ABB AC 800F Guide

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PROCESS AUTOMATION
Freelance 2019
Mounting and Installation Instructions
AC 800F Controller

Document Number: 3BDD012501-111
Revision: A
Release: December 2018
—
PROCESS AUTOMATION
Freelance 2019
Mounting and Installation Instructions
AC 800F Controller

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Notice
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Copyright © 2019 by ABB.
All rights reserved.

Mounting and Installation Instructions
Table of Contents
Contents Page
1 AC 800F System Overview...................................................................1-1
2 AC 800F Precautions ............................................................................2-1
2.1 Routine maintenance and cleaning...................................................................2-4
3 Mounting the AC 800F ..........................................................................3-1
3.1 Assembling the housing.....................................................................................3-1
3.1.1 Dimensions and mounting depth...........................................................................3-2
3.1.2 Cabinet or switch box mounting............................................................................3-3
3.1.2.1 Improved air circulation.........................................................................................3-5
3.1.3 Mounting on top hat rails.......................................................................................3-7
3.1.4 Wall mounting on top hat rails...............................................................................3-8
3.1.5 Vibration-resistant wall mounting ..........................................................................3-9
3.2 Grounding the AC 800F .................................................................................... 3-10
3.3 Mounting the modules......................................................................................3-11
3.3.1 Mounting power supply module SA 801F............................................................3-11
3.3.2 Mounting power supply module SA 811F............................................................3-14
3.3.3 Mounting power supply module SD 802F ...........................................................3-17
3.3.4 Mounting power supply module SD 812F ...........................................................3-20
3.3.5 MMounting Ethernet modules .............................................................................3-23
3.3.6 Mounting fieldbus modules..................................................................................3-32
3.3.7 Covering empty slots with caps (dummy panels)................................................3-35
3.4 Putting on cable shields................................................................................... 3-36
4 Cabling the AC 800F .............................................................................4-1
4.1 Cabling the power supply module.....................................................................4-1
4.1.1 Power supply module SA 801F (115 - 230 V AC).................................................4-1
4.1.2 Power supply module SA 811F (115 - 230 V AC).................................................4-3
4.1.3 Power supply module SD 802F (24 V DC)............................................................4-5
4.1.4 Power supply module SD 812F (24 V DC)............................................................4-7
4.1.5 Connection via RS232 interface for diagnosis ......................................................4-9
4.2 Cabling Ethernet modules................................................................................4-10
4.2.1 10Base2 (Cheapernet, Thin Ethernet) ................................................................4-11
4.2.2 10Base5 (Full Ethernet) ...................................................................................... 4-12
4.2.3 10BaseT (Full Ethernet)......................................................................................4-13
4.2.4 100BaseT or FF/HSE (Full Ethernet)..................................................................4-14

Mounting and Installation Instructions
4.2.5 10BaseFL ............................................................................................................4-15
4.2.6 Designing the network.........................................................................................4-17
4.2.6.1 General information .............................................................................................4-17
4.2.6.2 Acceptance measurement...................................................................................4-18
4.2.7 Installing a 10Base2 network (Cheapernet).........................................................4-19
4.2.7.1 General................................................................................................................4-19
4.2.7.2 Cabling a 10Base2 segment................................................................................4-20
4.2.7.3 Connecting 10Base2 nodes while the system is running ....................................4-22
4.2.7.4 Crimping 10Base2 cables....................................................................................4-25
4.2.8 Installing a 10Base5 network (Yellow Cable) ......................................................4-26
4.2.8.1 General................................................................................................................4-26
4.2.8.2 Linking 10Base5 cable segments........................................................................4-27
4.2.8.3 Cabling a 10Base5 segment................................................................................4-28
4.2.8.4 Connecting and disconnecting nodes while the system is running......................4-34
4.2.9 Installing a 10BaseT (twisted pair) network.........................................................4-35
4.2.9.1 General................................................................................................................4-35
4.2.9.2 Cabling a 10BaseT segment ...............................................................................4-35
4.2.10 Installing a 10BaseFL network (fiber optic cable)................................................4-38
4.2.10.1 General................................................................................................................4-38
4.2.10.2 Cabling via 10BaseFL transceivers.....................................................................4-40
4.2.10.3 Long-distance links within buildings.....................................................................4-43
4.2.10.4 Links between buildings.......................................................................................4-44
4.2.10.5 Redundant 10BaseFL cable link..........................................................................4-45
4.2.10.6 Protective separation via 10BaseFL....................................................................4-48
4.2.10.7 Max. permissible network length with 10BaseFL cable.......................................4-50
4.2.11 Mixed networks....................................................................................................4-53
4.2.12 Coupling cable segments via repeaters...............................................................4-54
4.2.13 Cabling AC 800F for operation in redundancy mode...........................................4-56
4.3 Cabling the fieldbus modules...........................................................................4-57
4.3.1 Cabling Profibus module FI 830F ........................................................................4-57
4.3.1.1 Connecting the Profibus via RS485.....................................................................4-58
4.3.1.2 Connecting the Profibus via fiber-optic cables (FO cables).................................4-62
4.3.1.3 Connecting a Profibus master redundancy..........................................................4-64
4.3.1.4 Connecting a Profibus line redundancy...............................................................4-64
4.3.1.5 Connecting Profibus-PA nodes............................................................................4-67
4.3.2 Cabling the serial fieldbus module FI 820F .........................................................4-70
4.3.2.1 Connection via RS232 interface..........................................................................4-72
4.3.2.2 Connection via RS422 interface..........................................................................4-74
4.3.2.3 Connection via RS485 interface..........................................................................4-78
4.3.3 Redundant cabling of two serial fieldbus modules...............................................4-83
4.3.3.1 Redundant connection via RS232 interface ........................................................4-83
4.3.3.2 Redundant connection via RS422 interface ........................................................4-84
4.3.3.3 Redundant connection via RS485 interface ........................................................4-86
4.3.4 Cabling CAN module FI 810F..............................................................................4-89
4.3.5 Redundant cabling of two CAN modules FI 810F................................................4-95

Mounting and Installation Instructions
4.3.5.1 Redundant connection of the CAN bus...............................................................4-95
4.3.6 Cabling the FF/HSE module FI 840F..................................................................4-99
4.3.6.1 Cabling FF/HSE or 100BaseT...........................................................................4-100
5 AC 800F Functional Description..........................................................5-1
5.1 Power supply modules ....................................................................................... 5-1
5.1.1 Power supply module SA 801F, input voltage 115 - 230 V AC.............................5-2
5.1.2 Power supply module SA 811F, input voltage 115 - 230 V AC.............................5-5
5.1.3 Power supply module SD 802F, input voltage 24 V DC........................................5-7
5.1.4 Power supply module SD 812F, input voltage 24 V DC........................................5-9
5.2 CPU board PM 802F/PM 803F...........................................................................5-11
5.2.1 Technical data of the CPU board PM 802F.........................................................5-15
5.2.2 Technical data of the CPU board PM 803F.........................................................5-17
5.3 Switching on the AC 800F ................................................................................5-19
5.3.1 Checking the IP address.....................................................................................5-19
5.3.2 Switching on the supply voltage..........................................................................5-21
5.3.3 Status indicators of the power supply module.....................................................5-22
5.3.4 Startup behavior..................................................................................................5-26
5.4 Diagnosing the AC 800F................................................................................... 5-29
5.4.1 Starting and setting up the MS-Windows NT 4.0 and
MS-Windows 2000 terminal emulation................................................................5-30
5.4.2 Hardware self-test...............................................................................................5-32
5.4.3 Messages of the hardware error memory ...........................................................5-33
5.4.4 Configuring the Boot Loader ...............................................................................5-34
5.4.5 Diagnosing the AC 800 controller via the AC 800F Web server .........................5-42
6 Functional Description of the Ethernet Modules...............................6-1
6.1 General features and handling...........................................................................6-2
6.1.1 General features....................................................................................................6-2
6.1.2 Installing an Ethernet module................................................................................6-3
6.1.3 Deinstalling an Ethernet module ...........................................................................6-4
6.2 10Base2 module EI 801F ....................................................................................6-5
6.2.1 Concept.................................................................................................................6-5
6.2.2 Hardware structure................................................................................................6-7
6.2.3 Operating elements...............................................................................................6-8
6.2.4 Technical data.....................................................................................................6-10
6.3 10Base2 module EI 811F ..................................................................................6-11
6.3.1 Concept...............................................................................................................6-11
6.3.2 Hardware structure..............................................................................................6-13
6.3.3 Operating elements.............................................................................................6-14

Mounting and Installation Instructions
6.3.4 Technical data .....................................................................................................6-16
6.4 AUI module EI 802F ...........................................................................................6-17
6.4.1 Concept ...............................................................................................................6-17
6.4.2 Hardware structure..............................................................................................6-18
6.4.3 Operating elements .............................................................................................6-20
6.4.4 Technical data .....................................................................................................6-22
6.5 AUI module EI 812F ...........................................................................................6-23
6.5.1 Concept ...............................................................................................................6-23
6.5.2 Hardware structure..............................................................................................6-25
6.5.3 Operating elements .............................................................................................6-26
6.5.4 Technical data .....................................................................................................6-28
6.6 10BaseT module EI 803F...................................................................................6-29
6.6.1 Concept ...............................................................................................................6-29
6.6.2 Hardware structure..............................................................................................6-31
6.6.3 Operating elements .............................................................................................6-33
6.6.4 Technical data .....................................................................................................6-35
6.7 10BaseT module EI 813F...................................................................................6-36
6.7.1 Concept ...............................................................................................................6-36
6.7.2 Hardware structure..............................................................................................6-38
6.7.3 Operating elements .............................................................................................6-40
6.7.4 Technical data .....................................................................................................6-42
7 Functional Description of the Fieldbus Modules ...............................7-1
7.1 General .................................................................................................................7-1
7.2 Profibus module FI 830F....................................................................................7-8
7.2.1 Concept .................................................................................................................7-9
7.2.2 Hardware structure..............................................................................................7-10
7.2.3 Technical data .....................................................................................................7-12
7.2.3.1 Transmission technology.....................................................................................7-14
7.2.3.2 Cable parameters ................................................................................................7-15
7.2.4 Installation instructions ........................................................................................7-16
7.2.5 Master redundancy..............................................................................................7-17
7.2.6 Line redundancy ..................................................................................................7-17
7.2.7 Profibus-PA operation..........................................................................................7-18
7.3 Serial module FI 820F (Modbus Protocol).......................................................7-20
7.3.1 Concept ...............................................................................................................7-20
7.3.2 Hardware structure..............................................................................................7-22
7.3.3 Technical data .....................................................................................................7-24
7.4 CAN module FI 810F (Industrial IT Protocol) ..................................................7-26
7.4.1 Concept ...............................................................................................................7-26

Mounting and Installation Instructions
7.4.2 Hardware structure..............................................................................................7-28
7.4.3 Technical data.....................................................................................................7-29
7.5 FF/HSEmodule FI 840F ..................................................................................... 7-31
7.5.1 Concept...............................................................................................................7-31
7.5.2 Hardware structure..............................................................................................7-33
7.5.3 Technical data.....................................................................................................7-35
8 Accessories...........................................................................................8-1
8.1 Battery module AM 801F ....................................................................................8-1
8.1.1 Concept.................................................................................................................8-1
8.1.2 Installing the battery module .................................................................................8-2
8.1.3 Deinstalling a battery module................................................................................ 8-3
8.1.4 Hardware structure................................................................................................8-5
8.1.5 Technical data.......................................................................................................8-7
8.2 Battery module AM 811F ....................................................................................8-8
8.2.1 Concept.................................................................................................................8-8
8.2.2 Installing the battery module .................................................................................8-9
8.2.3 Deinstalling a battery module.............................................................................. 8-10
8.2.4 Hardware structure..............................................................................................8-12
8.2.5 Technical data.....................................................................................................8-14
8.3 Connecting the radio clock to the AC 800F.................................................... 8-15
8.3.1 DCF77 radio clock...............................................................................................8-15
8.3.2 Radio clock deliverables......................................................................................8-15
8.3.3 Setting the radio clock......................................................................................... 8-16
8.3.4 Connecting the radio clock to the AC 800F.........................................................8-17
8.3.5 Diagnosing a AC 800F with radio clock...............................................................8-18
8.4 Connecting the GPS satellite radio clock to the AC 800F.............................8-18
8.4.1 GPS satellite radio clock 6841 ............................................................................8-18
8.4.2 Functional principle of the GPS satellite radio clock ...........................................8-19
8.4.3 GPS satellite radio clock deliverables.................................................................8-19
8.4.4 Satellite radio clock dimensions (half 19" size) ...................................................8-20
8.4.5 Setting the satellite radio clock............................................................................8-20
8.4.6 Connecting the radio satellite clock to the AC 800F............................................8-20
9 Technical Data of the AC 800F.............................................................9-1
9.1 Environmental specifications ............................................................................ 9-1
9.2 Mechanical specifications.................................................................................. 9-2
9.3 Electromagnetic compatibility (EMC)................................................................9-2
9.4 Safety specifications...........................................................................................9-3
9.5 Power loss specifications for cooling system calculation..............................9-5

Mounting and Installation Instructions
10 Approvals/certificates.........................................................................10-1
10.1 ISO 9001..............................................................................................................10-1
10.2 ISO 9000..............................................................................................................10-3
10.3 CE........................................................................................................................10-5
10.4 CSA .....................................................................................................................10-9
10.5 UL......................................................................................................................10-13
10.6 GUS certificate.................................................................................................10-17
11 Terminal Assignment..........................................................................11-1
11.1 Terminal assignment of the power supply modules......................................11-1
11.1.1 Terminal assignment of SA 801F ........................................................................11-1
11.1.2 Terminal assignment of SA 811F ........................................................................11-1
11.1.3 Terminal assignment of SD 802F........................................................................11-2
11.1.4 Terminal assignment of SD 812F........................................................................11-2
11.2 Terminal assignment of the Ethernet modules...............................................11-3
11.2.1 Terminal assignment of EI 801F..........................................................................11-3
11.2.2 Terminal assignment of EI 811F..........................................................................11-3
11.2.3 Terminal assignment of EI 802F..........................................................................11-3
11.2.4 Terminal assignment of EI 812F..........................................................................11-4
11.2.5 Terminal assignment of EI 803F..........................................................................11-4
11.2.6 Terminal assignment of EI 813F..........................................................................11-4
11.3 Terminal assignment of the fieldbus modules ...............................................11-5
11.3.1 Terminal assignment of FI 840F..........................................................................11-5
11.3.2 Terminal assignment of FI 830F..........................................................................11-5
11.3.3 Terminal assignment of FI 820F..........................................................................11-5
11.3.4 Terminal assignment of FI 810F..........................................................................11-6
12 Check-List for Mounting.....................................................................12-1
13 Glossary ...............................................................................................13-1
13.1 13-17
13.1 DFC 02 - AC 800F naming conventions.......................................................13-17
14 Index .....................................................................................................14-1

Mounting and Installation Instructions
List of Figures
1 System Overview ..........................................................................................................Page
Fig. 1-1 Configuration example: AC 800F integrated in the Freelance 2000 system......................1-2
Fig. 1-2 Basic AC 800F configuration.............................................................................................. 1-4
Fig. 1-3 AC 800F with five I/O units.................................................................................................1-6
Fig. 1-4 Profibus DP network, example...........................................................................................1-7
Fig. 1-5 Fieldbus Foundation H1 (FFH1) network, example ...........................................................1-8
3 Mounting AC 800F.........................................................................................................Page
Fig. 3-1 Dimensions of AC 800F housing........................................................................................ 3-2
Fig. 3-2 Housing dimensions with contact ledge, connectors and cables.......................................3-3
Fig. 3-3 Cabinet mounting...............................................................................................................3-4
Fig. 3-4 Air flow without air deflectors .............................................................................................3-5
Fig. 3-5 Air deflector DSU 65 ..........................................................................................................3-6
Fig. 3-6 Air flow with air deflectors ..................................................................................................3-6
Fig. 3-7 Hook AC 800F on top hat rail.............................................................................................3-7
Fig. 3-8 AC 800F snaps in...............................................................................................................3-7
Fig. 3-9 Wall mounting on top hat rail..............................................................................................3-8
Fig. 3-10 Grounding for cabinet mounting.......................................................................................3-10
Fig. 3-11 Ethernet module coding switch........................................................................................3-25
Fig. 3-12 Adjusting IP address........................................................................................................3-26
Fig. 3-13 Standard setting...............................................................................................................3-27
Fig. 3-14 Special setting..................................................................................................................3-28
Fig. 3-15 Redundancy case, standard setting.................................................................................3-29
Fig. 3-16 Redundancy case, special setting....................................................................................3-30
Fig. 3-17 Applying the communication cable...................................................................................3-37
4 Cabling the AC 800F .....................................................................................................Page
Fig. 4-1 Cabling power supply module SA 801F.............................................................................4-1
Fig. 4-2 Laying cables of power supply module SA 801F...............................................................4-2
Fig. 4-3 Cabling power supply module SA 811F.............................................................................4-3
Fig. 4-4 Laying cables of power supply module SA 811F...............................................................4-4
Fig. 4-3 Cabling power supply module SD 802F.............................................................................4-5
Fig. 4-6 Laying cables of power supply module SD 802F...............................................................4-6
Fig. 4-3 Cabling power supply module SD 812F.............................................................................4-7
Fig. 4-8 Laying cables of power supply module SD 812F...............................................................4-8
Fig. 4-9 Connection via RS232 interface for diagnostics ................................................................4-9
Fig. 4-10 Installing a 10Base2 network........................................................................................... 4-19
Fig. 4-11 10Base2 cabling with 3 nodes .........................................................................................4-21
Fig. 4-12 Grounding the 10Base2 cable.......................................................................................... 4-22
Fig. 4-13 10Base2 connection via junction boxes...........................................................................4-23
Fig. 4-14 10Base2 connection via transceiver ................................................................................4-24
Fig. 4-15 Installing a 10Base5 network........................................................................................... 4-26
Fig. 4-16 Cabling a 10Base5 network with 3 nodes........................................................................4-29

Mounting and Installation Instructions
Fig. 4-17 Connecting and grounding the AUI cable.........................................................................4-34
Fig. 4-18 Installing a 10BaseT network with 2 nodes......................................................................4-35
Fig. 4-19 Cabling a 10BaseT network with 4 nodes........................................................................4-36
Fig. 4-20 Cabling a 10BaseT network with 3 nodes........................................................................4-37
Fig. 4-21 Installing a 10BaseFL network (fiber optic cable).............................................................4-38
Fig. 4-22 Cabling a 10BaseFL network with 3 nodes......................................................................4-41
Fig. 4-23 10BaseFL cable link.........................................................................................................4-42
Fig. 4-24 Point-to-point connection with splice boxes......................................................................4-43
Fig. 4-25 Redundant 10BaseFL cabling, case 1..............................................................................4-46
Fig. 4-26 Redundant 10BaseFL cabling, case 2..............................................................................4-47
Fig. 4-27 Protective separation via Ethernet, 1st way .....................................................................4-48
Fig. 4-28 Protective separation via Ethernet, 2nd way....................................................................4-49
Fig. 4-29 Propagation delay calculation for an installation, example...............................................4-51
Fig. 4-30 Mixed network ..................................................................................................................4-53
Fig. 4-31 Coupling via a repeater ....................................................................................................4-54
Fig. 4-32 Large system with max. possible transmission distances................................................4-55
Fig. 4-33 Cabling AC 800F for operation in redundancy mode .......................................................4-56
Fig. 4-34 FI 830F connector pin assignment...................................................................................4-57
Fig. 4-35 Profibus connector, internal circuitry ................................................................................4-59
Fig. 4-36 Cabling FI 830F................................................................................................................4-60
Fig. 4-37 FI 830F bus termination....................................................................................................4-60
Fig. 4-38 Grounding FI 830F ...........................................................................................................4-61
Fig. 4-39 Profibus connector with ferrite-type RFI suppressor, example.......................................4-62
Fig. 4-40 Profibus master redundancy.............................................................................................4-64
Fig. 4-41 Connector pin assignment of RLM 01..............................................................................4-66
Fig. 4-42 Line redundancy...............................................................................................................4-66
Fig. 4-43 Block diagram LD 800P....................................................................................................4-67
Fig. 4-44 Connection diagram LD 800P ..........................................................................................4-68
Fig.4-45 Connection diagram for redundancy operation with LD 800P..........................................4-69
Fig. 4-46 FI 820F connector pin assignment...................................................................................4-70
Fig. 4-47 FI 820F internal termination..............................................................................................4-71
Fig. 4-48 CAN cable TK 821F with terminal block TB 870F............................................................4-71
Fig. 4-49 Cabling FI 820F via RS232 interface, channel 0..............................................................4-73
Fig. 4-50 Cabling FI 820F via RS422 interface on channel 0..........................................................4-75
Fig. 4-51 Internal RS422 termination of FI 820F .............................................................................4-76
Fig. 4-52 Activating the termination on the terminal block TB 870F................................................4-76
Fig. 4-53 External termination with external supply.........................................................................4-77
Fig. 4-54 Terminating voltage from external 5 V power supply .......................................................4-77
Fig. 4-55 Cabling FI 820F via RS485 interface, case 1...................................................................4-79
Fig. 4-56 Internal RS485 termination...............................................................................................4-80
Fig. 4-57 Activating the termination on the terminal block TB 870F................................................4-80
Fig. 4-58 External termination with external supply.........................................................................4-81
Fig. 4-59 Terminating voltage from external 5 V power supply .......................................................4-81
Fig. 4-60 Cabling FI 820F via RS485 interface, case 2...................................................................4-82
Fig. 4-61 Redundant cabling of two FI 820F via RS232 interfaces .................................................4-84
Fig. 4-62 Redundant cabling of two FI 820F via RS422 interfaces, using channel 0......................4-85
Fig. 4-63 Redundant cabling of FI 820F via RS485 interface..........................................................4-87
Fig. 4-64 FI 810F connector pin assignment..................................................................................4-89

Mounting and Installation Instructions
Fig. 4-65 Internal termination of FI 810F, channels 0, 1 and 2........................................................4-90
Fig. 4-66 CAN cable TK 811F.........................................................................................................4-90
Fig. 4-67 CAN cable DSU 11 ..........................................................................................................4-90
Fig. 4-68 CAN cable TK 817F.........................................................................................................4-90
Fig. 4-69 CAN cable DSU 07 ..........................................................................................................4-90
Fig. 4-70 CAN cable TK 831F with terminal block TB 870F............................................................4-91
Fig. 4-71 CAN bus connection example, with internal termination..................................................4-93
Fig. 4-72 FI 810F internal termination, channels 0, 1 and 2............................................................4-93
Fig. 4-73 CAN bus connection example, with external termination.................................................4-94
Fig. 4-74 Connection example, terminal assignment......................................................................4-94
Fig. 4-75 Redundant connection of the CAN bus, case 1...............................................................4-96
Fig. 4-76 External termination for redundant connection ................................................................4-96
Fig. 4-77 Redundant cabling of the CAN bus, case 2.....................................................................4-98
Fig. 4-78 External termination for redundant cabling ......................................................................4-98
Fig. 4-79 100BaseT network with 2 nodes....................................................................................4-100
Fig. 4-80 100BaseT network with 4 nodes....................................................................................4-101
5 AC 800F Functional Description..................................................................................Page
Fig. 5-1 Block diagram of power supply module SA 801F ..............................................................5-3
Fig. 5-2 Pin assignment of AC mains connector............................................................................. 5-3
Fig. 5-3 Pin assignment of diagnostic connector............................................................................. 5-3
Fig. 5-4 Block diagram of power supply module SA 811F ..............................................................5-5
Fig. 5-5 Pin assignment of AC mains connector............................................................................. 5-5
Fig. 5-6 Pin assignment of diagnostic connector............................................................................. 5-5
Fig. 5-7 Block diagram of power supply module SD 802F..............................................................5-7
Fig. 5-8 Pin assignment of DC mains connector.............................................................................5-7
Fig. 5-9 Pin assignment of diagnostic connector............................................................................. 5-8
Fig. 5-10 Block diagram of power supply module SD 812F.............................................................. 5-9
Fig. 5-11 Pin assignment of DC mains connector...........................................................................5-10
Fig. 5-12 Pin assignment of diagnostic connector...........................................................................5-10
Fig. 5-13 Basic unit with CPU board ...............................................................................................5-11
Fig. 5-14 Status indicators and operating elements on power supply module................................ 5-22
Fig. 5-15 Creating a new emulation ................................................................................................5-30
Fig. 5-16 Connecting the emulation ................................................................................................5-31
Fig. 5-17 Parameter setting for connection setup ...........................................................................5-31
Fig. 5-18 1st-Stage system messages............................................................................................5-33
Fig. 5-19 Boot Loader system messages up to the key prompt......................................................5-34
Fig. 5-20 Operating system startup, adjustment prompt.................................................................5-38
Fig. 5-21 Current parameters of the configuration block................................................................5-39
Fig. 5-22 Configuration example using the Microsoft Internet Explorer ..........................................5-43
Fig. 5-23 Requesting diagnostic data from the AC 800F Web server.............................................5-44

Mounting and Installation Instructions
6 Functional Description of the Ethernet Modules....................................................... Page
Fig. 6-1 Locking the module slide lock.............................................................................................6-3
Fig. 6-2 Unlocking the module slide lock.........................................................................................6-4
Fig. 6-3 10Base2 module block diagram.........................................................................................6-7
Fig. 6-4 10Base2 connector pin assignment ...................................................................................6-7
Fig. 6-5 Ethernet module coding switch...........................................................................................6-8
Fig. 6-6 10Base2 module block diagram.......................................................................................6-13
Fig. 6-7 10Base2 connector pin assignment .................................................................................6-13
Fig. 6-8 Ethernet module coding switch.........................................................................................6-14
Fig. 6-9 AUI module block diagram ...............................................................................................6-19
Fig. 6-10 Ethernet AUI connector pin assignment...........................................................................6-19
Fig. 6-11 AUI module coding switch................................................................................................6-20
Fig. 6-12 AUI module block diagram ...............................................................................................6-25
Fig. 6-13 AUI connector pin assignment..........................................................................................6-25
Fig. 6-14 AUI module coding switch................................................................................................6-26
Fig. 6-15 10BaseT module block diagram.......................................................................................6-31
Fig. 6-16 10BaseT module connector pin assignment ....................................................................6-31
Fig. 6-17 10BaseT module coding switch........................................................................................6-33
Fig. 6-18 10BaseT module block diagram.......................................................................................6-39
Fig. 6-19 10BaseT module connector pin assignment ....................................................................6-39
Fig. 6-20 10BaseT module coding switch........................................................................................6-40
7 Functional Description of the Fieldbus Modules ..................................................... Page
Fig. 7-1 Locking the module slide lock.............................................................................................7-4
Fig. 7-2 Unlocking the module slide lock.........................................................................................7-5
Fig. 7-3 FI 830F block diagram......................................................................................................7-11
Fig. 7-4 FI 830F connector pin assignment...................................................................................7-11
Fig. 7-5 FI 830F bus termination....................................................................................................7-14
Fig. 7-6 Cabling FI 830F................................................................................................................7-16
Fig. 7-7 Grounding FI 830F ...........................................................................................................7-16
Fig. 7-8 Profibus master redundancy.............................................................................................7-17
Fig. 7-9 LD 800P block diagram....................................................................................................7-19
Fig. 7-10 FI 820F block diagram......................................................................................................7-22
Fig. 7-11 FI 820F connector pin assignment...................................................................................7-23
Fig. 7-12 FI 810F block diagram......................................................................................................7-28
Fig. 7-13 FI 810F connector pin assignment...................................................................................7-29
Fig. 7-14 FF/HSE module block diagram.........................................................................................7-33
Fig. 7-15 FI 840F connector pin assignment...................................................................................7-34

Mounting and Installation Instructions
8 Accessories...................................................................................................................Page
Fig. 8-1 Locking the module slide lock............................................................................................8-2
Fig. 8-2 Unlocking the module slide lock.........................................................................................8-3
Fig. 8-3 Battery module block diagram............................................................................................8-5
Fig. 8-4 Locking the module slide lock............................................................................................8-9
Fig. 8-5 Unlocking the module slide lock.......................................................................................8-10
Fig. 8-6 Battery module block diagram..........................................................................................8-12
Fig. 8-7 Radio clock dimensions ...................................................................................................8-16
Fig. 8-8 Linking the radio clock with the AC 800F.........................................................................8-17
Fig. 8-9 Radio clock cable assignment.......................................................................................... 8-17
Fig. 8-10 Satellite radio clock (half 19" size) dimensions................................................................8-20
9 Technical Data of the AC 800F.....................................................................................Page
Fig. 9-1 Max. relative humidity ........................................................................................................9-1
10 Approvals/Certificates..................................................................................................Page
Fig. 10-1 ISO 9001..........................................................................................................................10-1
Fig. 10-2 ISO 9001..........................................................................................................................10-2
Fig. 10-3 ISO 9000..........................................................................................................................10-3
Fig. 10-4 ISO 9000..........................................................................................................................10-4
Fig. 10-5 CE certificate, page 1.......................................................................................................10-5
Fig. 10-6 CE certificate, page 2.......................................................................................................10-6
Fig. 10-7 CE certificate, page 3.......................................................................................................10-7
Fig. 10-8 CE certificate, supplement...............................................................................................10-8
Fig. 10-9 CSA certificate, page 1 ....................................................................................................10-9
Fig. 10-10 CSA certificate, page 2 ..................................................................................................10-10
Fig. 10-11 CSA certificate, page 3 ..................................................................................................10-11
Fig. 10-12 CSA certificate, page 4 ..................................................................................................10-12
Fig. 10-13 UL certificate..................................................................................................................10-13
Fig. 10-14 UL certificate, page 2.....................................................................................................10-14
Fig. 10-15 UL certificate, page 3.....................................................................................................10-15
Fig. 10-16 UL certificate, page 4.....................................................................................................10-16
Fig. 10-17 GUS certificate...............................................................................................................10-17

Mounting and Installation Instructions
11 Terminal Assignment................................................................................................... Page
Fig. 11-1 Terminal assignment mains plug, SA 801F......................................................................11-1
Fig. 11-2 Terminal assignment diagnostic plug, SA 801F...............................................................11-1
Fig. 11-3 Terminal assignment mains plug, SA 811F......................................................................11-1
Fig. 11-4 Terminal assignment diagnostic plug, SA 811F...............................................................11-1
Fig. 11-5 Terminal assignment mains plug, SD 802F......................................................................11-2
Fig. 11-6 Terminal assignment diagnostic plug, SD 802F...............................................................11-2
Fig. 11-7 Terminal assignment mains plug, SD 812F......................................................................11-2
Fig. 11-8 Terminal assignment diagnostic plug, SD 812F...............................................................11-2
Fig. 11-9 10Base2 terminal assignment, EI 801F............................................................................11-3
Fig. 11-10 10Base2 terminal assignment, EI 811F............................................................................11-3
Fig. 11-11 Terminal assignment AUI socket, EI 802F.......................................................................11-3
Fig. 11-12 Terminal assignment AUI socket, EI 812F.......................................................................11-4
Fig. 11-13 Terminal assignment Ethernet TP, EI 803F .....................................................................11-4
Fig. 11-14 Terminal assignment Ethernet TP, EI 813F .....................................................................11-4
Fig. 11-15 Terminal assignment Ethernet TP, FI 840F......................................................................11-5
Fig. 11-16 Terminal assignment FI 830F...........................................................................................11-5
Fig. 11-17 Terminal assignment FI 820F...........................................................................................11-5
Fig. 11-18 Terminal assignment FI 810F...........................................................................................11-6

1AC 800F System Overview
1-1
1 AC 800F System Overview
The AC 800F controller of the ABB IndustrialIT series is compatible with all standard
fieldbuses and is your key to the world of remote input/output. ABB's OperateIT
product range includes the appropriate program - e.g. Control Builder F –which you
can select according to your needs. This is the most comfortable way to user-friendly
operation, monitoring, configuration and data archiving.
At present, the following fieldbuses are available for the AC 800F:
•Profibus DP
•Fieldbus Foundation
•Modbus
•CAN
The integration of further fieldbuses is under preparation.
Most user-benefits can be achieved by using the AC 800F with the Control Builder F
software package. When we integrated the fieldbuses into the Freelance 2000
system, the configuration was in the center of interest. As a result, the entire system –
from the operator station down to the fieldbus device on the lowest level –can be
configured with the Control Builder F. No external configuration tools are needed for
the fieldbuses and fieldbus devices used.
Control Builder F is also compatible for use with the Freelance 2000 system.
Components of both the Freelance 2000 system and the AC 800F can be run with
Control Builder F in one system.
The following configurations are now possible (examples):
•Pure AC 800F system:
-ten or more operator stations,
-one or more engineering station(s) and
-ten or more AC 800F
•Mixed system made up of AC 800F and Freelance 2000 components.
-ten or more operator stations,
-one or more engineering station(s) and
-ten or more AC 800F or process stations, each with
-five Freelance I/O units per AC 800F or
-four I/O units per process station

1AC 800F System Overview
1-2
Figure 1-1 shows the AC 800F integrated in the Freelance 2000 automation system
as an example.
Fig. 1-1 Configuration example: AC 800F integrated in the Freelance 2000 system
The system bus (Ethernet) links the individual stations with each other. It transmits
data between the AC 800F controllers, the operator stations, the engineering station,
and the process stations via coaxial or fiber-optic cables.
The CAN bus connects the central unit to the I/O units. It is used to transmit the
input/output values from the AC 800F to the I/O modules. For this purpose, the
AC 800F is equipped with CAN module FI 810F.
Modbus connects subsystems –e.g. balances, bar code readers, etc. –to the system,
preferably via the RS485 interface. The serial fieldbus module FI 820F provides two
channels to the AC 800F to enable work with Modbus.

1AC 800F System Overview
1-3
An engineering station is a PC or laptop with MS-Windows 2000 or MS-
Windows NT 4.0 (with service pack 6) and the Control Builder F software package. It
is used by the operator for system configuration, documentation, and commissioning.
After these tasks have been completed, the engineering station can be disconnected
and used for other purposes.
An operator station is a PC with MS-Windows 2000 or MS-Windows NT 4.0 (with
service pack 6) and the Control Builder F software package. It is recommended to
use an industrial PC. Besides a 17" or 21" color monitor, standard keyboard and
mouse, several components to IP 65 are available on request. See also our Intranet
pages or contact the ABB customer service.
A maximum of two printers for message and report printing can be connected. The
operator station is usable for configuring and commissioning as well, provided that the
Control Builder F engineering software has been installed.
This manual describes how to mount, install and use the AC 800F. In most of the
application and configuration examples given in this manual the AC 800F is integrated
in the Freelance 2000 system.
However, this does not mean that it can be used with Freelance 2000 exclusively.
AC 800F is quite flexible and can be used with all other components of the ABB
IndustrialIT series as well.
The AC 800F consists of:
•the housing with CPU board and module slots,
•the power supply module
•at least one Ethernet module
•a maximum of four fieldbus modules

1AC 800F System Overview
1-4
Figure 1-2 shows the setup of AC 800F in its most simple configuration: the AC 800F
housing, one power supply module, one Ethernet module and one fieldbus module,
without their connection cables.
Fig. 1-2 Basic AC 800F configuration
At present, the following AC 800F modules are available:
•Power supply modules
SA 801F a wide range power supply module for 115 - 230 V AC input voltages
SA 811F a wide range power supply module for 115 - 230 V AC input voltages
with high output power for powering PM 803F
SD 802F a power supply module for redundant 24 V DC input voltages
SD 812F a power supply module for redundant 24 V DC input voltages with high
output power for powering PM 803F
•Ethernet modules
EI 801F 10Base2 module (Cheapernet) for thin coaxial cables
Contains battery holder for (optional) lithium battery, for buffering the
memory for the CPU board PM 802F.
EI 802F AUI module for connecting transceivers for 10Base5, 10Base2,
10BaseT, 10BaseFL or star coupler units
Contains battery holder for (optional) lithium battery for buffering the
memory for the CPU board PM 802F.
EI 803F 10BaseT module for connection to 10BaseT hubs or star coupler units
using twisted pair cables
Contains battery holder for (optional) lithium battery, for buffering the
memory for the CPU board PM 802F.