ABB S800 I/O User manual

S800 I/O
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User’s Guide
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The information in this document is subject to change without notice and should not be construed as a commitment by
ABB Automation Products AB. ABB Automation Products AB assumes no responsibility for any errors that may appear
in this document.
In no event shall ABB Automation Products AB be liable for direct, indirect, special, incidental, or consequential damages
of any nature or kind arising from the use of this document, nor shall ABB Automation Products AB be liable for
incidental or consequential damages arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation Products AB’s written
permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.
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This product meets the requirements specified in EMC Directive 89/336/EEC and in Low Voltage Directive 73/23/EEC.
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ABB Master, MasterFieldbus, and MasterBus are registered trademarks of ABB Asea Brown Boveri Ltd., Switzerland
Advant is a registered trademark of ABB Asea Brown Boveri Ltd., Switzerland.
Advant Controller is a trademark of ABB Asea Brown Boveri Ltd., Switzerland
PROFIBUS and PROFIBUS-DP are registered trademarks of Profibus International (P.I.).
HART is a registered trademark of HART Communication Foundation.
Copyright © ABB Automation Products AB 2000.

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1.1 About This Book....................................................................................................2
1.2 Product Overview...................................................................................................3
1.2.1 Product Scope........................................................................................7
1.2.1.1 CI810 Fieldbus Communication Interface .....................9
1.2.1.2 CI820 Fieldbus Communication Interface ...................10
1.2.1.3 CI830 Fieldbus Communication Interface ...................10
1.2.1.4 TB815 Interconnection Unit.........................................10
1.2.1.5 TB810/TB811 ModuleBus Optical Port.......................10
1.2.1.6 TB820 ModuleBus Modem..........................................11
1.2.1.7 Module Termination Units ...........................................13
1.2.1.8 I/O Modules..................................................................14
1.2.1.9 Power Supply................................................................15
1.2.1.10 Example of Enclosure Configurations..........................17
1.2.1.11 Support for External Intrinsic Safety System...............18
1.2.1.12 Support for HART........................................................19
1.3 Related Documentation........................................................................................20
1.4 Terminology .........................................................................................................21
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2.1 Site Planning ........................................................................................................23
2.1.1 Site Selection and Preparation ............................................................23
2.1.2 Environmental Considerations............................................................24
2.1.3 Electromagnetic Compatibility and CE Marking................................25
2.1.4 Layout of I/O Stations.........................................................................26
2.1.4.1 I/O Station with S800 I/O.............................................26
2.1.5 Grounding ...........................................................................................39
2.1.6 Signal Cable Considerations ...............................................................41
2.1.6.1 Recommendations for Signal and Process Cable.........42
2.1.7 Power Requirements ...........................................................................44
2.1.8 Hazardous Applications ......................................................................45

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2.1.9 High Voltage Switch-gear Applications..............................................45
2.1.10 Lightning Strike Protection.................................................................45
2.1.11 Mounting Dimensions.........................................................................45
2.2 Installation Procedures.........................................................................................48
2.2.1 Safety Regulations..............................................................................48
2.2.1.1 Personnel Safety...........................................................48
2.2.1.2 Equipment Safety.........................................................49
2.2.2 Grounding in enclosures.....................................................................49
2.2.3 Cable Routing in Enclosures...............................................................51
2.2.4 Power Connection...............................................................................52
2.2.5 I/O Station with S800 I/O ...................................................................53
2.2.6 Checklists............................................................................................56
2.2.6.1 Grounding Philosophy, Ground Plane System ............56
2.2.6.2 Process Cabling, Shielding, Grounding, Max. Length.56
2.2.6.3 Power Supply ...............................................................57
2.2.6.4 Lightning Protection.....................................................58
2.2.6.5 MTU, I/O Module........................................................58
2.2.6.6 Cabinet, Internal Cables...............................................59
2.2.6.7 Environmental Data .....................................................60
2.2.6.8 Airborne Contaminants................................................60
2.2.6.9 Miscellaneous...............................................................61
2.2.6.10 External Cables ............................................................61
2.2.7 Final Procedure Before Start-up .........................................................61
2.3 Start-up and Shut-down Procedures.....................................................................62
2.3.1 Start-up Procedures.............................................................................62
2.3.1.1 Safety Regulations .......................................................62
2.3.1.2 Controller and I/O ........................................................62
2.3.2 Shut-down Procedures........................................................................63
2.3.2.1 Safety Regulations .......................................................63
2.3.2.2 I/O Station ....................................................................63

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2.4 Product Verification .............................................................................................65
2.4.1 General................................................................................................65
2.4.1.1 Check of Process Input/Output Systems ......................65
2.4.2 Final Check .........................................................................................69
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3.1 Before You Start...................................................................................................71
3.1.1 Design Considerations ........................................................................71
3.1.1.1 I/O Station Layout Hardware Configuration Guidelines71
3.1.1.2 CI810/CI820/CI830 FCI...............................................76
3.1.1.3 TB820 ModuleBus Modem..........................................77
3.1.2 SD811 and SD812 Power Supply Configurations ..............................83
3.1.3 Power Supply Load Calculation..........................................................86
3.1.4 Heat Dissipation..................................................................................87
3.1.4.1 Cabinet Ventilation .......................................................87
3.1.4.2 Heat Dissipation Permitted in Cabinets........................87
3.1.4.3 Calculation of Heat Generated in a Cabinet.................87
3.1.5 Maintenance and Repair......................................................................88
3.1.6 Expansion Considerations...................................................................88
3.1.7 Power Supply Requirements...............................................................89
3.1.8 Power and Cooling..............................................................................90
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4.1 Operating Overview.............................................................................................93
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5.1 Preventive Maintenance.......................................................................................95
5.2 Hardware Indicators.............................................................................................95
5.2.1 Color....................................................................................................96
5.2.2 Location...............................................................................................96
5.2.3 Identification .......................................................................................97
5.3 Error Messages.....................................................................................................97

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5.4 Fault Finding and User Repair.............................................................................97
5.4.1 Introduction.........................................................................................97
5.4.2 Diagnostics and Fault Indications.......................................................98
5.4.3 List of General Fault Finding Procedures and Hints ..........................98
5.4.3.1 Location of Malfunction ..............................................98
5.4.3.2 External Factors ...........................................................98
5.4.3.3 Safety at Start/Stop.......................................................99
5.4.3.4 Check of Power Supply................................................99
5.4.4 User Repair .......................................................................................100
5.4.4.1 I/O Module Replacement...........................................100
5.4.4.2 Power Supply Module Replacement..........................100
5.4.4.3 Communication Module Replacement.......................102
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A.1 SD811/SD812 Power Supply Module, 24V d.c.................................................105
A.2 TB805/TB806 ModuleBus Cable Adapter-Out/In............................................. 111
A.3 TB807 ModuleBus Terminator..........................................................................114
A.4 TB810/TB811 ModuleBus Optical Port ............................................................117
A.5 TB820 ModuleBus Modem ...............................................................................121
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B.1 Power Up on S800 I/O.......................................................................................127
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Figure 1-1. S800 I/O Fieldbus Communication Interface with an I/O Module on
Compact and Extended MTUs ...................................................................1
Figure 1-2. Typical I/O Station Base Cluster with S800 I/O.........................................9
Figure 1-3. Typical I/O Station Base Cluster with Redundant FCIs to S800 I/O .........9
Figure 1-4. TB810/TB811 Optical ModuleBus Port installed in CI810 FCI..............11
Figure 1-5. TB820 ModuleBus Modem......................................................................12
Figure 1-6. TB820 ModuleBus Modem Dimensions..................................................13

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Figure 1-7. Installation Using Single Power Supply Unit...........................................15
Figure 1-8. Installation Using Redundant Power Supply Units ..................................16
Figure 1-9. RE810 Cabinet with 12 I/O Modules and Redundant Station
Power Supplies .........................................................................................17
Figure 1-10. Example of Connection between S800 I/O and Intrinsic Safety System
from ELCON ............................................................................................18
Figure 1-11. Example of Connection between S800 I/O and Intrinsic Safety System
from ELCON and HART Multiplexer Interface from HART ..................19
Figure 2-1. MTU Latching System..............................................................................27
Figure 2-2. I/O Station Installation Diagram...............................................................28
Figure 2-3. ModuleBus Release ..................................................................................29
Figure 2-4. Redundant CI820 FCIs and TB815 Interconnection Unit Layout............30
Figure 2-5. Connection of Redundant FCIs to I/O Modules.......................................31
Figure 2-6. ModuleBus Extension Cable Connections ...............................................32
Figure 2-7. Location of TB810/TB811 ModuleBus Optical Port in CI810 FCI .........33
Figure 2-8. Location of TB810/TB811 ModuleBus Optical Port on the TB815.........34
Figure 2-9. Optical ModuleBus Expansion, Simplex and Duplex Configurations.....35
Figure 2-10. MTU Mechanical Keys for I/O Module and Module Lock......................36
Figure 2-11. TB807 ModuleBus Terminator Installation..............................................37
Figure 2-12. I/O Station Layout with FCI and S800 I/O Modules................................37
Figure 2-13. I/O Station Layout with ModuleBus Modem and S800 I/O Modules......38
Figure 2-14. Compact and Extended MTU and Horizontal and Vertical Mounting .....38
Figure 2-15. Grounding of Electronic Equipment.........................................................40
Figure 2-16. Recommended Field Cable Wiring Distances ..........................................43
Figure 2-17. Minimum Distance to Cabinets ................................................................46
Figure 2-18. Minimum Distance from Rear and Side of Cabinet to a Wall..................46
Figure 2-19. Enclosure with 12 Modules and Redundant Station Power Supplies.......47
Figure 2-20. Power Supply Connection and Distribution .............................................52
Figure 2-21. Block Diagram of S800 I/O Input Channel, Test Points...........................66
Figure 2-22. Block Diagram of S800 I/O Output Channel, Test Points........................68
Figure 3-1. Maximum Layout of I/O Cluster with Compact MTUs ...........................72

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Figure 3-2. Maximum Layout of I/O Cluster with Extended MTUs ..........................73
Figure 3-3. I/O Cluster in Small Groups.....................................................................74
Figure 3-4. I/O Station with Redundant CI820 FCIs ..................................................75
Figure 3-5. Optical ModuleBus Extension..................................................................76
Figure 3-6. Front Panel of the TB820 ModuleBus Modem ........................................77
Figure 3-7. TB820 Optical ModuleBus Connections..................................................79
Figure 3-8. Typical Optical ModuleBus Designs........................................................80
Figure 3-9. TB820 Power Supply Connections ..........................................................81
Figure 3-10. SD811 and SD812 Power Supply Connections........................................83
Figure 3-11. SD811 or SD812 Wiring Diagram for Parallel Operation........................84
Figure 3-12. SD811 or SD812 Wiring Diagram for Redundant Mains.........................84
Figure 3-13. Connection Diagrams for Redundant Power Supplies to
Redundant FCIs........................................................................................85
Figure 2-1. Power-up Timing Diagram, No Configuration and
No Communications to Controller .........................................................131
Figure 2-2. Power-up Timing Diagram, No Configuration and
Communications to Controller ...............................................................132
Figure 2-3. Power-up Timing Diagram, With Configuration and
No Communications to Controller .........................................................133
Figure 2-4. Power-up Timing Diagram, With Configuration and
Communications to Controller ...............................................................134
Figure 2-5. Power-up Timing Diagram, Power-up of Backup in a Running System135
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Table 1-1. I/O Station with S800 I/O Components......................................................4
Table 1-2. Related documents....................................................................................20
Table 2-1. Requirements for d.c. Supply Sources .....................................................44
Table 2-2. Cable Categories in a Cabinet ..................................................................51
Table 2-3. Grounding Philosophy, Grounding System..............................................56
Table 2-4. Process Cabling, Shielding, Grounding, Max. Length.............................56
Table 2-5. Supply.......................................................................................................57

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Table 2-6. Lightning Protection .................................................................................58
Table 2-7. MTU, I/O Module.....................................................................................58
Table 2-8. Cabinets, Internal Cables..........................................................................59
Table 2-9. Immunity Requirements ...........................................................................60
Table 2-10. Miscellaneous ...........................................................................................61
Table 3-1. TB820 Power Connection Terminal X1A.................................................82
Table 3-2. TB820 Power Connection Terminal X1B.................................................82
Table 3-3. Estimated System Power Consumption....................................................89
Table 3-4. I/O Station Power and Cooling (Typical) .................................................90
Table 5-1. Meaning and Colors of LED’s..................................................................96
Table 5-2. Replacement Aspects of S800 I/O Modules...........................................103
Table A-1. SD811/SD812 Power Supply Module Specifications.............................106
Table A-2. SD811/SD812 Primary Power Connections ...........................................108
Table A-3. SD811/SD812 Output Power Connections.............................................108
Table A-4. TB805/TB806 ModuleBus Cable Adaptor Specifications .....................112
Table A-5. TB807 ModuleBus Terminator Specifications .......................................115
Table A-6. TB810 ModuleBus Optical Port Specifications.....................................118
Table A-7. Optical ModuleBus Connections (X2) ...................................................119
Table A-8. TB820 ModuleBus Modem Specifications.............................................122
Table A-9. Power Supply Connections.....................................................................124
Table A-10. Optical ModuleBus Connections (X4, X5).............................................124

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