this special function.
&KHFNWKH/RFDWLRQRIWKH(PHUJHQF\6WRSDQGXVHLWLQDQ(PHUJHQF\
6LWXDWLRQ
From the electrical and functional point of view, an emergency stop will have the
same consequences to the controller and associated equipment as a safety shut
down.
Safety Shut Down

The Advant Controller and its S800 I/O may be mounted in a row of joined cabinets
and are connected as a single unit to the mains power source. The I/O Station with
S800 I/O may also be located remotely in the process area and have its own power
source. Safety shut down, by disconnecting the controller or remote enclosure from
the mains, can be carried out in two ways:

3BSE 020 923R201

As prescribed in the site planning Section 2.1.7, Power Requirements, there

should be a common safety switch installed within 3 m (10 feet) of the
cabinets.

67

General Information and Installation Users Guide

Chapter 2 Installation

&KHFNWKH/RFDWLRQRIWKH6DIHW\6ZLWFKDQGXVHLWZKHQZRUNLQJZLWKWKH
(TXLSPHQW
The safety switch should be arranged to shut down the power of not only the
electronics system but also transmitters, transducers and other process devices. In
other words, a total power shut down for the plant section controlled.

Since the safety switch is a plant component this document can not stipulate and
describe the design exactly. Please check the plant documentation in this respect
carefully. Instructions, as to the extent of the power shut down, should preferably be
attached to the safety switch.
Regardless of the way, the results and consequences of a shut down will be:

Zero output to the process devices (S800 I/O).

De-energized output relays (S800 I/O). Not for normally closed contacts.

The system is ready for a restart. Restart can be performed when the
reason for the shut down is cleared away.

Manual Stop

Beyond the most drastic way of shut down, by disconnecting power, there is an
other way to stop the S800 I/O:

Stop program execution in the controller

Disconnect the I/O station from the fieldbus.

The results of the manual stop method:

Output modules goes to the OSP state.

The system is ready for a restart. Restart can be performed by starting the
execution in the controller or connecting the fieldbus.

After necessary measures, a restart can take place.

68

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General Information and Installation Users Guide

Section 2.4 Product Verification

2.4 Product Verification

As the test requirements vary considerably between different installations,
the system engineer is responsible for determining the functional requirements
which apply.
Equipment Required

The following equipment is a minimum requirement:

Necessary parts of the documentation listed in Section 1.3, Related

Documentation.

Specific documentation enclosed with the equipment.

In more complex installations which include closed loop control some additional
test equipment can be necessary/practical at tuning:

Access to an operator station for loop tuning.

2.4.1 General
A general description of how to set the controller in operation and start the
execution of application program is presented in the Advant Controller manuals.
Once the system is started and ready for operation the I/O can be checked.
General information for some functional tests, which can be made to verify the
S800 I/O are presented in the following sections.

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Chapter 2 Installation

2.4.1.1 Check of Process Input/Output Systems

With the application program running in the controller, the inputs and outputs can be
checked. This should be done by using a signal by signal procedure. The data base is
then used as a final check-point.
It may be necessary to simulate digital and analog input signals which are normally
generated by the process. Suitable methods are:

Digital inputs: Activate the input by connecting a voltage which corresponds to

the nominal value of the input. The 1 and 0 status is simulated by opening
and closing the terminal connections. Activate the input as close to the process
transducer as possible to test the process wiring as far as possible. Manual
operation of transducers, for example, limit switches can also give the required
change for the input signals.

Analog input signals: Use a signal generator for analog signals. A simple test
coupling can be used as a voltage source. This can consist of a potentiometer
across a suitable voltage source which gives +/- voltage. A current source,
which can give sufficient current, for example, 20 mA, is required for current
signals. Analog input test signals should be entered as close to the
transmitter/transducer as possible to test the process wiring.

Digital and analog output signals are obtained by setting the required values from
the overlaying controller.

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General Information and Installation Users Guide

Section 2.4.1 General

Input Signals

Figure 2-23 shows where an input signal can be checked in an S800 I/O application.
DI modules provide a field input connector and DI channel LEDs, and AI modules
provide a field input connector.

Engineering Tool

Process

Controller

Process
Device

Input
Module

FCI
Fieldbus
Interface

Application

DI ch.

)LJXUH  %ORFN'LDJUDPRI6,2,QSXW&KDQQHO7HVW3RLQWV

'LJLWDO,QSXW6LJQDOV
A digital input signal can be checked as shown in Figure 2-23. Use the
following procedure as a guide:

3BSE 020 923R201

Simulate the digital input signal as close to the process transducer as

possible or activate the transducer itself.

Check that the corresponding yellow LED on the input module concerned
illuminates and that the change is shown accordingly in the overlaying
controller

Change the input signal to a low level. Check that the yellow LED on the
input board extinguishes and that the display value has changed.

71

General Information and Installation Users Guide

Chapter 2 Installation

$QDORJ,QSXW6LJQDOV
Figure 2-23 shows where an analog input signal of an input channel can be
checked. Proceed as follows to check an analog input channel:

Simulate the analog input signal as close to the process

transmitter/transducer as possible.

Check that the simulated signal is available at the screw terminal of the
corresponding connection.

Check that the value shown on the display screen corresponds to the
simulated value set in the field. Check the complete signal range.

Output Signals

Figure 2-24 shows where an output signal can be checked in an S800 I/O
application.
DO Modules provide a field output connector and DO channel LEDs.
AO Modules provide a field output connector.

Engineering Tool

Controller

Application

Process
FCI
Fieldbus
Interface

Process
Device

Output
Module

DO ch.

)LJXUH  %ORFN'LDJUDPRI6,22XWSXW&KDQQHO7HVW3RLQWV

72

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General Information and Installation Users Guide

Section 2.4.1 General

'LJLWDO2XWSXW6LJQDOV
Typical digital output channels and where the signals can be tested are shown
in Figure 2-24. Digital output signals in a specific plant are shown in the
terminal diagrams for the plant.
Proceed as follows to check digital channels:

Check that the corresponding output shows that it is set to on.

Check that the corresponding yellow LED on the digital output module
illuminates.

Check the value on the screw terminal block, and if practical also at the
process device.

$QDORJ2XWSXW6LJQDOV

When checking analog output signals, use a multimeter to test for an output signal
over the complete signal range.
Typical analog output channels and where the signals can be tested are shown
in Figure 2-24. Analog output signals in a specific plant are shown in the
connection diagrams for the plant.
Proceed as follows to check analog channels:

3BSE 020 923R201

Set the output value, and check that the corresponding output shows this
value.

Measure the value on the screw terminal block, and if practical also at the
process.

When checking analog output signals use a multimeter to test that an

output signal is obtained over the complete signal range.

73

General Information and Installation Users Guide

Chapter 2 Installation

2.4.2 Final Check

When the test of the control system is complete, and the plant functions
satisfactorily, the following actions should be taken:

74

Check that all S800 I/O modules are properly inserted in the MTUs.

Check that all terminal screws on MTUs and S800L modules are properly
tightened and that all grounds are good.

Check that all cable connectors are properly mated.

Check that all cable coverings or tie wraps are installed properly to avoid cable
wear.

Check that no tools or debris from installation remain in the cubicle. Clean the
cabinet.

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General Information and Installation Users Guide

Section 3.1 Before You Start

Chapter 3 Configuration

3.1 Before You Start

3.1.1 Design Considerations
This section provides guidelines and other information that you need to know before
designing and configuring the S800 I/O. This information includes an overview of
the hardware and database configuration guidelines.

3.1.1.1 I/O Station Layout Hardware Configuration Guidelines

The S800 I/O is DIN rail mounted. The rail can be any practical length to fit the
needs of that particular I/O Station. A S800 I/O cluster can use a maximum of
2.5 meters (8.2 feet) on the rail. This is the maximum length of the ModuleBus from
the FCI, TB815 Interconnection Unit, or ModuleBus Modem to the ModuleBus
terminator. See Figure 3-1 for maximum layout of station using Compact MTUs.

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General Information and Installation Users Guide

Chapter 3 Configuration

Cable Adaptor, out

TB805
84 mm 58.5 mm
(3.3) (2.3)

Terminator
TB807

Cable Adaptor, in
TB806

TK801V0xx
Bus Cable
20 mm
(0.8)

22 mm
(0.86)

(6.4)

162 mm

Maximum 2.5 meters (98.4)

806 mm (37.7)

)LJXUH  0D[LPXP/D\RXWRI,2&OXVWHUZLWK&RPSDFW078V

76

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General Information and Installation Users Guide

Section 3.1.1 Design Considerations

See Figure 3-2 for maximum layout of I/O cluster using Extended MTUs.

84
(3.3)

467.5 mm (18.4)
120.5

162 mm
(6.37)

120.5
(4.74)

84

22 mm
(0.86)

Bus Cable
Length = 300 mm
(11.8)

1550 mm
(61)

1126.5 mm
(44.4)
mm
(inches)

20
(0.8)

109 mm
(4.3)

)LJXUH  0D[LPXP/D\RXWRI,2&OXVWHUZLWK([WHQGHG078V

3BSE 020 923R201

77

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

Status

(3.4)

S12345678910111213141516

Status

86.1 mm
Status

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516
Status

S12345678910111213141516

S12345678910111213141516
Status

mm
(inch)

1 2 3 45 6 7 8 9 1011 1213141516 1 23 4 5 6 78 9 10 11 1213141516 1 2 3 4 56 7 8 9 1011 1213141516 1 23 4 5 6 78 9 1011 1213141516 1 2 3 4 56 7 8 9 1011 1213141516 1 2 34 5 6 7 89 1011 12131415 16 12 3 4 5 67 8 9 1011 1213141516 1 2 34 5 6 7 89 1011 12131415 16 12 3 4 5 67 8 9 10 11 1213141516

Status

Status

22 mm
(0.87)
S12345678910111213141516

Status

Status

1137.2 mm
(44.8)
Status

S12345678910111213141516

Status
Status

Status

Status

Status

S12345678910111213141516

Status
Status

20 mm
(0.8)

110 mm
(4.3)

20 mm
(0.8)

Status

816.9 mm
(32.2)

Status

Status

1 23 4 5 67 8 9 1011 1213141516 1 2 3 45 6 7 8 9 1011 12131415 16 1 23 4 5 6 78 9 10 11 1213141516

12 3 4 56 7 8 9 1011 1213141516 1 2 3 45 6 7 89 1011 1213141516 1 2 34 5 6 78 9 10 11 1213141516 1 23 4 5 67 8 9 1011 1213141516 1 23 4 5 67 8 9 1011 12131415 16 12 3 4 56 7 8 9 1011 1213141516 1 2 3 45 6 7 89 1011 1213141516 1 2 34 5 6 78 9 10 11 1213141516 1 23 4 5 67 8 9 1011 1213141516 1 23 4 5 67 8 9 1011 12131415 16 12 3 4 56 7 8 9 1011 1213141516 1 2 3 45 6 7 89 1011 1213141516

Status

Bus Cable
Length = 300 mm
(11.8)
Status

S12345678910111213141516
Status

3BSE 020 923R201

78

Status

S12345678910111213141516

(6.38)

364.3 mm (14.3)

22 mm
(0.87)
86.1
84
84 mm
(3.3 )

S12345678910111213141516

86.1 mm
(3.4)

162 mm

General Information and Installation Users Guide

Chapter 3 Configuration

See Figure 3-3 for maximum layout of I/O cluster using S800L.

)LJXUH  0D[LPXP/D\RXWRI,2&OXVWHUZLWK6/

General Information and Installation Users Guide

Section 3.1.1 Design Considerations

An I/O cluster may be divided into smaller parts to fit a particular requirement, but
the 2.5 meter (8.2 feet) maximum must be observed at all times. The cluster may be
distributed because of space limitations or to keep signal types together.
See Figure 3-4 for a example of an I/O cluster divided up into four groups.

Analog Inputs

Digital Inputs

Terminator
TB807

TK801V0xx

Cable Adaptor, out

TB805

Status

S12345678910111213141516

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Cable Adaptor, in
TB806

Analog Outputs

Digital Outputs

)LJXUH  ,2&OXVWHULQ6PDOO*URXSV

The first unit of the I/O Station is the Fieldbus Communications Interface (FCI).
It connects to the fieldbus and is the communications interface to the I/O modules.
The FCI controls the ModuleBus and provides power to the logic-side of the I/O
modules. The FCI is a station on the fieldbus and must be set to the correct address.
Refer to respective FCI manual for more information.
The FCI connects to the first MTU or S800L module. Additional MTUs or S800L
modules connect to each other or through the ModuleBus Extension cable, up to a
maximum of 12. The ModuleBus is terminated by the TB807 Bus Terminator
module. The I/O Modules are installed onto the MTUs and connected to the process
in the field.

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General Information and Installation Users Guide

Chapter 3 Configuration

Redundant FCIs

An I/O Station with redundant CI820 FCIs requires that the ModuleBus Extension
cable be connected to the TB815 Interconnection Unit and then to the first I/O
Module. The maximum ModuleBus length from the TB815 to the ModuleBus
terminator is 2.5 meters. See Figure 3-5 for layout of a station.

Terminator
TB807

CI820 FCI

TK801V0xx
TB815
Interconnection
Unit
Cable adaptor, out
TB805

Cable adaptor, in
TB806

)LJXUH  ,26WDWLRQZLWK5HGXQGDQW&,)&,V

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Section 3.1.1 Design Considerations

I/O Clusters

I/O clusters 1-7 connect to the Optical ModuleBus port on the FCI or TB815
Interconnection Unit by Optical Expansion cables. Each I/O station can have up to
24 I/O modules and each I/O cluster can have up to 12 I/O modules. The 24V power
supply has to be connected to each cluster. See Figure 3-6 for an example of optical
ModuleBus Expansion cabling.

CI810 FCI

CI820 FCI

Base I/O Cluster

Optical ModuleBus
Port TB810

TB815
Interconnection
Unit

Base I/O Cluster

Optical ModuleBus
Port TB810

I/O Cluster 1
ModuleBus Modem TB820

I/O Cluster 1
ModuleBus Modem TB820

I/O Cluster 2

I/O Cluster 2

I/O Cluster 3

I/O Cluster 3

)LJXUH  2SWLFDO0RGXOH%XV([WHQVLRQ

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Chapter 3 Configuration

3.1.1.2 CI810/CI820/CI830 FCI

The FCI needs to be connected to the Advant Fieldbus 100 or PROFIBUS-DP and
have an address selected. It is also connected to a 24V d.c. power source to provide
power to the I/O Station. Also refer to appropriate FCI manual for information on
how to estimate the fieldbus and power loading of each I/O station configuration.

3.1.1.3 TB820 ModuleBus Modem

The TB820 ModuleBus Modem needs to be connected to the CI810/CI830 FCI, or
the TB815 Interconnection Unit, and have an I/O cluster address selected. It is also
connected to a 24V d.c. power source to provide power to the I/O modules of the
cluster.

R
P

ORx1

ORx2
ERx

CLUSTER
4 56
3
7
2
1

Cluster Address
Switch
(Address 4 shown)

TB820

L+ L+ SA
L- L- SB
X5
X4
Rx Rx
Tx
Tx

Optical ModuleBus
Interface Connector (X4, X5)

)LJXUH  )URQW3DQHORIWKH7%0RGXOH%XV0RGHP

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Section 3.1.1 Design Considerations

Cluster Address Switch

The TB820 is equipped with a rotary switch used as the I/O cluster address selector
for the I/O cluster. The I/O cluster address is in the range of 1 to 7. The FCI is base
cluster address 0 (zero). Figure 3-7 shows the front panel of the TB820.
Care must be taken that no I/O clusters have the same address setting. This could
result in output modules in the same ModuleBus position but in different I/O
clusters putting out the same value

A new cluster address should not be set during operation. If the address changes
during operation the cluster is disconnected from the ModuleBus, and no
communications is possible with the I/O modules on that cluster address. The new
address is set at reset or power up
Optical ModuleBus Connections

The TB820 has a connection to the optical ModuleBus by the optical ports on its
front. The fiber optic cable(s) connect to the X4 (Tx and Rx ports) and X5 (Tx and
Rx ports) connectors of the TB820. The optical ModuleBus can be connected to
duplex or simplex fiber optic cables. See Figure 3-8 for connection details.

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Chapter 3 Configuration

TB820

L+ L+ SA
L- L- SB
X4 X5
Rx Rx
Tx
Tx

Optical ModuleBus
Interface Connectors
(X4, X5)

Rx
X4
Tx
Duplex Fiber Optic Cable Connector

Rx
X5
Tx
Front View

Simplex Fiber Optic Cable Connector

)LJXUH  7%2SWLFDO0RGXOH%XV&RQQHFWLRQV

The connector style, either simplex or duplex, all provide snap-in action when
mated to the X4/X5 ports. Simplex connectors are color coded to facilitate
identification of transmitter (Tx) or receiver (Rx) connections. Duplex connectors
are keyed so that proper orientation is ensured during insertion.
Figure 3-9 shows a duplex, simplex and mixed configuration of the optical
ModuleBus. Duplex (two-way) is normally the best communication design, but may
not apply to all requirements. Duplex design allows additional TB820s to be added
down-stream on-line.
Simplex (one-way) connections provide a ring configuration from the FCI to the
first TB820, to the next TB820 and etc. and then back to the FCI. Simplex designs
will require that the home-run cable from the last TB820 back to the FCI, or
another TB820, be limited to the 15 meter (49 ft.) plastic fiber or 200 meter (667 ft.)
HCS fiber cable length. The 15 meter (49 ft.) cable length or 200 meter (667 ft.)
maximum applies from FCI to TB820, to TB820, etc. and back to the FCI.

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Section 3.1.1 Design Considerations

Also, duplex and simplex configurations can be mixed in the same optical
ModuleBus if required.

CI810/
CI810A
FCI
Rx

Example of a duplex connection of the optical ring.

Tx
X5-Rx

TB820

X4-Tx
X4-Rx

X5-Tx

TB820

X4-Tx

X5-Rx

X5-Rx

TB820

X5-Rx

X4-Rx

X4-Rx
X5-Tx

X4-Tx

TB820

X5-Tx

X5-Tx

max. 15 m (49 ft.)

or 200 m (667 ft.)
CI810/
CI810A
FCI
Rx

Example of a simplex connection of the optical ring.

Tx
X5-Rx

TB820

TB820

X4-Tx

TB820

X4-Tx

X5-Rx

TB820

X4-Tx

X4-Tx

X5-Rx

X5-Rx

max. 15 m (49 ft.)

or 200 m (667 ft.)
CI810/
CI810A
FCI
Rx

Example of a mixed simplex/duplex connection of the optical ring.

Tx
X5-Rx

TB820

X4-Tx
X4-Rx

TB820
X5-Rx

X4-Tx
X5-Rx

TB820

X4-Tx
X4-Rx

X5-Rx

TB820

X5-Tx
X5-Tx

X5-Tx

max. 15 m (49 ft.)

or 200 m (667 ft.)

)LJXUH  7\SLFDO2SWLFDO0RGXOH%XV'HVLJQV

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Chapter 3 Configuration

In a duplex connection a cable break or loss of a TB820 will only affect the
clusters down-stream of the break. In a simplex connection a cable break or loss
of a TB820 will affect all I/O expansion clusters on the ModuleBus.
Power Supply Connections

The TB820 requires 24V d.c. (19.2 - 30V) with a maximum current requirement of
1,4 Ampere. The TB820 can be powered by either a single or redundant power
supply. If a redundant power supply is used, the TB820 can monitor the status of
each supply and send the status back to the FCI of the I/O Station. See Figure 3-10
for power supply connections.
TB820

L+ L+ SA
L- L- SB
X5
X4
Rx Rx
Tx
Tx

X1B
X1A

Terminal
Headers
Power Supply B
Monitor

Power Supply A
Monitor
+24V d.c.
From Power Supply
0V d.c.

+24V d.c.
0V d.c.
1

To MTUs
(I/O Modules)

Jumper

)LJXUH  7%3RZHU6XSSO\&RQQHFWLRQV

The incoming power can then be distributed to other TB820s or the I/O modules if
desired. Refer to Figure 3-12 and Figure 3-13 for power supply connection
diagrams.
If the distributed power needs to be independent of whether the power plugs are
removed or not, then the L+ and L- terminals should be bridged

86

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Section 3.1.1 Design Considerations

Power connections can accept up to 0.2 - 2.5 mm2 (24 - 14 AWG) wire size.
FCI power supply connections are presented in Table 3-1 and Table 3-2.
7DEOH  7%3RZHU&RQQHFWLRQ7HUPLQDO;$
Pin

Designation

Description

L+

+24V d.c. Supply (can be jumpered to pin 2)

L+

+24V d.c. Supply

SB

Redundant Power Supply Monitoring Input

7DEOH  7%3RZHU&RQQHFWLRQ7HUPLQDO;%

Pin

Designation

L-

0V d.c. Supply (can be jumpered to pin 2)

L-

0V d.c. Supply

SA

Redundant Power Supply Monitoring Input

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Chapter 3 Configuration

3.1.2 SD811 and SD812 Power Supply Configurations

The SD811 (24V d.c. @ 2.5A) and the SD812 (24V d.c. @ 5.0A) can be used alone
or together for redundancy (Figure 3-11). The supplies can operate in a parallel
configuration which can be used to increase the total output current capacity.
The DCOK signal of the supplies can be connected to the supply monitoring inputs
(SA, SB) of the FCI in the case of redundant supplies.
The SD811 provides enough power to support a fully loaded I/O Station.
The SD812 is mainly used when field devices need to be powered.

SD811
L1
L2 (N)
PE
a.c. 110-240V
104VA
DCOK
DC Adj.
+24V
2.5A
0V
DCOK

SD812
L1
L2 (N)
PE
a.c. 110-240V
207VA
DCOK
DC Adj.
+24V
5A
0V
DCOK

)LJXUH  6'DQG6'3RZHU6XSSO\&RQQHFWLRQV

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Section 3.1.2 SD811 and SD812 Power Supply Configurations

Figure 3-12 shows a typical wiring diagram for parallel operation when more
capacity is needed. Figure 3-13 shows a wiring diagram for redundant mains.

CI810/
L+ L- SA SB
SD811/812
L
a.c.

N
PE

L+

L-

To MTUs
- or Field

DCOK

24V
d.c.

SD811/812
L+

L
a.c.

N
PE

LDCOK

24V
d.c.

)LJXUH  6'RU6':LULQJ'LDJUDPIRU3DUDOOHO2SHUDWLRQ

CI810/
L+ L- SA SB
Mains A

SD811/812
L
N

a.c.

PE

Mains B

24V
d.c.

L+

L-

To MTUs
- or Field

DCOK

SD811/812
L+

L
N
PE

a.c.

L24V
d.c.

DCOK

)LJXUH  6'RU6':LULQJ'LDJUDPIRU5HGXQGDQW0DLQV

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Chapter 3 Configuration

Figure 3-14 shows the connections to redundant CI820 FCIs.

TB815

SD811/812
+24V
0V
PowOK

CI820

L+
LSA
SB

L+
LSA
SB

CI820

Circuit
Breaker

Fuse
or MCB
SELV
Optional
Power to
field circuits
via MTUs

SD811/812
+24V
0V
PowOK
CI820

L+
LSA
SB

Diode
Voting
Unit

SD811/812
+24V
0V
PowOK

SD811/812
+24V
0V
PowOK

)LJXUH  &RQQHFWLRQ'LDJUDPVIRU5HGXQGDQW3RZHU6XSSOLHVWR

5HGXQGDQW)&,V
This power supply can be utilized for non-redundant and redundant applications and
does not require additional load-sharing control equipment such as diode voting
units.
Circuit breakers or a diode voting unit at the power supplies output are required LI
hot replacement of supplies is required

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Section 3.1.3 Power Supply Load Calculation

3.1.3 Power Supply Load Calculation

Appropriate Hardware

Different power supply systems are available for the S800 I/O Station. The number
of power supply units is calculated with respect to actual number of S800 I/O
modules supported by the Station, see Section 3.1.7, Power Supply Requirements
for details.
Normally you dont have to deal with current consumption calculations, however
there are occasions with special requirements, or designs when detailed information
regarding current consumption is valuable. Please find a description of special
power supply usage under the guidelines below.
Guidelines

A summary of the main requirements of the plant supply, from a planning point
of view, is found in Section 2.1, Site Planning.

Auxiliary equipment in the controlled system is normally powered separately

from the S800 I/O power supplies.

If field devices are grounded, be sure to use galvanic isolation.

Heavy current on/off loads are DOZD\V powered separately

It is possible to use the system power supply for transmitters/transducers:

There is idle capacity in the available power supply units

The transducer is grounded directly in the control system chassis

Number of Power Supply Units/Power Consumption

The I/O Station requires 24V d.c. @ 1 amp for the FCI and 12 I/O modules.
Additional power may be required for field devices.

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Chapter 3 Configuration

3.1.4 Heat Dissipation

3.1.4.1 Cabinet Ventilation
To avoid overheating, when ambient temperatures are high, the heat dissipated in
the electronics cabinet must be taken into consideration. This is particularly the case
with sealed cabinets (IP54) or tropicalized cabinets (IP41).
The frequency of faults is estimated to be doubled for each 20C increase in
temperature. It is therefore important to maintain a low temperature where the
equipment is installed.
The different hardware modules in the controller and the I/O system have different
outputs of heat. Accurate calculation of the heat produced by the system requires
knowledge of the modules and the work cycle.

3.1.4.2 Heat Dissipation Permitted in Cabinets

The maximum permitted temperature below the I/O station in the cabinet is 55 C.
The permissible amount of heat generated depends on the type of cabinet and its
location.
In critical applications with an I/O station fully equipped and cabinets arranged in
groups, it may be necessary to make a calculation of the actual power dissipation
and an estimation of the temperature rise within the cabinet. It is recommended that
you re-calculate when you expand the system as well.

3.1.4.3 Calculation of Heat Generated in a Cabinet

When calculating the heat generated in a cabinet, the heat generated by the different
I/O modules must be summed, and then added to the heat generated by the power
supply units and other equipment such as an extra modem, extra unit for supply of
power to transmitters etc.
Section 3.1.8, Power and Cooling gives the power dissipated as heat by hardware
modules in the S800 I/O system.

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Section 3.1.5 Maintenance and Repair

The total power dissipated in the cabinet can thus be written:

P Total = ( PFCI ) + ( P IO ) + ( P Voltagesupplyunit ) + ( P Sundry )

3
3
3
3

= Power of the FCI Module

= Power of each S800 I/O Module
= Power loss of the power supply unit(s)
= Miscellaneous power using equipment installed in the cabinet.

)&,
,2

9ROWDJHVXSSO\XQLW
6XQGU\

3.1.5 Maintenance and Repair

From the maintenance point of view, use as few module types as possible in the
hardware disposition of a control system. This is most relevant with the process I/O
design. Standardization of I/O signal types and other electrical qualities is important
to minimize the spare part stock.
Your solutions must make sense to the maintenance people in the event of
disturbances and following trouble-shooting.

3.1.6 Expansion Considerations

A new S800 I/O station can be connected to an existing fieldbus without affecting
other stations and controllers. The new I/O is automatically incorporated in the
communication system. Spare connections must be pre-installed as to not disturb
the existing bus.
The system fieldbus can be expanded in the following ways:

Process I/O or MTU unit

New I/O modules can be added on line. It is recommended to have approximately

10 - 20% of total capacity as spare channels, and spare space in subracks.

Spare MTUs need to be pre-mounted to add I/O modules on-line.

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Chapter 3 Configuration

3.1.7 Power Supply Requirements

A quick guide for power consumption to be used in a preliminary phase of a project
work or whenever you need estimated figures is provided in Table 3-3.
7DEOH  (VWLPDWHG6\VWHP3RZHU&RQVXPSWLRQ
I/O Station

24V d.c. Power

Consumption

Base Cluster (single FCI) and 6 I/O Modules

0.5A

Base Cluster (single FCI) and 12 I/O Modules

1.0A

Redundant FCIs (2) and 6 I/O Modules

1.0A

Redundant FCIs (2) and 12 I/O Modules

1.5A

Additional I/O Clusters and 6 I/O Modules

0.5A

Additional I/O Clusters and 12 I/O Modules

1.0A

The above estimates are based on an I/O Station with a mixed configuration of
AI/AO and DI/DO. Only power consumption on the 24V d.c. distributed via the
ModuleBus are included. External 24V connected directly to the I/O modules,
for external loads and transmitters, are not included. When using large quantities of
AO820s and/or DO820/DO821s, these load figures may be exceeded.

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Section 3.1.8 Power and Cooling

3.1.8 Power and Cooling

Table 3-4 shows the typical power and cooling values that can be used when
designing the S800 I/O.
7DEOH  ,26WDWLRQ3RZHUDQG&RROLQJ7\SLFDO

5 Volts
ModuleBus

24 Volts
ModuleBus

24 Volts
External

Power
Dissipation
(Watts)

Cooling
Load (1)
(BTU/H
Typical)

Maximum Ambient
Temperature

AI801

70 mA

30 mA

1.1

3.7

55/40C (131/104F)(2)

AI810

70 mA

40 mA

1.5

5.1

55/40C (131/104F)(2)

AI820

80 mA

70 mA

1.7

5.8

55/40C (131/104F)(2)

AI830

80 mA

80 mA

2.2

7.5

55/40C (131/104F)(2)

AI835

75 mA

50 mA

1.6

5.4

55/40C (131/104F)(2)

AI890

70 mA

200 mA

1.5

5.1

55/40C (131/104F)(2)

AO801

70 mA

200 mA

3.8

13

55/40C (131/104F)(2)

AO810

70 mA

200 mA

3.0

10

55/40C (131/104F)(2)

AO820

100 mA

200 mA

2.8

9.6

55/40C (131/104F)(2)

AO890

70 mA

200 mA

3.1

10

55/40C (131/104F)(2)

DI801

70 mA

2.2

7.5

55/40C (131/104F)(2)

DI810

50 mA

1.8

6.1

55/40C (131/104F)(2)

DI811

50 mA

2.7

9.2

55/40C (131/104F)(2)

DI814

50 mA

1.8

6.1

55/40C (131/104F)(2)

DI820

50 mA

2.8

9.6

55/40C (131/104F)(2)

DI821

50 mA

2.8

9.6

55/40C (131/104F)(2)

DI830

120 mA

2.3

7.8

55/40C (131/104F)(2)

DI831

120 mA

3.2

11

55/40C (131/104F)(2)

DI885

160 mA

91 mA(3)

91 mA(3)

3.0

10

55/40C (131/104F)(2)

DI890

50 mA

50 mA

1.4

5.7

55/40C (131/104F)(2)

Device

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Chapter 3 Configuration

7DEOH  ,26WDWLRQ3RZHUDQG&RROLQJ7\SLFDO&RQWLQXHG

Device

5 Volts
ModuleBus

24 Volts
ModuleBus

24 Volts
External

Power
Dissipation
(Watts)

Cooling
Load (1)
(BTU/H
Typical)

Maximum Ambient
Temperature

DO801

70 mA

(4)

2.1

7.2

55/40C (131/104F)(2)

DO810

80 mA

(5)

2.1

7.2

55/40C (131/104F)(2)

DO814

80 mA

(4)

2.1

7.2

55/40C (131/104F)(2)

DO815

130 mA

2 A (6)

4.0

14

55/40C (131/104F)(2)

DO820

60 mA

140 mA

2.9

9.9

55/40C (131/104F)(2)

DO821

60 mA

140 mA

2.9

9.9

55/40C (131/104F)(2)

DO890

80 mA

250 mA

4.4

15

55/40C (131/104F)(2)

DP820

120 mA

(4)

2.5

8.5

55/40C (131/104F)

CI810

110 mA

2.6

8.9

55C/(131F)

CI820

250 mA (7)

6.0

20

55C/(131F)

CI830

110 mA

2.6

8.9

55C/(131F)

TB810

100 mA

20 mA

0.5

1.7

55C/(131F)

TB811

100 mA

20 mA

0.5

1.7

55C/(131F)

TB820

100 mA

2.4

8.2

55C/(131F)

SD811

11

37

55C/(131F)(8)

SD812

22

75

55C/(131F)(8)

(1) Cooling load is the heat (BTU/H) produced by the equipment that may be required to meet room or enclosure cooling
specifications.
(2) 40C (104F) applies to Compact MTUs and S800L modules with I/O modules mounted on a vertical DIN rail.
(3) 24V from ModuleBus (91 mA) or 24V external (91 mA) or 48V external (22 mA).
(4) 500 mA per channel with maximum load per channel.
(5) 500 mA per channel with maximum load per channel.
(6) 2A per channel with maximum load per channel.
(7) CI820 in redundant configuration 2 x 250 mA
(8) Horizontal mounting only.

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Section 3.1.8 Power and Cooling

Calculation of 24V d.c. Power Consumption

Total 24V d.c. power consumption = 24V load ModuleBus + 5V load

ModuleBus*0.3 +
24V external load.
The calculated 24V ModuleBus load should not exceed 1.3A.

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Chapter 3 Configuration

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Section 4.1 Operating Overview

Chapter 4 Operation

4.1 Operating Overview

An I/O station is an autonomous station which normally is not handled by an
operator. Of course, it is started and sometimes stopped manually. This is done,
however, in specific situations such as the time of installation work and
maintenance.
Accordingly, operating instructions are spread out in this manual. See where the
specific activity is treated.
For general descriptions, see the beginning of this chapter. For concrete instructions,
see Chapter 2, Installation and Chapter 5, Maintenance.
Please see the controller manual or the 6,2)LHOGEXV&RPPXQLFDWLRQ,QWHUIDFH
IRU352),%86'3or6,2)LHOGEXV&RPPXQLFDWLRQ,QWHUIDFHIRU$GYDQW
)LHOGEXVmanuals.

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Chapter 4 Operation

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Section 5.1 Preventive Maintenance

Chapter 5 Maintenance

5.1 Preventive Maintenance

This chapter describes routine maintenance, replacement and installation procedures
necessary to maintain the operation of the S800 I/O equipment. The S800 I/O
modules do not need special adjustments such as zero and span of analog I/O
modules.
Analog I/O modules are factory calibrated and have calibration parameters for all
ranges stored in memory on the module. The FCI uses those calibration parameters
for calculations of the correct input and output signals.
Thermocouple and RTD modules use internal references for calibrations of the
measured values.

5.2 Hardware Indicators

Various visual indications (LEDs) are used in the I/O-system for showing module
status and for digital I/O modules also channel status.
These indications serve the purpose of informing the user about status or fault in the
system or in the process. They are intended to be a simple and easy to use help.
They should allow to spot faults in the station easily.

5.2.1 Color
A fixed meaning is assigned to the colors red, yellow and green:
5('

Danger or alarmWarning of potential danger or a situation which

requires immediate action

<(//2:

Caution

Change or impending change of condition, warning

*5((1

Safety

Indication of a safe situation or authorization to

proceed, clear way.

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Chapter 5 Maintenance

For digital I/O on-states a definite meaning can not be assigned. For them the color
yellow is chosen. The Table 5-1 shows the meaning and colors of LEDs.
7DEOH  0HDQLQJDQG&RORUVRI/('V
Meaning/Purpose
Fault; Error

Color
Red

Warning, I/O State Indications

and OSP (Outputs
Set as Predetermined)

Yellow

Normal Operation

Green

Examples
"FAULT
OSP, Process error,
Digital I/O on-state,
Process voltage low, Traffic.
RUN, Normal operation,
Power OK.

5.2.2 Location
For the location of LEDs the following rules are applied:
60,20RGXOHV

Indications having the same meaning on every I/O module (for example,
FAULT, RUN, WARNING, OSP) are at the same position.

The standard indications FAULT, RUN, WARNING and OSP (only output
modules), are always on the topmost position on every device (top: FAULT,
RUN, then WARNING, OSP).

6/,20RGXOHV

Have one LED 6 for module status showing FAULT (Red) or RUN (Green).

)&,

102

On the FCI: FAULT, RUN, POWER OK, TRAFFIC and for redundant FCI
also PRIMARY and REDUNDANCY OK.

3BSE 020 923R201

General Information and Installation Users Guide

Section 5.2.3 Identification

5.2.3 Identification
LEDs shall be identified by an appropriate symbol or abbreviation of an English
term. For the standard indications the abbreviation is as follows:

Fault in the module

FAULT or F

Device is in operation

RUN or R

External fault or minor fault in the module

WARNING or W

Output Set as Predetermined,

OSP or O

Digital I/O on-state

1, 2,... (channel number)

Digital I/O channel

FAULT or F

Power supply ok internal and/or external ok

POWER OK or P

Module status (S800L modules)

STATUS or S

5.3 Error Messages

Not applicable.

5.4 Fault Finding and User Repair

5.4.1 Introduction
Diagnostics are available in different forms for rapid localization of the source of
the equipment malfunction. Hardware error is usually corrected by replacing the
faulty module which is returned to ABB Service for repairs. The smallest
replaceable unit is normally a module or an apparatus like a power supply unit.
Disturbances and system halt caused by software error is commonly solved by a
manual system restart.
External faults in process wiring and transducers can also affect the function of the
S800 I/O system. However, this type of fault is not discussed in this manual.

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General Information and Installation Users Guide

Chapter 5 Maintenance

5.4.2 Diagnostics and Fault Indications

Hardware and software in a S800 I/O system is provided with supervision against
system faults.
LED indicators on modules:

Green LED, RUN, indicates normal function.

Yellow LED indicates an active signal, for example, status of digital input
(DI) or digital output (DO), OSP and Warning

Red LED, FAULT, indicates malfunction

Red/Green LED indicates module status (S800L modules)

Red = FAULT, Green = RUN normal function.

5.4.3 List of General Fault Finding Procedures and Hints

5.4.3.1 Location of Malfunction
Sometimes, you lack the information from the controller diagnostics, that tells you
where the fault is located. Suspicion about a fault is raised by the process behavior.
Experience indicates that approximately 85% of all faults occur in the process, 10%
in the control program and 5% in the control system hardware.
It is always advisable to localize the malfunction with these figures in mind to
minimize the down-time.

5.4.3.2 External Factors

In an electronics system which has given satisfactory service, most malfunctions
have external causes. It is therefore important, when tracing a fault, to determine if
any external factor such as incorrect handling of the equipment, short circuits,
welding work, lightning strike and/or power failure has caused the malfunction.

104

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General Information and Installation Users Guide

Section 5.4.3 List of General Fault Finding Procedures and Hints

5.4.3.3 Safety at Start/Stop

Voltage failure, component fault or manual restart usually affect the control system
function. I/O system failure affects the process in different ways:

In a system which is monitoring the process only, changes in the process status
are not registered but there is no immediate danger to the process operation.

In a system which is controlling a continuous processes (rolling mills and paper

manufacture) demands a high degree of continuity of the control system
functions.

A restart of the I/O system or controller can have very serious consequences. It is
important to be aware of the local requirements for safety when starting and
stopping the I/O system or controller.

5.4.3.4 Check of Power Supply

Check of Non-redundant Power Supply

The CI810/CI830, CI820 Fieldbus Communications Interface (FCI), or TB820

status LED - P is illuminated when 24V d.c. is supplied to the FCI, and 5V (from the
FCI) is supplied to the rest of the I/O Station.
The supply system consists at least of one power supply.
Power can be checked at the FCI or TB820 on terminals L+ and L- with a voltmeter.
The value should be 24V d.c. (19.2 to 30). Power can also be checked at the power
supply or on the distribution strip.
Check of Redundant Power Supply

The CI810/CI830, CI820 Fieldbus Communications Interface (FCI), or TB820

status LED - P is illuminated when 24V d.c. is supplied to the FCI, and 5V (from the
FCI) is supplied to the rest of the I/O Station.
The supply system consists at least of two power supplies.
Power can be checked at the FCI or TB820 on terminals L+ and L- with a voltmeter.
The value should be 24V d.c. (19.2 to 30). Power can also be checked at the power
supplies, diode unit or on the distribution strip.
To do a complete check each power supply has to be run as single.

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General Information and Installation Users Guide

Chapter 5 Maintenance

5.4.4 User Repair

5.4.4.1 I/O Module Replacement
General

All S800M I/O modules, except for relay output modules with normally closed
contacts, can be exchanged on-line and with the process power supply connected.
This is possible because the module deactivates when the I/O module lock switch is
turned to unlock.
It is important to understand the consequences of a module exchange on-line and
how it affects the process. Replacement of an S800 I/O module affects all channels
on the module. It also sometimes indirectly affects the outputs via some application
function, on another module.
To exchange a S800L module the power supply must be switched off.
The system software in the FCI checks automatically that all I/O modules function
correctly. In the event of module fault, and module exchange, the module and
associated signals are marked as faulty.
The system software checks that the module is inserted and correct. If this is the
case, the Fault-indicator (LED) extinguishes (after 10 seconds).

5.4.4.2 Power Supply Module Replacement

General

In single or parallel operation of power supplies, there will always be a disturbance

of the function when a power supply must be replaced; the station will not have
power.
In a redundant power supply configuration, it is possible to replace a power supply
module without disturbance of the function. To achieve that the installation see
Section 3.1.2, SD811 and SD812 Power Supply Configurations and the correct
replacement procedure that follows.

106

3BSE 020 923R201

General Information and Installation Users Guide

Section 5.4.4 User Repair

Practical Execution

Replace faulty or suspect power supply module in the following way:

For single or parallel operation do steps 1, 2 and 4 to13.
For redundant configuration do steps 1 to 14.
1.

Read Section 2.2.1, Safety Regulations.

2.

Check that the new module can replace the old.

3.

Switch off the output from the module (only redundant configuration).

4.

Switch off input power to the module.

5.

Disconnect the wires.

6.

Unmount the module by loosening the module locking.

7.

Mount the new module.

8.

Connect the input wires.

9.

Switch on input power to the module.

10. Perform a function test on the new module.

11. Switch off input power to the module.
12. Connect the output wires.
13. Switch on input power to the module.
14. Switch on the output from the module (only redundant configuration).

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General Information and Installation Users Guide

Chapter 5 Maintenance

5.4.4.3 Communication Module Replacement

General

Normally communications modules cant be exchanged on-line, the only exception

is the CI820 in a redundant configuration.
It is important to understand the consequences of a module exchange and how it
affects the process.

108

Replacement of a communication module type CI810/CI830 or a CI820 in a

single configuration affects all channels on all the modules in an I/O station.
The station will loose power.

Replacement of a single communication module type CI820 in a redundant

configuration has no affects on channels in an I/O station.

Replacement of a communication module type TB810/TB811 affects all

channels on all the modules in all clusters except cluster 0. The communication
will be broken to all clusters except for cluster 0.

Replacement of a communication module type TB815 affects all channels on

all the modules in an I/O station. The station will loose power.

Replacement of a communication module type TB820, connected via a

simplex optical cable, affects all channels on all the modules in all clusters
except cluster 0. The communication will be broken to all clusters except for
cluster 0. The cluster where the TB820 should be replaced will be power less.

Replacement of a communication module type TB820, connected via a duplex

optical cable, affects all channels on all the modules in all clusters after and
including the cluster where the replaced TB820 is located. The communication
will be broken to all clusters after where the replaced TB820 is located.
The cluster where TB820 should be replaced will be power less.

3BSE 020 923R201

General Information and Installation Users Guide

Section 5.4.4 User Repair

Additional Aspects on Individual S800 Communications Modules

Table 5-2 lists S800 I/O modules. Descriptions of these types are referred individually in the
table.

7DEOH  5HSODFHPHQW$VSHFWVRI6,20RGXOHV

Module Type - Settings
TB810/811 No settings

Comments
Optical ModuleBus cable can be removed by
pulling the connector(s) out of the unit.
Extract the module.

TB820
ModuleBus
Modem

Switch setting for I/O Cluster

address
F
ORx1

R
P
ORx2
ERx

CLUSTER
4 56
3
7
2
1
TB820

L+ L+ SA
L- L- SB
X4 X5
Rx TxRx Tx

Cluster Address
Switch

Can not be replaced with power applied.

Needs room to the left of an MTU in order to be
removed.
In normal operation mode, before a TB820 is
replaced, the supply to the S800 I/O is to be
switched off. Power connections can be
removed by pulling the header terminals out of
the unit.
Optical ModuleBus connections can be removed
by pulling the connector(s) out of the unit.

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General Information and Installation Users Guide

Chapter 5 Maintenance

110

3BSE 020 923R201

General Information and Installation Users Guide

Section A.1 SD811/SD812 Power Supply Module, 24V d.c.

Appendix A Specifications

A.1 SD811/SD812 Power Supply Module, 24V d.c.

)HDWXUHV

SD811

SD811 24V d.c. @ 2.5A

X1

SD812 24V d.c. @ 5.0A

Input 110 - 240V a.c. (45 - 65 Hz), or 185 - 250V d.c.

L1
L2 (N)
PE
a.c. 110-240V
104VA
DCOK
DC Adj.

Power OK status indicator and output signal

+24V
2.5A
0V

X2

DIN-rail mounted.

DCOK

'HVFULSWLRQ

The SD811 Power Supply Module provides 24V d.c. at 2.5A

and the SD812 Power Supply Module provides 24V d.c. at
5.0A.
The SD811(SD812) is a switch-mode power supply unit
converting main voltage to 24 Volts d.c. This power supply
can be utilized for non-redundant and redundant applications
and does not require additional load-sharing control
equipment or diode voting units.
Two or more power supply devices can be connected in
parallel. No special efforts are included to get the paralleled
devices sharing the load equally. Connecting units in parallel
can be used for increasing the power output or to get n+1
redundancy.

SD812

X1

L1
L2 (N)
PE
a.c. 110-240V
207VA
DCOK
DC Adj.

X2

+24V
5A
0V
DCOK

Normal function, DCOK, is indicated by a green Light Emitting Diode (LED).

Status Signal, DCOK terminal, Power Good = active high; 24V source with a series resistance = 270
ohms, signal return = 0V

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General Information and Installation Users Guide

Appendix A Specifications

Signal voltage output (in parallel with DCOK LED) is derived from the output terminal voltage, but
the device signal status is independent of external voltage injection from power supply units
connected in parallel.
The output voltage is adjustable within the range 22.5 Volts to 28.5 Volts, and is factory set at 24
Volts 1%.
Primary voltage setting needs no selection or adjustment, the full voltage range specified is covered
by the design.
The modules can be mounted on a standard DIN rail. It has a mechanical latch that locks it to the
DIN rail. The latch can be released with a screwdriver.
7HFKQLFDO'DWD

7DEOH $ 6'6'3RZHU6XSSO\0RGXOH6SHFLILFDWLRQV

Item

SD811 Value

SD812 Value

Output

24V d.c. @ 2.5A

24V d.c. @ 5.0A

Mains input voltage

110 - 240V a.c.

185 - 250V d.c.

110 - 240V a.c.

185 - 250V d.c.

Mains frequency
a.c.
d.c.

45 - 65 Hz
0 Hz

45 - 65 Hz
0 Hz

Rated input power, a.c.

Power factor

104 VA
0.67 typical

207 VA
0.67 typical

Rated input power, d.c.

70 Watts

140 Watts

Rated output power (at

24V)

60 Watts

120 Watts

Efficiency (50 - 100%

loading)

0.85

0.85

Power dissipation (full load) 11 W

22 W

Over-voltage protection

35V d.c.

112

35V d.c.

3BSE 020 923R201

General Information and Installation Users Guide

Section A.1 SD811/SD812 Power Supply Module, 24V d.c.

7DEOH $ 6'6'3RZHU6XSSO\0RGXOH6SHFLILFDWLRQV&RQWLQXHG

Item

SD811 Value

SD812 Value

Rated Input Current

230V a.c.
110V a.c.
220V d.c.

0.45A
0.8A
0.32A

0.9A
1.6A
0.65A

Power on surge current

3.5A

7A

Primary power protection

Fusable links

Fusable links

Output power protection

Electronic short-circuit protection

Electronic short-circuit protection

Ambient temperature
Transport (max)
Storage (max)
Operating (nominal)

-25oC to 70oC (-13F to 158F)

-25oC to 55oC (-13F to 131F)
5oC to 55oC (41F to 131F)

-25oC to 70oC (-13F to 158F)

-25oC to 55oC (-13F to 131F)
5oC to 55oC (41F to 131F)

Relative humidity

10% - 75%

10% - 75%

Approvals

Also meeting the requirements for

a CE mark based upon the Low
Voltage Directive 73/23/EEC;
requirements referring to EN
50178 including EMC capabilities
meeting the EN 50081-2, EN
50082-2.

Also meeting the requirements for

a CE mark based upon the Low
Voltage Directive 73/23/EEC;
requirements referring to EN
50178 including EMC capabilities
meeting the EN 50081-2, EN
50082-2.

Safety classification

Class I according to IEC 536;

(earth protected)

Class I according to IEC 536;

(earth protected)

Protection rating

IP20 according to IEC 529, (IEC

144)

IP20 according to IEC 529, (IEC

144)

Rated insulation voltage

300V

300V

Dielectric test voltage

2,2kV a.c.

2,2kV a.c.

Width

50 mm (2)

125 mm (5)

Depth

130 mm (5.1)

138 mm (5.4)

Height

102 mm (4)

134 mm (5.25) with mounting

ears

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113

General Information and Installation Users Guide

Appendix A Specifications

130 mm

50 mm

(5.1")

X2

(1.3")

DCOK
DC Adj.

(1.4")

(4")

102 mm

L1
L2 (N)
PE
a.c. 110-240V
104VA

33 mm

SD811
X1

36 mm

(2")

+24V
2.5A
0V

Label

DCOK

)LJXUH $ 6'3RZHU6XSSO\&RQQHFWLRQV

114

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General Information and Installation Users Guide

Section A.1 SD811/SD812 Power Supply Module, 24V d.c.

(5.4")

DCOK
DC Adj.

(4.7")

(4")

(5.3")

102 mm

134 mm

X1

119.5 mm

SD812
L1
L2 (N)
PE
a.c. 110-240V
207VA

(1.3")

d = 4 mm
(0.16")

(1.4")

(0.7")

138 mm

33 mm

19 mm

125 mm
(4.9")
87 mm
(3.4")

36 mm

9 mm
(0.35")

+24V
5A
0V

X2

Label

DCOK

16 mm
(0.63")

)LJXUH $ 6'3RZHU6XSSO\&RQQHFWLRQV

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115

General Information and Installation Users Guide

Appendix A Specifications

&RQQHFWLRQV

7DEOH $ 6'6'3ULPDU\3RZHU&RQQHFWLRQV

Terminal

Description

X1 - L1

Mains power Line

X1 - L2 (N)

Mains power Neutral

X1 - PE

Mains power ground (Protected Earth)

7DEOH $ 6'6'2XWSXW3RZHU&RQQHFWLRQV

Terminal
X2 - 1

24V d.c.

X2 - 2

24V d.c.

X2 - 3

0V

X2 - 4

0V

X2 - 5

116

Description

DCOK Status Signal

3BSE 020 923R201

General Information and Installation Users Guide

Section A.1 SD811/SD812 Power Supply Module, 24V d.c.

&RQQHFWLRQ'LDJUDP

The diagram shows the connections needed for redundant power supplies to
redundant FCIs with power supply hot swap possibilities.

TB815

CI820

SD811/812

L+
LSA
SB

L+
LSA
SB

CI820

Circuit
Breaker

Fuse
or MCB

+24V
0V
PowOK

Optional
Power to
field circuits
via MTUs

SD811/812
+24V
0V
PowOK

L+
LSA
SB

CI820
Diode
Voting
Unit

SD811/812
+24V
0V
PowOK

SD811/812
+24V
0V
PowOK

Circuit breakers or a diode voting unit at the power supplies output are required if
hot replacement of supplies is required.

3BSE 020 923R201

117

General Information and Installation Users Guide

Appendix A Specifications

%ORFN'LDJUDP6'6'

L1
x
L2 (N)
x

PE

BUV48A

0V
35V

+24V

270 ohms
1W

SD811/SD812

118

DCOK

3BSE 020 923R201

General Information and Installation Users Guide

Section A.2 TB805/TB806 ModuleBus Cable Adapter-Out/In

A.2 TB805/TB806 ModuleBus Cable Adapter-Out/In

)HDWXUHV

Passive unit used for connection and extension of the

ModuleBus

TB805 ModuleBus
Connector (X1)

DIN rail mounting.

'HVFULSWLRQ
1

The TB805 ModuleBus Cable Adaptor-Out and TB806

ModuleBus Cable Adaptor-In with the ModuleBus
Extension Cables, TK801V0xx, are used to extend the
ModuleBus.

14

DB25 Female
Connector (X2)

Using the TB805 and TB806, I/O modules on the same

electrical ModuleBus of an I/O cluster, can be mounted
on different DIN rails. This makes the installation of I/O
Modules more flexible when laying out an enclosure
design. Please refer to Section 2.1.4.1, I/O Station with
S800 I/O for details on layouts.

25
13

TB806 ModuleBus
Connector (X1)

The ModuleBus extension cables used with the

TB805/TB806 comes in 3 standard lengths:
VTK801V003 - 300 mm
TK801V006 - 600 mm
TK801V012 - 1.2 meters.
Overall ModuleBus length must not exceed 2.5 meters
including all cables and MTUs.
The TB805/TB806 mounts on the standard DIN rail.
It has a mechanical latch that locks it to the rail. It is
grounded to the DIN-rail through a metallic spring
connector. The latch can be released with a screwdriver.

3BSE 020 923R201

DB25 Male
Connector (X2)

13
25

14
1

119

General Information and Installation Users Guide

Appendix A Specifications

7HFKQLFDO'DWD

7DEOH $ 7%7%0RGXOH%XV&DEOH$GDSWRU6SHFLILFDWLRQV

Item

TB805

TB806

Direction

Out

In

Connections

2
DIN41612 Type R/4 (X1)
DB25 Female (X2)

2
DIN41612 Type R/4 (X1)
DB25 Male (X2)

ModuleBus:
Maximum 5V current distribution 1.5A
Maximum 24V current
1.5A
distribution

1.5A
1.5A

Module catch

Locks module to previous

device

Locks module to previous device

Module DIN rail lock

Locks module and provide

ground connection

Locks module and provide

ground connection

Safety Classification

Class I according to IEC 536; Class I according to IEC 536;

(earth protected)
(earth protected)

Protection Rating

IP20 according to IEC 529,

(IEC 144)

IP20 according to IEC 529, (IEC

144)

Rated Insulation Voltage

50V

50V

Dielectric test voltage

500V a.c.

500V a.c.

Width

22 mm (0.88)

22 mm (0.88)

Depth

25 mm (0.98)

25 mm (0.98)

Height

109 mm (4.3)

109 mm (4.3)

Weight

55 g (0.12 lbs.)

55 g (0.12 lbs.)

120

3BSE 020 923R201

General Information and Installation Users Guide

Section A.2 TB805/TB806 ModuleBus Cable Adapter-Out/In

%ORFN'LDJUDP7%

X1

X2

7
/

POWOK
DAT, DAT-N
+24V, 0V24

2
/
2
/
5

+5V

0V

CLK+, CLK-

Shield

ModuleBus Connector DB25 Female

ModuleBus Connector R/4 Female

POS 0 - 6

EM

%ORFN'LDJUDP7%

X2
POS 0 - 6

+24V, 0V24

2
/
2
/
5

+5V

/
4

0V

CLK+, CLKShield

ModuleBus Connector R/4 Male

ModuleBus Connector DB25 Male

POWOK
DAT, DAT-N

X1

EM

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General Information and Installation Users Guide

Appendix A Specifications

A.3 TB807 ModuleBus Terminator

)HDWXUHV

ModuleBus
Connector (X1)

Passive unit used for termination of the

electrical ModuleBus.

Top View

'HVFULSWLRQ

The TB807 ModuleBus Terminator is used to

terminate the electrical ModuleBus.

TB807

Use the TB807 to terminate the electrical

ModuleBus of an I/O cluster. The ModuleBus
terminator connects to the outlet ModuleBus
connector of the last MTU.
E
F

ModuleBus Terminator
Latch

A
B
C

E
F

MTU Assembly

A
B
C

L1+ C1 2
L1+ B1 2
L1- A1 2

122

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

A8 L2-

3BSE 020 923R201

General Information and Installation Users Guide

Section A.3 TB807 ModuleBus Terminator

7HFKQLFDO'DWD

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Item

3BSE 020 923R201

Value

Connections

1
DIN41612 Type R/4 (X1)

Module catch

Attaches module MTU

Safety Classification

Class I according to IEC 536;

(earth protected)

Protection Rating

IP20 according to IEC 529,

(IEC 144)

Rated Insulation Voltage

50V

Dielectric test voltage

500V a.c.

Width

13 mm (0.5)

Depth

19 mm (0.7)

Height

24 mm (0.94)
module projects 17 mm (0.67)

Weight

10 g (0.022 lbs.)

123

General Information and Installation Users Guide

Appendix A Specifications

%ORFN'LDJUDP7%

ModuleBus Connector R/4 Female

X1

124

DAT

DAT-N

CLK+

CLK-

3BSE 020 923R201

General Information and Installation Users Guide

Section A.4 TB810/TB811 ModuleBus Optical Port

A.4 TB810/TB811 ModuleBus Optical Port

)HDWXUHV

1 fiber optic port for the Optical ModuleBus expansion

ModuleBus (electrical) connection to the CI810/CI830, FCI and TB815.
'HVFULSWLRQ7%

The TB810 ModuleBus Optical Port is a communication interface between

the CI810 FCI electrical ModuleBus and the TB820 ModuleBus Modem of an
I/O cluster or ABB drives units via the Optical ModuleBus.
The TB810 can be used in both a simplex optical configuration as well as in a
duplex optical configuration. In a simplex configuration, the optical
Modulebus nodes are connected in a ring. In a duplex configuration,
the optical Modulebus nodes are connected in a row.
The TB810 has two connectors for fiber optic connections and a connection to
the communication interface module. The module is equipped with
Transmitter/Receiver for up to 10 Mbit/s. Both plastic and HCS (Hard Clad
Silica) optic fiber with connectors (HP Versatile Link) can be used with the
TB810.
'HVFULSWLRQ7%

7[ 5[

5[

7[

The TB811 ModuleBus Optical Port is a communication interface between the

FCI electrical ModuleBus and the ABB drives units via the Optical
ModuleBus.
The TB811 can be used in a simplex optical ring configuration.
The TB811 has two connectors for fiber optic connections and a connection to the communication
interface module. The module is equipped with Transmitter/Receiver for up to 5 Mbit/s. Plastic and
optic fiber with connectors (HP Versatile Link) can be used with the TB811.

3BSE 020 923R201

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General Information and Installation Users Guide

Appendix A Specifications

7HFKQLFDO'DWD

7DEOH $ 7%0RGXOH%XV2SWLFDO3RUW6SHFLILFDWLRQV

Item

TB810

TB811

Application

S800 I/O clusters and ABB

variable drives

ABB variable drives

Configuration

Simplex and duplex

Simplex

Fibers

Plastic and HCS (Hard Clad

Silica)

Plastic

Connector

HP Versatile Link

HP Versatile Link

Optical ModuleBus

Fiber optic interface, one

transmit and one receive
connection for max. 10 Mbit/s.

Fiber optic interface, one

transmit and one receive
connection for max. 5 Mbit/s.

Indicators

Tx LED: Yellow indicates

transmitting of data on the
optical ModuleBus

Tx LED: Yellow indicates

transmitting of data on the
optical ModuleBus

Rx LED: Yellow indicates

receiving of data on the optical
ModuleBus

Rx LED: Yellow indicates

receiving of data on the optical
ModuleBus

Current consumption +5V

100 mA

100 mA

Current consumption +24V

20 mA

20 mA

Power dissipation

0.5 W

0.5 W

Safety Classification

Class I according to IEC 536;

(earth protected)

Class I according to IEC 536;

(earth protected)

Protection Rating

IP20 according to IEC 529,

(IEC 144)

IP20 according to IEC 529,

(IEC 144)

Rated insulation voltage

50V

50V

Dielectric test voltage

500V a.c.

500V a.c.

Width

20 mm (0.79)

20 mm (0.79)

Depth

39.6 mm (1.6)

39.6 mm (1.6)

Height

39.6 mm (1.6)

39.6 mm (1.6)

Weight

19 g (0.042 lbs.)

19 g (0.042 lbs.)

126

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General Information and Installation Users Guide

Section A.4 TB810/TB811 ModuleBus Optical Port

&RQQHFWLRQV

7DEOH $ 2SWLFDO0RGXOH%XV&RQQHFWLRQV;

Port

Duplex Signals

Simplex Signals

Tx

Transmit data to down-stream Transmit data to next

device
device

Rx

Receive data from up-stream

device

Receive data from last

device

2SWR&DEOHIRU7%DFFRUGLQJWR+3

Plastic Optical Fiber (POF) up to 15 meters.

Extra low loss attenuation

Simplex or duplex cable

Latching simplex or duplex connector.

Hard Clad Silica (HCS) fiber up to 200 meters.

Riser or plenum

Simplex cable

Standard simplex connector.

2SWR&DEOHIRU7%DFFRUGLQJWR+3

Plastic Optical Fiber (POF) up to 10 meters.

Extra low loss attenuation

Simplex cable

Latching simplex connector.

3BSE 020 923R201

127

General Information and Installation Users Guide

Appendix A Specifications

%ORFN'LDJUDP7%7%

X1
E
O

X2

128

RX
TX

3BSE 020 923R201

General Information and Installation Users Guide

Section A.5 TB820 ModuleBus Modem

A.5 TB820 ModuleBus Modem

)HDWXUHV

2 fiber optic ports to optical ModuleBus

ModuleBus (electrical) to the I/O Modules

ORx1

R
P
ORx2
ERx

Supervisory functions of I/O ModuleBus and power supply

Isolated power supply to I/O modules
DIN rail mounting.
'HVFULSWLRQ

The TB820 ModuleBus Modem is a communication interface

for connection of S800 I/O modules via the optical and
electrical ModuleBus.

CLUSTER
4 56
3
7
2
1

The TB820 can be used in both a simplex optical

configuration as well as in a duplex optical configuration. In a
simplex configuration, the optical Modulebus nodes are
connected in a ring. In a duplex configuration, the optical
Modulebus nodes are connected in a row.

TB820

L+ L+SA
L- L- SB

TB820 has two basic parts: Module termination board and the
power supply/communications board (see block diagram).

X4 X5
RxTxRx Tx
X1B

The termination board is a unit where most of the connections

X1A
to the outside takes place. It is grounded to the DIN rail
through a metallic spring connector. The board carries screw
terminals for power supply and redundant power supply monitoring, connector for the electrical
Modulebus, a current limit fuse for the +24V supply of the I/O modules and the electrical
Modulebus.
The power supply board has an isolated power converter that generates a short circuit proof +5V
supply for the TB820 and connected I/O modules. This board also contains the Modulebus
interfaces, LED indicators and one screwdriver maneuvered rotary switch for the Modulebus I/O
cluster address. The Modulebus I/O cluster address (1-7) is set by a rotary decimal code switch, any
other value than 1-7 is not allowed and will turn the Run LED off.

3BSE 020 923R201

129

General Information and Installation Users Guide

Appendix A Specifications

The Modulebus has an electrical and an optical interface which are logically the same bus.
A maximum of twelve I/O modules can be connected to the electrical Modulebus and up to seven
clusters can be connected to the fiber optic Modulebus expansion. The fiber-optical interface is
intended for local distribution of I/O clusters and where more than 12 I/O modules per station are
required. Any distribution of I/O modules across the base cluster and the remote cluster(s) is
allowed, however not more than 24 I/O modules per station can be used.
The module is equipped with optical Transmitter/Receiver for up to 10 Mbit/s. Both plastic and HCS
(Hard Clad Silica) optic fiber with connectors (HP Versatile Link) can be used with TB820.
7HFKQLFDO'DWD

7DEOH $ 7%0RGXOH%XV0RGHP6SHFLILFDWLRQV

Item

Value

Power input

24V d.c. (19.2 - 30)

Power consumption at 24V d.c.

100 mA

Power dissipation

2.4 W

Power supply monitoring inputs

Max. input voltage: 30V

Min. input voltage for high level: 15 V
Max. input voltage for low level: 8 V

Power output (ModuleBus)

24V max. = 1.5A

5V max. = 1.25A

Electrical ModuleBus

Maximum of 12 I/O modules

Optical ModuleBus

Maximum of 7 I/O clusters

Fiber optic interface, two transmitters

and two receivers for
Max. 10 Mbit/s

130

3BSE 020 923R201

General Information and Installation Users Guide

Section A.5 TB820 ModuleBus Modem

7DEOH $ 7%0RGXOH%XV0RGHP6SHFLILFDWLRQV&RQWLQXHG

Item
Indicators

Value
R(un) LED: Green indicates that the
TB820 is operational
F(ault) LED: Red indicates a fault
condition; Reset and communications
errors on the electrical ModuleBus turns
the LED on.
P(owok) LED: Green indicates that the
d.c./d.c. converter generates a valid
+5V d.c.
ORx1 and ORx2 traffic LEDs: Yellow
(blinking) indicates that the TB820 is
receiving data on the two optical
ModuleBus channels respectively.
ERx traffic LED: Yellow (blinking)
indicates the TB820 is receiving data on
the electrical ModuleBus. It also
indicates that the electrical Modulebus
channel is supervised.

Safety Classification

Class I according to IEC 536; (earth

protected)

Protection Rating

IP20 according to IEC 529, (IEC 144)

Rated insulation voltage

50V

Dielectric test voltage

500V a.c.

Width

58 mm (2.39)

Depth

122 mm (4.8)

Height

170 mm (6.7) including latch

Weight

0.3 kg (0.66 lbs.)

3BSE 020 923R201

131

General Information and Installation Users Guide

Appendix A Specifications

122 mm (4.8)

58 mm (2.3)

67.5 mm
(2.66)

P
ORx1

ORx2

170 mm (6.7)

ERx

99.5 mm
(3.92)

CLUSTER
4 5 6
3
7
2

TB820

L+ L+ SA
L- L- SB

5 mm
(0.2)

40 mm
(1.57)

)LJXUH $ 7%0RGXOH

&RQQHFWLRQV

132

7DEOH $ 3RZHU6XSSO\&RQQHFWLRQV

Pin

Designation

Description

X1B - 1

L+

+24V d.c. Supply In

X1B - 2

L+

+24V d.c. Supply Out

X1B - 3

SA

Redundant Power Supply A

Monitoring Input

X1A - 1

L-

0V d.c. Supply In

3BSE 020 923R201

General Information and Installation Users Guide

Section A.5 TB820 ModuleBus Modem

7DEOH $ 3RZHU6XSSO\&RQQHFWLRQV&RQWLQXHG

Pin

Designation

Description

X1A - 2

L-

0V d.c. Supply Out

X1A - 3

SB

Redundant Power Supply B

Monitoring Input

7DEOH $ 2SWLFDO0RGXOH%XV&RQQHFWLRQV;;

Port

Duplex Signals

Simplex Signals

X4 - Tx

Transmit data to down-stream Transmit data to next

device
device

X4 - Rx

Receive data from downstream device

Not used

X5 - Tx

Transmit data to up-stream

device

Not used

X5 - Rx

Receive data from up-stream

device

Receive data from last

device

Opto connectors type HP Versatile Link can handle both plastic and HCS optic
fiber.
2SWR&DEOHDFFRUGLQJWR+3

Plastic Optical Fiber (POF) up to 15 meters.

Extra low loss attenuation

Simplex or duplex cable

Latching simplex or duplex connector.

Hard Clad Silica (HCS) fiber up to 200 meters.

Riser or plenum

Simplex cable

Standard simplex connector.

3BSE 020 923R201

133

General Information and Installation Users Guide

Appendix A Specifications

%ORFN'LDJUDP7%

RS-485
RS-485

X2

TB820-1
Reset logic,
+5V Supervision

MBI-4

P(owok)
ORx1
ORx2

Electrical Modulebus
Connector

POS(9:0)
MB +5V

F(ault)
R(un)

X3
POWOK
D+,DCLK+,CLK-

0V

MB +5V

MB +5V

+5V

+5V

0V

0V

+5V

MB+5V
0V
LMB+24V

0V

ERx

Current
Limit

DC

DIN-rail

DC
SB

X1A
3
2

L-

POS(9:7)
SA

X1B
3
2

L+

E
O
X4

134

E
O

E
O

TB820-2

X5

3BSE 020 923R201

General Information and Installation Users Guide

Section B.1 Power Up on S800 I/O

$SSHQGL[% 3RZHU8S

% 3RZHU8SRQ6,2
S800 I/O will start under four different conditions.
1.

Without configuration and without communication with the controller. Start the
first time or after a long power off.

2.

Without configuration but with communication with the controller. Start the
first time or after a long power off.

3.

With configuration but without communication with the controller. Start after a
short power off.

4.

With configuration and with communication with the controller. Start after a
short power off.

Below follows a description how to start and how S800 behaves during start-up
under different conditions.
1.

Check that the circuit breakers on the power switch units are switched off.

2.

Switch on the mains power, and check for correct mains voltage with a
multimeter.

3.

Switch on the circuit breaker on the power switch unit(s).

Without configuration and without communications with the controller:

See timing diagram Figure B-1.
,QGLFDWLRQVRQ)&,
F (fault)
R (run)
P (pow ok)
T1
T2
PR
DU

3BSE 020 923R201

on at power up and off after self-test ok

off
on if power supply ok
off
off
on (only primary FCI in a redundant configuration)
off (both FCI in a redundant configuration).

135

General Information and Installation Users Guide

Appendix B Power Up

,QGLFDWLRQVRQ,20RGXOHV
F (fault)
R (run)
W (warning)
O (osp only outputs)

on
off
off
off

Without configuration but with communications with the controller:

See timing diagram Figure B-2.
,QGLFDWLRQVRQ)&,
F (fault)
R (run)

P (pow ok)
T1
T2
PR
DU

on at power up and off after self-test ok

off at power up and on after configuration ok
and commanded operational from the controller
(can take about 1 to 4 minutes)
on if power supply ok
on if cable 1 ok
on if cable 2 ok
on (only primary FCI in a redundant configuration)
off (both FCI in a redundant configuration)

The backup will be started up after the I/O. When the backup has started
PR
DU

on (only primary FCI in a redundant configuration)

on (both FCI in a redundant configuration)

,QGLFDWLRQVRQ,20RGXOHV
F (fault
R (run)

W (warning
O (outputs only)

on at power up and off after the first access

from the FCI
off at power up and on for AI, DI after
configuration and for AO, DO after configuration and
commanded operational from the controller
off at power up and after module operational
updated from the module
off at power up and after module operational
updated from the module

With configuration but without communications with the controller:

See timing diagram Figure B-3.

136

3BSE 020 923R201

General Information and Installation Users Guide

Section B.1 Power Up on S800 I/O

,QGLFDWLRQVRQ)&,
F (fault)
R (run)
P (pow ok)
T1
T2
PR
DU

on at power up and off after self-test ok

off
on if power supply ok
off
off
on (only primary FCI in a redundant configuration)
off (both FCI in a redundant configuration)

,QGLFDWLRQVRQ,20RGXOHV
F (fault)
R (run)

W (warning)
O (osp only outputs)

on at power up and off after the first access from

the FCI
off at power up and on for AI, DI after
configuration from the FCI. AO and DO
remains in off
off at power up and after module operational
updated from the module
off

With configuration and communications with the controller:

See timing diagram Figure B-4.
,QGLFDWLRQVRQ)&,
F (fault)
R (run)

P (pow ok)
T1
T2

on at power up and off after self-test ok

off at power up and on after configuration and
commanded operational from the controller.
(can take about 1 to 4 minutes)
on if power supply ok
on if cable 1 ok
on if cable 2 ok

The backup will be started up after the I/O. When the backup has started
PR
DU

3BSE 020 923R201

on (only primary FCI in a redundant configuration)

on (both FCI in a redundant configuration)

137

General Information and Installation Users Guide

Appendix B Power Up

,QGLFDWLRQVRQ,20RGXOHV
F (fault)
R (run)

W (warning)
O (osp only outputs)

on at power up and off after the first access from

the FCI
off at power up and on for AI, DI after
configuration and for AO,DO after configuration and
commanded operational from the controller
off at power up and after the module operational
updated from the module
off at power up and after module is operational
it is handled by the module

Power up of backup FCI in a running system

See timing diagram Figure B-5.
,QGLFDWLRQVRQ)&,

138

Primary
F (fault)
R (run)
P (pow ok)
T1
T2
PR
DU

off
on
on
on
on
on
off (on when the backup is running)

Backup
F (fault)
R (run)
P (pow ok)
T1
T2
PR
DU

off
off (on when the backup is running)
on
on
on
off
off (on when the backup is running)

3BSE 020 923R201

General Information and Installation Users Guide

Section B.1 Power Up on S800 I/O

FCI
F
R
P
T1/T2
DU (both)
PR (primary)
PR (backup)
I/O module
F
R
W
OSP

Power up
S800 I/O

INIT in
FCI

)LJXUH % 3RZHUXS7LPLQJ'LDJUDPQR&RQILJXUDWLRQDQGQR&RPPXQLFDWLRQVWR&RQWUROOHU

3BSE 020 923R201

139

General Information and Installation Users Guide

Appendix B Power Up

FCI

FCI operational

F
R
P
T1
T2
PR (primary)
DU (both)

PR (backup)
R (backup)
I/O module
F
R (AI, DI)
R (AO, DO)
W (AI, DI)
W, OSP (AO, DO)
Start of I/O
Power up
S800 I/O

INIT
in FCI

INIT
backup

)LJXUH % 3RZHUXS7LPLQJ'LDJUDPQR&RQILJXUDWLRQDQG&RPPXQLFDWLRQVWR&RQWUROOHU

140

3BSE 020 923R201

General Information and Installation Users Guide

Section B.1 Power Up on S800 I/O

FCI
F
R
P
T1/T2
DU (both)
PR (primary)
PR (backup)
I/O module
F
R (AI, DI)
R (AO, DO)
W (AI, DI)
W (AO, DO)

Power up
S800 I/O

INIT
in FCI

Start of I/O

)LJXUH % 3RZHUXS7LPLQJ'LDJUDPZLWK&RQILJXUDWLRQDQGQR&RPPXQLFDWLRQVWR&RQWUROOHU

3BSE 020 923R201

141

General Information and Installation Users Guide

Appendix B Power Up

FCI

FCI operational

F
R
P
T1
T2
PR (primary)
DU (both)

PR (backup)
R (backup)
I/O module
F
R (AI, DI)
R (AO, DO)
W (AI, DI)
W, OSP (AO, DO)
Start of I/O
Power up
S800 I/O

INIT

INIT
backup

)LJXUH % 3RZHUXS7LPLQJ'LDJUDPZLWK&RQILJXUDWLRQDQG&RPPXQLFDWLRQVWR&RQWUROOHU

142

3BSE 020 923R201

General Information and Installation Users Guide

Section B.1 Power Up on S800 I/O

FCI
Primary
F
R
P
T1/T2
PR
DU
Backup
F
R
P
T1/T2
PR
DU

Power-up
backup

INIT
backup

)LJXUH % 3RZHUXS7LPLQJ'LDJUDP3RZHUXSRI%DFNXSLQD5XQQLQJ6\VWHP

3BSE 020 923R201

143

General Information and Installation Users Guide

Appendix B Power Up

144

3BSE 020 923R201

General Information and Installation Users Guide

Index

INDEX
A

A.C. supply 46
Address jumpering 58
Advant Fieldbus 100 57
AI801 4
AI810 4
AI820 4
AI830 4
AI835 4
AI890 4
AO801 4
AO810 4
AO820 4
AO890 4

D.C. supply 46
DI801 4
DI810 4
DI811 4
DI814 5
DI820 5
DI821 5
DI830 5
DI831 5
DI885 5
DI890 5
DIN-rail 26
Dissipation permitted in cabinets 92
Distributed MTUs 57
DO801 5
DO810 5
DO814 5
DO815 5
DO820 5
DO821 5
DO890 5
DP820 5

C
Cable adaptor 5
Cable considerations 43
Check of non-redundant power supply 105
Check of redundant power supply 105
CI810/CI810A 4, 10
CI820 4, 10
CI830 4, 10, 57
Cooling load 95
Current consumption 116

E
Environmental considerations 24
Extension cables 8

F
FCI 10, 21
CI810 82
CI810A 82
CI820 82
CI830 82
FCI and I/O module replacement 106
Fieldbus connection 57

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145

General Information and Installation Users Guide

Index

Ground contact 29
Grounding 41, 52
Process signals 53
Protective ground 42
Signals and voltage supply 42

Optical ModuleBus expansion 35

H
Hardware configuration 75
Hazardous applications 47
Heat dissipation 92
High voltage switch-gear applications 47

I
I/O clusters (1-7) 57
I/O module installation 38
I/O modules 14
I/O Station
Assembly 56
I/O station 21, 26
Industrial environments 44
Installation
Checklists 59

P
Personnel safety 51
Power
A.C. supply 46
D.C. supply 46
Requirements 46
Power and cooling 95
Power consumption 94
Power supply 15, 88
Load calculation 91
Power watts 95
Procedure
Power up 135
Process signals 58
Profibus-DP 4, 10, 22

R
RE810 7
Redundant FCI installation 32

S
L
LED
Location 102
LEDs 101
Lightning strike protection 47

M
Maximum ambient temperature 95
Module termination units 14
ModuleBus extension 6
ModuleBus extension cable 34
ModuleBus modem 109, 129
ModuleBus optical port 35
TB810 35
ModuleBus terminator 39

146

S800 I/O
Assembly 56
Installation 23
Safety regulations 50
SD811 7, 15, 88
SD812 7, 15, 88
Shut down
Emergency 67
Manual stop 68
Safety 67
Start-up 59

3BSE 020 923R201

General Information and Installation Users Guide

Index

T
TB805 5
TB806 5
TB807 5, 39
TB810 5, 35
TB810/811 109
TB811 6
TB815 6
TB820 6, 109
TC501V150 6
TC505 6
Temperature 24, 95
Cabinetry factors 25
I/O module factors 24
Terminator 6
TK801V003 6
TK801V006 6
TK801V012 6
TK811V015 6
TK811V050 6
TK811V150 6
TK812V015 6
TK812V050 6
TK812V150 6
TU810 6
TU811 6
TU814 6
TU830 6
TU831 6
TU835 7
TU836 7
TU837 7
TU838 7
TU890 7

V
Ventilation 92
Vibration 25

3BSE 020 923R201

147

General Information and Installation Users Guide

Index

148

3BSE 020 923R201

3BSE 020 923R201

July 2000