ABB Advant Controller 80 User manual

ABB Drives User’s Manual
Advant Controller 80

© 2000 ABB Industry Oy. All Rights Reserved.
User’s Manual
Advant Controller 80
3BFE 64116487 R0125 REV A
EFFECTIVE: 21.2.2000
SUPERSEDES: 1.6.1999

AC 80 User’s Manual i
Safety Instructions
General Safety
Instructions
WARNING! All electrical installation and maintenance work on the
drive should be carried out by qualified electricians.
Any installation work must be done with the power off, and power is not
to be reconnected unless the installation work is complete. Dangerous
residual voltages remain in capacitors when the disconnecting device
is opened. Wait 5 minutes after switching off the supply before starting
work. Always ensure that the measured voltage between terminals
UDC+ and UDC- and frame is close to 0 V and that the supply has
been switched off before performing any work on the equipment or
making main circuit connections.
If the main circuit of the inverter unit is live, the motor terminals are also
live even if the motor is not running!
If there are inverters in parallel, open the switch fuses of all parallel
connected inverters before installation or maintenance work on any of
them.
If the auxiliary voltage circuit of the drive is powered from an external
power supply, opening the disconnecting device does not remove all
voltages. Control voltages of 115/230 VAC may be present on the
digital inputs or outputs even though the inverter unit is not powered.
Before starting work, check which circuits remain live after opening of
the disconnecting device by referring to the circuit diagrams for your
particular delivery. Ensure by measuring that the part of the cabinet
you are working on is not live.
Control boards of the drive may be at the main circuit potential.
Dangerous voltages may be present between the control cards and the
frame of the converter unit when the main circuit voltage is on. It is
critical that the use of measuring instruments, such as an oscilloscope,
and their connection to the drive is done with caution and safety always
a priority.
Live parts on the inside of doors are protected against direct contact.
Special safety attention shall be paid when handling shrouds made of
sheet metal.
Do not make any voltage withstand tests on any part of the unit while
the unit is connected. Disconnect motor cables before making any
measurements on motors or motor cables.
Do not open the drive section switch fuses when the inverter is running.

Safety Instructions
ii AC 80 User’s Manual
CAUTION! Fans may continue to rotate for a while after the
disconnection of the electrical supply.
CAUTION! Some parts like heatsinks of power semiconductors inside
of cabinet remain hot for a while after the disconnection of the electrical
supply.

AC 80 User’s Manual iii
Table of Contents
Safety Instructions
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Chapter 1 – Introduction
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
What This Manual Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
AC 80 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Terms, Abbreviations and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Chapter 2 – AC 80 Hardware and Connections
AC 80 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Circuit Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bus Indicator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Special Purpose LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
General Purpose LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Station Address Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
The INIT Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
AC 80 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Power Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Power Supply Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Non-redundant Power Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Redundant Power Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Power-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
ModuleBus Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Electrical ModuleBus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Optical ModuleBus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Size of the I/O Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
DriveBus Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Panel/Printer Connection (Ch2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Wiring Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
AF 100 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Special I/O Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Fieldbus Adapter Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Tool Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

iv AC 80 User’s Manual
Chapter 3 – AC 80 Software
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
AC 80 CPU System Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Boot Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Base Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Application Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
AC 80 NCB System Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
AMC Boot Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
NCBOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
AMC Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
AC 80 Software Support on PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AC 80 CPU Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AC 80 Loader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AdvaBuild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AC 80 Libraries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AC 80 NCB Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
NCB Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
DriveDebug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Chapter 4 – Programming the AC 80
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
The PM825 Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Base Part Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
AF 100 Part Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Serial IF Part Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Control of Drives through Optical ModuleBus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
PC Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DB Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Configuration of DB Elements for ACS 600 Standard Drive . . . . . . . . . . . . . . . . . . . . . . . . 4-4
DB Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Essential Settings for ACS 600 Standard Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Configuration of DB Elements for ACS 600 MultiDrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
DB Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Essential Settings for ACS 600 MultiDrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Example: ACS 600 MultiDrive on Optical ModuleBus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Control of Drives through DriveBus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
DB Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
PC Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Essential Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Example: ACS 600 MultiDrive on DriveBus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Configuring the Electrical ModuleBus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
DB Elements for S800 I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
S800 Analogue Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
S800 Analogue Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

AC 80 User’s Manual v
S800 Digital Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
S800 Digital Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Essential Terminal Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Control of the Panel/Printer Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Panel/Printer Link in Panelbus Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
DB Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
PC Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Essential Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Panel/Printer Link in MultiVendor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
PC Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
DB Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Essential Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Control of the AF 100 Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Addressing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Communication between Advant Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
DB Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
PC Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Essential Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Example: AF 100 Communication between AC 80s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Control of the Special I/O Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
DB Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
PC Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Essential Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Example: DSU (Diode Supply Unit) on the Special I/O Link . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Control of the Fieldbus Adapter Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Chapter 5 – Diagnostics
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Bus Indicator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Purpose LEDs S0 to S7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Checking the System Status Using FCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
PC Element Error Terminals and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Using DriveDebug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

vi AC 80 User’s Manual

AC 80 User’s Manual 1-1
Chapter 1 – Introduction
Overview
The Advant® Controller 80 (AC 80) is a high-performance
programmable logic controller specially designed for drives.
Here are a few basic functions of the AC 80:
• Execution of fast drive control application programs
• Communication with drives
• Communication with other controllers
• Communication with S800 I/O, special I/O and fieldbus adapter units
• Modbus-protocol panel/printer port.
The AdvaBuild for Windows program suite (more specifically, the
Function Chart Builder) can be used for programming, configuring and
diagnosing of the AC 80. Configuring and programming the AC 80
looks and feels the same as other Advant controllers. Compatibility to
the APC2 (Application Program Controller; the previous-generation
controller) is preserved when using function blocks from the APC2
library.
PM825, the processor module of the AC 80, is based on an MC68360
microprocessor running at 25 MHz in 16-bit mode. The system and
user application programs are stored in 1024 KB and 512 KB of FLASH
PROM respectively. 1024 kilobytes (512K*16bit) of RAM is available for
the execution of the system and user application programs.
The AC 80 may be used either independently (stand-alone) or as part
of an AF 100 (Advant Fieldbus 100) network. The user interfaces of the
AC 80 are Drive
Window, Modbus-protocol panels and printers, and the
Man-Machine Interface via AF 100.
What This Manual
Contains
Chapter 2 contains a description of the AC 80 hardware and
connections, including terminal designations and bus topology
diagrams.
Chapter 3 is a summary of the software relating to the AC 80. It deals
with the programs residing in the AC 80 as well as supporting PC
software.
Chapter 4 explains how the connections of the AC 80 are set up in the
AC 80 application program. This chapter is mainly intended for persons
responsible for the application program of the AC 80. The reader is
expected to have a knowledge of AdvaBuild/Function Chart Builder
programming.
Chapter 5 gives information on diagnosing the AC 80 using its LEDs
and the supporting PC software.

Chapter 1 – Introduction
1-2 AC 80 User’s Manual
AC 80 Connections
Figure 1-1 AC 80 Connections.
Service Link (RS 232C)
Panel/Printer Link (Modbus/RS-485)
I/O Clusters (S800 I/O Devices)
Optical ModuleBus
Inverter
Inverter Inverter Inverter Inverter Inverter

Supply

Supply
NDBU
NDBU
NAMC
Motor
Control
NDBU
NDBU
NAMC
Motor
Control
NAMC
Motor
Control
DriveBus
Advant Fieldbus 100
Drives,
Supply Units
Electrical ModuleBus S800 I/O Devices
AC110 Series
Controller
Fieldbus Link
Special I/O Link
Tools Link
Special I/O Devices,
DSU Supply Units
Fieldbus Adapter
(e.g. PROFIBUS)
NMBC
NMBC
AC400 Series
Controller
PC Tools (e.g. Drive
Deb
u
NAPI
NAPI

Chapter 1 – Introduction
AC 80 User’s Manual 1-3
Terms, Abbreviations
and Definitions
AdvaBuild (for Windows)
A package of programming tools.
Advant Fieldbus 100 (AF 100)
A twisted pair fieldbus that provides communication between Advant
Controllers, I/O stations and higher-level computer systems.
APC2
Application Program Controller; previous-generation drive-specific
control system.
Control Panel
A separate device which can be used for diagnostics and control, e.g.
CDP 80, AOS.
DDCS
Distributed Drives Communication System; a communication protocol
used in fibre optic links in ABB drives.
Drive
A single NAMC-based inverter, or several inverters each containing an
NAMC board, connected to one line-up.
DSU
Diode Supply Unit; one of ACS 600 supply unit types.
FCB
Function Chart Builder; part of AdvaBuild; a PC tool for writing
application programs.
FCI
Fieldbus Communication Interface; contains an interface to the AF 100
fieldbus, a ModuleBus interface, and power regulators. The FCI uses
S800 I/O devices. For further information on FCI units, refer to the
S800 I/O User’s Guide .
Fieldbus Adapter
A device that allows communication with another fieldbus system, e.g.
PROFIBUS DP, InterBus-S.
GOP
Graphic Operator Panel; a type of control panel used especially in Pulp
& Paper applications.
I/O
Input/output.
I/O Cluster
An extension of the ModuleBus optical link of an AC 80. Consists of a
ModuleBus modem with I/O devices.
I/O Device
A complete I/O device consists of one MTU and one I/O module.
I/O Module
The active, electronic, and signal conditioning part of an I/O device.

Chapter 1 – Introduction
1-4 AC 80 User’s Manual
I/O Station
An I/O station consists of an AC 80 (or an FCI), 1 to 7 I/O clusters and
up to 24 I/O devices.
ISU
Inverter Supply Unit; one of ACS 600 supply unit types.
ModuleBus
An incremental, electrical or optical bus for interconnection of I/O
devices.
MTU
Module Termination Unit; a passive unit onto which an I/O module is
mounted. The MTU contains the process I/O terminals and part of
Electrical ModuleBus.
OSP
Outputs Set as Predetermined; a user-configurable action on an output
module when communication is lost to the AC 80.
S800 I/O
Type of a distributed modular I/O unit which communicateswith Advant
controllers over an AF100 bus or directly with AC 80.
Special I/O
An interface for special I/O, such as the NBIO-31 I/O unit, the NPCT-01
Pulse Counter Board, or DSU connections.
Tools
PC software (such as Drive Window and FCB) used for monitoring and
controlling drives, or designing drive application programs.
TSU
Thyristor Supply Unit; one of ACS 600 supply unit types.
Related Publications
AC 80 PC Elements Reference Manual (3BFE 64021737, English)
Advant Fieldbus 100 User’s Guide (3BSE 000 506, English)
Firmware Manual for ACS 600 System Application Program
(3AFY 63700177, English)
Firmware Manual for ACS 600 Standard Application Program
(3AFY 61201441, English)
Function Blocks for APC2 (3AFY 61281240, English)
S800 I/O User’s Guide (3BSE 008 878, English)
Use of PROFIBUS-DP Protocol in Advant Controller 80
(3BFE 64248260, English).

AC 80 User’s Manual 2-1
Chapter 2 – AC 80 Hardware and Connections
AC 80 Hardware
The AC 80 is built in a ventilated plastic housing. It can be mounted
onto a horizontal or vertical DIN 50022 rail. The module can be
removed by pulling the locking spring (at the bottom of the unit)
downwards e.g. with a screwdriver.
Figure 2-1 The AC 80.
1
2
34567
8
9
0
1
2
34567
8
9
0
Ch2
Ch1
SERVICE
L+ L+ SA
L– L– SB AF10012
Tx
Rx
x10
x1
STN. ADDR.
INIT
F
B
T1
S7
S6
S5
S4
R
P
T2
S3
S2
S1
S0
Tx Rx
PC
Dbus
I/O
FBA

Chapter 2 – AC 80 Hardware and Connections
2-2 AC 80 User’s Manual
Circuit Board Layout
Figure 2-2 The circuit boards of the AC 80.
Block Diagram
Figure 2-3 AC 80 block diagram.
1 – CPU board PM820-2
2 – NCB board PM825-1
3 – Power supply PM820-1
4 – Terminal board TC820-1
1
2
3
4
68360
MAIN
PROCESSOR
(68360)
FLASH (SYS)
(256k x 32 bit)
RAM
(512k x 16 bit)
FLASH (USER)
(256k x 16 bit)
WATCHDOG
REAL TIME
CLK/CALEND.
BUS
BUFFERS
COMM.
COMM.
CONTROLLER
(BAP)
CONTROLLER
(DDCC+)
CH1
CH2
AF100
MODEM
RS-485
X
10
AF100
MODEM
RS-485
RS-232
RS-232
DP RAM
(16k x 16 bit)
RAM
(128k x24bit)
BOOT PROM
(32k x 8 bit)
FLASH
(512k x 8 bit)
I/O PROCESSOR
(DSP 56002)
COMM.
CONTROLLER
(ICMC 2A)
CH3
CH2
CH1
CH0
PM820-2 CPU board
PM820-1 Terminal b.
PM825-1 NCB
TB810 or TB811
SERVICE
PANEL/PRINTER (MODBUS) (MMI)
AF100 (1)
AF100 (2)
MODULEBUS (ELECTRICAL)
MODULEBUS (OPTICAL)
DDCS (PC)
DDCS (FIELDBUS ADAPTER)
DDCS (SPECIAL I/O)
DDCSe (DRIVEBUS)

Chapter 2 – AC 80 Hardware and Connections
AC 80 User’s Manual 2-3
LEDs The LEDs on the AC 80 can be divided into three groups, i.e. bus
indicator LEDs, general purpose LEDs, and special purpose LEDs.
(Further information on the LEDs is given in Chapter 5 – Diagnostics).
Figure 2-4 LEDs of the AC 80.
Bus Indicator LEDs
These LEDs show the status of the fibre optic channels. The LEDs are
laid out in the same order as the optic terminals on the AC 80.
Note that the Rx LEDs light when data is received from the fibre optic
link. The Tx LEDs are controlled by the AC 80 itself.
Special Purpose LEDs F– Fault (red): This LED switches automatically on after the power-up
ofthe AC 80. The system application program also lights thisLED if the
self test fails. In case of a serious hardware or program error, this LED
lights. Simultaneously, the general purpose LEDs indicate an error
code.
Note: The error codes are given in Chapter 5 – Diagnostics.
R– Run (green): This LED is lit when the system application starts to
run. It turns off upon serious hardware or program errors.
P– Power (green): This LED indicates that the power supply to the
AC 80 is good. The P LED is independent of system program status.
B– Battery (green): This LED indicates that the voltage level of the
battery is sufficient for backing up the internal real time clock and
buffered read/write memory. If no battery is inserted, or it is low, the B
LED is turned off.
T1, T2 (yellow): These LEDs indicate data being received on the
AF 100 channels 1 and 2 respectively. If the AC 80 is not connected to
AF 100, these LEDs are off. If the AC 80 is connected to the AF 100
with only one cable, one of the LEDs should be on, the other LED off.
B
FR
S3
S2
S1
S5
S6
S7
S0
S4
T2T1
P
Dbus
PC
FBA
I/O
Tx Rx
Bus Indicator
LEDs
Special
Purpose LEDs
General
Purpose LEDs

Chapter 2 – AC 80 Hardware and Connections
2-4 AC 80 User’s Manual
General Purpose LEDs When the S7 LED is on, and the FLED is off, S0 to S6 indicate the
AC 80 status as follows:
The normal operation state (P1) is indicated as shown below:
When the S7 LED is off, and the FLED is on, S0 to S6 indicate an
error code. See
Chapter 5 – Diagnostics for details.
S7 S6 S5 S4 S3 S2 S1 S0 AC 80 Status
on P- CPU in initial phase
on on P1 CPU in operational mode
on on on P3 CPU has stopped after initialisation. START MODE attribute at
DB element has been set to STOP
on on P4 CPU is not running an application program
on on on P5 CPU is loading an application program from the internal PROM
on on on P6 Programming tool is connected (CPU is in on-line mode)
on on on on -- Boot-up program erasing system PROM (prepare for loading)
on on on on on on on on PL Boot-up program waiting for system program download (after
erasure or detection of corrupt program in system PROM)
B
FR
S3
S2
S1
S5
S6
S7
S0
S4
T2T1
P

Chapter 2 – AC 80 Hardware and Connections
AC 80 User’s Manual 2-5
Station Address
Selection
The AC 80 is equipped with two address selection switches. They are
used for defining an exclusive station address for the AC 80 on the
AF 100 bus. The address must be in the range of 1 to 79; setting the
address outside this range renders the AC 80 unaccessible via AF 100.
Note: The address selected with the hardware switches must match
the station number setting in the application program (STNNO in
PM825 element, AF 100 part).
The INIT Button Pressing the INIT button performs a “cold start”, i.e. the AC 80
performs self tests, checks the user memory for a valid application and
activates it, runs a complete initialisation and I/O module configuration.

Chapter 2 – AC 80 Hardware and Connections
2-6 AC 80 User’s Manual
AC 80 Connections
*Colour codes: Grey: Transmitter, Blue: Receiver.
Name Terminal
(see above) For connection of Cable Data Remark
Power
Supply L+ L+ SA L– L– SB Power Supply 0.2 to 2.5 mm2+24 V d.c.
(19.2 to 30 V) Redundancy available
AF 100 AF100 1
AF100 2 AF 100 (Advant Fieldbus 100) Screenedtwisted pair Max. length 750 m Max. no. of nodes 32 Redundancy available
Service Ch1
(Terminal
Board X4)
PC (Configuration
and Maintenance) RS-232 RS-232 signal levels Max. comm. 20 kbit/s D-sub 9-pole
Panel/Printer Ch2
(Terminal
Board X5)
CDP 80 Ctrl. Panel
Alarm printer
GOP Panel
RS-485 Protocol: Modbus
RS-485 signal levels
Max. comm. TBD
D-sub
15-pole
Battery Battery – Lithium 3.6 V 900 mAh 14.5 × 25 mm
Tool*
(NCB CH3) PC tools (Drive
Debug )Fibre optic Protocol: DDCS 10 MBd optical components
DriveBus*
(NCB CH0) ABB drives Branching units Fibre optic Protocol: DDCS, DDCSe 10 MBd optical components
Special I/O*
(NCB CH1) NBIO-21, NBIO-31, NPCT-01, DSU Fibre optic Protocol: DDCS 5 MBd optical components
Fieldbus
Adapter* (NCB CH2) Fieldbus Adapters, e.g. NPBA-80 Fibre optic Protocol: DDCS 5 MBd optical components
Optical
ModuleBus
(optional)*
TB820 Modems
ABB drives Fibre optic Protocol: DDCS Max. 12 I/O units in
max. 7 clusters
Requires
TB810/811
Optical Port
Electrical
ModuleBus S800 I/O units C/4 Plug-in Max. 12 I/O units 24 V supply 1.0 A
5 V supply 2 A
1
2
34567
8
9
0
1
2
34567
8
9
0
L+ L+ SA
L– L– SB
Ch1
Ch2
SERVICE
AF100 21
Tx
Rx
+
–
SH
SH
+
–
SH
SH
Tx
Rx
3
4
5
6
2
7
1
1
2
3
4
5
6
7