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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.
Copyright © 2015 by ABB.
All rights reserved.
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
/
