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3BSE020923-510 en S800 I O Getting Started
3BSE020923-510 en S800 I O Getting Started
Getting Started
ABB may have one or more patents or pending patent applications protecting the intel-
lectual property in the ABB products described in this document.
The information in this document is subject to change without notice and should not be
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In no event shall ABB be liable for direct, indirect, special, incidental or consequential
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The software or hardware described in this document is furnished under a license and
may be used, copied, or disclosed only in accordance with the terms of such license. This
product meets the requirements specified in EMC Directive 2004/108/EEC and in Low
Voltage Directive 2006/95/EEC.
TRADEMARKS
All rights to copyrights, registered trademarks, and trademarks reside with their respec-
tive owners.
Section 1 - Introduction
Product Overview ............................................................................................................24
Product Scope ..................................................................................................................33
ModuleBus ...........................................................................................................34
CI801 Fieldbus Communication Interface ...........................................................36
CI810/CI810A/CI810B Fieldbus Communication Interface ...............................36
CI820/CI820V1 Fieldbus Communication Interface ...........................................37
TB815 Interconnection Unit ................................................................................37
CI830 Fieldbus Communication Interface ...........................................................37
CI840 Fieldbus Communication Interface ...........................................................38
TB810/TB811 ModuleBus Optical Port ..............................................................38
TB842 ModuleBus Port .......................................................................................38
TB820/TB820V2 ModuleBus Modem ................................................................43
TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849
Module Termination Unit....................................................................46
TB825 Optical Media Converter ..........................................................................52
Module Termination Units ...................................................................................52
I/O Modules .........................................................................................................53
S800 I/O Modules ................................................................................................53
3BSE020923-510 5
Table of Contents
Section 2 - Installation
Site Planning ................................................................................................................... 62
Site Selection and Preparation ............................................................................. 62
Environmental Considerations............................................................................. 62
Electromagnetic Compatibility and CE Marking ................................................ 64
Layout of I/O Stations.......................................................................................... 64
Mechanical Installation........................................................................................ 87
Grounding ............................................................................................................ 92
Signal Cable Considerations ................................................................................ 94
Power Requirements ............................................................................................ 96
Hazardous Location – North American Approval (cULus)................................. 96
Hazardous Location – European Approval (ATEX) ............................................ 97
High Voltage Switch-gear Applications............................................................... 97
Lightning Strike Protection.................................................................................. 97
Inductive Load Suppression................................................................................. 98
Mounting Dimensions.......................................................................................... 98
Electrical Installation Overview......................................................................... 101
Installation Procedures .................................................................................................. 103
Safety Regulations ............................................................................................. 103
Grounding in Enclosures ................................................................................... 104
Cable Routing .................................................................................................... 106
I/O Station with S800 I/O .................................................................................. 107
Checklists .......................................................................................................... 111
Final Procedure Before Start-up ........................................................................ 116
Start-up and Shut-down Procedures .............................................................................. 117
6 3BSE020923-510
Table of Contents
Section 3 - Configuration
Design Considerations...................................................................................................125
I/O Station Layout Hardware Configuration Guidelines ...................................125
Redundant FCIs for Advant Fieldbus 100..........................................................130
Redundant FCIs and I/O Modules for PROFIBUS ............................................130
I/O Clusters ........................................................................................................131
CI801/CI810/CI820/CI820V1/CI830/CI840 FCI ..............................................136
TB820/TB820V2 and TB840/TB840A ModuleBus Modem ............................137
TB825 Optical Media Converter ........................................................................144
Power Supply System ....................................................................................................149
Powering S800 I/O System............................................................................................149
Powering Field Equipment ............................................................................................149
Interference ........................................................................................................149
Short-circuit at the output...................................................................................149
Sectioning the field equipment...........................................................................150
Cable protection .................................................................................................150
Connection alternatives ......................................................................................150
Power Supply Load Calculation ....................................................................................153
Appropriate Hardware........................................................................................153
Guidelines ..........................................................................................................153
Heat Dissipation ............................................................................................................154
Cabinet Ventilation.............................................................................................154
Heat Dissipation Permitted in Cabinets .............................................................154
Calculation of Heat Generated in a Cabinet.......................................................154
Maintenance and Repair ................................................................................................155
Expansion Considerations .............................................................................................155
Power Supply Requirements .........................................................................................156
3BSE020923-510 7
Table of Contents
Section 4 - Operation
Operating Overview ...................................................................................................... 165
Section 5 - Maintenance
Preventive Maintenance ................................................................................................ 167
Hardware Indicators ...................................................................................................... 167
Color .......................................................................................................... 167
Location .......................................................................................................... 168
Identification ...................................................................................................... 169
Error Messages.............................................................................................................. 169
Fault Finding and User Repair ...................................................................................... 169
Introduction........................................................................................................ 169
Diagnostics and Fault Indications...................................................................... 170
List of General Fault Finding Procedures and Hints ......................................... 170
User Repair ........................................................................................................ 172
8 3BSE020923-510
Table of Contents
EMC ............................................................................................................................182
Overvoltage Categories ......................................................................................184
Equipment Class and Insulation Voltages .....................................................................184
Equipment Class.................................................................................................184
Insulation Voltage...............................................................................................184
Insulation Test Voltage .......................................................................................185
Certifications .................................................................................................................186
Appendix B - Specifications
SD82x Power Supply Modules, 24 V d.c. .....................................................................193
Key Features.......................................................................................................193
Equipment Class.................................................................................................193
Ingress Protection...............................................................................................194
Power Supply Units Types SD821 / 822 / 823 - Description.............................196
Insulation of Power Supply Units (PSU) ...........................................................198
Fuses and Protective Devices .............................................................................198
Technical Data....................................................................................................199
SD83x Power Supply Modules, 24 V d.c. .....................................................................201
Key Features.......................................................................................................201
Equipment Class.................................................................................................201
Ingress Protection...............................................................................................201
Dimensions and Connections ...........................................................................202
Power Supply Units Types SD831 / 832 / 833 / 834- Description.....................204
Dielectric strength ..............................................................................................208
DC-OK relay contact (SD834 only)...................................................................208
SD834 in parallel to increase output power .......................................................209
Installation, Fuses and Protective Devices .........................................................209
Technical Data....................................................................................................210
Voting Unit - (for Redundant Power Supply) ................................................................212
SS822 ...........................................................................................................212
SS823 ...........................................................................................................216
SS832 ...........................................................................................................221
TB805/TB806 ModuleBus Cable Adapter-Out/In ........................................................227
3BSE020923-510 9
Table of Contents
10 3BSE020923-510
Table of Contents
3BSE020923-510 11
Table of Contents
12 3BSE020923-510
Table of Contents
Technical Data....................................................................................................290
Configuration .....................................................................................................291
Horizontal and Vertical Mounting Profile .....................................................................292
Features ...........................................................................................................292
Description .........................................................................................................292
Dimensions.........................................................................................................293
Appendix C - Power Up
Power Up on S800 I/O...................................................................................................295
INDEX
3BSE020923-510 13
Table of Contents
14 3BSE020923-510
Safety Summary
Page-104: Work with care when supply voltage is applied to the system.
Voltages within the cabinet can cause serious injury or death.
Page-117: Work with care when supply voltage is applied in the system.
The voltage in the cabinet can cause serious injury or death.
Page -118: Work with care when supply voltage is applied in the system.
The voltage in the cabinet can cause serious injury or death.
Page-171: 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.
3BSE020923-510 15
Safety Summary
SPECIFIC Page-172: Switch off the process voltage before removal of the module, if
WARNINGS the plastic cover for the I/O modules DI802, DI803, DI820, DI821, DO802,
(continued) DO820 or DO821 is damaged, and there is risk for contact with live parts.
SPECIFIC Page-82: Do not turn the I/O Module Lock/Switch counter-clockwise from
CAUTIONS the unlocked position. This will cause it to break and will make the MTU
and the I/O module inoperative.
Page:-139: Care must be taken that no I/O clusters have the same
address setting. This could result in output modules in the same Module-
Bus position but in different I/O clusters putting out the same value.
16 3BSE020923-510
About This Book
General
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 procedure, and information regarding capacity
and performance. This book is not intended to be the sole source of instruction for
the S800 I/O system.
Document Conventions
Microsoft Windows conventions are normally used for the standard presentation of
material when entering text, key sequences, prompts, messages, menu items, screen
elements, etc.
Electrical warning icon indicates the presence of a hazard which could result in
electrical shock.
Warning icon indicates the presence of a hazard which could result in personal
injury.
3BSE020923-510 17
Terminology About This Book
Tip icon indicates advice on, for example, how to design your project or how to
use a certain function
Although Warning hazards are related to personal injury, and Caution hazards are
associated with equipment or property damage, it should be understood that
operation of damaged equipment could, under certain operational conditions, result
in degraded process performance leading to personal injury or death. Therefore,
fully comply with all Warning and Caution notices.
Terminology
A complete and comprehensive list of Terms is included in the IndustrialIT
Extended Automation System 800xA, Engineering Concepts instruction
(3BDS100972*). The listing included in Engineering Concepts includes terms and
definitions as they that apply to the 800xA system where the usage is different from
commonly accepted industry standard definitions and definitions given in standard
dictionaries such as Webster’s Dictionary of Computer Terms.
Table 1. Terminology
Term Description
AF 100 Advant Fieldbus 100 is the communications bus between
the I/O stations and the Advant Controllers. (FCI to CI52x)
Base cluster Consists of single or redundant ModuleBus masters plus
I/O modules connected directly to the ModuleBus master.
FCI The Fieldbus Communication Interface (FCI) device
contains the interface to the fieldbus (for example
PROFIBUS or AF 100).
18 3BSE020923-510
About This Book Terminology
Term Description
G3 compliant The module withstand more severe environmental
conditions according to ISA-S71.04.
I/O cluster An extension of the I/O Station’s ModuleBus connected to
the ModuleBus master 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.
I.S. Intrinsic Safety is a protection technique to prevent
explosion in hazardous areas of a process plant.
ModuleBus Is an incremental, electrical or optical, bus for
interconnection of I/O devices.
ModuleBus master ModuleBus master can be a controller (AC 800M) or a FCI.
A ModuleBus master contains a ModuleBus interface and
power regulators. The FCI module can manage 24 I/O
devices and the controller up to 96 I/O modules (up to 12
directly and to the others in 1 to 7 I/O clusters).
(ModuleBus) Is used when extending the electrical ModuleBus (within
Extension cable the max. 2 meters).
MTU The Module Termination Unit is a passive base unit
containing process terminals and a part of the ModuleBus.
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.
PROFIBUS-DPV1 PROFIBUS-DPV1 is a fieldbus standard.
3BSE020923-510 19
Related Documentation About This Book
Term Description
RTD Resistance Temperature Detector.
SOE Sequence of events. Time stamping of status changes for
digital inputs.
TC Thermocouples
Related Documentation
The following is a listing of documentation related to the S800 I/O system.
Title Description
S800 I/O Modules and Termination Units Describes the I/O modules and
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
system.
S800 I/O Fieldbus Communication Describes the AF100 FCI in the S800
Interface for Advant Fieldbus 100 I/O system.
User’s Guide
S800 I/O Fieldbus Communication Describes the PROFIBUS-DP FCI in the
Interface for PROFIBUS-DP/DPV1 S800 I/O system.
S800 I/O PROFIBUS FCI Describes the memory mapping on
Memory Maps for CI801 PROFIBUS for the S800 I/O system in
CI801.
S800 I/O PROFIBUS FCI Describes the memory mapping on
Memory Maps for CI830 PROFIBUS for the S800 I/O system in
CI830.
20 3BSE020923-510
About This Book Related Documentation
Title Description
S800 I/O PROFIBUS FCI Describes the memory mapping on
Memory Maps for CI840 PROFIBUS for the S800 I/O system in
CI840.
Advant Fieldbus 100 User’s Guide Describes the equipment and contains
information required to install and
commission AF100.
3BSE020923-510 21
Related Documentation About This Book
22 3BSE020923-510
Section 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/DPV1 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 both in single or fully redundant applications.
Figure 1. S800 I/O with Fieldbus Communication Interface CI801 and I/O Modules
Mounted on Compact Type of Termination Units.
3BSE020923-510 23
Product Overview Section 1 Introduction
Controller
Base Cluster
Base Cluster
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 the most types of signals, HART and Intrinsic Safety
Interface.
24 3BSE020923-510
Section 1 Introduction Product Overview
The S800 I/O modules and a Fieldbus Communication Interface (FCI) are combined
to form an I/O Station. S800 I/O can be used in both single and redundant
applications.
In general, all S800 I/O units are G3 compliant. G3 compliant units withstand more
severe environmental conditions according to ISA-S71.04. The following S800 I/O
units are G2 compliant - SD821, SD822, SD823, SD831, SD832, SD833, SD834,
SS822, SS832, TB811 and CI830. G3 compliant versions of SD822 and SS822 are
available, refer to SD822Z and SS822Z.
The modules are marked with a bar code that shows serial number, article ID and
product revision number. A separate bar code strip is enclosed for optional placing
on the module. The bar code is of type Bar-code 128.
The equipment that is used as part of the I/O Station with S800 I/O is presented in
Table 3.
Device Type
Function
Designator
AI801 8 AI channels (1x8), 0(4)...20 mA
AI810 8 AI channels (1x8), 0(4)...20 mA, 0(2)...10 V
AI815 8 AI channels (1x8) 4...20 mA, 0...20 mA, 1...5 V, 0...5 V.
Advanced diagnostics, HART interface, for single
application.
AI820 4 AI channels (differential), -20...20 mA, 0(4)...20 mA, -
10...10V, 0(2)...10 V, -5...5 V, 0(1)...5 V
AI825 4 AI channels (4 x 1) for applications requiring galvanic
isolated channels, -20...20 mA, 0(4)...20 mA, -10...10V,
0(2)...10 V
AI830/ 8 AI channel for Resistance Measurements (e.g. Pt 100
AI830A sensors)
AI835/ 7+1 AI channels for Thermocouple or mV Inputs
AI835A
3BSE020923-510 25
Product Overview Section 1 Introduction
Device Type
Function
Designator
AI843 8 AI channels for Thermocouple or mV Inputs. Advanced
diagnostics, for single and redundant applications.
AI845 8 AI channels (1x8) 4...20 mA, 0...20 mA, 1...5 V, 0...5 V.
Advanced diagnostics, HART interface, for single and
redundant applications.
AI880/AI880A 8 High Integrity AI channels (1x8) 0...20 mA, 4...20 mA. For
single and redundant applications, HART interface. Also
used in function Loop Supervised DI.
AI890 8 AI channels (1x8), 0(4)...20 mA, I.S. interface
AI893 8 AI channels for RTD or Thermocouple/mV Inputs, I.S.
interface.
AI895 8 AI channels (1x8), 4...20 mA, I.S. and HART interface.
AO801 8 AO channels (1x8), 0(4)...20 mA
AO810/ 8 AO channels (1x8), 0(4)...20 mA
AO810V2
AO815 8 AO channels (1x8), 4...20mA. Advanced diagnostics,
HART interface, for single application.
AO820 4 AO channels (4 x 1) galv. isolated (bipolar), -20...20 mA,
0(4)...20 mA, -10...10V, 0(2)...10 V
AO845/ 8 AO channels (1x8) 4...20mA. Advanced diagnostics,
AO845A HART interface, for single or redundant applications.
AO890 8 AO channels (1x8), 0(4)...20 mA, I.S. interface
AO895 8 AO channels (1x8), 4...20 mA, I.S. and HART interface.
CI801 Fieldbus Communication Interface (FCI) for PROFIBUS-
DPV1, Hot Configuration In Run and HART pass-through.
26 3BSE020923-510
Section 1 Introduction Product Overview
Device Type
Function
Designator
CI810/ Fieldbus Communication Interface (FCI) for Advant Fieldbus
CI810A/ 100
CI810B
CI820/CI820V1 Redundant Fieldbus Communication Interface (FCI) for
Advant Fieldbus 100
CI830 Fieldbus Communication Interface (FCI) for PROFIBUS-DP
CI840/ Fieldbus Communication Interface (FCI) for PROFIBUS-
CI840A DPV1, redundant application, Hot Configuration In Run and
HART pass-through.
DI801 16 DI channels (1x16), 24 V d.c., current sinking
DI802 8 DI channels (1x8), 120 V d.c., current sinking
DI803 8 DI channels (1x8), 230 V d.c., current sinking
DI810 16 DI channels (2x8), 24 V d.c., current sinking.
DI811 16 DI channels (2x8), 48 V d.c., current sinking
DI814 16 DI channels (2x8), 24 V d.c. current sourcing
DI820 8 galvanic isolated DI channels (8x1), 120 V a.c./d.c.,
current sinking.
DI821 8 galvanic isolated DI channels, (8x1) 230 V a.c./d.c.,
current sinking.
DI825 8 galvanic isolated DI channels, (8x1) 125 V d.c. with
sequence of event (SOE) handling
DI830 16 DI channels (2x8) 24 V d.c. with sequence of event
(SOE) handling, current sinking
DI831 16 DI channels (2x8) 48 V d.c. with sequence of event
(SOE) handling, current sinking
3BSE020923-510 27
Product Overview Section 1 Introduction
Device Type
Function
Designator
DI840 16 DI channels (2x8) 24 V d.c. with sequence of event
(SOE) handling. Advanced diagnostics, for single or
redundant applications.
DI880 16 High Integrity DI channels (1x16) 24 V d.c. with
sequence of event (SOE) handling.
For single and redundant applications.
DI885 8 DI channels, (1x8) 24/48 V d.c. with sequence of event
(SOE) handling, current sinking
DI890 8 DI channels (8x1), I.S. interface
DO801 16 DO channels (1x16), 24 V d.c., 0.5 A, current sourcing
DO802 8 DO channels (1x8), 24-110 V d.c./250 V a.c., relay
normally open
DO810 16 DO channels (2x8), 24 V d.c., 0.5 A, current sourcing.
DO814 16 DO channels (2x8), 24 V d.c., 0.5 A, current sinking
DO815 8 DO channels (2x4), 24 V d.c., 2 A, current sourcing.
DO820 8 DO channels (8x1), Relay, 250 V, 3 A a.c. normally open.
DO821 8 DO channels (8x1), Relay, 250 V, 3 A a.c. normally closed
DO840 16 DO channels (16x1), Relay, 24 V, 0.5 A a.c. with
advanced diagnostics, for single or redundant applications.
DO880 16 High Integrity DO channels (1 x 16) 24 V d.c.
For single and redundant applications.
DO890 4 channels (4x1), 11 V 40 mA, I.S. interface
DP820 2 channels, pulse count and frequency measurement,
maximum 1.5 MHz. Interface for RS422, current, 5V, 12 V or
24 V.
28 3BSE020923-510
Section 1 Introduction Product Overview
Device Type
Function
Designator
DP840 8 channels, pulse count and frequency measurement,
maximum 20 kHz. With advanced diagnostics, for single or
redundant applications. Interface for NAMUR, 12 V and
24 V.
The input can be read as digital input signals.
SD821 Power supply, 115/230 V a.c. to 24 V d.c. @ 2.5 A
SD822/SD822Z Power supply, 115/230 V a.c. to 24 V d.c. @ 5.0 A.
SD823 Power supply, 115/230 V a.c. to 24 V d.c. @ 10 A
SD831 Power supply, 100-240 V a.c. or 110-300 V d.c. to 24 V d.c.
@ 3 A.
SD832 Power supply, 100/120 V or 200/240 a.c. to 24 V d.c. @ 5 A.
SD833 Power supply, 100-120 V or 200-240 a.c. to 24 V d.c. @ 10
A.
SD834 Power supply, 100-240 V a.c. or 110-300 V d.c. to 24 V d.c.
@ 20 A.
SS822/SS822Z Voting Unit for redundant power supply, 24 V d.c. @ 20.0 A.
SS823 Power Voter with overvoltage protection, 24 V d.c., 20 A.
SS832 Voting unit for redundant power supply, 24 V d.c. @ 12.5 A.
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. Used together with CI810, CI820/CI820V1 and
CI830.
3BSE020923-510 29
Product Overview Section 1 Introduction
Device Type
Function
Designator
TB811 ModuleBus Optical Port Module 5 Mbit driver, fiber optic
connection. Used together with CI810, CI820/CI820V1 and
CI830.
TB815 ModuleBus Interconnection Unit to redundant FCIs
(CI820/CI820V1)
TB820/TB820V2 ModuleBus Modem, fiber optic ModuleBus interface of an
I/O cluster. 10 Mbit driver.
TB825 ModuleBus Optical media converter, converts between
plastic opto fiber or HCS fiber with Versatile link connectors
and glass optical fiber with ST connectors.
TB840/TB840A ModuleBus Modem, fiber optic ModuleBus interface of an
I/O cluster. 10 Mbit driver. Redundant application.
TB842 ModuleBus Optical Port Module 10 Mbit driver, fiber optic
connection. Used together with CI840.
TB845 Cable adaptor out module (double electrical ModuleBus)
TB846 Cable adaptor in module (double electrical ModuleBus)
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
30 3BSE020923-510
Section 1 Introduction Product Overview
Device Type
Function
Designator
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
TU805 Terminal Unit 2 x18 terminals, 50 V. Used to enable 2- and
3-wire connections on DI801 and DO801. The Terminal Unit
is mounted direct on DI801 or DO801.
TU807 Terminal Unit for single TB840A
TU810/TU810V1 Compact MTU, 3x8 + 2x3 terminals, 50 V.
TU811/TU811V1 Compact MTU, 2x8 terminals, 250 V.
TU812/TU812V1 Compact MTU, 25 pin D-sub Connector for field connection,
50 V
TU813 Compact MTU, Crimp Snap-in Connector for field
connection, 250 V.
TU814/TU814V1 Compact MTU, Crimp Snap-in Connector for field
connection
50 V.
TU830/TU830V1 Extended MTU, 3x16 + 2x4 terminals, 50 V
TU831/TU831V1 Extended MTU, 8x2 terminals, 250 V
TU833 Extended MTU, 3*16 + 2*4 spring-case terminals, 50 V.
TU834 Extended MTU, 2x16 terminals, 50 V, 8 channels with
individual shunt sticks
TU835/TU835V1 Extended MTU, 4x2 groups + 2x4 power terminals, 50 V,
individually fused per channel
3BSE020923-510 31
Product Overview Section 1 Introduction
Device Type
Function
Designator
TU836/TU836V1 Extended MTU, 2x4 groups + 2x6 power terminals, 250 V,
individually fused per channel
TU837/TU837V1 Extended MTU, 2x4 groups + 2x6 power return terminals,
250 V, fused
TU838 Extended MTU, 2x4 groups + 2x4 power return terminals,
50 V, fused
TU839 Extended MTU, 3x2 groups + 2x3 power return terminals,
250 V, fused
TU840 MTU for redundant TB840, dual ModuleBus
TU841 MTU for redundant TB840, single ModuleBus
TU842 16 channel, 50 V, horizontal dual MTU for redundant I/O
TU843 16 channel, 50 V, vertical dual MTU for redundant I/O
TU844 8 channel with individual shunt sticks, 50 V, horizontal dual
MTU for redundant I/O
TU845 8 channel with individual shunt sticks, 50 V, vertical dual
MTU for redundant I/O
TU846 MTU for redundant CI840, dual ModuleBus
TU847 MTU for redundant CI840, single ModuleBus.
TU848 MTU for redundant TB840, dual ModuleBus and dual power
supply connections
TU849 MTU for redundant TB840, single ModuleBus and dual
power supply connections
TU850 Extended MTU, 2x8 current limited sensor power + 16
signal + 2x4 fused power connections terminals, 50 V.
TU890 Compact MTU for I.S. interface Module, 50 V. For use in I.S.
applications.
32 3BSE020923-510
Section 1 Introduction Product Scope
Device Type
Function
Designator
TU891 Compact MTU for I.S. interface Module, 50 V. Not for use in
I.S. applications.
TY801 Shunt stick for current or voltage signals together with AI845
or AI880/AI880A and TU844 or TU845, 2 x 125 Ω.
TY804 Shunt stick for NAMUR signals together with DP840 and
TU844 or TU845, 1 kΩ
TY820 Temperature sensor with 4-wire connection, and used
together with AI835 and AI843.
Mounting Kit Used for horizontal mounting of CI801, CI840 and TB840 on
a vertical DIN-rail.
Mounting profile Horizontal mounting profile with one DIN-rail and one cable
duct
Mounting profile Vertical mounting profile with 4 + 1 DIN-rails
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 single or redundant Fieldbus Communication
Interface (FCI) module and up to 12 single I/O modules (on single MTUs) or 6 pairs
of redundant I/O modules (on redundant MTUs). It is not allowed to mix single and
redundant I/O modules on the base cluster.
I/O clusters 1 to 7 consist of a ModuleBus Modem and up to 12 single I/O modules.
I/O clusters 1 to 7 are connected to the FCI through 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.
3BSE020923-510 33
ModuleBus Section 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, 200m (656ft) with HCS glass fiber, and
1000m (3281ft) using TB825 Optical Media Converter. Factory made optical duplex
or simplex cables (plastic fiber) are available in lengths of 1.5, 5 and 15 m (5, 16.7
or 50 ft.).
ModuleBus
Each S800 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 ModuleBus master or a
cluster’s ModuleBus Modem and then each of the remaining MTUs or S800L
modules connect to the previous MTU or S800L module.
A ModuleBus master 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 clusters.
The base cluster consists of the ModuleBus master (single or redundant) and I/O
modules (single or redundant). Additional I/O clusters (1 to 7) consist of a
ModuleBus Modem and I/O modules. The ModuleBus Modems are connected to an
optional ModuleBus Optical Port module on the ModuleBus master, using optical
cables.
Within a cluster, the ModuleBus is made up of increments that are integrated into
each MTU or S800L module. The ModuleBus master 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 ModuleBus master or
a ModuleBus Modem, the bus is automatically expanded up to a maximum of 12
single MTUs (this number includes the number of S800L modules) or 6 redundant
MTUs. It is not allowed to mix single and redundant I/O modules within a cluster. In
a "Hot Replacement" configuration, you can install up to 6 I/O modules on up to
6 redundant MTUs.
34 3BSE020923-510
Section 1 Introduction ModuleBus
Unique position codes are automatically assigned to each MTU or S800L module as
the bus is expanded. An inserted S800 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.
The S800 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.
Figure 3 shows a typical base cluster in an I/O station with single I/O modules and
single FCI connected to PROFIBUS or Advant Fieldbus 100.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Figure 3. Typical I/O Station Base Cluster with S800 I/O, Single or Redundant FCI
Figure 4 shows a typical base cluster in an I/O station with single I/O modules and
redundant FCI connected to Advant Fieldbus 100.
3BSE020923-510 35
CI801 Fieldbus Communication Interface Section 1 Introduction
Redundant I/O modules and redundant FCI connected to PROFIBUS are shown in
Figure 22.
Status
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Figure 4. I/O Station Base Cluster with Redundant FCIs to S800 I/O for AF100
36 3BSE020923-510
Section 1 Introduction CI820/CI820V1 Fieldbus Communication Interface
3BSE020923-510 37
CI840 Fieldbus Communication Interface Section 1 Introduction
38 3BSE020923-510
Section 1 Introduction TB842 ModuleBus Port
STN. ADDR.
4 56
3 7 x 10
2 8
109
5 6
3
4
7x1
LED Status
CI810A
2 8 Indicators
109
SWX.X/Y
AF100 Tx Rx TB810/TB811
L+ L+ SA 1 2 Optical ModuleBus Port
L- L- SB
+ + Tx
- -
SH SH
SH SH Rx
3BSE020923-510 39
TB842 ModuleBus Port Section 1 Introduction
F F
R R
P P
Rx/Tx Rx/Tx
PRIM PRIM
DUAL DUAL
CI840 CI840
TB842
TB806
TU847
Figure 6. TB842 Optical ModuleBus Port mounted on TB806 module for connection
to TU847
40 3BSE020923-510
Section 1 Introduction TB842 ModuleBus Port
3BSE020923-510 41
TB842 ModuleBus Port Section 1 Introduction
LED Status
Indicators
ModuleBus
Interface
Connector
Power Supply
Address
TB842 Switch #1
TB806
Address
PROFIBUS-DP Switch #2
Connector
Figure 8. TB842 Optical ModuleBus Port mounted on TB806 module for connection
to CI801
42 3BSE020923-510
Section 1 Introduction TB820/TB820V2 ModuleBus Modem
3BSE020923-510 43
TB820/TB820V2 ModuleBus Modem Section 1 Introduction
LED Status
F R Indicators
P
ORx1 ORx2
ERx
Electrical ModuleBus
DIN Rail Interface Connector
CLUSTER
4 56
3 7 Cluster Address
2 Switch
1
(Address 4 shown)
TB820 V2
L
L+ X4 X5
Power Supply RxTxRx Tx
Connections SA Optical ModuleBus
SB Interface Connector
Redundant Power
Supervision
The ModuleBus Modem communicates with the FCI or Controller via the Optical
ModuleBus.
The TB820/TB820V2 ModuleBus Modem provides 24 V d.c. current limited (from
the source) and an isolated, current limited 5 V dc power to the cluster’s I/O
modules by way of the electrical ModuleBus connection. One power source (single
or redundant 24 V d.c.) can be connected to the power terminals (L+ & L-).
Redundant power supply can be supervised via inputs SA and SB.
44 3BSE020923-510
Section 1 Introduction TB820/TB820V2 ModuleBus Modem
F R
P
ORx1 ORx2
ERx
170 mm (6.7”)
CLUSTER
4 5 6
3 7
2
1
TB820
L L+L- + - SAB
L+
SA
SB
3BSE020923-510 45
TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849 Module Termination
S
P
Rx1
Rx2
ERx1
ERx2
TB840
46 3BSE020923-510
Section 1 IntroductionTB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849
3BSE020923-510 47
TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849 Module Termination
Electrical ModuleBus
interface connectors
Redundant power
supervision
48 3BSE020923-510
Section 1 IntroductionTB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849
Electrical ModuleBus
interface connectors
CUSTER ADDR.
Redundant power
supervision
3BSE020923-510 49
TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849 Module Termination
Electrical ModuleBus
interface connectors
Redundant
power supervision
50 3BSE020923-510
Section 1 IntroductionTB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849
128 mm
(5.04”)
47 mm
(1.85”)
124 mm (4.88”)
162 mm 186 mm
(6.38”) (7.32”)
3BSE020923-510 51
TB825 Optical Media Converter Section 1 Introduction
85.6
67.5
114
136
14.2
57.2
58.5
52 3BSE020923-510
Section 1 Introduction I/O Modules
I/O Modules
There are two different types of I/O modules; S800 modules and S800L modules.
S800 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.
Power Supply
The SD82x and SD83x are switch-mode power supply units which convert the
mains voltage to 24 volts d.c. These power supplies can be utilized for non-
redundant and redundant applications. Redundant applications require diode voting
units SS822, SS823 or SS832.
3BSE020923-510 53
Power Supply Section 1 Introduction
Power
Supply 24 V
A
B
FCI I/O station
24 V power supply
or ModuleBus Modem
I/O modules
The ModuleBus master 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.
54 3BSE020923-510
Section 1 Introduction G3 Compliant Modules
FCI
or ModuleBus Modem
Power
Supply Voting 24 V
Unit
A
A
B
Power I/O station
Supply
B 24 V d.c. power supply
Supervision 24V A, 24V B
I/O modules
G3 Compliant Modules
In general, all S800 units are G3 compliant (for exceptions, see Product Overview
on page 24).
G3 is a severity level in the standard ISA-S71.04 Environmental Conditions for
Process Measurement and Control Systems: Airborne Contaminants, for further
information about the environment turn to the standard ISA-S71.04.
During transport, storage and installation special caution must be taken:
• Dividable connectors/terminals must not be left unconnected/open in G3
environment if the are intended to be used later.
• Module must not be stored in G3 environment due to unprotected
connectors/terminals, also valid for modules in packaging.
3BSE020923-510 55
Example of Enclosure Configurations Section 1 Introduction
800 mm (31.5")
FCI
1000 mm (39.4")
POW POW
Figure 19. RE820 Cabinet with 12 I/O Modules and Redundant Station Power
Supplies
56 3BSE020923-510
Section 1 Introduction Support for External Intrinsic Safety System
S800 I/0
Figure 20. Example of Connection between S800 I/O and Intrinsic Safety System
from Pepperl+Fuchs Elcon
3BSE020923-510 57
Support for External HART Communication Section 1 Introduction
To PC
S800 I/O RS485
Figure 21. Example of Connection between S800 I/O and Intrinsic Safety System
from Pepperl+Fuchs Elcon and HART Multiplexer Interface from HART
Redundancy
Figure 2 shows the basic construction of I/O Stations without any redundancy. To
increase the up-time, a number of component can be set up with redundancy:
• Power Supply
• I/O Module
• Fieldbus Communication Interface (FCI)
• Fieldbus
• Electrical ModuleBus
58 3BSE020923-510
Section 1 Introduction Redundancy
Redundant
Controller
I/O Cluster
Fieldbus
I/O Cluster
Optical
ModuleBus
Figure 22. I/O Station Overview with Maximum Redundancy and Additional Single
I/O Modules
It is not necessary to implement redundancy on all components, but there are some
dependencies:
• Redundant power supply requires no other redundancy.
• Redundant Advant Fieldbus 100 requires no other redundancy.
3BSE020923-510 59
Redundancy Section 1 Introduction
Redundancy Functionality
Input Modules. When using redundant input modules, all reading is done from the
primary input module. The input module will diagnose itself, and when the primary
input module fails the reading will be done from the secondary input module.
The secondary AI module is checked for error status at a lower cycle rate than the
primary.
Analogue Output Modules. When using redundant AO modules, half the output
current is generated from each AO module. The AO module will diagnose itself, and
when one fails, it disconnects and a direct communication between the two
redundant AO modules will ensure that the second AO module quickly doubles its
output current.
Digital Output Module. When using redundant DO modules, they both work
parallel to each other. They give the same output.
When one DO module fails it will give output signals set to low. The DO module
that still work will override by setting active signals to high.
60 3BSE020923-510
Section 2 Installation
This section contains guidelines for planning the installation of the S800 I/O
equipment.
This section 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 section relates to standard equipment.
For installation of Advant Fieldbus 100 and Advant Fieldbus 100 modems, see S800
I/O Fieldbus Communication Interface for Advant Fieldbus 100 (3BSE020925*)
manual.
For installation of PROFIBUS, see PROFIBUS DP Wiring and Installation
(3BDS009029*) manual.
For installations of S800 I/O modules with Intrinsic Safety Interface see S800 I/O
Modules and Termination Units with Intrinsic Safety Interface (3BSE020927*)
manual.
3BSE020923-510 61
Site Planning Section 2 Installation
Site Planning
Site Selection and Preparation
When planning an S800 I/O installation, 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.
• 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 connection to the grounding plane.
• 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.
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.
62 3BSE020923-510
Section 2 Installation Environmental Considerations
Temperature
I/O Module Factors. The maximum ambient air temperature around S800 modules
is 55°C (131°F) for I/O modules mounted on Extended MTUs on vertical or
horizontal orientated DIN-rails, or I/O modules mounted on compact MTUs on
horizontal oriented DIN-rails. I/O modules mounted in Compact MTUs on a vertical
DIN-rail allows operation at 40°C (104°F).
The maximum ambient air temperature around S800L modules is 55°C (131°F) for
I/O modules mounted on horizontal orientated DIN-rails. It is 40°C (104°F) for I/O
modules mounted on vertical oriented DIN-rails.
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.
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. Refer to Power and Cooling on page 157 for more information.
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
3BSE020923-510 63
Electromagnetic Compatibility and CE Marking Section 2 Installation
64 3BSE020923-510
Section 2 Installation Layout of I/O Stations
3BSE020923-510 65
Layout of I/O Stations Section 2 Installation
DO801
66 3BSE020923-510
Section 2 Installation 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 25).
I/O Module
DIN-rail Lock/Switch
To
Lock
E
F
D
A
Ground
C
B
Clip Spring
E
F
D
A
C
B
L1+ C1 2 3 4 5 6 7 C8 L2+
Pry down to
release rail
latch
Snapping the FCI, ModuleBus Modem or MTU to the DIN-rail makes contact by a
grounding spring with the chassis.
3BSE020923-510 67
Layout of I/O Stations Section 2 Installation
F R
P
T1 T2
E
F
F
D D
A A
SERVICE
C
B
B
STN. ADDR.
4 56 E
E
F
F
3 7 x 10 D D
2 8 A A
109
C
C
B
B
4 56
3 7x1
2 8
CI810 109
SWX.X/Y AF100 Tx Rx
L+ L+ SA 1 2
L- L- SB
+ + Tx L1+ C1 2 3 4 5 6 7 C8 L2+ L1+ C1 2 3 4 5 6 7 C8 L2+
- -
SH SH L1+ B1 2 3 4 5 6 7 B8 L2+ L1+ B1 2 3 4 5 6 7 B8 L2+
SH SH Rx
L1- A1 2 3 4 5 6 7 A8 L2- L1- A1 2 3 4 5 6 7 A8 L2-
68 3BSE020923-510
Section 2 Installation 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 S800L module by using a screw
driver and pressing it between the two items.
F R
P
T1 T2
E
F
D
A
SERVICE C
DO801
STN. ADDR. B
4 56
E
F
3 7 x 10 D
2 8 A
109
C
B
4 56
3 7x1
2 8
CI810 109
SWX.X/Y AF100 Tx Rx
L+ L+ SA 1 2
L- L- SB
+ + Tx L1+ C1 2 3 4 5 6 7 C8 L2+
- -
SH SH L1+ B1 2 3 4 5 6 7 B8 L2+
SH SH Rx
L1- A1 2 3 4 5 6 7 A8 L2-
3BSE020923-510 69
Layout of I/O Stations Section 2 Installation
F R F R
P M P
O
T1 T2 D T1 T2
U
PR DU L PR DU
E
B
U
S
SERVICE SERVICE
SWX.X/Y SWX.X/Y
L+ L+ SA AF100 L+ L+ SA AF100
L- L- SB L- L- SB
+ Tx +
- -
SH SH
Rx
SH SH
Figure 28. Redundant CI820 FCIs and TB815 Interconnection Unit Layout
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 29).
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).
70 3BSE020923-510
Section 2 Installation 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.
F R F R
P M P F F F
O
T1 T2 D T1 T2 R R R
U
PR DU L PR DU W W W
E
B
U 1 1 1
S
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
SERVICE SERVICE 7 7 7
8 8 8
9 9 9
E
F
F
10 D 10 D 10 D
A A A
11 11 11
C
STN. ADDR STN. ADDR
B
4 56 4 56 12 12 12
3 7 3 7
E
13 13 13
F
2 8 x 10 2 8 x 10 D D D
109 109 14 A 14 A 14 A
C
4 56 4 56 15 15 15
B
3 7 3 7
8 x1 2 8 x1 16 16 16
2
CI820 109 TB815 CI820 109
DI810 DI810 DI810
24V 24V 24V
L+ L+ SA AF100 L+ L+ SA AF100
L- L- SB L- L- SB
+
-
Tx +
- TB806 L1+C1 2 3 4 5 6 7 C8 L2+ L1+C1 2 3 4 5 6 7 C8 L2+ L1+C1 2 3 4 5 6 7 C8 L2+
TK801V003
(300 mm)
(1 ft.)
3BSE020923-510 71
Layout of I/O Stations Section 2 Installation
F F Connection to
R R Electrical ModuleBus
P P
Rx/Tx Rx/Tx
PRIM PRIM
DUAL DUAL
CI840 CI840
Service
ports
Address Switches
The total length of the electrical ModuleBus, must not exceed 2.5 meters (8.2 feet).
72 3BSE020923-510
Section 2 Installation Layout of I/O Stations
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 31.
In case of redundant I/O two TK801V0xx ModuleBus Extension cables, a Cable
Adapter-out TB845 instead of TB805 and a Cable Adapter-in TB846 instead of
TB806 are needed. See Figure 32.
The TB805/TB806 ModuleBus Cable Adapter-Out/In adapters mount on the DIN-
rail. 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.
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.).
3BSE020923-510 73
Layout of I/O Stations Section 2 Installation
ModuleBus length must not exceed 2.5 meters (8.2 feet) from FCI, TB815
Interconnection Unit, or ModuleBus Modem to the last MTU or S800L module
including extension cables.
TB805
F TB806 F
R R
W W
1 Latch Release 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
E
E
F
F
10 D
A 10 D
A
11 11
C
C
B
B
12 12
13 13
E
E
F
F
14 D A 14 D A
15 15
C
C
B
B
16 16
DI810 DI810
24 V 24 V
Male Cable Female Cable
Connector Connector
L1+ C1 2 3 4 5 6 7 C8 L2+ L1+ C1 2 3 4 5 6 7 C8 L2+
74 3BSE020923-510
Section 2 Installation Layout of I/O Stations
TB84x TB84x
TB845
TB846
I/O I/O
TK801V0xx
3BSE020923-510 75
Layout of I/O Stations Section 2 Installation
STN. ADDR.
4 56
3 7 x 10
2 8
109
4 56
3 7x1
2 8
CI810 109
AF100
TB810
Tx Rx
L+ L+ SA 1 2
L- L- SB
+ + Tx
- -
SH SH
SH SH Rx
SERVICE SERVICE
L+ L+ SA AF100 L+ L+ SA AF100
L- L- SB L- L- SB
+ Tx +
- -
SH SH
SH Rx SH
TB810
76 3BSE020923-510
Section 2 Installation Layout of I/O Stations
The TB842 ModuleBus Optical Port must be connected to CI840 via TB806 or
TB846 and TU846 or TU847. TB806 and TU847 for single I/O, see Figure 35, and
TB846 and TU846 for redundant I/O, see Figure 36.
TB810 and TB842 has 10 Mbit drivers and is used with the TB820/TB820V2 (S800
I/O) and ABB drives equipment. TB811 has 5 Mbit drivers and is used with ABB
drives 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
CI801 or
TB806 CI840/TU847
TB842
Figure 35. TB842 and TB806 Connected to CI801 or Redundant CI840 FCIs
Through TU847
3BSE020923-510 77
Layout of I/O Stations Section 2 Installation
TU846
CI840
TB846
TB842
Figure 36. TB842 and TB846 Connected to Redundant CI840 FCIs Through TU846
After optical expansion of the Modulebus, only single I/O configurations can be
used.
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 37.
78 3BSE020923-510
Section 2 Installation Layout of I/O Stations
FCI FCI
3BSE020923-510 79
Layout of I/O Stations Section 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.
80 3BSE020923-510
Section 2 Installation Layout of I/O Stations
R
W I/O Module Lock/Switch
(shown locked)
1
2 I/O Module Lock/Switch
3 (shown unlocked)
4
5
6
7 Turn clockwise
8 to lock I/O Module
9
E
F
E
F
10 D
A
D
A
11
C
C I/O Module
B
B
12
13
E Key #1
E
F
F
D D
14 A A
C
15
C
B
B
16
I/O Module
DI810 Key #2
24V
Figure 39. MTU Mechanical Keys for I/O Module and Module Lock
3BSE020923-510 81
Layout of I/O Stations Section 2 Installation
At the mounting of a S800 I/O Box on a Termination Unit the following should
be observed:
Press the Box straight and right on to stop into the Termination Unit. Above
shown angle shall be 0°.
Turn the Locking Device clockwise to its end position. Above shown state with
the Locking Device in a position before end position shall not exist for an active
module.
Do not 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.
82 3BSE020923-510
Section 2 Installation 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 cluster. The TB807 has a snap latch (Figure 41) 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 ModuleBus
5 Terminator
6 Latch
7
8
3BSE020923-510 83
Layout of I/O Stations Section 2 Installation
826 mm (32.5")
End Stop End Stop
DIN-rail
mm 10 84 58.5 20
(inches) (0.4) (3.3) (2.3) (0.8)
Figure 42. I/O Station Layout with FCI and S800 I/O Modules
443,8 mm (17.5")
Fiber Optic
ModuleBus Cables
10 58 58.5 20 mm
(0.4) (2.2) (2.3) (0.8) (inches)
Figure 43. I/O Station Layout with ModuleBus Modem and S800 I/O Modules
In all installations, two end stops must be mounted on the DIN-rail, one at each
end of the cluster, to prevent the modules from moving along the rail, see
Figure 42.
84 3BSE020923-510
Section 2 Installation Layout of I/O Stations
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 44.
S1 2 34 5 6 7 89 10 1112 1314 15 16
Status
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Status
S 12 3 4 5 67 8 9 10 1112 13 1415 16
Figure 44. Compact, Extended MTU and S800L Modules showing Horizontal and
Vertical Mounting
3BSE020923-510 85
Layout of I/O Stations Section 2 Installation
The Mounting Kit is locked to the vertical DIN-rail by a DIN rail lock, which is
screwed and tightened to the Mounting Kit by two M4 screws, see Figure 45.
DIN-rail lock
Below DIN-rail Below DIN-rail
86 3BSE020923-510
Section 2 Installation Mechanical Installation
The modules will be placed on the Mounting Kit, locked by the locking device, and
screwed with M4 screws into the Mounting Kit, see Figure 46.
M4 screws
Mechanical Installation
There are two ways of mounting AC 800M and S800 I/O in cabinets, open rack, or
other types of installations:
• Mounting on DIN rail attached to a metal sheet
• Mounting on prefabricated aluminium profile
3BSE020923-510 87
Mechanical Installation Section 2 Installation
All cabinet structure components must be bonded together with good and permanent
ground connections. The connections should preferably be made with
self-tapping Taptite screws with cutting head. Where self-tapping Taptite screws
cannot be used on painted components, the paint must be removed under the head of
the screw and the nut and the surface must be smeared with conductive grease.
The metallic parts in the cabinet shall be properly connected to plant ground.
88 3BSE020923-510
Section 2 Installation Mechanical Installation
3BSE020923-510 89
Mechanical Installation Section 2 Installation
90 3BSE020923-510
Section 2 Installation Mechanical Installation
3BSE020923-510 91
Grounding Section 2 Installation
Grounding
General
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. The
interference suppression for external signals, are normally directly grounded to
plant ground.
For interference free operation, the S800 I/O system need to be connected properly
to plant ground.
92 3BSE020923-510
Section 2 Installation Grounding
Each S800 I/O module's 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 therefore have a good bond to the cabinet structure
which shall be connected to plant ground. How to get a good bond from DIN-rail to
cabinet structure is described in the mechanical installation section.
The ground wire which joins the grounding systems and connects to the cabinet to
plant ground should be ≥35 mm2 (2 AWG) copper (Cu), see Figure 51. The ground
wire should be fastened firmly to a unpainted surface of the cabinet structure.
Cabinets
or enclosure
Shield bar
Connection to
ground plane
Ground Plane
> 35 mm2
(> 2 AWG)
3BSE020923-510 93
Signal Cable Considerations Section 2 Installation
94 3BSE020923-510
Section 2 Installation Signal Cable Considerations
2. Shielded cables should be used for low level (RTDs, TC...) analog signals,
HART1 signals, pulse transducer signals and High Integrity I/O modules.
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. Usage of binary and analog signals in a multi-core cable works fine, if the
following conditions are fulfilled:
– All binary signals are 24 V d.c. or slow varying analog signals.
– Field power supply is earthed to S800 earth.
– All multi-core cable signals are earthed to S800 earth (same earth as the
field power supply).
– Binary signals are suppressed. (S800 semiconductor binary outputs have
built-in free-wheel diodes for smooth inductive load switching.)
– If cable shield, it should be connected to S800 earth.
– Three wire analog transducers with voltage outputs should have individual
power return wires to avoid voltage drop caused by binary loads’ return
current.
In other cases 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 (power supply cables > 600V)
should be in separate conduits or at least 30 cm 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 Table 5.
7. Advant Fieldbus cable installed per S800 I/O Fieldbus Communication
Interface for Advant Fieldbus 100 (3BSE020925*).
8. PROFIBUS-DP cable installed. Refer to PROFIBUS DP Wiring and
Installation 3BDS009029* manual.
3BSE020923-510 95
Power Requirements Section 2 Installation
Power Requirements
General
Power supplied to ABB system’s 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 100 - 240 V a.c. Installation Category II denotes a higher quality
than III mains. The S800 I/O power supplies SD82x and SD83x are rated for
Overvoltage Category II on the secondary side and Overvoltage Category III on
primary side.
D.C. Supply
96 3BSE020923-510
Section 2 Installation Hazardous Location – European Approval (ATEX)
Please notice that the following restrictions must be followed when equipment are
installed in hazardous locations:
Explosion hazard!
Do not disconnect equipment unless power has been removed or the area is
known to be non-hazardous.
Explosion hazard!
Substitution of components may impair suitability for Class 1 Zone 2 and
Class 1 Division 2.
Explosion hazard!
Do not replace batteries unless power has been switched off or the area is known
to be non-hazardous.
Explosion hazard!
Do not remove fuses unless the area is known to be non-hazardous.
3BSE020923-510 97
Inductive Load Suppression Section 2 Installation
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.
Mounting Dimensions
When placing a control cabinet, specified minimum distances to walls and ceiling
must be kept to ensure satisfactory performance.
Overhead Clearances
Min 150 mm
(6”)
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 52.
98 3BSE020923-510
Section 2 Installation Mounting Dimensions
(1.6 inches)
Min 40 mm
Standoffs for Wall
Mounted Enclosures
Min 40 mm
(1.6 inches)
Figure 53. Minimum Distance from Rear and Side of Cabinet to a Wall
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 53. 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.
3BSE020923-510 99
Mounting Dimensions Section 2 Installation
800 mm (31.5")
FCI
Min
100 mm (3.9”)
Min
1000 mm (39.4")
8 mm
(0,03”)
Min
8 mm (0,03”) Min
100 mm (3,9”)
SD SD
822 822
I/O
Min 40 mm (1.6”)
Min 100 mm (3.9”)
Cable channel
I/O
Figure 54. Enclosure with 12 Modules mounted horizontally and Redundant Station
Power Supplies
100 3BSE020923-510
Section 2 Installation Electrical Installation Overview
Clearances within an enclosure with vertically mounted I/O modules are described
in Figure 55.
Min
100 mm (3.9”) Min
100 mm (3.9”)
Min
FCI
822 822
SD SD
100 mm (3.9”)
Min
100 mm (3,9”)
800 mm (31.5")
100 mm (3.9”)
Min
Min
100 mm (3.9”)
(3.9”)
100 mm
Min
1000 mm (39.4")
3BSE020923-510 101
Electrical Installation Overview Section 2 Installation
Overvoltage Categories
Overvoltage categories are based on magnitude of surges caused by lightning strikes
and overvoltage generated by circuit components, primary hard contacts breaking
inductive load circuits. Spacings, creepage distances and clearances given by
product standards are based on Overvoltage categories.
Overvoltage Category IV
Public mains, voltage >600 V a.c, and all over head lines.
102 3BSE020923-510
Section 2 Installation Installation Procedures
Installation Procedures
After some general information in the following section, you will find individual
setup descriptions for different parts of the system.
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.
3BSE020923-510 103
Grounding in Enclosures Section 2 Installation
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.
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 cannot to be
exchanged with power applied, for example, processor units, extension cable
adaptors and extension cables, see Section 5, Maintenance. Wait for a
sufficient time for the capacitors to discharge before removing a power
sensitive module.
Grounding in Enclosures
This section describes where and how grounding is to be done in a cabinet or small
enclosures.
General
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.
104 3BSE020923-510
Section 2 Installation Grounding in Enclosures
The interference suppression for external signals, are normally directly grounded to
plant ground. For interference-free operation, the S800 I/O system need to be
connected properly to plant ground.
Each S800 I/O module's grounding spring connects to the metallic DIN-rail, which
serves as the module electronics ground conductor between the inter-connected
devices.
This ensures 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 therefore
have a good bond to the cabinet structure which shall be connected to plant ground.
For details on how to obtain a good bond from DIN-rail to cabinet structure, see
Mechanical Installation on page 87.
Protective Earth
Cabinets supplied with 120/230 V a.c. always must be connected to protective earth
(PE) grounding. The main power source distribution normally includes a protective
ground wire. This shall be connected to the protected earth (PE) terminal block on
the power supply. Use cable lug connectors when connecting on the ground screw.
Ground Line
The cabinet is to be grounded with a copper lead (≥35 mm2, 2 AWG) to the plant
ground line. Cabinets in a row shall be individually connected to the plant ground
plane. To form an even stronger ground plane, cabinets placed next to each other
should be connected together.
3BSE020923-510 105
Cable Routing Section 2 Installation
Cable Routing
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 5 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 as
described in Table 5.
106 3BSE020923-510
Section 2 Installation I/O Station with S800 I/O
Cable Cable
Separation for
category X category Y Separation Separation for
installation in cable
[OVC = [OVC = for standard installation with
duct with grounded
Overvoltage Overvoltage installation shielded cables
conducting barrier
category] category]
OVC IV OVC III 300 mm No separation No separation
required required
OVC IV OVC II 350 mm No separation No separation
required required
OVC IV Modulebus 350 mm No separation No separation
extension required required
OVC III OVC II 50 mm No separation No separation
required required
OVC III Modulebus 50 mm No separation No separation
extension required required
OVC II Modulebus No separation No separation No separation
extension required required required
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.
• Install a DIN-rail sized to allow installation of the FCI, ModuleBus Modem,
MTUs, and S800L modules, terminator and power supplies. Some extra DIN-
rail should be allowed for expansion or the moving of the FCI, ModuleBus
Modem, MTUs or S800L modules during maintenance.
3BSE020923-510 107
I/O Station with S800 I/O Section 2 Installation
• 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.
• 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.
Electric Installation
108 3BSE020923-510
Section 2 Installation I/O Station with S800 I/O
Process Signals
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 Cable Routing on page 106.
• Grounding of cable shields and Process signals, see Grounding in Enclosures
on page 104.
A carefully done electrical installation is the basis for future interference-free
operation.
3BSE020923-510 109
I/O Station with S800 I/O Section 2 Installation
Address Setting
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 address or
Advant Fieldbus 100 station set by the station address switches. Refer to S800 I/O
Fieldbus Communication Interface for PROFIBUS-DP/DPV1 (3BSE020926*) or
S800 I/O Fieldbus Communication Interface for Advant Fieldbus 100
(3BSE020925*) 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 TB820/TB820V2 ModuleBus
Modem on page 43.
110 3BSE020923-510
Section 2 Installation Checklists
Checklists
The following checklists, Table 6 to Table 12, are a summary of important
information that should be checked for the installation.
3BSE020923-510 111
Checklists Section 2 Installation
112 3BSE020923-510
Section 2 Installation Checklists
Power Supply
Lightning Protection
3BSE020923-510 113
Checklists Section 2 Installation
114 3BSE020923-510
Section 2 Installation Checklists
Environmental Data
See Appendix A, General Specifications.
Airborne Contaminants
See Appendix A, General Specifications.
3BSE020923-510 115
Final Procedure Before Start-up Section 2 Installation
Miscellaneous
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.
116 3BSE020923-510
Section 2 Installation Start-up and Shut-down Procedures
Safety Regulations
The instructions given in Safety Regulations on page 103 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.
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.
3BSE020923-510 117
Shut-down Procedures Section 2 Installation
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.
Safety Regulations
The instructions given in Safety Regulations on page 103 are applicable in all
situations when working with a 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.
118 3BSE020923-510
Section 2 Installation Product Verification
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.
Product Verification
As the test requirements vary considerably between different installations,
the system engineer is responsible for determining the functional requirements
which apply.
3BSE020923-510 119
General Section 2 Installation
Equipment Required
The following equipment is a minimum requirement:
• Necessary parts of the documentation listed in Related Documentation on page
20.
• 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.
General
A general description of how to set the controller in operation and start the
execution of application program is presented in the 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.
120 3BSE020923-510
Section 2 Installation General
Input Signals
Figure 57 shows where an input signal can be checked in an S800 I/O application.
DI modules provide a field input connector and DI channel LED’s, and AI modules
provide a field input connector.
Engineering Tool
Process Controller
FCI
Process Fieldbus
Input
Interface Application
Device Module
DI ch.
Figure 57. Block Diagram of S800 I/O Input Channel, Test Points
3BSE020923-510 121
General Section 2 Installation
– 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.
• Analog Input Signals
Figure 57 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 58 shows where an output signal can be checked in an S800 I/O application.
DO Modules provide a field output connector and DO channel LED’s.
AO Modules provide a field output connector.
122 3BSE020923-510
Section 2 Installation General
Engineering Tool
Controller Process
FCI
Fieldbus
Output Process
Application Interface
Module Device
DO ch.
Figure 58. Block Diagram of S800 I/O Output Channel, Test Points
3BSE020923-510 123
Final Check Section 2 Installation
Typical analog output channels and where the signals can be tested are shown
in Figure 58. Analog output signals in a specific plant are shown in the
connection diagrams for the plant.
Proceed as follows to check analog channels:
– 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.
Final Check
When the test of the control system is complete, and the plant functions
satisfactorily, the following actions should be taken:
• Check that all S800 I/O modules are properly inserted in the MTUs.
• Check that the I/O module lock/switch is in its locked position.
• 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.
124 3BSE020923-510
Section 3 Configuration
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.
3BSE020923-510 125
I/O Station Layout Hardware Configuration Guidelines Section 3 Configuration
20 mm
22 mm (0.8”)
(0.86”)
Maximum 2.5 meters (98.4”)
162 mm
(6.4”)
816 mm (32.1”)
855 mm (33.6”) *
126 3BSE020923-510
Section 3 Configuration I/O Station Layout Hardware Configuration Guidelines
See Figure 60 for maximum layout of I/O cluster using Extended MTUs.
469 mm (18.5”)
508 mm (20”) *
84 (3.3”)
84 120 22 mm
123 (8.44)*
123* (0.86”)
120
162 mm
(6.37”)
(4.74”)
Bus Cable
Length = 300 mm
(11.8”)
1554 mm
(61,2”)
1593 mm
(62.7”)* 1129 mm
(44.5”)
mm
(inches)
109 mm
(4.3”)
20
(0.8”) * Measurements for TU847 and CI840
3BSE020923-510 127
Section 3 Configuration
3BSE020923-510
821 mm
(32.3“)
20 mm
(0.8”)
(3.4”)
22 mm
(0.87”)
22 mm
(0.87”)
110 mm
S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516
(4.3”)
Status
Status
Status
Status
Status
Status
Status
Status
Status
Status
367mm (14.4”)
S12345678910111213141516
Length = 300 mm
406 mm (16”)*
(11.8”)
Status
Bus Cable
S12345678910111213141516
I/O Station Layout Hardware Configuration Guidelines
85.8
Status
(inch)
mm
123*
84
1182 mm (46.5”)*
1143 mm (45”)
(6.38”)
162 mm
123 mm (8.43”)*
84 mm (3.3”)
85.8 mm
20 mm
(0.8”)
(3.4”)
S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516 S12345678910111213141516
Status
Status
Status
Status
Status
Status
Status
Status
Status
Status
Status
Status
1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 1011 1213141516
128
Section 3 Configuration I/O Station Layout Hardware Configuration Guidelines
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 62 for a example of an I/O cluster divided up into four groups.
Terminator
TB807
Digital Inputs
Analog Inputs
TK801V0xx
Status
TB805
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Cable Adaptor, in
TB806
Analog Outputs Digital Outputs
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.
3BSE020923-510 129
Redundant FCIs for Advant Fieldbus 100 Section 3 Configuration
Terminator
CI820 FCI TB807
TK801V0xx
TB815
Interconnection
Unit
130 3BSE020923-510
Section 3 Configuration I/O Clusters
The maximum ModuleBus length from the TU846 to the ModuleBus terminator is
2.5 meters. See Figure 64 for layout of a station.
CI840 FCI
Terminator
MTU TB807
TU846
Cable adaptor, in
TB846
Figure 64. I/O Station with Redundant CI840 FCIs and Redundant I/O Modules
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.
3BSE020923-510 131
I/O Clusters Section 3 Configuration
Status
I/O Cluster 1
I/O Cluster 2
132 3BSE020923-510
Section 3 Configuration I/O Clusters
3BSE020923-510 133
I/O Clusters Section 3 Configuration
I/O Cluster 1
I/O Cluster 2
Figure 67. Optical ModuleBus Extension non-redundant, CI840 with single I/O
134 3BSE020923-510
Section 3 Configuration I/O Clusters
TB842
I/O Cluster 1
I/O Cluster 2
Figure 68. Optical ModuleBus Extension non-redundant, CI840 with redundant I/O
3BSE020923-510 135
CI801/CI810/CI820/CI820V1/CI830/CI840 FCI Section 3 Configuration
CI801/CI810/CI820/CI820V1/CI830/CI840 FCI
The FCI needs to be connected to a fieldbus and have an address selected. It is also
connected to a 24 V 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.
136 3BSE020923-510
Section 3 Configuration TB820/TB820V2 and TB840/TB840A ModuleBus Modem
F R
P
ORx1 ORx2
ERx
CLUSTER
4 56
3 7 Cluster Address
2
1 Switch
(Address 4 shown)
TB820 V2
L+
L- X4
Rx Rx
X5
Tx Tx
SA Optical ModuleBus
SB Interface Connector (X4, X5)
3BSE020923-510 137
TB820/TB820V2 and TB840/TB840A ModuleBus Modem Section 3 Configuration
CLUSTER ADDR.
138 3BSE020923-510
Section 3 Configuration TB820/TB820V2 and TB840/TB840A ModuleBus Modem
cluster address 0 (zero). Figure 70 shows the front panel of the TB820/TB820V2
and Figure 71 the front panel of the TB840/TB840A.
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.
On TB820/TB820V2, a new cluster address should not be set during operation. If
the address changes are done 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. If the address changes are done on
TB840 during operation, the cluster will get a warning signal and the new address
will not be set until reset or power up.
TB820/TB820V2 can not handle High Integrity I/O modules (AI880/AI880A,
DI880 and DO880).
3BSE020923-510 139
TB820/TB820V2 and TB840/TB840A ModuleBus Modem Section 3 Configuration
TB820
L+ L+ SA
Optical ModuleBus
L- L- SB Interface Connectors
X4 X5 (X4, X5)
Rx Rx
Tx Tx
Rx Tx2
X4 X4
Tx Rx2
Duplex Fiber Optic Cable Connector
Rx Tx1
X5 X5
Tx Rx1
Simplex Fiber Optic Cable Connector
Front View Front View
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 73 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 TB820/TB820V2’s
or TB840/TB840As to be added down-stream on-line.
Simplex (one-way) connections provide a ring configuration from the FCI to the
first TB820/TB820V2/TB840/TB840A, then to the next and so on and then back to
the FCI. Simplex designs will require that the “home-run” cable from the last
TB820/TB820V2/TB840/TB840A back to the FCI, or another
TB820/TB820V2/TB840/TB840A, is 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
140 3BSE020923-510
Section 3 Configuration TB820/TB820V2 and TB840/TB840A ModuleBus Modem
FCI/
Controller Example of a “duplex” connection of the optical “ring”.
FCI/
Controller Example of a “simplex” connection of the optical ring.
FCI/
Controller Example of a mixed “simplex/duplex” connection of the optical “ring”.
Rx Tx TB820/
TB820/ X4-Tx TB820/ X4-Tx TB820/ X4-Tx
X5-Rx TB820V2/
TB820V2/ TB820V2/ TB820V2/
X5-Rx X5-Rx TB840/ X5-Rx
TB840/ X4-Rx TB840/ X4-Rx TB840/
X5-Tx TB840A * TB840A * TB840A * TB840A *
X5-Tx X5-Tx
3BSE020923-510 141
TB820/TB820V2 and TB840/TB840A ModuleBus Modem Section 3 Configuration
TB840 TB840
TB820 V2
From
Power Supply
X4 X5
Rx Rx
Tx Tx Terminal
Headers
+24 V d.c.
L+ L -- SA SB
0 V d.c.
142 3BSE020923-510
Section 3 Configuration TB820/TB820V2 and TB840/TB840A ModuleBus Modem
Table 13. TB820/TB820V2 Power Connection Terminal valid for Figure 74.
TB820
L+ L+ SA
L- L- SB
X4 X5
Rx Rx
X1B Tx Tx
X1A
Terminal
Headers
Power Supply “B”
Monitor
3
Power Supply “A” 1 2
+24 V d.c.
Monitor To MTUs
+24 V d.c. 0 V d.c. (I/O Modules)
3
1 2
From Power Supply
0 V d.c.
Jumper
Power connections can accept up to 0.2 - 2.5 mm2 (24 - 14 AWG) wire size.
3BSE020923-510 143
TB825 Optical Media Converter Section 3 Configuration
144 3BSE020923-510
Section 3 Configuration TB825 Optical Media Converter
3BSE020923-510 145
TB825 Optical Media Converter Section 3 Configuration
146 3BSE020923-510
Section 3 Configuration TB825 Optical Media Converter
Connection Description
Tx1 Transmitting port local fiber 1
Rx1 Receiving port local fiber 1
Tx2 Transmitting port field fiber
Rx2 Receiving port field fiber
Tx3 Transmitting port local fiber 2
Rx3 Receiving port local fiber 2
3BSE020923-510 147
TB825 Optical Media Converter Section 3 Configuration
The delay values in Table 18 can be used to calculate the maximum delay in an
optical ModuleBus configuration.
Maximum fiber length between two modems is 15 m for plastic fiber, 200 m for
HCS fiber and 1000 m for glass fiber.
LF
AC800 15 m
TB820 I/O
LF
15 m
TB820 I/O
LF
15 m
TB820 I/O
LF LF = Local fiber
15 m FF = Field fiber
TB820 I/O E = Electrical Modulebus
LF
1.5 m
TB820 I/O
LF LF
1.5 m FF 1.5 m E
TB825 TB825 TB820 I/O
1000 m
148 3BSE020923-510
Section 3 Configuration Power Supply System
3BSE020923-510 149
Sectioning the field equipment Section 3 Configuration
S800 I/O system from any of the field equipment, it is strongly recommended that
independent power supply modules for both the S800 I/O system and the field
equipment are installed.
Cable protection
Fuses in the 24 V d.c. distribution system for cable protection only can be used.
Connection alternatives
It is recommended to power the S800 I/O system and field equipment from different
power supplies; however, the power supply for field equipment can be connected in
the same manner as that used for connecting and powering the S800 I/O system, see
Figure 79.
It should be pointed out however, that the same Mains Breaker Unit can be used to
control and isolate both power supplies or, alternatively, independent Mains
Breakers can be used on each spur, see the examples shown in Figure 80.
150 3BSE020923-510
Section 3 Configuration Connection alternatives
To
Single Power Supply S800 I/O
system
SD
Mains 8xx
24 V dc
Mains Breaker Power Distribution
Supply Terminals
SS To
Mains SD
8xx 832 S800 I/O
system
Mains Breaker
SS 24 V dc
SD Distribution
832 Terminals
8xx
Power Voting
Supplies Device
To
Mains 1 SD SS S800 I/O
8xx 832(1) system
Mains Breaker
24 V dc
SD SS Distribution
Mains 2 Terminals
8xx 832(1)
Mains Breaker
Power Voting
Supplies Device
(1)
or SS823.
If the individual power supplies are
5A or lower, only one SS832 is required.
3BSE020923-510 151
Connection alternatives Section 3 Configuration
To
S800 I/O
system
Mains SD
8xx
Mains Breaker 24 V dc
Distribution
Independent
Power Supply To
Modules Field
equipment
SD
8xx
24 V dc
Distribution
To
S800 I/O
system
SD
Mains 8xx
Mains Breaker 24 V dc
Independent Power Distribution
Supply Modules
To Field Equipment
SD
8xx
Mains Breaker 24 V dc
Distribution
Independent Mains
Breaker Units
152 3BSE020923-510
Section 3 Configuration Power Supply Load Calculation
Guidelines
• A summary of the main requirements of the plant supply, from a planning point
of view, is found in Section 2, Installation.
• 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 always 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.
3BSE020923-510 153
Heat Dissipation Section 3 Configuration
Heat Dissipation
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 20°C 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.
154 3BSE020923-510
Section 3 Configuration Maintenance and Repair
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.
Spare MTUs need to be pre-mounted to add I/O modules on-line.
3BSE020923-510 155
Power Supply Requirements Section 3 Configuration
24 V d.c. Power
I/O Station
Consumption
Base Cluster (single FCI) and 6 I/O Modules 0.5 A
Base Cluster (single FCI) and 12 I/O Modules 1.0 A
Redundant FCIs (2) and 6 I/O Modules 1.0 A
Redundant FCIs (2) and 12 I/O Modules 1.5 A
Additional I/O Clusters and 6 I/O Modules 0.5 A
Additional I/O Clusters and 12 I/O Modules 1.0 A
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 24 V d.c. distributed via the
ModuleBus are included. External 24 V connected directly to the I/O modules,
for external loads and transmitters, are not included. When using large quantities
of AO820s, DI885s, DO815s and/or DO820/DO821s, these load figures may be
exceeded.
156 3BSE020923-510
Section 3 Configuration Power and Cooling
• Single DO880 and SD834: The basic load must not exceed 20 A, with voting
unit 20 A.
• Redundant DO880 and SD833: The basic load must not exceed 4 A, with
voting unit 4 A, if the power supply voltage >26 V
• Redundant DO880 and SD834: The basic load must not exceed 20 A, with
voting unit 20 A.
• Single DO880 and voting unit SS823: The basic load must not exceed 20 A.
• Redundant DO880 and voting unit SS823: The basic load must not exceed
16A.
Cooling
Power
5 Volts 24 Volts 24 Volts Load (1) Maximum Ambient
Device Dissipation
ModuleBus ModuleBus External (BTU/H Temperature
(Watts)
Typical)
AI801 70 mA - 30 mA 1.1 3.7 55/40°C
(131/104°F)(2)
AI810 70 mA 40 mA - 1.5 5.1 55/40°C
(131/104°F)(2)
AI815 100 mA 50 mA 22 mA + 3.5 12 55/40°C
sensor (131/104°F)(2)
current
AI820 80 mA 70 mA - 1.7 5.8 55/40°C
(131/104°F)(2)
AI825 100 mA 110 mA - 3.2 11 55/40°C
(131/104°F)(2)
3BSE020923-510 157
Power and Cooling Section 3 Configuration
Table 20. I/O Station Power and Cooling (Typical) Values (Continued)
Cooling
Power
5 Volts 24 Volts 24 Volts Load (1) Maximum Ambient
Device Dissipation
ModuleBus ModuleBus External (BTU/H Temperature
(Watts)
Typical)
AI830/ 70 mA 50 mA - 1.6 5.4 55/40°C
AI830A (131/104°F)(2)
AI835/ 75 mA 50 mA - 1.6 5.4 55/40°C
AI835A (131/104°F)(2)
AI843 60 mA 50 mA - 1.5 5.1 55/40°C
(131/104°F)(2)
AI845 100 mA 50 mA 22 mA + 3.5 12 55/40°C
sensor (131/104°F)(2)
current
AI880/ 45 mA 50 mA 4 mA + 2.4 8.2 55/40°C
AI880A sensor (131/104°F)(2)
current
AI890 150 mA - 300 mA 3.3 11 55/40°C
including (131/104°F)(2)
sensor
current
AI893 125 mA - - 0.6 2.0 55/40°C
(131/104°F)(2)
AI895 130 mA - 370 mA 4.75 16 55/40°C
including (131/104°F)(2)
sensor
current
AO801 70 mA - 200 mA 3.8 13 55/40°C
including (131/104°F)(2)
load
current
158 3BSE020923-510
Section 3 Configuration Power and Cooling
Table 20. I/O Station Power and Cooling (Typical) Values (Continued)
Cooling
Power
5 Volts 24 Volts 24 Volts Load (1) Maximum Ambient
Device Dissipation
ModuleBus ModuleBus External (BTU/H Temperature
(Watts)
Typical)
AO810 70 mA - 200 mA 3.0 10 55/40°C
including (131/104°F)(2)
load
current
AO810V 70 mA - 245 mA 2.3 7.8 55/40°C
2(3) including (131/104°F)(2)
load
current
AO815 125 mA - 165 mA 3.5 12 55/40°C
including (131/104°F)(2)
load
current
AO820 100 mA 260 mA - 6.0 20 55/40°C
(131/104°F)(2)
AO845/ 125 mA - 165 mA 3.5 12 55/40°C
AO845A including (131/104°F)(2)
load
current
AO890 150 mA - 300 mA 3.5 12 55/40°C
including (131/104°F)(2)
load
current
AO895 130 mA - 330 mA 4.25 14.5 55/40°C
including (131/104°F)(2)
output
current
CI801 - - 140 mA 5.4 W(4) 19 55/40°C
(131/104°F)(2)
3BSE020923-510 159
Power and Cooling Section 3 Configuration
Table 20. I/O Station Power and Cooling (Typical) Values (Continued)
Cooling
Power
5 Volts 24 Volts 24 Volts Load (1) Maximum Ambient
Device Dissipation
ModuleBus ModuleBus External (BTU/H Temperature
(Watts)
Typical)
CI810 - - 110 mA 2.6 8.9 55°C/(131°F)
CI820/ - - 250 mA (5) 6.0 20 55°C/(131°F)
CI820V1
CI830 - - 110 mA 2.6 8.9 55°C/(131°F)
(5)
CI840/ - - 190 mA 7.7 26 55/40°C
CI840A (131/104°F)(2)
DI801 70 mA - - 2.2 7.5 55/40°C
(131/104°F)(2)
DI802 50 mA - - 2.8 9.6 55/40°C
(131/104°F)(2)
DI803 50 mA - - 2.8 9.6 55/40°C
(131/104°F)(2)
DI810 50 mA - - 1.8 6.1 55/40°C
(131/104°F)(2)
DI811 50 mA - - 2.7 9.2 55/40°C
(131/104°F)(2)
DI814 50 mA - - 1.8 6.1 55/40°C
(131/104°F)(2)
DI820 50 mA - - 2.8 9.6 55/40°C
(131/104°F)(2)
DI821 50 mA - - 2.8 9.6 55/40°C
(131/104°F)(2)
DI825 90 mA - - 4.9 15 55/40°C
(131/104°F)(2)
160 3BSE020923-510
Section 3 Configuration Power and Cooling
Table 20. I/O Station Power and Cooling (Typical) Values (Continued)
Cooling
Power
5 Volts 24 Volts 24 Volts Load (1) Maximum Ambient
Device Dissipation
ModuleBus ModuleBus External (BTU/H Temperature
(Watts)
Typical)
DI830 120 mA - - 2.3 7.8 55/40°C
(131/104°F)(2)
DI831 120 mA - - 3.2 11 55/40°C
(131/104°F)(2)
DI840 100 mA - 15 mA + 2.7 9.0 55/40°C
sensor (131/104°F)(2)
current
DI880 125 mA - 15 mA + 2.4 8.2 55/40°C
sensor (131/104°F)(2)
current
DI885 160 mA 91 mA(6) 91 mA(6) 3.0 10 55/40°C
(131/104°F)(2)
DI890 150 mA - 70 mA 1.6 5.4 55/40°C
including (131/104°F)(2)
sensor
current
(7)
DO801 80 mA - 2.1 7.2 55/40°C
(131/104°F)(2)
DO802 70 mA 80 mA - 2.2 7.5 55/40°C
(131/104°F)(2)
(7)
DO810 80 mA - 2.1 7.2 55/40°C
(131/104°F)(2)
DO814 80 mA - (7) 2.1 7.2 55/40°C
(131/104°F)(2)
(8)
DO815 120 mA - 4.0 14 55/40°C
(131/104°F)(2)
3BSE020923-510 161
Power and Cooling Section 3 Configuration
Table 20. I/O Station Power and Cooling (Typical) Values (Continued)
Cooling
Power
5 Volts 24 Volts 24 Volts Load (1) Maximum Ambient
Device Dissipation
ModuleBus ModuleBus External (BTU/H Temperature
(Watts)
Typical)
DO820 60 mA 140 mA - 2.9 9.9 55/40°C
(131/104°F)(2)
DO821 60 mA 140 mA - 2.9 9.9 55/40°C
(131/104°F)(2)
DO840 130 mA - 200 mA (7) 4.3 14 55/40°C
+ channel (131/104°F)(2)
load
162 3BSE020923-510
Section 3 Configuration Power and Cooling
Table 20. I/O Station Power and Cooling (Typical) Values (Continued)
Cooling
Power
5 Volts 24 Volts 24 Volts Load (1) Maximum Ambient
Device Dissipation
ModuleBus ModuleBus External (BTU/H Temperature
(Watts)
Typical)
SD821 - - - 8.6 29 55°C/(131°F)(12)
SD822 - - - 13.3 45 55°C/(131°F)(12)
SD823 - - - 26.7 90 55°C/(131°F)(12)
SD831 - - - 10/8(13) 34/27 55°C/(131°F)(12)
SD832 - - - 14/13(13) 47/44 55°C/(131°F)(12)
SD833 - - - 24/22(13) 81/75 55°C/(131°F)(12)
SD834 - - - 40/31(13) 136/105 55°C/(131°F)(12)
SS822 - - - 2.5(14) 8.5 55°C/(131°F)(12)
SS823 - - - 24 82 55°C/(131°F)(12)
SS832 - - - 7,9 27 55°C/(131°F)(12)
(1) Cooling load is the heat (BTU/H) produced by the equipment that may be required to meet room or enclosure cooling
specifications.
(2) 40°C (104°F) applies to Compact MTUs with I/O modules, S800L, CI801 or CI840 mounted on a vertical DIN rail.
(3) AO810V2 replaces AO810
(4) With maximum load at ModuleBus 24 V and 5V
(5) In redundant configuration twice
(6) 24 V from ModuleBus (91 mA) or 24 V external (91 mA) or 48 V external (22 mA).
(7) 500 mA per channel with maximum load per channel.
(8) 2 A per channel with maximum load per channel.
(9) With maximum channel load
(10) Sensor power
NAMUR: 56 + 0.5 x external load [mA]
12 V: 89 + 0.7 x external load [mA]
24 V: 97 + external load [mA]
(11) 40°C (104°F) mounter on a vertical DIN rail.
(12) Horizontal mounting only.
(13) a.c. 120/230V.
(14) 2,5 W at 5A, for calculation use W=0,5 V x Output current.
3BSE020923-510 163
Calculation of 24 V d.c. Power Consumption Section 3 Configuration
164 3BSE020923-510
Section 4 Operation
Operating Overview
An I/O station is an autonomous station, which is normally not handled by an
operator. Of course, it is started and sometimes stopped manually. This is done in
specific situations, for example during installation work and maintenance.
Consequently, operating instructions are spread out in this manual and will be
discussed in the appropriate section.
For specific instructions, see Section 2, Installation and Section 5, Maintenance.
For more information regarding operation, refer to the controller manual or the
S800 I/O Fieldbus Communication Interface for PROFIBUS-DP/DPV1
(3BSE020926*) or the S800 I/O Fieldbus Communication Interface for Advant
Fieldbus 100 (3BSE020925*) manuals.
3BSE020923-510 165
Operating Overview Section 4 Operation
166 3BSE020923-510
Section 5 Maintenance
Preventive Maintenance
This section 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 ModuleBus master 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.
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.
Color
A fixed meaning is assigned to the colors red, yellow and green:
RED Danger or alarmWarning of potential danger or a situation which
requires immediate action
YELLOW Caution Change or impending change of condition, warning
3BSE020923-510 167
Location Section 5 Maintenance
Location
For the location of LEDs the following rules are applied:
S800 I/O Modules (except S800L)
• 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).
S800L I/O Modules
• Have one LED S for module status showing FAULT (Red) or RUN (Green).
FCI
• On the FCI: FAULT, RUN, POWER OK, TRAFFIC and for redundant FCI also
PRIMARY and DUAL.
Optical ModuleBus Modem
• On TB820/TB820V2: FAULT, RUN, POWER OK, ORx1, ORx2 and ERx.
168 3BSE020923-510
Section 5 Maintenance Identification
Identification
LED's 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 moduleFAULT or F
• Device is in operationRUN or R
• External fault or minor fault in the moduleWARNING or W
• Output Set as Predetermined, OSP or O
• Digital I/O on-state1, 2,... (channel number)
• Digital I/O channel FAULT or F
• Power supply ok internal and/or external okPOWER OK or P
• Module status (S800L modules and Optical
ModuleBus Modem TB840)STATUS or S
• Traffic on FieldbusTRAFFIC, T1, T2 or Rx/Tx
• Primary in redundant FCI configurationPRIMARY, PR or PRIM
• Both FCI in a redundant pair are in operationDUAL or DU
• Traffic on the Optical ModuleBusORx1, ORx2, Rx1 or Rx2
• Traffic on the electrical ModuleBus.ERx, ERx1 or ERx2
Error Messages
Not applicable.
3BSE020923-510 169
Diagnostics and Fault Indications Section 5 Maintenance
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.
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.
170 3BSE020923-510
Section 5 Maintenance List of General Fault Finding Procedures and Hints
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.
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.
3BSE020923-510 171
User Repair Section 5 Maintenance
User Repair
172 3BSE020923-510
Section 5 Maintenance User Repair
At exchange of faulty I/O modules, it is important to check that the new modules
start up correctly. If the module does not start up correctly within about one minute
the module is faulty or of wrong type and should be taken out from the system and
changed to a correct module.
3BSE020923-510 173
User Repair Section 5 Maintenance
174 3BSE020923-510
Section 5 Maintenance User Repair
The communication will be broken to all clusters after where the replaced
TB820/TB820V2/TB840/TB840A is located. The cluster where
TB820/TB820V2/TB840/TB840A should be replaced will be power less.
• Replacement of a communication module type TB840/TB840A in a redundant
configuration has no affects on channels in an I/O station.
Bus ERx
X4 X5
header terminals out of the unit.
Rx TxRx Tx
3BSE020923-510 175
User Repair Section 5 Maintenance
176 3BSE020923-510
Appendix A General Specifications
Directives
EMC Directive
All products, mentioned in this document, that bares the CE marking, meet the
requirement of the EMC Directive EMCD 2004/108/EC. The following standards
have been applied:
• EN 61000-6-4 (2007) EMC, Emission
• EN 61000-6-2 (2005) EMC, Immunity
ATEX directive
All products, mentioned in this document, that bares the Ex symbol, meet the
requirement of the ATEX Directive ATEX 94/9/EC. For more information, see
Certifications on page 186.
3BSE020923-510 177
Standards and Approvals Appendix A General Specifications
Electrical Safety
Table 23. Electrical Safety
See Certifications on page 186 for each module type certification details.
178 3BSE020923-510
Appendix A General Specifications CE-marking
CE-marking
S800 products fulfill the requirements of EU-directives 2004/108/EC
"Electromagnetic Compatibility" (EMC Directive) and 2006/95/EC "Electrical
Equipment Designed for Use between Certain Voltage Limits" (Low Voltage
Directive). Declarations of conformity are available on request.
See Certifications on page 186 for each module type certification details.
G3 Compliant
G3 compliant modules fulfills the severity level in the standard ISA-S71.04
Environmental Conditions for Process Measurement and Control Systems: Airborne
Contaminants.
G3 compliant modules shall not be stored in more severe environment than G2 if the
contacts are unconnected.
3BSE020923-510 179
Transport and Storage Conditions Appendix A General Specifications
180 3BSE020923-510
Appendix A General Specifications Climatic operating conditions
3BSE020923-510 181
EMC Appendix A General Specifications
EMC
Table 28. Radiated Radio Frequency Emission IEC/EN 61000-6-4 (Class A),
IEC/EN 61131-2
Table 29. Conducted Radio Frequency Emission, AC mains port IEC 61000-6-4
(Class A), IEC/EN 61131-2
182 3BSE020923-510
Appendix A General Specifications EMC
Transients immunity
Electrostatic 4 kV contact discharge IEC 61000-6-2,
discharge 8 kV air discharge IEC 61131-2
Electrical fast 2 kV, AC/DC, process I/O AC IEC 61000-6-2,
transient/Burst 1 kV, Process I/O DC, analog I/O and IEC 61131-2
com
Surge 2 kV common mode, AC/DC power ports, IEC 61000-6-2,
process I/O AC IEC 61131-2
1 kV differential mode, Process I/O DC,
analog I/O and com
3BSE020923-510 183
Overvoltage Categories Appendix A General Specifications
Overvoltage Categories
AC mains power supplies are compliant with Overvoltage Category III networks
(industrial mains). All I/O signals are overvoltage II compliant.
Insulation Voltage
All accessible ports on S800 modules are galvanically isolated from ground and
system. For actual module isolation configuration, please consult module data
sheets.
184 3BSE020923-510
Appendix A General Specifications Insulation Test Voltage
1. Modules with a working voltage of less than 50 V have RIV 50 V. RIV 250 V applies to all modules having a
working voltage greater than 50 V. It should be noted that insulation test voltage specifications, according to
electrical safety standards, do not imply that permanent connection to circuits with voltages greater than the
specified Rated Insulation Voltage is allowed. Connection to voltages higher than specified RIV violates
electrical safety codes and may expose users to electric shock.
3BSE020923-510 185
Certifications Appendix A General Specifications
Certifications
The S800 I/O system is continuously enhanced with additional certificates. The
table below describes the situation at the printing of this manual.
cULus
FM CSA ATEX
El. safety ATEX Zone
Module El. safety El. safety Zone 2 cULus
CE Haz loc 2 Category SIL1-3
Type Haz loc Haz loc Category (3) El. safety
C1 Zone 3G
(1) C1, Div 2 C1, Div 2 3 (1) G (2)
2
Analog Input Modules
AI801 X X X X
AI810 X X X X
AI820 X X X X
AI815 X X
AI825 X X
AI830 X X X X
AI830A X X X X
AI835 X X X X
AI835A X X X X
AI843 X X
AI845 X X
AI880/ X X X X
AI880A
AI890 X X(4) X(4) X
AI893 X X
AI895 X X(4) X(4) X
186 3BSE020923-510
Appendix A General Specifications Certifications
cULus
FM CSA ATEX
El. safety ATEX Zone
Module El. safety El. safety Zone 2 cULus
CE Haz loc 2 Category SIL1-3
Type Haz loc Haz loc Category (3) El. safety
C1 Zone 3G
(1) C1, Div 2 C1, Div 2 3 (1) G (2)
2
Analog Output Modules
AO801 X X X X
AO810 X X X X
AO810V2 X X X X
AO815 X X
AO820 X X X X
AO845 X X
AO845A X X
AO890 X X(4) X(4) X
AO895 X X(4) X(4) X
3BSE020923-510 187
Certifications Appendix A General Specifications
cULus
FM CSA ATEX
El. safety ATEX Zone
Module El. safety El. safety Zone 2 cULus
CE Haz loc 2 Category SIL1-3
Type Haz loc Haz loc Category (3) El. safety
C1 Zone 3G
(1) C1, Div 2 C1, Div 2 3 (1) G (2)
2
Advant Fieldbus 100
TC501V150 X
TC506 X
TC513V1 X
TC514V2 X
TC515V2 X
188 3BSE020923-510
Appendix A General Specifications Certifications
cULus
FM CSA ATEX
El. safety ATEX Zone
Module El. safety El. safety Zone 2 cULus
CE Haz loc 2 Category SIL1-3
Type Haz loc Haz loc Category (3) El. safety
C1 Zone 3G
(1) C1, Div 2 C1, Div 2 3 (1) G (2)
2
DI880 X X X X
DI885 X X X X
DI890 X X(4) X(4) X
3BSE020923-510 189
Certifications Appendix A General Specifications
cULus
FM CSA ATEX
El. safety ATEX Zone
Module El. safety El. safety Zone 2 cULus
CE Haz loc 2 Category SIL1-3
Type Haz loc Haz loc Category (3) El. safety
C1 Zone 3G
(1) C1, Div 2 C1, Div 2 3 (1) G (2)
2
SD833 X
SD834 X
SS823 X X
SS832 X
190 3BSE020923-510
Appendix A General Specifications Certifications
cULus
FM CSA ATEX
El. safety ATEX Zone
Module El. safety El. safety Zone 2 cULus
CE Haz loc 2 Category SIL1-3
Type Haz loc Haz loc Category (3) El. safety
C1 Zone 3G
(1) C1, Div 2 C1, Div 2 3 (1) G (2)
2
TU834 X X
TU835V1 X X X X
TU836V1 X X
TU837V1 X X X X
TU838 X X X
TU839 X X
TU840 X X X
TU841 X X X
TU842 X X X
TU843 X X X
TU844 X X X
TU845 X X X
TU846 X X
TU847 X X
TU848 X X
TU849 X X
TU890 X X(4) X(4) X
TU891 X
TY801 X X X
TY804 X
3BSE020923-510 191
Certifications Appendix A General Specifications
cULus
FM CSA ATEX
El. safety ATEX Zone
Module El. safety El. safety Zone 2 cULus
CE Haz loc 2 Category SIL1-3
Type Haz loc Haz loc Category (3) El. safety
C1 Zone 3G
(1) C1, Div 2 C1, Div 2 3 (1) G (2)
2
ModuleBus Communication Parts
TB805 X X X X
TB806 X X X X
TK801V003 X
TK801V006 X
TK801V0012 X
TB807 X X X X
TB810 X X X X
TB811 X X X X
TB820V2 X X X X
TB825 X X
TB840/ X X X
TB840A
TB842 X X
TB845 X X
TB846 X X
(1) Marking for mounting and interface: Class 1 Zone 2 AEx nC (or nA) IIC T4 and CL 1 DIV 2 GP A B C D T4
(2) Marking for mounting: Ex II 3G EEx nA [ia] IIC T4
Marking for interface: Ex II (1)G [EEx ia] IIC
(3) Marking for mounting and interface: Ex II 3G EEx nA II T5
(4) Provides Intrinsically safe circuit for Cl. I, Div 1; Cl. II, Div. 1; Cl. III, Div 1 or Cl. I, Zone 0 group IIc
(5) cULus; UL508, UL1950, CSA 22.2 No 950
192 3BSE020923-510
Appendix B Specifications
Equipment Class
The Power Supply Units, (PSU), are designed to meet all the applicable electrical
safety data stated by the EN 50178 harmonized European Standard Publication and
the additional safety and function data required by EN 61131-2 and UL 508.
The secondary output circuitry is accepted for SELV or PELV applications.
SELV according to EN 50178, EN 60950 and VDE 0100 Part 410.
For PELV applications; in accordance with EN 50178.
3BSE020923-510 193
Ingress Protection Appendix B Specifications
Ingress Protection
IP20 according to EN 60529, IEC 60529
Protective Class I according to EN 50718; 3.56
110
50 103
97
L+ L+ L- L-
OK
125
SD821 44
N L PE
230
Mains Voltage
Selection Switch
(115 / 230)
194 3BSE020923-510
Appendix B Specifications Ingress Protection
110
65 103
97
L+ L+ L- L-
OK
125
SD822 44
N L PE
3BSE020923-510 195
Power Supply Units Types SD821 / 822 / 823 - Description Appendix B Specifications
110mm (4.3")
120mm (4.7") 103mm (4.1")
97mm (3.8")
(4.9")
125mm
115V
230V
SD823
44mm
(1.7")
N L PE L+ L+ L- L-
OK
196 3BSE020923-510
Appendix B Specifications Power Supply Units Types SD821 / 822 / 823 - Description
The mains input voltage is set to either 115 V or 230 V by means of a switch
mounted on the front face of the module. The factory default for this switch is in the
230 V position.
The output voltage of all three PSUs is, as stated, a regulated, low noise, 24 V d.c. A
green LED, mounted on the PSU front panel, indicates that the output circuit is
providing the correct output voltage level. The double connectors, provided on the
24 V d.c. output terminals, allow for the connection of more than one equipment.
A surge current limiter within the PSU circuit, provides a soft-start feature. The
controlled power-on of a PSU therefore, will not trip fuses or earth-fault circuit
breakers. In addition, the normal disturbances that occur within an industrial main
network will not cause any transient fault conditions or trips to occur.
This means that the surge current limiter will effectively reduce the peak inrush
current, caused by a power disruption, to a level that the PSU can tolerate.
This soft-start, surge current limiter facility provides ease of design for the system
power distribution circuits.
X1 X2
L Fuse
L+
L+
LED
N
L-
L-
PE Chopper
3BSE020923-510 197
Insulation of Power Supply Units (PSU) Appendix B Specifications
198 3BSE020923-510
Appendix B Specifications Technical Data
Technical Data
Table 35. PSUs SD821, 822 and 823 - Technical Data
3BSE020923-510 199
Technical Data Appendix B Specifications
Table 35. PSUs SD821, 822 and 823 - Technical Data (Continued)
200 3BSE020923-510
Appendix B Specifications SD83x Power Supply Modules, 24 V d.c.
Equipment Class
The Power Supply Units, (PSU), are designed to meet all the applicable electrical
safety data stated by the EN 50178 harmonized European Standard Publication and
the additional safety and function data required by EN 61131-2 and UL 508.
The secondary output circuitry is accepted for SELV or PELV applications.
SELV according to EN 50178, EN 60950 and VDE 0100 Part 410.
For PELV applications; in accordance with EN 50178.
UL 508, listed E 198865.
Ingress Protection
IP20 according to EN 60529, IEC 60529
Protective Class I according to EN 50718; 3.56
3BSE020923-510 201
Dimensions and Connections Appendix B Specifications
202 3BSE020923-510
Appendix B Specifications Dimensions and Connections
3BSE020923-510 203
Power Supply Units Types SD831 / 832 / 833 / 834- Description Appendix B Specifications
204 3BSE020923-510
Appendix B Specifications Power Supply Units Types SD831 / 832 / 833 / 834- Description
disturbances that occur within an industrial main network will not cause any
transient fault conditions or trips to occur.
3BSE020923-510 205
Power Supply Units Types SD831 / 832 / 833 / 834- Description Appendix B Specifications
206 3BSE020923-510
Appendix B Specifications Power Supply Units Types SD831 / 832 / 833 / 834- Description
3BSE020923-510 207
Dielectric strength Appendix B Specifications
Dielectric strength
Basic with protective conductor. The primary circuit is separated from all other live
circuits by reinforced insulation.
A B C
Dielectric test a.c. 2500V a.c. 3000V a.c. 500V
voltage
Field test a.c. 2000V a.c. 2000V a.c. 500V
Rules for Field test:
Use appropriate test equipment which applies the voltage with a
slow ramp. Connect L and N together as well as all output poles.
208 3BSE020923-510
Appendix B Specifications SD834 in parallel to increase output power
3BSE020923-510 209
Technical Data Appendix B Specifications
Table 40. PSU’s SD831, 832, 833, 834 - Mounting space and weight.
Technical Data
Table 41. Technical Data PSU’s SD831, 832, 833 and 834
SD831 SD832 SD833 SD834
Parameter
Converter Converter Converter Converter
Rated output current (A) 3A 5A 10 A 20 A
Rated power output 72 W 120 W 240 W 480 W
Rated output voltage d.c. 24 V d.c. 24 V d.c. 24 V d.c. 24 V
Rated input power 134/143 VA 240/283 VA 447/514 VA 547/568 VA
a.c. 120/230 V 82/80 W 134/133 W 264/262 W 519/511 W
Mains/input voltage, a.c. 100-240 V a.c. 100-120 V a.c. 100-120 V a.c. 100-240 V
nominal. a.c. 47-63Hz d.c. 110-300 V a.c. 200-240 V a.c. 200-240 V d.c. 110-300 V
Auto-select Auto-select
input input
Mains voltage variation a.c. 90-264 V a.c. 90-132 V a.c. 90-132 V a.c. 85-276 V
allowed d.c. 88-375 V a.c. 180-264 V a.c. 180-264 V d.c. 88-375 V
Max input voltage <0.5s a.c. 264-300 V a.c. 264-300 V a.c. 264-300 V a.c. 276-300 V
Primary peak current at <28/<54 A <10 A <10 A <13 A
power on at a.c.120/230V
210 3BSE020923-510
Appendix B Specifications Technical Data
Table 41. Technical Data PSU’s SD831, 832, 833 and 834 (Continued)
SD831 SD832 SD833 SD834
Parameter
Converter Converter Converter Converter
Power Factor (at rated 0.61/0.56 0.56/0.47 0.59/0.51 0.95/0.90
output power)
a.c. 120/230V typ
Heat dissipation 10/8 W 14/13 W 24/22 W 39.6/31.4 W
a.c. 120/230 V
Efficiency factor 88/89.8% 89.4/90.2% 91/91.6% 92.4/93.9%
a.c. 120/230 V typ
Line/load regulation < 50 mV /< < 70 mV /< < 70 mV /< 100 < 10mV /< 100mV
100 mV 100 mV mV
Ripple (peak to peak) < 50 mV < 50 mV < 50 mV < 100mV
Holdup time at mains 29/120 ms 80/78 ms 46/47 ms 32/51 ms
blackout a.c. 120/230 V
typ
Maximum output current 3.3 A 6A 12 A 30 A < 4 s
At ambient At ambient
temp < 45 oC temp < 45 oC
Maximum ambient 55 oC 55 oC 55 oC 55 oC
temperature(1)
Acceptable wire sizes Solid: 0.5 – 6 mm2
Power connection Stranded wire: 0.5 – 4 mm2, 20 – 10 AWG
terminals
Recommended torque: 0.8 Nm
Acceptable wire sizes Solid: 0.3 - 4 mm2
DC-OK-signal terminals Stranded wire:
0.3 - 2.5 mm2,
26 - 12 AWG
(1) Mounting on a horizontal DIN rail.
3BSE020923-510 211
Voting Unit - (for Redundant Power Supply) Appendix B Specifications
SS822
For SS822 Block diagram and Dimensions see Figure 92 and Figure 93.Table 43
and Table 44 shows the supervision data and the technical data respectively. For
connection of SS822 in a redundant configuration see Figure 94.
212 3BSE020923-510
Appendix B Specifications SS822
X1 X2
A+ OK
B+ + A
L+ A+
L+ OK
+ B
B+
L-
3BSE020923-510 213
SS822 Appendix B Specifications
110
50 103
97
OK+ F OK+ F
A B
125
SS822
44
A+B+L+L+L-
214 3BSE020923-510
Appendix B Specifications SS822
3BSE020923-510 215
SS823 Appendix B Specifications
SA Supervision
signals to
SB CI8X0/TB8X0
L+ L+ L- L- L+ L+ L- L- OK+ F OK + F
OK OK A B
L+
+24V
Mains
Input
L-
Protective Earth 0V
SS823
The SS823 Voting Unit has double overvoltage protection circuit on both inputs. It
is also able to detect both short and open circuit in the voting element. For details
see Table 46.
Block diagram and dimensions for SS823 see Figure 95 and Figure 96. Table 45
and Table 46 shows supervision data and technical data for SS823. For connection
of SS823 in a redundant configuration see Figure 97.
216 3BSE020923-510
Appendix B Specifications SS823
3BSE020923-510 217
SS823 Appendix B Specifications
218 3BSE020923-510
Appendix B Specifications SS823
3BSE020923-510 219
SS823 Appendix B Specifications
SA
SB
From Mains L+
Breaker L-
From Mains
Breaker
220 3BSE020923-510
Appendix B Specifications SS832
SS832
SS832 is can be used directly for load up to 10 A and for loads up to 20 A two
SS832 modules must be used. See Figure 99 and Figure 100.
For Block diagram and connections of SS832 see Figure 98 and Figure 101.
Table 47 and Table 48 shows supervision data and technical data respectively.
Figure 102 shows connection of SS832 in redundant configuration with maximum
10 A load, see Figure 103 for load up to 20 A.
Alarm Input 1
Input Alarm
Input 1 Voltage Relay
ok contact
Monitor
VIN 1
+ + VOUT
- -
Chassis
Ground
VIN 2
+
-
Input
Input 2 Voltage Input 2
ok Alarm Alarm
Monitor Relay contact
AC AC
DC DC
IN 1 IN 2
OUT
-
+
Load
3BSE020923-510 221
SS832 Appendix B Specifications
AC AC
DC DC
IN 1 IN 2 IN 1 IN 2
OUT OUT
-
+ Load
222 3BSE020923-510
Appendix B Specifications SS832
3BSE020923-510 223
SS832 Appendix B Specifications
224 3BSE020923-510
Appendix B Specifications SS832
3BSE020923-510 225
SS832 Appendix B Specifications
226 3BSE020923-510
Appendix B Specifications TB805/TB806 ModuleBus Cable Adapter-Out/In
Description
1
The TB805 ModuleBus Cable Adaptor- 14
3BSE020923-510 227
Technical Data Appendix B Specifications
TB806 is also used for connection of the optical port TB842 to CI801 or TU847
(CI840).
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.
Technical Data
228 3BSE020923-510
Appendix B Specifications Block Diagram TB805
X1 7 X2
POS 0 - 6
POWOK
DAT, DAT-N 2
/
+24 V, 0 V24 2
/
+5 V 5
/
0V 4
/
CLK+, CLK- 2
/
Shield
EM
3BSE020923-510 229
Block Diagram TB806 Appendix B Specifications
X2 X1
7
POS 0 - 6
/
POWOK
ModuleBus Connector DB25 Male
Shield
EM
230 3BSE020923-510
Appendix B Specifications TB807 ModuleBus Terminator
Description
TB807
The TB807 ModuleBus
Terminator is used to terminate
ModuleBus Terminator
the electrical ModuleBus. Latch
E
F
D
A
terminator connects to the outlet
C
B
ModuleBus connector of the last MTU Assembly
E
F
MTU. D
A
C
B
L1+ C1 2 3 4 5 6 7 C8 L2+
L1+ B1 2 3 4 5 6 7 B8 L2+
L1- A1 2 3 4 5 6 7 A8 L2-
3BSE020923-510 231
Technical Data Appendix B Specifications
Technical Data
Table 50. TB807 ModuleBus Terminator Specifications
Item Value
Connections 1
DIN41612 Type R/4 (X1)
Module catch Attaches module MTU
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Rated Insulation Voltage 50 V
Dielectric test voltage 500 V a.c.
Width 13 mm (0.51”)
Depth 19 mm (0.75”)
Height 24 mm (0.94”)
module projects 17 mm (0.67”)
Weight 10 g (0.022 lbs.)
232 3BSE020923-510
Appendix B Specifications Block Diagram TB807
X1
DAT
CLK+
CLK-
3BSE020923-510 233
TB810/TB811 ModuleBus Optical Port Appendix B Specifications
Description TB810
The TB810 ModuleBus Optical Port is a communication
interface between the CI810 FCI electrical ModuleBus and
the TB820/TB820V2 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 Tx Rx
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 Rx
Description TB811
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
(Agilent’s, former Hewlett-Packard, Versatile Link) can be used with the TB811.
234 3BSE020923-510
Appendix B Specifications Technical Data
Technical Data
Table 51. TB810 ModuleBus Optical Port Specifications
3BSE020923-510 235
Connections Appendix B Specifications
Connections
Table 52. Optical ModuleBus Connections (X2)
236 3BSE020923-510
Appendix B Specifications Opto Cable for TB811 according to HP
X1 E
O
X2
E
O
RX
TX
3BSE020923-510 237
TB820/TB820V2 ModuleBus Modem Appendix B Specifications
Description
The TB820/TB820V2 ModuleBus Modem is a CLUSTER
communication interface for connection of S800 4 56
3 7
I/O modules via the optical and electrical 2
1
ModuleBus.
TB820 V2
The module can not handle High Integrity I/O
modules (AI880/AI880A, DI880 and DO880).
The TB820/TB820V2 can be used in both a
L+
simplex optical configuration as well as in a L-
X4 X5
Rx2 Rx1
duplex optical configuration. In a simplex SA Tx2 Tx1
SB
configuration, the optical ModuleBus nodes are
connected in a ring. In a duplex configuration,
the optical ModuleBus nodes are connected in a
row.
TB820/TB820V2 has two basic parts: Module termination board and the power
supply/communications board (see block diagram).
The termination board is a unit where most of the connections 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 +24 V supply
of the I/O modules and the electrical ModuleBus.
238 3BSE020923-510
Appendix B Specifications Description
The power supply board has an isolated power converter that generates a short
circuit proof +5 V supply for the TB820/TB820V2 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.
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 (Agilent’s, former
Hewlett-Packard, Versatile Link) can be used with TB820/TB820V2.
3BSE020923-510 239
Technical Data Appendix B Specifications
Technical Data
Table 53. TB820/TB820V2 ModuleBus Modem Specifications
Item Value
Power input 24 V d.c. (19.2 - 30)
Power consumption at 24V d.c. 100 mA
Power dissipation 6.0 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) 24 V max. = 1.4 A
5 V max. = 1.5 A
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
Wavelength 650 nm
Maximum ambient temperature 55oC/(131°F)
240 3BSE020923-510
Appendix B Specifications Technical Data
Item Value
Indicators R(un) LED: Green indicates that the
TB820/TB820V2 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
+5 V d.c.
ORx1 and ORx2 traffic LEDs: Yellow
(blinking) indicates that the
TB820/TB820V2 is receiving data on the
two optical ModuleBus channels
respectively.
ERx traffic LED: Yellow (blinking) indicates
the TB820/TB820V2 is receiving data on
the electrical ModuleBus.
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Rated insulation voltage 50 V
Dielectric test voltage 500 V a.c.
Acceptable wire sizes Solid: 0.2 - 2.5 mm2
Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm
Width 58 mm (2.28”)
Depth 122 mm (4.80”)
Height 170 mm (6.69”) including latch
Weight 0.3 kg (0.66 lbs.)
3BSE020923-510 241
Connections Appendix B Specifications
F R
P
ORx1 ORx2
ERx
170 mm (6.7”)
CLUSTER
4 5 6
3 7
2
1
TB820
L L+L- + - SAB
L+
SA
SB
Connections
Table 54. Power Supply Connections TB820/TB820V2/TB820V1
Designation Description
L+ +24 V d.c. Supply In
L+ +24 V d.c. Supply Out
SA Redundant Power Supply “A” Monitoring
Input
L- 0 V d.c. Supply In
242 3BSE020923-510
Appendix B Specifications Connections
Designation Description
L- 0 V d.c. Supply Out
SB Redundant Power Supply “B” Monitoring
Input
Designation Description
L+ +24 V d.c. Supply
L- 0 V d.c. Supply
SA Redundant Power Supply “A” Monitoring
Input
SB Redundant Power Supply “B” Monitoring
Input
3BSE020923-510 243
Opto Cable according to HP Appendix B Specifications
Opto connectors type Agilent’s, former Hewlett-Packard, Versatile Link can handle
both plastic and HCS optic fiber.
244 3BSE020923-510
Appendix B Specifications Block Diagram TB820/TB820V2
RS-485
RS-485 X3
POWOK
D+,D-
X2 CLK+,CLK-
TB820-1 POS(9:0) Electrical ModuleBus
MB +5 V Connector
MB+5 V
F(ault) 0V
Reset logic,
R(un) MBI-4 +5 V Supervision L-
0V MB+24 V
P(owok) MB +5 V MB +5 V
+5 V +5 V +5 V
ORx1
0V
ORx2
0V 0V
ERx Current
DC Limit DIN-rail
DC X1A
SB 3
2
L- 1
POS(9:7) X1B
SA 3
2
L+ 1
E E E E
O O O O TB820-2
X4 X5
3BSE020923-510 245
TB825 Optical Media Converter Appendix B Specifications
Description
ModuleBus Optical media converter, converts
between plastic opto fiber or HCS fiber with
Versatile link connectors and glass optical
fiber with ST connectors.
Signal routing between Tx1/Rx1 and
Tx2/Rx2 and between Tx1/Rx1 and Tx3/Rx3.
Technical Data
Item Value
Power input 24 V (19.2 - 30)
Power consumption at 24V d.c. 96 mA
Power input fuse 2A
Power dissipation 2.3 W
Optical ModuleBus Local Optical ModuleBus 1, 2 and Field
Fiber optic interface, three Optical ModuleBus
transmitters and three receivers for
246 3BSE020923-510
Appendix B Specifications Technical Data
Item Value
Indicators (S) Status LED: Red indicates module fault.
Green indicates Module OK (FPGA
configuration).
Rx1 LED: Yellow indicates data received on
opto port 1.
Tx1 LED: Yellow indicates data transmitted
on opto port 1.
Rx2 LED: Yellow indicates data received on
opto port 2.
Tx2 LED: Yellow indicates data transmitted
on opto port 2.
Rx3 LED: Yellow indicates data received on
opto port 3.
Tx3 LED: Yellow indicates data transmitted
on opto port 3.
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Acceptable wire sizes Solid: 0.2 - 2.5 mm2
Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm
Rated insulation voltage 50 V
Dielectric test voltage 500 V a.c.
Width 85.6 mm (3.37”)
Depth 58.5 mm (2.30”)
Height 136 mm (5.35”) including latch
Weight 0.21 kg (0.46 lbs.)
3BSE020923-510 247
Opto Connection Appendix B Specifications
85.6 mm (3.37")
67.5 mm (2.66")
114 mm (4.49")
136 mm (5.35")
5 mm
14.2 mm (0.20")
(0.56")
57.2 mm (2.25")
58.5 mm (2.30")
Opto Connection
248 3BSE020923-510
Appendix B Specifications Opto Connection
3BSE020923-510 249
Block Diagram TB825 Appendix B Specifications
X2
Status
LOAD OF FPGA
Rx3
Rx1
Rx2
FPGA
Tx2
Tx3
Tx1
CONFIGURATION DATA
PROM
O RX1 SIGNAL
E INTER- SYNC
FACE
O TX1 SIGNAL
E ROUTING
FIELD FIBER
INTERFACE
O RX3 SIGNAL
E INTER- SYNC TX2 E
FACE INTER- O
O TX3 FACE
E SIGNAL RX2 E
SYNC O
5.0V
X1
L+ FUSE 5V 3.3V
L- 0V 2.5V
250 3BSE020923-510
Appendix B Specifications TB840/TB840A ModuleBus Modem
Description
The TB840/TB840A ModuleBus Modem is a
communication interface for connection of
S800 I/O modules via the optical and
electrical ModuleBus.
TB840/TB840A is designed to be used in 1+1
redundant applications.
TB840/TB840A can be used in both a
simplex optical configuration as well as in a
duplex optical configuration. In a simplex TB840
configuration, the optical ModuleBus nodes
are connected in a ring. In a duplex
configuration, the optical ModuleBus nodes
are connected in a daisy-chain.
TB840/TB840A must be mounted on a Module Termination Unit TU841.
TU841 carries screw terminals for power supply and redundant power supply
monitoring, connector for the electrical ModuleBus and a rotary switch for setting
of the cluster address.
TB840/TB840A has isolated power converters that generates internal power for
TB840/TB840A and short circuit proof +5 V supply for two electrical
3BSE020923-510 251
Description Appendix B Specifications
ModuleBuses. It also contains two ModuleBus interfaces and LED indicators. The
ModuleBus I/O cluster address (1-7) is set by a rotary decimal code switch, on the
Module Terminal Unit TU841.
TB840/TB840A has two electrical and one Optical ModuleBus Interface which are
logically the same bus. Only one electrical ModuleBus is connected if
TB840/TB840A is mounted on TU841. 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 I/O station can be
used.
Both plastic and HCS (Hard Clad Silica) optic fiber with connectors (Agilent’s,
former Hewlett-Packard, Versatile Link) can be used with TB840/TB840A.
252 3BSE020923-510
Appendix B Specifications Technical Data
Technical Data
Table 58. TB840/TB840A ModuleBus Modem Specifications
Item Value
Power input 24 V d.c. (19.2 - 30)
Power consumption at 24V d.c. 120 mA
Power input fuse 2 AF
Power dissipation 6W
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) 24 V max. = 1.4 A
5 V max. = 1.5 A
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
Wavelength 650 nm
3BSE020923-510 253
Technical Data Appendix B Specifications
Item Value
Indicators S(tatus) LED: Green indicates that the
TB840 is operational.
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 valid internal
power and +5 V d.c. on the electrical
ModuleBus.
Rx1 and Rx2 traffic LEDs: Yellow (blinking)
indicates that the TB840 is receiving data
on the two optical ModuleBus channels
respectively.
ERx1 traffic LED: Yellow (blinking) indicates
the TB840 is receiving data on the electrical
ModuleBus A.
ERx2 traffic LED: Yellow blinking, indicates
that the TB840 is receiving data on the
electrical ModuleBus B.
MTU Keying code AB
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Rated insulation voltage 50 V
Dielectric test voltage 500 V a.c.
Width 54 mm (2.13”)
Depth 96 mm (3.78”)
Height 119 mm (4.69”) including latch
Weight 0.2 kg (0.44 lbs.)
254 3BSE020923-510
Appendix B Specifications Connections
54 mm (2.13”)
X4
96 mm
119 mm
(3.78”)
(4.69”)
X5
Connections
Opto connectors type Agilent’s, former Hewlett-Packard, Versatile Link can handle
both plastic and HCS optic fiber.
3BSE020923-510 255
Opto Cable according to HP Appendix B Specifications
• Riser or plenum.
• Simplex or duplex cable.
• Latching simplex or duplex connector.
• Cable attenuation maximum 2 dB .
256 3BSE020923-510
Termination Unit for Redundant TB840/TB840A TU841
3BSE020923-510
ModuleBus
x4 ModuleBus Optical Modem
S(TATUS)
Tx2 TB840/TB840A
E P(OWER)
Rx2
Appendix B Specifications
4 L+
4 5 6
3 7
3 L- 8
2
1 0 9
2 SA
CLUSTER ADDRESS
1 SB
257
Connection Diagram TB840/TB840A
TB842 ModuleBus Optical Port Appendix B Specifications
Description TB842
TB842 ModuleBus Optical Port is a communication
interface between the CI801 or CI840 FCI and the
TB820/TB820V2 ModuleBus Modem of an I/O
cluster or ABB drives units via the Optical
ModuleBus.
TB842 connects to CI801 via TB806 or CI840 via
TU847 and TB806.
TB842 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.
TB842 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 (Agilent’s, former Hewlett-Packard,
Versatile Link) can be used with the TB842.
258 3BSE020923-510
Appendix B Specifications Technical Data
Technical Data
Table 60. Technical Data TB824
Item TB842
Application S800 I/O clusters and ABB variable drives
Configuration Simplex and duplex optical fiber
Fibers Plastic and HCS (Hard Clad Silica)
Connector Agilent’s, former Hewlett-Packard, Versatile
Link
Optical ModuleBus Fiber optic interface, one transmit and one
receive connection for max. 10 Mbit/s.
Wavelength 650 nm
Indicators Tx LED: Yellow indicates transmitting of
data on the optical ModuleBus
Rx LED: Yellow indicates receiving of data
on the optical ModuleBus
Current consumption +5 V 100 mA
Current consumption +24 V 20 mA
Power dissipation 0.5 W
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Width 17.6 mm (0.69”)
Depth 42.3 mm (1.67”)
Height 56.7 mm (2.23”)
Weight 40 g (0.088 lbs.)
3BSE020923-510 259
Connections Appendix B Specifications
Connections
Table 61. Optical ModuleBus Connections (X2)
260 3BSE020923-510
Appendix B Specifications Block Diagram TB842
X1
E
O
X2
E
O
RX
TX
3BSE020923-510 261
TB845/TB846 ModuleBus Cable Adapter-Out/In Appendix B Specifications
262 3BSE020923-510
Appendix B Specifications Technical Data
The TB845/TB846 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.
Technical Data
3BSE020923-510 263
Block Diagram TB845 Appendix B Specifications
X1 7 X2
POS 0 - 6
POWOK
DAT, DAT-N 2
/
+24 V, 0 V24 2
/
+5 V 5
/
0V 4
/
CLK+, CLK- 2
/
Shield
EM
264 3BSE020923-510
Appendix B Specifications Block Diagram TB846
X2 X1
7
POS 0 - 6
/
POWOK
ModuleBus Connector DB25 Male
Shield
EM
3BSE020923-510 265
TU807, MTU for TB840/TB840A Appendix B Specifications
Description
The TU807 is a module termination unit (MTU) for
single configuration of Optical ModuleBus Modem
TB840/TB840A.
The MTU is a passive unit having connections for
power supply, a single electrical ModuleBus, one
TB840/TB840A and a rotary switch for cluster
address (1 to 7) setting.
Two mechanical keys are used to configured the MTU for the right types of
modules. Each key has six positions, which gives a total number of 36 different
configurations. The configurations can be changed with a screwdriver.
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has a BLOCK signal that keeps the module in its INIT state until it is
locked in its position.
266 3BSE020923-510
Appendix B Specifications Technical Data
Technical Data
Table 63. TU807 Single MTU for TB840/TB840A
Item Value
Power input 24 V d.c. (19.2 - 30 V)
ModuleBus current distribution
Maximum 5 V 1.5 A
24 V 1.5 A
Mechanical keys (2) 36 different combinations
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Acceptable wire sizes Solid: 0.2 - 2.5 mm2
Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm
Rated insulation voltage 50 V
Dielectric test voltage 500 V a.c.
Width 59 mm (1.57”)
Depth 47 mm (1.85”)
Height 186.5 mm (7.34”) including latch
Weight 0.45 kg (0.99 lbs.)
3BSE020923-510 267
Dimensions Appendix B Specifications
Dimensions
99.5 mm (3.92")
5 mm (0.20")
59 mm (2.32")
Connections
Table 64. TU807 Power Supply Connections
Designation Description
L+ +24 V d.c. Supply In
L- 0 V d.c. Supply In
SA Redundant Power Supply “A” Monitoring Input
SB Redundant Power Supply “B” Monitoring Input
268 3BSE020923-510
Appendix B Specifications Block Diagram TU807
CLUSTER TU807
ADDRESS TB840A
4 5 6
+24V_A
3 7
+24V_B
2
BLOCK-N 0V24
1
+5V_A
ADDR
+5V_B
L+ X6
0V
L-
POWOK_A
SA
SB
POWOK_B &
DATA
MTU_SEL
CLK 0V
0V
+5V
POWOK
POSx
POSy
0V24
+24V
DAT
CLK
+5V
SA
SB
0V
L+
L-
0V
X1 X3
3BSE020923-510 269
TU840, MTU for Redundant TB840/TB840A with Dual ModuleBus Appendix B Specifications
Description
The TU840 is a module termination CLUSTER ADDR.
270 3BSE020923-510
Appendix B Specifications Technical Data
Technical Data
Table 65. TU840 Redundant MTU for TB840/TB840A
Item Value
Power input 24 V d.c. (19.2 - 30 V)
ModuleBus current distribution
Maximum 5 V 1.5 A
24 V 1.5 A
Mechanical keys (2) 36 different combinations
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Acceptable wire sizes Solid: 0.2 - 2.5 mm2
Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm
Rated insulation voltage 50 V
Dielectric test voltage 500 V a.c.
Width 124 mm (4.88”)
Depth 47 mm (1.85”)
Height 186 mm (7.32”) including latch
Weight 0.45 kg (0.99 lbs.)
3BSE020923-510 271
Dimensions Appendix B Specifications
Dimensions
162.9 mm
(6.41”)
Center of
DIN rail
99.5 mm 186.9 mm
(3.92”) (7.36”)
CLUSTER ADDR.
17 mm
5mm (0.67”)
(0.2”)
47 mm (1.85”)
90 mm (3.54”)
272 3BSE020923-510
Appendix B Specifications Connections
Connections
Table 66. TU840 Power Supply Connections
Designation Description
L+ +24 V d.c. Supply In
L- 0 V d.c. Supply In
SA Redundant Power Supply “A” Monitoring Input
SB Redundant Power Supply “B” Monitoring Input
3BSE020923-510 273
Block Diagram TU840 Appendix B Specifications
CLUSTER
4 5 6
3 7 TB840
2 +24V_A
1
Pos A +24V_B
BLOCK_A-N 0V24
POS +5V_A
POS
L+ +5V_B
L- X6A 0V
SA POWOK_A
SB POWOK_B
DAT_A
DAT_B
CLK_A
SL CLK_B
TB840
SL +24V_A
Pos B +24V_B
BLOCK_B-N 0V24
POS +5V_A
L+ +5V_B
L- X6B 0V
SA POWOK_A
SB POWOK_B
DAT_A
DAT_B
CLK_A
CLK_B
+5V_A +5V_B
POWOK_A
POWOK_B
POSx_A
POSy_A
POSx_B
POSy_B
+24V_A
+24V_B
DAT_A
DAT_B
CLK_A
CLK_B
+5V_A
+5V_B
0V 0V
0V24
0V24
SA
SB
0V
0V
L+
L-
X1 X3A X3B
274 3BSE020923-510
Appendix B Specifications TU841, MTU for Redundant TB840/TB840A with Single ModuleBus
Description
The TU841 is a module termination CLUSTER ADDR.
3BSE020923-510 275
Technical Data Appendix B Specifications
Technical Data
Table 67. TU841 Redundant MTU for TB840/TB840A
Item Value
Power input 24 V d.c. (19.2 - 30 V)
ModuleBus current distribution
Maximum 5 V 1.5 A
24 V 1.5 A
Mechanical keys (2) 36 different combinations
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Acceptable wire sizes Solid: 0.2 - 2.5 mm2
Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm
Rated insulation voltage 50 V
Dielectric test voltage 500 V a.c.
Width 124 mm (4.88”)
Depth 47 mm (1.85”)
Height 186 mm (7.32”) including latch
Weight 0.45 kg (0.99 lbs.)
276 3BSE020923-510
Appendix B Specifications Dimensions
Dimensions
162.9 mm
(6.41”)
Center of
DIN rail
99.5 mm 186.5 mm
(3.92”) (7.34”)
CLUSTER ADDR.
17 mm
5mm (0.67”)
(0.2”)
47 mm (1.85”)
90 mm (3.54”)
3BSE020923-510 277
Connections Appendix B Specifications
Connections
Table 68. TU841 Power Supply Connections
Designation Description
L+ +24 V d.c. Supply In
L- 0 V d.c. Supply In
SA Redundant Power Supply “A” Monitoring Input
SB Redundant Power Supply “B” Monitoring Input
278 3BSE020923-510
Appendix B Specifications Block Diagram TU841
CLUSTER
4 5 6
3 7 TB840
2 +24V_A
1
Pos A
BLOCK_A-N 0V24
POS +5V_A
POS
L+
L- X6A 0V
SA POWOK_A
SB
DAT_A
CLK_A
SL
TB840
SL +24V_A
Pos B
BLOCK_B-N 0V24
POS +5V_A
L+
L- X6B 0V
SA POWOK_A
SB
DAT_A
CLK_A
+5V_A
POWOK_A
POSx_A
POSy_A
+24V_A
DAT_A
CLK_A
+5V_A
0V
0V24
SA
SB
0V
L+
L-
X1 X3A
3BSE020923-510 279
TU848, MTU for Redundant TB840/TB840A with Dual ModuleBus and Dual Power Supply
Description
The TU848 is a module termination
unit (MTU) for redundant configuration
of Optical ModuleBus Modem
TB840/TB840A.
The MTU is a passive unit having connections for double power supply (one for
each modem), double electrical ModuleBus, two TB840/TB840A and a rotary
switch for cluster address (1 to 7) setting.
Two mechanical keys are used to configured the MTU for the right types of
modules. Each key has six positions, which gives a total number of 36 different
configurations. The configurations can be changed with a screwdriver.
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has a BLOCK signal that keeps the modules in its INIT state until it is
locked in its position.
280 3BSE020923-510
Appendix B Specifications Technical Data
Technical Data
Table 69. TU848 Redundant MTU for TB840/TB840A
Item Value
Power input 24 V d.c. (19.2 - 30 V)
ModuleBus current distribution
Maximum 5 V 1.5 A
24 V 1.5 A
Mechanical keys (2) 36 different combinations
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Acceptable wire sizes Solid: 0.2 - 2.5 mm2
Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm
Rated insulation voltage 50 V
Dielectric test voltage 500 V a.c.
Width 124 mm (4.88”)
Depth 47 mm (1.85”)
Height 186.5 mm (7.34”) including latch
Weight 0.45 kg (0.99 lbs.)
3BSE020923-510 281
Dimensions Appendix B Specifications
Dimensions
Center of
162.9 mm (6.41")
167.4 mm (6.59")
DIN-rail
186.5 mm (7.34")
99.5 mm (3.92")
5 mm (0.20")
31.5 mm
17 mm (0.67") 90 mm (3.54") (1.24")
124 mm (4.88") 47 mm (1.85")
Connections
Table 70. TU848 Power Supply Connections
Designation Description
L+ +24 V d.c. Supply In
L- 0 V d.c. Supply In
SA Redundant Power Supply “A” Monitoring Input
SB Redundant Power Supply “B” Monitoring Input
282 3BSE020923-510
Appendix B Specifications Block Diagram TU848
CLUSTER
5 TB840
4 6
+24V_A
3 7
2 +24V_B
BLOCK_A-N 0V24
1
+5V_A
POS
POS
+5V_B
L+
0V
L-
X6A POWOK_A
X1A SA X3A
POWOK_B
SB
DAT_A
DAT_B
CLK_A
CLK_B +5V_A
POSx_A
POSy_A
LINK
0V
TB840
+24V_A
+24V_B
BLOCK_B-N
0V24
+5V_A
POS
+5V_B
L+
0V
L-
X6B POWOK_A
X1B SA
POWOK_B X3B
SB
DAT_A
DAT_B
CLK_A
CLK_B
+5V_A
POSx_B
POSy_B
0V
3BSE020923-510 283
TU849, MTU for Redundant TB840/TB840A with Single ModuleBus and Dual Power Supply
Description
The TU849 is a module termination unit
(MTU) for redundant configuration of
Optical ModuleBus Modem
TB840/TB840A.
The MTU is a passive unit having connections for double power supply, one for
each modem, a single electrical ModuleBus, two TB840/TB840A and a rotary
switch for cluster address (1 to 7) setting.
Four mechanical keys, two for each position, are used to configured the MTU for
the right types of modules. Each key has six positions, which gives a total number of
36 different configurations. The configurations can be changed with a screwdriver.
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has two BLOCK signals, one for each module position, that keeps the
modules in its INIT state until it is locked in its position.
284 3BSE020923-510
Appendix B Specifications Technical Data
Technical Data
Table 71. TU849 Redundant MTU for TB840/TB840A
Item Value
Power input 24 V d.c. (19.2 - 30 V)
ModuleBus current distribution
Maximum 5 V 1.5 A
24 V 1.5 A
Mechanical keys (2) 36 different combinations
Equipment Class Class I according to IEC 60536; (earth
protected)
Ingress Protection IP20 according to IEC 60529
Acceptable wire sizes Solid: 0.2 - 2.5 mm2
Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm
Rated insulation voltage 50 V
Dielectric test voltage 500 V a.c.
Width 124 mm (4.88”)
Depth 47 mm (1.85”)
Height 186.5 mm (7.34”) including latch
Weight 0.45 kg (0.99 lbs.)
3BSE020923-510 285
Dimensions Appendix B Specifications
Dimensions
Center of
162.9 mm (6.41")
167.4 mm (6.59")
DIN-rail
186.5 mm (7.34")
99.5 mm (3.92")
5 mm (0.20")
31.5 mm
17 mm (0.67") 90 mm (3.54") (1.24")
124 mm (4.88") 47 mm (1.85")
Connections
Table 72. TU849 Power Supply Connections
Designation Description
L+ +24 V d.c. Supply In
L- 0 V d.c. Supply In
SA Redundant Power Supply “A” Monitoring Input
SB Redundant Power Supply “B” Monitoring Input
286 3BSE020923-510
Appendix B Specifications Block Diagram TU849
CLUSTER
5 TB840
4 6
+24V_A
3 7
2 +24V_B
BLOCK_A-N
1 0V24
+5V_A
POS
POS
+5V_B
L+
0V
L-
X6A POWOK_A
X1A SA X3A
POWOK_B &
SB
DAT_A
DAT_B
0V
CLK_A
CLK_B +5V_A
POSx_A
POSy_A
LINK
0V
TB840
+24V_A
+24V_B
BLOCK_B-N
0V24
+5V_A
POS
+5V_B
L+
0V
L- X6B POWOK_A
X1B SA
POWOK_B
SB
DAT_A
DAT_B
CLK_A
CLK_B
3BSE020923-510 287
TK811 Opto Cable, Duplex Plastic Fibre Appendix B Specifications
Figure 117.
Features
• Available in lengths of 1.5, 5 and 15 m.
• LSZH (Low Smoke Zero Halogene) plastic fiber.
• Classified according to UL1581.
• Classified according to AWM VW-1.
• Opto connectors type Agilent’s, former Hewlett-Packard, Versatile Link
Latching connector.
• Extra low loss attenuation.
288 3BSE020923-510
Appendix B Specifications TK812 Opto Cable, Simplex Plastic Fibre
Figure 118.
Features
• Available in lengths of 1.5, 5 and 15 m.
• LSZH (Low Smoke Zero Halogene) plastic fiber
• Classified according to UL1581
• Classified according to AWM VW-1
• Opto connectors type Agilent’s, former Hewlett-Packard, Versatile Link
Latching connector
• Extra low loss attenuation
3BSE020923-510 289
Mounting Kit Appendix B Specifications
Mounting Kit
Features
• Prepared for 9 different
configurations
• DIN rail locking
mechanism
Description
The Mounting Kit is used for
horizontal mounting of CI801,
CI840/CI840A and
TB840/TB840A on a vertical
DIN rail.
ModuleBus cable adapters can be mounted on the Mounting Kit together with
communication modules.
Technical Data
Table 73. Mounting Kit
Item Value
Width 200 mm (7.87”)
Depth 170 mm (6.69”)
Height 17 mm (0.67”)
Weight 0.5 kg (1.10 lbs.)
290 3BSE020923-510
Appendix B Specifications Configuration
Configuration
There are 9 different configurations for mounting of MTU:s on the Mounting Kit,
see Figure 119.
3BSE020923-510 291
Horizontal and Vertical Mounting Profile Appendix B Specifications
Description
On the horizontal aluminium profile are mounted:
• one DIN-rail with height 7.5 mm type NS 35/7.5 according to EN 50022
• one cable duct u-profile
The profile are available in three different lengths; 465 mm (19”), 592 mm (24”) and
719 mm (28.31”).
On the vertical aluminium profile are mounted:
• two DIN-rail, one vertical and one horizontal, with height 7.5 mm type NS
35/7.5 according to EN 50022
• one cable duct u-profile
The profile are available in lengths; 1800 mm (70.87”). The profile can be mounted
to left, centered or to right in a cabinet.
292 3BSE020923-510
Appendix B Specifications Dimensions
Dimensions
253.3 mm (9.97")
44.45 mm
(1.75")
76 mm
(2.99")
3BSE020923-510 293
Dimensions Appendix B Specifications
294 3BSE020923-510
Appendix C Power Up
3BSE020923-510 295
Power Up on S800 I/O Appendix C Power Up
T2 “off”
PR “on” (only primary FCI in a redundant configuration)
DU “off” (both FCI in a redundant configuration).
Indications on I/O Modules
F (fault) “on”
R (run) “off”
W (warning) “off”
O (osp only outputs) “off”
Without configuration but with communications with the controller:
See timing diagram Figure 123.
Indications on FCI
F (fault) “on” at power up and “off” after self-test ok
R (run) “off” at power up and “on” after configuration ok
and commanded operational from the controller
(can take about 1 to 4 minutes)
P (pow ok) “on” if power supply ok
T1 “on” if cable 1 ok
T2 “on” if cable 2 ok
PR “on” (only primary FCI in a redundant configuration)
DU “off” (both FCI in a redundant configuration)
The backup will be started up after the I/O. When the backup has started
PR “on” (only primary FCI in a redundant configuration)
DU “on” (both FCI in a redundant configuration)
Indications on I/O Modules
F (fault “on” at power up and “off” after the first access
from the FCI
R (run) “off” at power up and “on” for AI, DI after
configuration and for AO, DO after configuration and
commanded operational from the controller
W (warning “off” at power up and after module operational
updated from the module
O (outputs only) “off” at power up and after module operational
updated from the module
296 3BSE020923-510
Appendix C Power Up Power Up on S800 I/O
3BSE020923-510 297
Power Up on S800 I/O Appendix C Power Up
298 3BSE020923-510
Appendix C Power Up Power Up on S800 I/O
FCI
F
T1/T2
DU (both)
PR (primary)
PR (backup)
I/O module
OSP
Power up INIT in
S800 I/O FCI
3BSE020923-510 299
Power Up on S800 I/O Appendix C Power Up
T1
T2
PR (primary)
DU (both)
PR (backup)
R (backup)
I/O module
R (AI, DI)
R (AO, DO)
W (AI, DI)
Start of I/O
Power up INIT INIT
S800 I/O in FCI backup
300 3BSE020923-510
Appendix C Power Up Power Up on S800 I/O
FCI
T1/T2
DU (both)
PR (primary)
PR (backup)
I/O module
R (AI, DI)
R (AO, DO)
W (AI, DI)
W (AO, DO)
Start of I/O
Power up INIT
S800 I/O in FCI
3BSE020923-510 301
Power Up on S800 I/O Appendix C Power Up
T1
T2
PR (primary)
DU (both)
PR (backup)
R (backup)
I/O module
R (AI, DI)
R (AO, DO)
W (AI, DI)
Start of I/O
Power up INIT INIT
S800 I/O backup
302 3BSE020923-510
Appendix C Power Up 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 INIT
backup backup
3BSE020923-510 303
Power Up on S800 I/O Appendix C Power Up
304 3BSE020923-510
INDEX
A CI830 27, 37, 109
A.C. supply 96 CI840 27
Address setting 110 Cooling load 157
Advant Fieldbus 100 108
AI801 25 D
AI810 25 D.C. supply 96
AI820 25 DI801 27
AI825 25 DI802 27
AI830 25 DI803 27
AI830A 25 DI810 27
AI835 25 DI811 27
AI843 26 DI814 27
AI845 26 DI820 27
AI880 26 DI821 27
AI880A 26 DI825 27
AI890 26 DI830 27
AI893 26 DI831 27
AI895 26 DI840 28
AO801 26 DI880 28
AO810 26 DI885 28
AO810V2 26 DI890 28
AO820 26 DIN-rail 64
AO845 26 Dissipation permitted in cabinets 154
AO845A 26 Distributed MTUs 109
AO890 26 DO801 28
AO895 26 DO802 28
DO810 28
C DO814 28
Cable adaptor 29 to 30 DO815 28
Cable considerations 94 DO820 28
Check of non-redundant power supply 171 DO821 28
Check of redundant power supply 171 DO840 28
CI801 26 DO880 28
CI810/CI810A/CI810B 27, 36 DO890 28
CI820 27, 37 DP820 28
3BSE020923-510 305
Index
H P
Hardware configuration 125 Personnel safety 104
Hazardous Location - North American Power
Approval 96 A.C. supply 96
Heat dissipation 154 D.C. supply 96
High voltage switch-gear applications 97 Requirements 96
Power and cooling 157
I Power consumption 156
I/O clusters (1-7) 109 Power Dissipation 157
I/O module installation 80 Power supply 53
I/O module replacement 172 Load calculation 153
I/O modules 53 Procedure
I/O Station Power up 295
Assembly 107 Process signals 109
I/O station 19, 64 PROFIBUS-DP 19, 27, 37
PROFIBUS-DPV1 19, 27, 36, 38
306 3BSE020923-510
Index
R TK801V012 30
Redundant FCI installation 69 TK811V015 30
TK811V050 30
S TK811V150 31
S800 I/O TK812V015 31
Assembly 107 TK812V050 31
Installation 62 TK812V150 31
Safety regulations 103 TU805 31
SD821 29 TU807 31, 266
SD822 29 TU810 31
SD823 29 TU811 31
Shut down TU813 31
Emergency 118 TU814 31
Manual stop 119 TU830 31
Safety 118 TU831 31
SS822 29 TU833 31
SS823 29 TU834 31
TU835 31
TU836 32
T
TU837 32
TB805 29
TU838 32
TB806 29
TU840 32
TB807 29, 83
TU841 32
TB810 29, 75
TU842 32
TB810/811 175
TU843 32
TB811 30
TU844 32
TB815 30
TU845 32
TB820 30, 175
TU846 32
TB825 30
TU847 32
TB840 30
TU848 32, 280
TB842 30
TU849 32
TB845 30
TU890 32
TB846 30
TU891 33
TC501V150 30
TY801 33
TC505 30
TY804 33
Temperature 63
Cabinetry factors 63
I/O module factors 63 V
Terminator 30 Ventilation 154
TK801V003 30 Vibration 63
TK801V006 30
3BSE020923-510 307
Index
308 3BSE020923-510
Contact us
3BSE020923-510
ABB AB Copyright © 2003-2010 by ABB.
Control Systems All Rights Reserved
Västerås, Sweden
Phone: +46 (0) 21 32 50 00
Fax: +46 (0) 21 13 78 45
E-Mail: [email protected]
www.abb.com/controlsystems
ABB Inc.
Control Systems
Wickliffe, Ohio, USA
Phone: +1 440 585 8500
Fax: +1 440 585 8756
E-Mail: [email protected]
www.abb.com/controlsystems