Introduction to ABB AC 800F controller

The Features of the AC 800F controller

❖ The AC 800F controller has a modular structure.

❖ The CPU is 32-bit super scalar RISC processor.

❖ It consists of RAM16 MB (SD-RAM).

❖ This controller supports around 1000 I/O.

❖ The CPU is designed as a backplane to which power supply, Ethernet, and Fieldbus modules can be connected in line.

❖ Fieldbus and device configuration can be performed offline without connection to the field devices.

❖ The controller has built-in Fieldbus capability.

❖ It has 4 high-speed Fieldbus modules.

❖ The ring topology is used to increase the availability of the control network

❖ The installation is easy for wall mounting or using DIN rail.

❖ Uses Ethernet communication to connect with other controllers.

❖ It is a compact and rugged design.

❖ Task execution time is 5 ms for cyclic.

❖ Serial Communication RS485/422/232.

❖ Ambient temperature 0°C to 60°C.

❖ It covers all major Fieldbuses used in process automation with a set of Fieldbus modules.

❖ These controllers can work in redundant or non-redundant topology.

Introduction to ABB AC700F controller

The AC 800F controller consists of

  1. The base unit.
  2. The power supply module.
  3. Ethernet module.
  4. Fieldbus modules.

What are the available modules for the ABB 800F?

The modules are shown below.

1. Power supply modules

❖ SA 801F: provides AC input voltages from 115 … 230 V AC

❖ SD 802F: provides redundant 24 V DC voltage.

2. Ethernet modules

❖ EI 801F: 10Base2 module for thin coaxial cable.

❖ EI 803F: 10/100BaseTP module for shielded twisted pair cables.

❖ EI 802F:for connecting transceivers for 10Base5, 10Base2, 10BaseFL or star coupler units.

3. Fieldbus modules

❖ FI 830F: for direct operation of field devices.

❖ FI 820F: Serial module, continuously being expanded.

❖ FI 810F: CAN module, 3 channels, and protocols available.

4. The battery module

❖ AM 801F: Battery module for redundant battery backup.

PM 803F the base unit AC 800F controller

Features of PM 803F controllers

❖ It has super scalar RISC microprocessor up to 150 MIPS.

❖ It has an internal CPU of 16K.

❖ The base unit PM 803F is a 16 MB battery buffered.

❖ It has 2 slots of the 32-bit data bus for Ethernet communications with a speed of 10 Mb/s.

❖ The OS needs to be loaded during software installation.

❖ The PM 803F scans signal from the fieldbus lines via the corresponding fieldbus modules cyclically.

❖ These signals are processed accordingly by the application programs installed by the user and send appropriate signals to the Fieldbus actuators via the Fieldbus modules.

❖ The controller redundancy is achieved by using two AC 800F controllers.

❖ The smooth and quick takeover is done in milliseconds by secondary controllers in case of a failure of the primary.

❖ The control network enables the data communication between controllers, engineering, and operator stations.

❖ Downloading the new or updated configuration files to the controller is done by the engineering station.

❖ Processing time is different for different instructions.

❖ 1000 binary instructions are 0.78 ms

❖ 1000 word instructions are 0.78 ms.

❖ 1000 floating-point instructions are 1.09 ms.

The power supply modules of AC800F

❖ The SA 811F and SD 812F are two power supply modules for AC 800F controllers.

❖ Both modules supply 5 VDC / 5.5 A and 3.3 VDC / 6.5 A to the AC 800F.

❖ The output is electrically isolated has a self-adjusting input voltage 115 - 230 V AC.

❖ The power supply modules are of open circuit type. The controlled output voltage provides high stability and low residual ripple.

❖ When the power fails this module generates a power-fail signal and is used by the CPU module to shut down operations to enter the safe state.

❖ It has a 20 ms backup energy power failure.

❖ It has five LED status indications for Run stop status.

Green Active State
Flashing Green Process is now started.
Red Inactive
Flashing Red Process is now stopped
Orange Self-test.

Redundancy in AC 800F

The controller redundancy:

❖ This can be achieved by installing two AC 800F controllers.

❖ The secondary controller controls the process in case the primary controller gets turned off ensuring quick and smooth operation.

❖ The dedicated redundancy communications links through the second Ethernet module.

❖ Both AC 800F controllers must be always synchronized using the second Ethernet communication links.

❖ The I/O’s are designed to support redundant operation.

Profibus line redundancy

❖ The non-redundant Profibus line is converted into two reciprocal redundant lines using Redundancy Link Module (RLM 01)

❖ The Redundancy Link Module can be positioned directly after the Profibus master prior to the bus segment having several slaves or prior to individual slaves.

❖ The Redundancy Link Module enables the direct connection of Profibus stations to set redundant.

❖ The Profibus station that has one interface can be assigned to the other line.

❖ The Fibre Optic Ring replaces the Profibus line redundancy.

FOUNDATION Fieldbus redundancy

❖ The FOUNDATION Fieldbus redundancy can be achieved by installing two LD 800HSE controllers both devices are linked via a redundancy cable (COM).

❖ The secondary controller LD 800HSE controls the process in case the primary controller LD 800HSE gets turned off ensuring quick and smooth operation.

Controller redundancy with Profibus line redundancy.

The advantages of controller redundancy and Profibus line redundancy by using two AC 800F controllers with one Redundancy Link Module makes to achieve the highest availability.

What are the different types of communication modules used in AC800F?

The different types of communication modules used in AC800F are.

1. Ethernet modules in AC 800F

❖ The EI 813F is the Ethernet module used in AC 800F.

❖ It is the EEE802.3 Ethernet standard.

❖ It has a 32-bit data bus.

❖ It has a transmission rate of 10 Mbit/s.

❖ The Ethernet module develops the communication between Controllers, operator stations, and engineering stations.

2. Fieldbus modules in AC 800F

❖ The FI 810F is the Fieldbus module used in AC 800F.

❖ This module collects and processes real-time data.

❖ This module provides connectivity to the freelance rack with 5 I/O.

❖ The transmission speed is 1Mb/s

❖ A total of four field bus modules can be mounted.

❖ This module provides electrical isolation between process and controller.

❖ It has independent fault detection and signaling.

❖ The field bus provides the status LED lamps for all four modules.

❖ There are two communication profiles in Fieldbus.

❖ In Fieldbus, the LD 800HSE serves as a gateway between the field devices on the H1 link and the HSE subnet.

❖ The LD 800HSE also supports redundancy.

What are the Fieldbus communication profiles?

There are two Fieldbus communication profiles that are

A. H1 profile has a transmission rate of 31.25 Kbit/s and is used for direct communication between field devices in one link.

B. HSE profile based on standard Ethernet with a transmission rate of 100 Mbit/s the HSE profile serves as a backbone for the connection between H1 links.

3. Profibus module in AC 800F

❖ The FI 830F is the Profibus module used in AC 800F.

❖ The transmission rate of the Profibus module is 12 Mb/s

❖ It acts as a master in the Profibus line and supports up to 126 slaves.

❖ The AC 800F provides high-speed communication to both PROFIBUS DP and FOUNDATION Fieldbus (FF-HSE).

❖ But intelligent linking devices are used to connect the slower buses FF-H1 and PROFIBUS PA

❖ This communication device allows several slow buses to connect to one fast bus.

❖ The more field devices are connected to an AC800F. Instead of directly connecting the slow field bus.

❖ The PROFIBUS DP and the PROFIBUS PA are connected to each other through the PROFIBUS Power hub in combination with field barriers and segment protectors to establish the link between control systems and field devices in an intrinsically safe area.

❖ The field barriers and segment protectors can be connected to the non-intrinsically safe outputs of PROFIBUS Power Hub.

System Communication in AC800F

To establish a control network connection between controllers and operator stations and engineering station with a speed of 10 Mb/s

Twisted Pair Max length: 400m
Optical Fibre Cable Max length: 4500m.
Thin Ethernet Max length: 185m.
Full Ethernet:(Yellow Cable) Max length: 500m.

What is Freelance?

❖ Freelance is the engineering tool used to configure and commission the whole system including the controllers, the Fieldbus line, and the connected field device.

❖ It is a simple software that runs on Microsoft windows.

❖ Freelance provides both, operator level and process level control.

❖ The operator level consists of the functions for operation, process monitoring, archives and logs, trends, and alarms.

❖ The open- and closed-loop control functions are processed in the controllers which communicate with actuators and sensors in the field.

❖ The configuration in both the office and process site can be controlled using a portable device such as a laptop

❖ The operator station can also be used for system engineering configuration.

❖ It is not necessary to have a permanent connection to the engineering station.

❖ The Freelance Operations supports the dual-monitor operation.

❖ It allows continuing watching the essential information like the alarm list while inspecting sequential function charts, and trend archives. The process plant consists of several Freelance Operator workplaces that work seamlessly together.

The engineering and operator station requirements

  1. PC with MS-Windows 7, 8, or 10.
  2. Monitor size 21” or more.
  3. The ABB Freelance and the
  4. SCADA packageDigiVis.
  5. Operator level.