ABB AC 900F Mounting And Installation Instructions Manual

Process Automation

Power and productivity

for a better world

TM

Freelance 2016

Mounting and Installation Instructions

AC 900F Controller

Freelance 2016

Mounting and Installation Instructions

AC 900F Controller

NOTICE

This document contains information about one or more ABB products and may include a

description of or a reference to one or more standards that may be generally relevant to

the ABB products. The presence of any such description of a standard or reference to a

standard is not a representation that all of the ABB products referenced in this document

support all of the features of the described or referenced standard. In order to determine

the specific features supported by a particular ABB product, the reader should consult the

product specifications for the particular ABB product.

ABB may have one or more patents or pending patent applications protecting the intel-

lectual property in the ABB products described in this document.

The information in this document is subject to change without notice and should not be

construed as a commitment by ABB. ABB assumes no responsibility for any errors that

may appear in this document.

In no event shall ABB 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 be

liable for incidental or consequential damages arising from use of any software or hard-

ware described in this document.

This document and parts thereof must not be reproduced or copied without written per-

mission from ABB, and the contents thereof must not be imparted to a third party nor used

for any unauthorized purpose.

The software or hardware described in this document is furnished under a license and

may be used, copied, or disclosed only in accordance with the terms of such license. This

product meets the requirements specified in EMC Directive 2014/30/EU and in Low Volt-

age Directive 2014/35/EU.

TRADEMARKS

All rights to copyrights, registered trademarks, and trademarks reside with their respec-

tive owners.

Release: September 2015

Document number: 2PAA109295R0201

M&I – AC 900F Controller 5

Table of Contents

About this book

Use of warning, caution, information, and tip icons .............................................................. 9

Terminology.......................................................................................................................... 10

Section 1 - Overview

AC 900F Controller ..............................................................................................................11

Features ..................................................................................................................... 13

Communication .................................................................................................................... 14

System ....................................................................................................................... 14

Fieldbus ..................................................................................................................... 15

Section 2 - Configuration

Configuration levels.............................................................................................................. 17

Controller redundancy .......................................................................................................... 19

Section 3 - Modules

PM CPU modules ................................................................................................................. 23

CPU modules PM 902F and PM 901F...................................................................... 24

Features ..................................................................................................................... 24

Interfaces ................................................................................................................... 25

LED display and control elements ............................................................................ 30

Battery ....................................................................................................................... 33

Display unit ............................................................................................................... 33

CI/CM PROFIBUS modules ................................................................................................ 33

CI 930F PROFIBUS-DP Master Interface................................................................ 34

CI 773F PROFIBUS-DP Master Interface................................................................ 37

CM 772F PROFIBUS-DP Master Interface.............................................................. 39

PROFIBUS connector and cables ............................................................................. 41

Table of Contents

6 M&I – AC 900F Controller

CI CAN Bus module .............................................................................................................43

CI 910F CAN Bus interface.......................................................................................43

Connection of Freelance I/O racks ............................................................................46

CP-C switch-mode power supply units and accessories .......................................................49

Switch-mode power supply units CP-C 24/5.0 and CP-C 24/10.0 ............................49

CP-A RU redundancy unit .........................................................................................52

CP-A CM control module.........................................................................................54

CP-C MM messaging module....................................................................................56

Section 4 - Accessories

Controller accessories ...........................................................................................................59

TD 951F display unit .................................................................................................59

TA 951F battery for RAM buffering..........................................................................61

Dummy couplers TA 924F and TA 724F...................................................................63

Diagnostic cables TK 890F and TK 891F .................................................................64

TA525 inscription labels ............................................................................................64

CAN Bus accessories ............................................................................................................66

TP 910F CAN Bus termination plug .........................................................................66

TK 811F CAN cable ..................................................................................................67

TK 831F CAN cable ..................................................................................................68

TB 870F terminal block.............................................................................................69

Section 5 - Mounting

Mounting to the DIN rail.......................................................................................................72

PM 902F CPU module...............................................................................................72

TU terminal blocks ....................................................................................................73

CP-C switch-mode power supply units and CP-C RU redundancy unit....................74

Wall mounting .......................................................................................................................76

PM 902F CPU module...............................................................................................76

TU terminal blocks ....................................................................................................77

Coupler bus slots ...................................................................................................................78

PM housing front...................................................................................................................79

Dimensional drawings...........................................................................................................80

Table of Contents

M&I – AC 900F Controller 7

Dimensional drawings of the PM CPU-module........................................................ 80

Dimensional drawings of the CP-C 24/5.0 and CP-C 24/10.0.................................. 81

Dimensional drawing of the CP-A RU...................................................................... 82

Dimensional drawings of the CP-C MM and CP-A CM .......................................... 82

Section 6 - Wiring

Safety instructions ................................................................................................................ 83

General instructions.............................................................................................................. 83

Controller earthing................................................................................................................ 84

Cable routing ........................................................................................................................ 85

Cable shields......................................................................................................................... 85

Switch cabinet ...................................................................................................................... 86

Minimum distances .............................................................................................................. 86

Reference potential............................................................................................................... 86

Equipotential bonding .......................................................................................................... 87

Power consumption .............................................................................................................. 88

Fuse dimensions ................................................................................................................... 89

Bus termination .................................................................................................................... 90

Serial interfaces of the CPU module......................................................................... 90

Section 7 - Commissioning

Data backup .......................................................................................................................... 95

Insertion of the TA 951F battery ............................................................................... 95

Controller configuration via terminal program .................................................................... 97

Controller configuration via display unit............................................................................ 105

Boot configuration................................................................................................... 105

Section 8 - Service

Module replacement ........................................................................................................... 109

CI communication interfaces .................................................................................. 109

I/O modules............................................................................................................. 110

Replacement of accessories................................................................................................ 110

TD 951F .................................................................................................................. 110

Table of Contents

8 M&I – AC 900F Controller

Battery change .........................................................................................................110

Online functions of the display unit ....................................................................................111

Start menu ................................................................................................................112

Main menu ...............................................................................................................113

Controller menu .......................................................................................................113

Maintenance menu...................................................................................................116

Offline functions of the display unit ...................................................................................119

Update/Restore.........................................................................................................119

Section 9 - Technical Data

Modules and accessories .....................................................................................................124

General technical data..............................................................................................124

PM 902F, PM 901F..................................................................................................125

CI 930F ....................................................................................................................128

CI 773F ....................................................................................................................130

CM 772F ..................................................................................................................132

CI 910F ....................................................................................................................134

Certificates ...............................................................................................................135

TD 951F...................................................................................................................136

TA 951F ...................................................................................................................137

TA 924F ...................................................................................................................138

TA 724F ...................................................................................................................139

Switch-mode power supply units and accessories ..............................................................140

General technical data..............................................................................................140

CP-C 24/5.0 .............................................................................................................141

CP-C 24/10.0 ...........................................................................................................143

CP-C RU ..................................................................................................................145

CP-C MM ................................................................................................................147

CP-A CM .................................................................................................................149

Index

M&I – AC 900F Controller 9

About this book

Use of warning, caution, information, and tip icons

This publication includes Warning, Caution, and Information where appropriate

to point out safety related or other important information. It also includes Tip to

point out useful hints to the reader. The corresponding symbols should be

interpreted as follows:

Although Warning hazards are related to personal injury, and Caution hazards are

associated with equipment or property damage, it should be understood that

operation of damaged equipment could, under certain operational conditions, result

in degraded process performance leading to personal injury or death. Therefore,

comply fully with all Warning and Caution notices.

Electrical warning icon indicates the presence of a hazard which could result in

electrical shock.

Warning icon indicates the presence of a hazard which could result in personal

injury.

Caution icon indicates important information or warning related to the concept

discussed in the text. It might indicate the presence of a hazard which could

result in corruption of software or damage to equipment/property.

Information icon alerts the reader to pertinent facts and conditions.

Tip icon indicates advice on, for example, how to design your project or how to

use a certain function

Terminology About this book

10 M&I – AC 900F Controller

Terminology

The Glossary contains terms and abbreviations that are unique to ABB or have a

usage or definition that is different from standard industry usage. Please make

yourself familiar to that.

You will find the glossary at the end of the Engineering Manual System

Configuration.

M&I – AC 900F Controller 11

Section 1 Overview

AC 900F Controller

The PM 902F or PM 901F CPU module is the core component of an AC 900F

controller. As there are only minor differences in appearance between both CPU

module types, the drawings and photos of the PM 902F included in the present

document also apply to the PM 901F.

The term “controller” used in this manual is equivalent to the term “process station”

in Freelance Engineering or to the precise type designation “AC 900F”.

AC 900F_ Controller.png

Unless a description refers to special features and functions of a specific module

type variant, the general type designations PM, CI, TA, TU etc. are used throughout

this document.

Depending on the application and requirements, the controller can be

complemented by additional modules. These modules are fieldbus communication

interfaces and I/O modules.

AC 900F Controller Section 1 Overview

12 M&I – AC 900F Controller

The AC 900F comprises the following components:

• PM CPU module with

– PM 902F: four Ethernet interfaces

– PM 901F: three Ethernet interfaces

– one diagnostic interface

– two serial interfaces

– one TD display unit (optional)

• up to ten S700 I/O modules with I/O terminal blocks

• max. two CI/CM fieldbus communication interfaces

The controller can be used in single or redundant configuration. It supports remote

I/Os, transmitters, actuators, drives, and other devices using PROFIBUS and other

fieldbus protocols. ABB offers a wide range of different devices and

network components for applications in standard and hazardous areas.

In the present version, the AC 900F controller supports the following fieldbus

technologies:

• PROFIBUS-DP V0/V1

• Modbus RTU (serial) and Modbus TCP

• Telecontrol protocol (serial) and Telecontrol TCP

• ABB CAN Bus protocol

Depending on type and number of process signals, input/output modules are used

either as “direct” I/O or as remote I/O. For more detailed information on assembly

and installation of I/O modules, please refer to Mounting and Installation

Instructions, I/O Modules for AC 700F / AC 900F.

Similar to the AC 700F and AC 800F, the hardware configuration of the AC 900F is

based on the hardware function block principle.

The AC 900F controller is designed for the combination with fieldbus-compliant

components like remote I/O, field devices and network components. ABB offers

equipment for applications in standard and hazardous areas.

Section 1 Overview Features

M&I – AC 900F Controller 13

Features

The AC 900F exhibits the following main features:

CPU module

– PowerPC (II Pro family)

– RISC architecture

Main memory

– Main memory for data and application

Battery

– Lithium battery for RAM buffering

Interfaces

– Four or three Ethernet interfaces depending on the CPU module. The first

interface is used for Control Net, the second as redundancy link and the

remaining interfaces three and four are available for other connections or

Control Net redundancy.

Coupler bus

– Two slots C1 and C2

– Supports fieldbus communication interfaces

I/O bus

– Ten slots L1 to L10 for up to ten I/O modules

– Supports different I/O module types

Communication Section 1 Overview

14 M&I – AC 900F Controller

Display and control elements

– SD card reader

– LEDs

– Switches/buttons

– Display unit (optional accessory)

Power supply unit

– Terminals for 24 V DC power supply

Communication

System

TCP/IP, UDP/IP

The Control Net (Ethernet) connects the individual stations with each other. It

transfers data between the controllers and between Freelance Operations, the

gateways and Freelance Engineering. The AC 900F controller supports data sending

and receiving through TCP/IP (Ethernet-based sending/receiving) and/or UDP/IP

(lateral communication). Additional application layers can be implemented by

downloading them on the controllers. Simultaneous operation of TCP/IP, UDP/IP

and application layer is also ensured.

The data distribution at the bus is based on the Ethernet switch. The max. data

transmission rate is 10 Mbit/s for 10 Base T and max. 100 Mbit/s for Fast-Ethernet.

Twisted pair cables with RJ45 connector are used as transmission medium. The

maximum cable length is 100 m at a maximum transmission speed of Mbit/s.

Detailed diagnostic messages for rapid fault localization can be retrieved via the

diagnostic interface and/or the Freelance Engineering software.

Section 1 Overview Fieldbus

M&I – AC 900F Controller 15

Fieldbus

PROFIBUS

®

PROFIBUS-DP is designed for rapid data exchange in the field area. Central control

units communicate with decentralized field devices like remote I/O, transmitters or

drives etc. using a fast serial connection. The data exchange with the distributed

modules is mainly performed on a cyclic basis. PROFIBUS-DP is optimized in

terms of high speed and simple device connection. This protocol variant is

specifically designed for the communication between programmable controllers and

a distributed I/O level. The AC 900F controller supports PROFIBUS Master

redundancy.

For additional information on PROFIBUS-DP and the PROFIBUS CI/CM modules,

please refer to Section 3, Modules as well as to the Engineering Manual,

Communication and Fieldbusses.

Modbus

Numerous automation systems support the Modbus protocol by default or as an

optional feature. This ensures easy communication with the AC 900F process

station via on-board SER interfaces using the RS232/RS485 standards

(MODBUS

®

) or TCP/IP (MODBUS TCP

®

). The Modbus protocol also ensures

process data exchange with other systems via the serial or the Ethernet interfaces of

the AC 900F.

This protocol allows data to be transmitted in either master or slave mode. For the

configuration with serial interface, a specific MODM_DEV interface object must be

assigned in the hardware structure. The interface-specific parameters are defined in

this block.

For the TCP configuration (Ethernet), a specific MTCP_DEV interface object must

be assigned in the hardware structure.

Please refer to the Engineering Manual, Communication and Fieldbusses and the

Engineering manual, System Configuration, Hardware Structure for more

detailed information.

Fieldbus Section 1 Overview

16 M&I – AC 900F Controller

Telecontrol protocol

The function blocks of the telecontrol library are designed for the connection

between the Freelance Engineering tool and external systems. The link is made via

the serial interface (RS-232) or the Ethernet interface of the CPU module. The

telecontrol protocol complying to IEC 60870-5-101 (serial)/IEC 60870-5-104

(TCP/Ethernet) is used.

For the serial interface, the telecontrol protocol provides device modules for

symmetrical data transmission (FWK_DEV), asymmetrical data transmission as a

master (FWK_DEV_M) and asymmetrical data transmission as a slave

(FWK_DEV_SL). These modules are configured in the hardware structure. Please

refer to the Engineering Manual, System Configuration, Hardware Structure for

more detailed information.

For Ethernet-supported communication, the Ethernet interface and the parameters of

the IEC 60870-5-104 compliant protocol must be set in the FWK_DEV_104

function block designed for telecontrol connection in the Ethernet network. The

FWK_DEV_104 device module can be configured in the hardware structure below

the Ethernet interface of the AC 900F.

ABB CAN Bus protocol

The CAN Bus of the AC 900F controller is intended to be used for connecting rack-

based Freelance I/O modules only. With this feature, the current AC 900F controller

CPU modules of type PM 902F/901F can alternatively take over the tasks of the

CPU module types DCP 02/10 of the Freelance rack system.

M&I – AC 900F Controller 17

Section 2 Configuration

This section provides information on the AC 900F controller configuration for

single and redundant operation.

The AC 900F controller features a modular design. The basic components are a PM

CPU module, CI/CM PROFIBUS communication interfaces and S700 I/O modules.

The external 24 VDC voltage required to operate the controller can be provided by a

CP-C power supply unit, for example.

Configuration levels

The AC 900 F controller in basic configuration comprises the PM CPU module and

two TA dummy couplers designed to protect the unused C1/C2 slots. The on-board

Ethernet interfaces and serial interfaces of the CPU module are available for field

communication.

AC 900F_only CPU.png

Configuration levels Section 2 Configuration

18 M&I – AC 900F Controller

The controller of the medium configuration level is composed of a PM CPU module

and up to two CI/CM modules for PROFIBUS communication. Alternatively, a

CAN Bus module can be plugged into one of these two slots.

Medium configuration.png

The high configuration level controller is composed of a PM CPU module and up to

two CI modules for PROFIBUS communication. Alternatively, a CAN Bus module

can be plugged into one of these two slots. S700 I/O modules are used as “direct

I/O”.

AC 900F_ Controller.png

Section 2 Configuration Controller redundancy

M&I – AC 900F Controller 19

The S700 I/O modules are connected on the right side of the I/O bus, i.e. they are

simply plugged to the TU terminal blocks that were previously added to the CPU

modules. Up to ten I/O modules can be connected to the I/O bus of the CPU module.

The configuration in the Freelance Engineering hardware structure should

correspond to the actual controller configuration (local DIN rail). Make sure that

there are no blank TU terminal blocks between the individual I/O modules. I/O

modules connected on the right side of a gap (i.e. of a blank terminal block) are not

controlled by the CPU module.

Controller redundancy

Two controllers of identical configuration - hereinafter referred to as redundant

controllers - are used for redundant operation. While the active controller has the

“Primary“ status, the “Secondary“ status is assigned to the other controller. During

normal operation, the primary is the active controller and the secondary the passive

one (hot standby).

For synchronization purposes, a point-to-point Ethernet connection (100 MBit/s)

must be established between the controllers. This connection is also referred to as

redundancy link.

A redundant configuration may be composed of two controllers of basic or medium

level configuration. Make sure to use only the CI 930F, CI 910F or CI 773F

communication interface modules for the medium configuration level as only these

module types are suitable for redundant operation.

The S700 Direct I/O and the CM 772F communication module are not supported

with redundant controller arrangement.

Controller redundancy Section 2 Configuration

20 M&I – AC 900F Controller

If the primary controller (Primary) fails, the secondary controller is activated via a

designated communication connection (redundancy link).

The cyclical adjustment ensures smooth change over from the primary to the

secondary controller, i.e.

• the outputs of fieldbus-connected I/O components are maintained.

• the internal status (component data, variables) is maintained.

• the configuration and operating data of the primary and secondary controllers

are automatically adapted.

AC 900F in redundant configuration using the on-board interfaces for Modbus and

telecontrol protocols.

Controller Redundancy us.png

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ABB AC 900F Mounting And Installation Instructions Manual

ABB AC 900F Mounting And Installation Instructions Manual

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