S800 I/O

Getting Started

Power and productivity

for a better world

TM

S800 I/O
Getting Started

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
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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 intellectual 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
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In no event shall ABB be liable for direct, indirect, special, incidental or consequential
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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 written permission 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 2004/108/EEC and in Low
Voltage Directive 2006/95/EEC.

TRADEMARKS
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.

Copyright 2003-2011 by ABB.

All rights reserved.

Release:
Document number:

December 2011
3BSE020923-510 A

Table of Contents
About This Book
General ............................................................................................................................17
Document Conventions ...................................................................................................17
Warning, Caution, Information, and Tip Icons................................................................17
Terminology.....................................................................................................................18
Related Documentation ...................................................................................................20

Section 1 - Introduction
Product Overview ............................................................................................................24
Product Scope ..................................................................................................................33
ModuleBus ...........................................................................................................34
CI801 Fieldbus Communication Interface ...........................................................36
CI810/CI810A/CI810B Fieldbus Communication Interface ...............................36
CI820/CI820V1 Fieldbus Communication Interface ...........................................37
TB815 Interconnection Unit ................................................................................37
CI830 Fieldbus Communication Interface ...........................................................37
CI840 Fieldbus Communication Interface ...........................................................38
TB810/TB811 ModuleBus Optical Port ..............................................................38
TB842 ModuleBus Port .......................................................................................38
TB820/TB820V2 ModuleBus Modem ................................................................43
TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849
Module Termination Unit....................................................................46
TB825 Optical Media Converter ..........................................................................52
TB826 Optical Media Converter ..........................................................................52
Module Termination Units ...................................................................................53
I/O Modules .........................................................................................................53

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S800 I/O Modules ................................................................................................ 54

S800L I/O Modules ............................................................................................. 54
Power Supply ....................................................................................................... 54
G3 Compliant Modules........................................................................................ 56
Example of Enclosure Configurations ................................................................. 57
Support for External Intrinsic Safety System ...................................................... 58
Support for External HART Communication ...................................................... 59
Redundancy.......................................................................................................... 59

Section 2 - Installation
Site Planning ................................................................................................................... 64
Site Selection and Preparation ............................................................................. 64
Environmental Considerations............................................................................. 64
Electromagnetic Compatibility and CE Marking ................................................ 66
Layout of I/O Stations.......................................................................................... 66
Mechanical Installation........................................................................................ 89
Grounding ............................................................................................................ 94
Signal Cable Considerations ................................................................................ 96
Power Requirements ............................................................................................ 98
Hazardous Location North American Approval (cULus)................................. 98
Hazardous Location European Approval (ATEX) ............................................ 99
High Voltage Switch-gear Applications............................................................... 99
Lightning Strike Protection.................................................................................. 99
Inductive Load Suppression............................................................................... 100
Mounting Dimensions........................................................................................ 100
Electrical Installation Overview......................................................................... 103
Installation Procedures .................................................................................................. 105
Safety Regulations ............................................................................................. 105
Grounding in Enclosures ................................................................................... 106
Cable Routing .................................................................................................... 108
I/O Station with S800 I/O .................................................................................. 109
Checklists .......................................................................................................... 113
Final Procedure Before Start-up ........................................................................ 118

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Start-up and Shut-down Procedures ..............................................................................119

Start-up Procedures ............................................................................................119
Shut-down Procedures........................................................................................120
Product Verification .......................................................................................................121
General

...........................................................................................................122

Final Check ........................................................................................................126

Section 3 - Configuration
Design Considerations...................................................................................................127
I/O Station Layout Hardware Configuration Guidelines ...................................127
Redundant FCIs for Advant Fieldbus 100..........................................................132
Redundant FCIs and I/O Modules for PROFIBUS ............................................132
I/O Clusters ........................................................................................................133
CI801/CI810/CI820/CI820V1/CI830/CI840 FCI ..............................................138
TB820/TB820V2 and TB840/TB840A ModuleBus Modem ............................139
TB825 Optical Media Converter ........................................................................146
TB826 Optical Media Converter ........................................................................151
Calculation of Maximum Optical ModuleBus Configuration............................154
Power Supply System ....................................................................................................156
Powering S800 I/O System............................................................................................157
Powering Field Equipment ............................................................................................157
Interference ........................................................................................................157
Short-circuit at the output...................................................................................157
Sectioning the field equipment...........................................................................157
Cable protection .................................................................................................158
Connection alternatives ......................................................................................158
Power Supply Load Calculation ....................................................................................161
Appropriate Hardware........................................................................................161
Guidelines ..........................................................................................................161
Heat Dissipation ............................................................................................................162
Cabinet Ventilation.............................................................................................162
Heat Dissipation Permitted in Cabinets .............................................................162
Calculation of Heat Generated in a Cabinet.......................................................162

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Maintenance and Repair................................................................................................ 163

Expansion Considerations ............................................................................................. 163
Power Supply Requirements ......................................................................................... 164
Power Supply for DO880................................................................................... 164
Power and Cooling ........................................................................................................ 165
Calculation of 24 V d.c. Power Consumption ................................................... 172

Section 4 - Operation
Operating Overview ...................................................................................................... 173

Section 5 - Maintenance
Preventive Maintenance ................................................................................................ 175
Hardware Indicators ...................................................................................................... 175
Color

.......................................................................................................... 175

Location .......................................................................................................... 176

Identification ...................................................................................................... 177
Error Messages.............................................................................................................. 177
Fault Finding and User Repair ...................................................................................... 177
Introduction........................................................................................................ 177
Diagnostics and Fault Indications...................................................................... 178
List of General Fault Finding Procedures and Hints ......................................... 178
User Repair ........................................................................................................ 180

Appendix A - General Specifications

Directives....................................................................................................................... 185
EMC Directive ................................................................................................... 185
Low Voltage Directive ....................................................................................... 185
ATEX directive .................................................................................................. 185
Standards and Approvals............................................................................................... 186
Electrical Safety ................................................................................................. 186
Hazardous Classified Locations......................................................................... 186
CE-marking........................................................................................................ 187
G3 Compliant..................................................................................................... 187

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Transport and Storage Conditions .................................................................................187

Climatic operating conditions........................................................................................189
Mechanical operating conditions...................................................................................189
EMC ............................................................................................................................190
Overvoltage Categories ......................................................................................192
Equipment Class and Insulation Voltages .....................................................................192
Equipment Class.................................................................................................192
Insulation Voltage...............................................................................................192
Insulation Test Voltage .......................................................................................193
Certifications .................................................................................................................194

Appendix B - Specifications
SD82x Power Supply Modules, 24 V d.c. .....................................................................201
Key Features.......................................................................................................201
Equipment Class.................................................................................................201
Ingress Protection...............................................................................................202
Power Supply Units Types SD821 / 822 / 823 - Description.............................204
Insulation of Power Supply Units (PSU) ...........................................................206
Fuses and Protective Devices .............................................................................206
Technical Data....................................................................................................207
SD83x Power Supply Modules, 24 V d.c. .....................................................................209
Key Features.......................................................................................................209
Equipment Class.................................................................................................209
Ingress Protection...............................................................................................209
Dimensions and Connections ...........................................................................210
Power Supply Units Types SD831 / 832 / 833 / 834- Description.....................212
Dielectric strength ..............................................................................................216
DC-OK relay contact (SD834 only)...................................................................216
SD834 in parallel to increase output power .......................................................217
Installation, Fuses and Protective Devices .........................................................217
Technical Data....................................................................................................218
Voting Unit - (for Redundant Power Supply) ................................................................220
SS822

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Table of Contents

SS823

.......................................................................................................... 224

SS832

.......................................................................................................... 229

TB805/TB806 ModuleBus Cable Adapter-Out/In ........................................................ 235

Features

.......................................................................................................... 235

Description......................................................................................................... 235
Technical Data ................................................................................................... 236
Block Diagram TB805....................................................................................... 237
Block Diagram TB806....................................................................................... 238
TB807 ModuleBus Terminator ..................................................................................... 239
Features

.......................................................................................................... 239

Description......................................................................................................... 239
Technical Data ................................................................................................... 240
Block Diagram TB807....................................................................................... 241
TB810/TB811 ModuleBus Optical Port ....................................................................... 242
Features

.......................................................................................................... 242

Description TB810............................................................................................. 242

Description TB811............................................................................................. 242
Technical Data ................................................................................................... 243
Connections ....................................................................................................... 244
Opto Cable for TB810 according to HP ............................................................ 244
Opto Cable for TB811 according to HP ............................................................ 245
Block Diagram TB810/TB811........................................................................... 245
TB820/TB820V2 ModuleBus Modem ......................................................................... 246
Features

.......................................................................................................... 246

Description......................................................................................................... 246
Technical Data ................................................................................................... 248
Connections ...................................................................................................... 250
Opto Cable according to HP .............................................................................. 252
Block Diagram TB820/TB820V2...................................................................... 253
TB825 Optical Media Converter ................................................................................... 254
Features

.......................................................................................................... 254

Description......................................................................................................... 254

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Technical Data....................................................................................................254
Opto Connection ................................................................................................256
Block Diagram TB825 .......................................................................................258
TB826 Optical Media Converter ...................................................................................259
Features ...........................................................................................................259
Description .........................................................................................................259
Technical Data....................................................................................................259
Opto Connection ................................................................................................261
Block Diagram TB826 .......................................................................................263
TB840/TB840A ModuleBus Modem............................................................................264
Features ...........................................................................................................264
Description .........................................................................................................264
Technical Data....................................................................................................266
Connections........................................................................................................268
Opto Cable according to HP ..............................................................................268
Connection Diagram TB840/TB840A ...............................................................270
TB842 ModuleBus Optical Port ....................................................................................271
Features ...........................................................................................................271
Description TB842 .............................................................................................271
Technical Data....................................................................................................272
Connections........................................................................................................273
Opto Cable for TB842 according to HP.............................................................273
Block Diagram TB842 .......................................................................................274
TB845/TB846 ModuleBus Cable Adapter-Out/In ........................................................275
Features ...........................................................................................................275
Description .........................................................................................................275
Technical Data....................................................................................................276
Block Diagram TB845 .......................................................................................277
Block Diagram TB846 .......................................................................................278
TU807, MTU for TB840/TB840A ................................................................................279
Features ...........................................................................................................279
Description .........................................................................................................279

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Table of Contents

Technical Data ................................................................................................... 280

Dimensions ........................................................................................................ 281
Connections ....................................................................................................... 281
Block Diagram TU807....................................................................................... 282
TU840, MTU for Redundant TB840/TB840A with
Dual ModuleBus ................................................................................................ 283
Features

.......................................................................................................... 283

Description......................................................................................................... 283
Technical Data ................................................................................................... 284
Dimensions ........................................................................................................ 285
Connections ....................................................................................................... 286
Block Diagram TU840....................................................................................... 287
TU841, MTU for Redundant TB840/TB840A with Single ModuleBus ...................... 288
Features

.......................................................................................................... 288

Description......................................................................................................... 288
Technical Data ................................................................................................... 289
Dimensions ........................................................................................................ 290
Connections ....................................................................................................... 291
Block Diagram TU841....................................................................................... 292
TU848, MTU for Redundant TB840/TB840A with
Dual ModuleBus and Dual Power Supply Connections .................................... 293
Features

.......................................................................................................... 293

Description......................................................................................................... 293
Technical Data ................................................................................................... 294
Dimensions ........................................................................................................ 295
Connections ....................................................................................................... 295
Block Diagram TU848....................................................................................... 296
TU849, MTU for Redundant TB840/TB840A with Single ModuleBus and Dual Power
Supply Connection............................................................................................. 297
Features

.......................................................................................................... 297

Description......................................................................................................... 297
Technical Data ................................................................................................... 298
Dimensions ........................................................................................................ 299

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Connections........................................................................................................299
Block Diagram TU849 .......................................................................................300
TK811 Opto Cable, Duplex Plastic Fibre......................................................................301
Features ...........................................................................................................301
TK812 Opto Cable, Simplex Plastic Fibre ....................................................................302
Features ...........................................................................................................302
Mounting Kit .................................................................................................................303
Features ...........................................................................................................303
Description .........................................................................................................303
Technical Data....................................................................................................303
Configuration .....................................................................................................304
Horizontal and Vertical Mounting Profile .....................................................................305
Features ...........................................................................................................305
Description .........................................................................................................305
Dimensions.........................................................................................................306

Appendix C - Power Up
Power Up on S800 I/O...................................................................................................307

INDEX
Revision History
Introduction ...................................................................................................................321
Revision History ............................................................................................................321
Updates in Revision Index A.........................................................................................322

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3BSE020923-510 A

Safety Summary
Electrostatic Sensitive Device
Devices labeled with this symbol require special handling precautions as
described in the installation section.

GENERAL
WARNINGS

Equipment Environment
All components, whether in transportation, operation or storage, must be
in a noncorrosive environment.
Electrical Shock Hazard During Maintenance
Disconnect power or take precautions to insure that contact with energized parts is avoided when servicing.

SPECIFIC
WARNINGS

Page-99: Explosion hazard!

Do not disconnect equipment unless power has been removed or the
area is known to be non-hazardous.
Page-99: Explosion hazard!
Substitution of components may impair suitability for Class 1, Division 2.
Page-99: Explosion hazard!
Do not replace batteries unless power has been switched off or the area
is known to be non-hazardous.
Page-106: Work with care when supply voltage is applied to the system.
Voltages within the cabinet can cause serious injury or death.
Page-119: Work with care when supply voltage is applied in the system.
The voltage in the cabinet can cause serious injury or death.
Page -120: Work with care when supply voltage is applied in the system.
The voltage in the cabinet can cause serious injury or death.
Page-179: A restart of the I/O system or controller can have very serious
consequences. It is important to be aware of the local requirements for
safety when starting and stopping the I/O system or controller.

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15

Safety Summary
SPECIFIC
WARNINGS
(continued)

Page-180: Switch off the process voltage before removal of the module, if
the plastic cover for the I/O modules DI802, DI803, DI820, DI821, DO802,
DO820 or DO821 is damaged, and there is risk for contact with live parts.

SPECIFIC
CAUTIONS

Page-84: Do not turn the I/O Module Lock/Switch counter-clockwise from

the unlocked position. This will cause it to break and will make the MTU
and the I/O module inoperative.
Page-106: Observe the following safety rules:
- Avoid direct contact with the bus connector of the I/O modules.
- Always switch off the voltage before extracting a module which can not
to be exchanged with power applied, for example, processor units, extension cable adaptors and extension cables, see Section 5, Maintenance.
Wait a sufficient time for the capacitors to discharge before removing a
power sensitive module.
Page-112: Be aware of the risk of accidents. Short-circuit and over-voltage can damage the equipment, for example, a process I/O board or field
element.
Page:-141: Care must be taken that no I/O clusters have the same
address setting. This could result in output modules in the same ModuleBus position but in different I/O clusters putting out the same value.
Page-182: If TB842 should be replaced in a running system the carrier
(TB806 or TB846) of TB842 have to be disconnected from the FCI first.
Page-184: If TB842 should be replaced in a running system the carrier
(TB806 or TB846) of TB842 have to be disconnected from the FCI first.

16

3BSE020923-510 A

About This Book

General
This book provides a general description of the S800 I/O and reference information
about equipment common to all types of installations, for example power supplies
and ModuleBus components. It provides overall instructions for site planning and
installation, start-up and shutdown procedure, and information regarding capacity
and performance. This book is not intended to be the sole source of instruction for
the S800 I/O system.

Document Conventions
Microsoft Windows conventions are normally used for the standard presentation of
material when entering text, key sequences, prompts, messages, menu items, screen
elements, etc.

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:
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.

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17

Terminology

About This Book

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
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,
fully comply with all Warning and Caution notices.

Terminology
A complete and comprehensive list of Terms is included in the IndustrialIT
Extended Automation System 800xA, Engineering Concepts instruction
(3BDS100972*). The listing included in Engineering Concepts includes terms and
definitions as they that apply to the 800xA system where the usage is different from
commonly accepted industry standard definitions and definitions given in standard
dictionaries such as Websters Dictionary of Computer Terms.
Table 1. Terminology

18

Term

Description

AF 100

Advant Fieldbus 100 is the communications bus between

the I/O stations and the Advant Controllers. (FCI to CI52x)

Base cluster

Consists of single or redundant ModuleBus masters plus

I/O modules connected directly to the ModuleBus master.

FCI

The Fieldbus Communication Interface (FCI) device

contains the interface to the fieldbus (for example
PROFIBUS or AF 100).

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About This Book

Terminology

Table 1. Terminology (Continued)

Term

Description

G3 compliant

The module withstand more severe environmental

conditions according to ISA-S71.04.

I/O cluster

An extension of the I/O Stations ModuleBus connected to

the ModuleBus master by fiber optic connections. Up to 12
I/O devices per cluster.

I/O device

A complete I/O device consists of one MTU and one I/O

module.

I/O module

Is an active, electronic and signal conditioning unit. Can be

a part of an I/O device or a S800L I/O module.

I/O station

An I/O station consists of one or two FCI(s), 1-7 I/O clusters

and up to 24 I/O devices.

I.S.

Intrinsic Safety is a protection technique to prevent

explosion in hazardous areas of a process plant.

ModuleBus

Is an incremental, electrical or optical, bus for

interconnection of I/O devices.

ModuleBus master

ModuleBus master can be a controller (AC 800M) or a FCI.

A ModuleBus master contains a ModuleBus interface and
power regulators. The FCI module can manage 24 I/O
devices and the controller up to 96 I/O modules (up to 12
directly and to the others in 1 to 7 I/O clusters).

(ModuleBus)
Extension cable

Is used when extending the electrical ModuleBus (within

the max. 2 meters).

MTU

The Module Termination Unit is a passive base unit

containing process terminals and a part of the ModuleBus.

OSP

Outputs Set as Predetermined. A user configurable action

on an output module when communications is lost to the
FCI or Controller.

PROFIBUS-DP

PROFIBUS-DP is a fieldbus standard.

PROFIBUS-DPV1

PROFIBUS-DPV1 is a fieldbus standard.

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19

Related Documentation

About This Book

Table 1. Terminology (Continued)

Term

Description

RTD

Resistance Temperature Detector.

SOE

Sequence of events. Time stamping of status changes for

digital inputs.

TC

Thermocouples

Related Documentation
The following is a listing of documentation related to the S800 I/O system.
Table 2. Related Documentation
Title

Description

S800 I/O Modules and Termination Units Describes the I/O modules and
termination units in the S800 I/O system.
S800 I/O Modules and Termination Units Describes I/O modules and termination
with Intrinsic Safety Interface
units with I.S. interface in the S800 I/O
system.

20

S800 I/O Fieldbus Communication

Interface for Advant Fieldbus 100
Users Guide

Describes the AF100 FCI in the S800

I/O system.

S800 I/O Fieldbus Communication

Interface for PROFIBUS-DP/DPV1

Describes the PROFIBUS-DP FCI in the

S800 I/O system.

S800 I/O PROFIBUS FCI

Memory Maps for CI801

Describes the memory mapping on

PROFIBUS for the S800 I/O system in
CI801.

S800 I/O PROFIBUS FCI

Memory Maps for CI830

Describes the memory mapping on

PROFIBUS for the S800 I/O system in
CI830.

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About This Book

Related Documentation

Table 2. Related Documentation (Continued)

Title

Description

S800 I/O PROFIBUS FCI

Memory Maps for CI840

Describes the memory mapping on

PROFIBUS for the S800 I/O system in
CI840.

Advant Fieldbus 100 Users Guide

Describes the equipment and contains

information required to install and
commission AF100.

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Related Documentation

22

About This Book

3BSE020923-510 A

Section 1 Introduction
The S800 I/O is distributed modular I/O which communicates with numerous
controllers over a Advant Fieldbus 100 (AF 100), PROFIBUS-DP/DPV1 or directly.
The S800 I/O provides easy installation of the I/O modules and process cabling. It is
highly modularized and flexible so that I/O modules can be combined to suit many
applications. The S800 I/O can be mounted in many configurations to fit most
requirements both in single or fully redundant applications.

Figure 1. S800 I/O with Fieldbus Communication Interface CI801 and I/O Modules
Mounted on Compact Type of Termination Units.

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Product Overview

Section 1 Introduction

Controller

Electrical
ModuleBus

FCI

I/O Module

Base Cluster

ModuleBus Optical Port

Optical ModuleBus Modem
Fieldbus
I/O Station
I/O Cluster

Optical
ModuleBus

I/O Cluster

Base Cluster
Scope of this book

Figure 2. S800 I/O Station Overview

Product Overview
The S800 I/O provides easy installation of the I/O modules and process cabling. It is
highly modularized and flexible so that the I/O modules can be combined to suit
many applications including the most types of signals, HART and Intrinsic Safety
Interface.

24

3BSE020923-510 A

Section 1 Introduction

Product Overview

The S800 I/O modules and a Fieldbus Communication Interface (FCI) are combined
to form an I/O Station. S800 I/O can be used in both single and redundant
applications.
In general, all S800 I/O units are G3 compliant. G3 compliant units withstand more
severe environmental conditions according to ISA-S71.04. The following S800 I/O
units are G2 compliant - SD821, SD822, SD823, SD831, SD832, SD833, SD834,
SS822, SS832, TB811 and CI830. G3 compliant versions of SD822 and SS822 are
available, refer to SD822Z and SS822Z.
The modules are marked with a bar code that shows serial number, article ID and
product revision number. A separate bar code strip is enclosed for optional placing
on the module. The bar code is of type Bar-code 128.
The equipment that is used as part of the I/O Station with S800 I/O is presented in
Table 3.
Table 3. I/O Station with S800 I/O Components
Device Type
Designator

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Function

AI801

8 AI channels (1x8), 0(4)...20 mA

AI810

8 AI channels (1x8), 0(4)...20 mA, 0(2)...10 V

AI815

8 AI channels (1x8) 4...20 mA, 0...20 mA, 1...5 V, 0...5 V.

Advanced diagnostics, HART interface, for single
application.

AI820

4 AI channels (differential), -20...20 mA, 0(4)...20 mA, 10...10V, 0(2)...10 V, -5...5 V, 0(1)...5 V

AI825

4 AI channels (4 x 1) for applications requiring galvanic

isolated channels, -20...20 mA, 0(4)...20 mA, -10...10V,
0(2)...10 V

AI830/
AI830A

8 AI channel for Resistance Measurements (e.g. Pt 100

sensors)

AI835/
AI835A

7+1 AI channels for Thermocouple or mV Inputs

25

Product Overview

Section 1 Introduction

Table 3. I/O Station with S800 I/O Components (Continued)

Device Type
Designator
AI843

8 AI channels for Thermocouple or mV Inputs. Advanced

diagnostics, for single and redundant applications.

AI845

8 AI channels (1x8) 4...20 mA, 0...20 mA, 1...5 V, 0...5 V.

Advanced diagnostics, HART interface, for single and
redundant applications.

AI880/AI880A

8 High Integrity AI channels (1x8) 0...20 mA, 4...20 mA. For

single and redundant applications, HART interface. Also
used in function Loop Supervised DI.

AI890

8 AI channels (1x8), 0(4)...20 mA, I.S. interface

AI893

8 AI channels for RTD or Thermocouple/mV Inputs, I.S.

interface.

AI895

8 AI channels (1x8), 4...20 mA, I.S. and HART interface.

AO801

8 AO channels (1x8), 0(4)...20 mA

AO810/
AO810V2

8 AO channels (1x8), 0(4)...20 mA

AO815

8 AO channels (1x8), 4...20mA. Advanced diagnostics,

HART interface, for single application.

AO820

4 AO channels (4 x 1) galv. isolated (bipolar), -20...20 mA,

0(4)...20 mA, -10...10V, 0(2)...10 V

AO845/
AO845A

26

Function

8 AO channels (1x8) 4...20mA. Advanced diagnostics,

HART interface, for single or redundant applications.

AO890

8 AO channels (1x8), 0(4)...20 mA, I.S. interface

AO895

8 AO channels (1x8), 4...20 mA, I.S. and HART interface.

CI801

Fieldbus Communication Interface (FCI) for PROFIBUSDPV1, Hot Configuration In Run and HART pass-through.

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Section 1 Introduction

Product Overview

Table 3. I/O Station with S800 I/O Components (Continued)

Device Type
Designator
CI810/
CI810A/
CI810B
CI820/CI820V1

3BSE020923-510 A

Function
Fieldbus Communication Interface (FCI) for Advant Fieldbus
100
Redundant Fieldbus Communication Interface (FCI) for
Advant Fieldbus 100

CI830

Fieldbus Communication Interface (FCI) for PROFIBUS-DP

CI840/
CI840A

Fieldbus Communication Interface (FCI) for PROFIBUSDPV1, redundant application, Hot Configuration In Run and
HART pass-through.

DI801

16 DI channels (1x16), 24 V d.c., current sinking

DI802

8 DI channels (1x8), 120 V d.c., current sinking

DI803

8 DI channels (1x8), 230 V d.c., current sinking

DI810

16 DI channels (2x8), 24 V d.c., current sinking.

DI811

16 DI channels (2x8), 48 V d.c., current sinking

DI814

16 DI channels (2x8), 24 V d.c. current sourcing

DI820

8 galvanic isolated DI channels (8x1), 120 V a.c./d.c.,

current sinking.

DI821

8 galvanic isolated DI channels, (8x1) 230 V a.c./d.c.,

current sinking.

DI825

8 galvanic isolated DI channels, (8x1) 125 V d.c. with

sequence of event (SOE) handling

DI830

16 DI channels (2x8) 24 V d.c. with sequence of event

(SOE) handling, current sinking

DI831

16 DI channels (2x8) 48 V d.c. with sequence of event

(SOE) handling, current sinking

27

Product Overview

Section 1 Introduction

Table 3. I/O Station with S800 I/O Components (Continued)

Device Type
Designator

28

Function

DI840

16 DI channels (2x8) 24 V d.c. with sequence of event

(SOE) handling. Advanced diagnostics, for single or
redundant applications.

DI880

16 High Integrity DI channels (1x16) 24 V d.c. with

sequence of event (SOE) handling.
For single and redundant applications.

DI885

8 DI channels, (1x8) 24/48 V d.c. with sequence of event

(SOE) handling, current sinking

DI890

8 DI channels (8x1), I.S. interface

DO801

16 DO channels (1x16), 24 V d.c., 0.5 A, current sourcing

DO802

8 DO channels (1x8), 24-110 V d.c./250 V a.c., relay

normally open

DO810

16 DO channels (2x8), 24 V d.c., 0.5 A, current sourcing.

DO814

16 DO channels (2x8), 24 V d.c., 0.5 A, current sinking

DO815

8 DO channels (2x4), 24 V d.c., 2 A, current sourcing.

DO820

8 DO channels (8x1), Relay, 250 V, 3 A a.c. normally open.

DO821

8 DO channels (8x1), Relay, 250 V, 3 A a.c. normally closed

DO840

16 DO channels (16x1), Relay, 24 V, 0.5 A a.c. with

advanced diagnostics, for single or redundant applications.

DO880

16 High Integrity DO channels (1 x 16) 24 V d.c.

For single and redundant applications.

DO890

4 channels (4x1), 11 V 40 mA, I.S. interface

DP820

2 channels, pulse count and frequency measurement,

maximum 1.5 MHz. Interface for RS422, current, 5V, 12 V or
24 V.

3BSE020923-510 A

Section 1 Introduction

Product Overview

Table 3. I/O Station with S800 I/O Components (Continued)

Device Type
Designator

Function

DP840

8 channels, pulse count and frequency measurement,

maximum 20 kHz. With advanced diagnostics, for single or
redundant applications. Interface for NAMUR, 12 V and
24 V.
The input can be read as digital input signals.

SD821

Power supply, 115/230 V a.c. to 24 V d.c. @ 2.5 A

SD822/SD822Z

Power supply, 115/230 V a.c. to 24 V d.c. @ 5.0 A.

SD823

Power supply, 115/230 V a.c. to 24 V d.c. @ 10 A

SD831

Power supply, 100-240 V a.c. or 110-300 V d.c. to 24 V d.c.

@ 3 A.

SD832

Power supply, 100/120 V or 200/240 a.c. to 24 V d.c. @ 5 A.

SD833

Power supply, 100-120 V or 200-240 a.c. to 24 V d.c. @ 10

A.

SD834

Power supply, 100-240 V a.c. or 110-300 V d.c. to 24 V d.c.

@ 20 A.

SS822/SS822Z

3BSE020923-510 A

Voting Unit for redundant power supply, 24 V d.c. @ 20.0 A.

SS823

Power Voter with overvoltage protection, 24 V d.c., 20 A.

SS832

Voting unit for redundant power supply, 24 V d.c. @ 12.5 A.

TB805

Cable adaptor out module (electrical ModuleBus).

TB806

Cable adaptor in module (electrical ModuleBus).

TB807

Terminator module for electrical ModuleBus.

TB810

ModuleBus Optical Port Module 10 Mbit driver, fiber optic

connection. Used together with CI810, CI820/CI820V1 and
CI830.

29

Product Overview

Section 1 Introduction

Table 3. I/O Station with S800 I/O Components (Continued)

Device Type
Designator
TB811

ModuleBus Optical Port Module 5 Mbit driver, fiber optic

connection. Used together with CI810, CI820/CI820V1 and
CI830.

TB815

ModuleBus Interconnection Unit to redundant FCIs

(CI820/CI820V1)

TB820/TB820V2

ModuleBus Modem, fiber optic ModuleBus interface of an

I/O cluster. 10 Mbit driver.

TB825

ModuleBus Optical media converter, converts between

plastic opto fiber or HCS fiber with Versatile link connectors
and glass optical fiber with ST connectors.

TB826

Modulebus Optical media converter, converts plastic opto

fiber or HCS fiber with Versatile link connectors to single
mode glass opto fiber with SC connectors.

TB840/TB840A

ModuleBus Modem, fiber optic ModuleBus interface of an

I/O cluster. 10 Mbit driver. Redundant application.

TB842

ModuleBus Optical Port Module 10 Mbit driver, fiber optic

connection. Used together with CI840.

TB845

Cable adaptor out module (double electrical ModuleBus)

TB846

Cable adaptor in module (double electrical ModuleBus)

TC501V150
TC505

30

Function

Cable terminator for AF 100 twisted pairs, 150 ohms

Connector: AF 100 Trunk Tap to FCI

TK801V003

Cable, ModuleBus Extension, 300 mm (11.8"),

TK801V006

Cable, ModuleBus Extension, 600 mm (23.6")

TK801V012

Cable, ModuleBus Extension, 1.2 m (47.25")

TK811V015

Cable, Optical ModuleBus Extension, 1.5 m (59"), duplex,

plastic

3BSE020923-510 A

Section 1 Introduction

Product Overview

Table 3. I/O Station with S800 I/O Components (Continued)

Device Type
Designator

Function

TK811V050

Cable, Optical ModuleBus Extension, 5 m (16), duplex,

plastic

TK811V150

Cable, Optical ModuleBus Extension, 15 m (50), duplex,

plastic

TK812V015

Cable, Optical ModuleBus Extension, 1.5 m simplex, plastic

TK812V050

Cable, Optical ModuleBus Extension, 5 m simplex, plastic

TK812V150

Cable, Optical ModuleBus Extension, 15 m simplex, plastic

TU805

Terminal Unit 2 x18 terminals, 50 V. Used to enable 2- and

3-wire connections on DI801 and DO801. The Terminal Unit
is mounted direct on DI801 or DO801.

TU807

Terminal Unit for single TB840A

TU810/TU810V1

Compact MTU, 3x8 + 2x3 terminals, 50 V.

TU811/TU811V1

Compact MTU, 2x8 terminals, 250 V.

TU812/TU812V1

Compact MTU, 25 pin D-sub Connector for field connection,

50 V

TU813

Compact MTU, Crimp Snap-in Connector for field

connection, 250 V.

TU814/TU814V1

Compact MTU, Crimp Snap-in Connector for field

connection
50 V.

TU830/TU830V1

Extended MTU, 3x16 + 2x4 terminals, 50 V

TU831/TU831V1

Extended MTU, 8x2 terminals, 250 V

3BSE020923-510 A

TU833

Extended MTU, 3*16 + 2*4 spring-case terminals, 50 V.

TU834

Extended MTU, 2x16 terminals, 50 V, 8 channels with

individual shunt sticks

31

Product Overview

Section 1 Introduction

Table 3. I/O Station with S800 I/O Components (Continued)

Device Type
Designator

32

Function

TU835/TU835V1

Extended MTU, 4x2 groups + 2x4 power terminals, 50 V,

individually fused per channel

TU836/TU836V1

Extended MTU, 2x4 groups + 2x6 power terminals, 250 V,

individually fused per channel

TU837/TU837V1

Extended MTU, 2x4 groups + 2x6 power return terminals,

250 V, fused

TU838

Extended MTU, 2x4 groups + 2x4 power return terminals,

50 V, fused

TU839

Extended MTU, 3x2 groups + 2x3 power return terminals,

250 V, fused

TU840

MTU for redundant TB840, dual ModuleBus

TU841

MTU for redundant TB840, single ModuleBus

TU842

16 channel, 50 V, horizontal dual MTU for redundant I/O

TU843

16 channel, 50 V, vertical dual MTU for redundant I/O

TU844

8 channel with individual shunt sticks, 50 V, horizontal dual

MTU for redundant I/O

TU845

8 channel with individual shunt sticks, 50 V, vertical dual

MTU for redundant I/O

TU846

MTU for redundant CI840, dual ModuleBus

TU847

MTU for redundant CI840, single ModuleBus.

TU848

MTU for redundant TB840, dual ModuleBus and dual power

supply connections

TU849

MTU for redundant TB840, single ModuleBus and dual

power supply connections

TU850

Extended MTU, 2x8 current limited sensor power + 16

signal + 2x4 fused power connections terminals, 50 V.

3BSE020923-510 A

Section 1 Introduction

Product Scope

Table 3. I/O Station with S800 I/O Components (Continued)

Device Type
Designator

Function

TU890

Compact MTU for I.S. interface Module, 50 V. For use in I.S.

applications.

TU891

Compact MTU for I.S. interface Module, 50 V. Not for use in

I.S. applications.

TY801

Shunt stick for current or voltage signals together with AI845

or AI880/AI880A and TU844 or TU845, 2 x 125

TY804

Shunt stick for NAMUR signals together with DP840 and

TU844 or TU845, 1 k

TY820

Temperature sensor with 4-wire connection, and used

together with AI835 and AI843.

Mounting Kit

Used for horizontal mounting of CI801, CI840 and TB840 on

a vertical DIN-rail.

Mounting profile

Horizontal mounting profile with one DIN-rail and one cable

duct

Mounting profile

Vertical mounting profile with 4 + 1 DIN-rails

Product Scope
The S800 I/O is a modular I/O system. The modular system allows for easy
configuration of the I/O type and size.
An S800 I/O Station can consist of a base cluster and up to 7 additional I/O clusters.
The base cluster consists of a single or redundant Fieldbus Communication
Interface (FCI) module and up to 12 single I/O modules (on single MTUs) or 6 pairs
of redundant I/O modules (on redundant MTUs). It is not allowed to mix single and
redundant I/O modules on the base cluster.
I/O clusters 1 to 7 consist of a ModuleBus Modem and up to 12 single I/O modules.
I/O clusters 1 to 7 are connected to the FCI through a fiber optic expansion of the
ModuleBus. An S800 I/O Station can have up to 24 I/O modules. This means that an

3BSE020923-510 A

33

ModuleBus

Section 1 Introduction

I/O Station can have a maximum of 384 digital channels or a maximum of 192
analog channels.
Each I/O cluster can be divided in groups using ModuleBus extension cables
between the groups. The maximum length of the electrical ModuleBus of an I/O
cluster is 2.5 meters (8.2 ft.) including extension cables. The factory made extension
cables which plug into the cable adaptors are available in lengths of 0.3, 0.6 and
1.2 m (1, 2 and 4 ft.).
The maximum length of the optical ModuleBus expansion is dependent on the
number of ModuleBus Modems. The maximum length between any two clusters is
15m (50ft) with plastic fiber, 200m (656ft) with HCS glass fiber, and
1000m (3281ft) using TB825 Optical Media Converter. Maximum fiber length
between two modems is 15m (50ft) with plastic fiber, 200m (656ft) with HCS fiber
and up to 5000m (20000m for S800 I/O HI) using TB826 Optical Media Converter.
Factory made optical duplex or simplex cables (plastic fiber) are available in lengths
of 1.5, 5 and 15 m (5, 16.7 or 50 ft.).

ModuleBus
Each S800 I/O module is installed on a Module Termination Unit (MTU). The first
MTU with its I/O module or S800L module connects to the ModuleBus master or a
clusters ModuleBus Modem and then each of the remaining MTUs or S800L
modules connect to the previous MTU or S800L module.
A ModuleBus master communicates with its I/O modules over the ModuleBus. The
ModuleBus can be divided into 8 clusters, one base cluster and up to 7 I/O clusters.
The base cluster consists of the ModuleBus master (single or redundant) and I/O
modules (single or redundant). Additional I/O clusters (1 to 7) consist of a
ModuleBus Modem and I/O modules. The ModuleBus Modems are connected to an
optional ModuleBus Optical Port module on the ModuleBus master, using optical
cables.
Within a cluster, the ModuleBus is made up of increments that are integrated into
each MTU or S800L module. The ModuleBus master and ModuleBus Modems
have a ModuleBus outlet connector to connect to an MTU or a S800L module. An
MTU and S800L module have a bus inlet and a bus outlet connector.
By adding, on the DIN rail, an MTU or a S800L module to a ModuleBus master or
a ModuleBus Modem, the bus is automatically expanded up to a maximum of 12

34

3BSE020923-510 A

Section 1 Introduction

ModuleBus

single MTUs (this number includes the number of S800L modules) or 6 redundant
MTUs. It is not allowed to mix single and redundant I/O modules within a cluster. In
a "Hot Replacement" configuration, you can install up to 6 I/O modules on up to
6 redundant MTUs.
Unique position codes are automatically assigned to each MTU or S800L module as
the bus is expanded. An inserted S800 module is assigned the unique position
identity of its MTU. Through the incremental bus design, the physical size of an
S800 I/O installation is directly proportional to the number of installed MTUs or
S800L modules.
The S800 I/O modules can be inserted and removed from MTUs without disturbing
system operation. The physical lock, which locks an I/O module to its MTU, allows
I/O module removal only when the lock is in its unlock position. The locking
mechanism also acts as a logic lock so that an I/O module is only operational when
the lock is in the locked position. If the lock is in its unlocked position, output
channels are de-energized and I/O modules can be inserted/removed without need to
remove system or field power.
The MTUs are totally passive units with all active circuitry allocated to the I/O
module. The ModuleBus requires a terminator to be installed after the last MTU or
S800L module of a cluster.
Figure 3 shows a typical base cluster in an I/O station with single I/O modules and
single FCI connected to PROFIBUS or Advant Fieldbus 100.
2.5 meters (8.2 feet) maximum
Status

S1 2 3 4 56 7 8 910 1112 13 1415 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Figure 3. Typical I/O Station Base Cluster with S800 I/O, Single or Redundant FCI
Figure 4 shows a typical base cluster in an I/O station with single I/O modules and
redundant FCI connected to Advant Fieldbus 100.

3BSE020923-510 A

35

CI801 Fieldbus Communication Interface

Section 1 Introduction

Redundant I/O modules and redundant FCI connected to PROFIBUS are shown in
Figure 23.
2.5 meters (8.2 feet) maximum
Status

S 1 2 34 5 6 78 9 101112 1314 1516

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Figure 4. I/O Station Base Cluster with Redundant FCIs to S800 I/O for AF100

CI801 Fieldbus Communication Interface

The CI801 Fieldbus Communication Interface (FCI) module is a configurable
communication interface that performs operations such as signal processing,
gathering of various supervision information, OSP handling, Hot Configuration In
Run, HART pass-through, and configuration of I/O modules. The FCI connects to
the controller through of the PROFIBUS-DPV1 fieldbus.
Refer to specifications in S800 I/O Fieldbus Communication Interface for
PROFIBUS-DP/DPV1 (3BSE020926*) for more information.

CI810/CI810A/CI810B Fieldbus Communication Interface

The CI810/CI810A/CI810B Fieldbus Communication Interface (FCI) module is a
configurable communication interface which performs operations such as signal
processing, gathering of various supervision information, OSP handling and
configuration of re-inserted I/O modules. The FCI connects to the controller through
the Advant Fieldbus 100 (AF 100) twisted pair segment. The FCI supports
redundant media configurations.
Refer to specifications in S800 I/O Fieldbus Communication Interface for Advant
Fieldbus 100 (3BSE020925*) for more information.

36

3BSE020923-510 A

Section 1 Introduction

CI820/CI820V1 Fieldbus Communication Interface

CI820/CI820V1 Fieldbus Communication Interface

The CI820/CI820V1 Fieldbus Communication Interface (FCI) module is a
configurable communication interface which performs operations such as signal
processing, gathering of various supervision information, OSP handling and
configuration of
re-inserted I/O modules. The FCI connects to the controller by way of the Advant
Fieldbus 100 (AF 100) twisted pair segment. The FCI supports redundant fieldbus
communication interface.
Refer to specifications in S800 I/O Fieldbus Communication Interface for Advant
Fieldbus 100 (3BSE020925*) for more information.

TB815 Interconnection Unit

The TB815 Interconnection Unit is used with redundant CI820/CI820V1 FCIs to
provide an interface to the ModuleBus (electrical and optical) and service port
connections. All signals between the redundant FCIs such as AF 100 signals and
control signals are routed through the TB815 and it also provides the termination of
the electrical ModuleBus.
Refer to specifications in S800 I/O Fieldbus Communication Interface for Advant
Fieldbus 100 (3BSE020925*) for more information.

CI830 Fieldbus Communication Interface

The CI830 Fieldbus Communication Interface (FCI) module is a configurable
communication interface which performs operations such as signal processing,
gathering of various supervision information, OSP handling and configuration of
I/O modules. The FCI connects to the controller by way of the PROFIBUS-DP
fieldbus.
Refer to specifications in S800 I/O Fieldbus Communication Interface for
PROFIBUS-DP/DPV1 (3BSE020926*) for more information.

3BSE020923-510 A

37

CI840 Fieldbus Communication Interface

Section 1 Introduction

CI840 Fieldbus Communication Interface

The CI840 Fieldbus Communication Interface (FCI) module is a configurable
communication interface that performs operations such as signal processing,
gathering of various supervision information, OSP handling, Hot Configuration In
Run, HART pass-through and configuration of I/O modules. CI840 is designed for
redundant applications. The FCI connects to the controller by way of the
PROFIBUS-DPV1 fieldbus.
Refer to specifications in S800 I/O Fieldbus Communication Interface for
PROFIBUS-DP/DPV1 (3BSE020926*) for more information.

TB810/TB811 ModuleBus Optical Port

The TB810/TB811 Optical ModuleBus Port is used with the CI810 or CI830 FCI or
the TB815 Interconnection Unit to provide an interface for the Optical ModuleBus
expansion. The TB810/TB811 has connectors for fiber optic connections and a
connection to the communication interface module.
TB810 is used with TB820/TB820V2 and ABB Drives equipment with 10 Mbit
driver.
TB811 is used with ABB Drives equipment with 5 Mbit driver. Figure 5 shows the
TB810/TB811 installed in the CI810 FCI.

TB842 ModuleBus Port

The TB842 optical port is used for optical extension of the ModuleBus. The TB842
Optical ModuleBus Port is used with the CI801 or the CI840 redundant FCI. The
TB842 module can be connected to CI801 through TB806 or redundant CI840
through TB806 and TU847 (single I/O) or through TB846 and TU846 (redundant
I/O), see Figure 6, Figure 7 and Figure 8. The TB842 has two connectors for fiber
optic connections and a connection to the communication interface module.

38

3BSE020923-510 A

Section 1 Introduction

TB842 ModuleBus Port

4
3
2
1
4
3
2
1

CI810A
SWX.X/Y
L+ L+ SA
L- L- SB

AF100
1

56
09
56
09

7 x 10
8

LED Status
Indicators

7x1
8

TB810/TB811
Optical ModuleBus Port

Tx Rx
2

SH
SH

SH
SH

Tx

Rx

Figure 5. TB810/TB811 Optical ModuleBus Port installed in CI810A FCI

3BSE020923-510 A

39

TB842 ModuleBus Port

Section 1 Introduction

F
R
P
Rx/Tx
PRIM
DUAL

F
R
P
Rx/Tx
PRIM
DUAL

TB842

CI840

CI840

TB806

TU847

Figure 6. TB842 Optical ModuleBus Port mounted on TB806 module for connection
to TU847

40

3BSE020923-510 A

Section 1 Introduction

TB842 ModuleBus Port

Figure 7. TB842 Optical ModuleBus Port mounted on TB846 for connection to

TU846

3BSE020923-510 A

41

TB842 ModuleBus Port

Section 1 Introduction

LED Status
Indicators

ModuleBus
Interface
Connector

Power Supply

TB842
TB806
PROFIBUS-DP
Connector

Address
Switch #1
Address
Switch #2

Figure 8. TB842 Optical ModuleBus Port mounted on TB806 module for connection
to CI801

42

3BSE020923-510 A

Section 1 Introduction

TB820/TB820V2 ModuleBus Modem

TB820/TB820V2 ModuleBus Modem

The TB820/TB820V2 ModuleBus Modem is a fiber optic interface to the
ModuleBus. The ModuleBus Modem has an electrical and an optical interface
which are logically the same bus. A maximum of 12 I/O modules can be connected
to the electrical ModuleBus and up to seven clusters can be connected to the fiber
optic ModuleBus. The fiber optic interface is intended for local distribution of I/O
clusters and where more then 12 I/O modules are required in an I/O Station.
The TB820/TB820V2 ModuleBus Modem has a rotary switch that selects its cluster
number, 1 to 7, on the optical ModuleBus. Figure 9 shows the layout of
TB820/TB820V2.

3BSE020923-510 A

43

TB820/TB820V2 ModuleBus Modem

Section 1 Introduction

F
ORx1

LED Status
Indicators

R
P
ORx2
ERx

Electrical ModuleBus
Interface Connector

DIN Rail

CLUSTER
4 56
3
7
2
1

Cluster Address
Switch
(Address 4 shown)

TB820 V2

Power Supply
Connections

L+
SA

X4 X5
RxTxRx Tx

SB

Optical ModuleBus
Interface Connector

Redundant Power
Supervision

Figure 9. TB820/TB820V2 ModuleBus Modem

The ModuleBus Modem communicates with the FCI or Controller via the Optical
ModuleBus.
The TB820/TB820V2 ModuleBus Modem provides 24 V d.c. current limited (from
the source) and an isolated, current limited 5 V dc power to the clusters I/O
modules by way of the electrical ModuleBus connection. One power source (single
or redundant 24 V d.c.) can be connected to the power terminals (L+ & L-).
Redundant power supply can be supervised via inputs SA and SB.

44

3BSE020923-510 A

Section 1 Introduction

TB820/TB820V2 ModuleBus Modem

58 mm (2.3)

122 mm (4.8)

R
P

ORx1

ORx2

170 mm (6.7)

ERx

CLUSTER
4 5 6
3
7
2

TB820

L L+L- + - SAB
L+
SA
SB

Figure 10. TB820/TB820V2 ModuleBus Modem Dimensions

Refer to specifications in Appendix B, Specifications for more information.

3BSE020923-510 A

45

TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849 Module Termination

TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849

Module Termination Unit
The TB840/TB840A ModuleBus Modem is a fiber optic interface to the Optical
ModuleBus. TB840/TB840A is used in redundancy configurations where each
module is connected to different optical ModuleBus lines, but connected to the same
electrical ModuleBus.
The ModuleBus Modem has an electrical and an optical ModuleBus interface which
are logically the same bus. A maximum of 12 I/O modules can be connected to the
electrical ModuleBus and up to seven clusters can be connected to the fiber optic
ModuleBus. The fiber optic interface is intended for local distribution of I/O
clusters and where more then 12 I/O modules are required in an I/O Station.
The cluster address sets by a rotary switch on the Termination Unit
TU807/TU840/TU841/TU848/TU849 in range 1 to 7.
Figure 11 shows the layout of TB840.

S
P
Rx1
Rx2

ERx1
ERx2

TB840

Figure 11. TB840 ModuleBus Modem

46

3BSE020923-510 A

Section 1 IntroductionTB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849

The TB840/TB840A ModuleBus Modem provides 24 V d.c. short circuit proof

(from the source) and an isolated, short circuit proof 5 V dc power to the clusters
I/O modules by way of the electrical ModuleBus connection. One power source
(single or redundant 24 V d.c.) can be connected to the power terminals (L+ & L-).
Redundant power supply can be supervised via inputs SA and SB.
The rotary switch and the connector for power supply is located on the terminal unit.
Terminal unit TU807 is for single TB840/TB840A and single ModuleBus.
TU840/TU848 is for redundant TB840/TB840A and redundant ModuleBus.
TU841/TU849 is for redundant TB840/TB840A and single ModuleBus.
TU848 and TU849 have dual power supply connections.

3BSE020923-510 A

47

TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849 Module Termination

Electrical ModuleBus
interface connectors

MTU code keys

Power supply
connections

Cluster address switch

Redundant power
supervision

Figure 12. TU807 Module Termination Unit for TB840/TB840A

48

3BSE020923-510 A

Section 1 IntroductionTB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849

Electrical ModuleBus
interface connectors

MTU code keys

Cluster address switch

Power supply
connections

CUSTER ADDR.

Redundant power
supervision

Figure 13. TU840/TU841 Module Termination Unit for TB840/TB840A

3BSE020923-510 A

49

TB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849 Module Termination

Electrical ModuleBus
interface connectors

MTU code keys

Power supply
connections

Cluster address switch

Redundant
power supervision

Figure 14. TU848/TU849 Module Termination Unit for TB840/TB840A

50

3BSE020923-510 A

Section 1 IntroductionTB840/TB840A ModuleBus Modem and TU807/TU840/TU841/TU848/TU849

128 mm
(5.04)

47 mm
(1.85)
124 mm (4.88)

162 mm
(6.38)

186 mm
(7.32)

Figure 15. TB840/TB840A and TU841 Dimensions

Refer to specifications in Appendix B, Specifications for more information.

3BSE020923-510 A

51

TB825 Optical Media Converter

Section 1 Introduction

TB825 Optical Media Converter

ModuleBus Optical media converter, converts between plastic opto fiber or HCS
fiber with Versatile link connectors and glass optical fiber with ST connectors.
The TB825 is built in S800L mechanics and DIN rail mounted.

136

114

67.5

85.6

14.2

57.2

58.5

Figure 16. TB825 Optical Media Converter

TB826 Optical Media Converter

TB826 is a Long Range Optical Media Converter for the Modulebus. It is used to
convert between plastic/opto fiber or HCS fiber with Versatile link connectors and
single mode field fiber with SC connector.

52

3BSE020923-510 A

Section 1 Introduction

Module Termination Units

The TB826 is built in S800L mechanics and DIN rail mounted.

Figure 17. TB826Optical Media Converter

Module Termination Units

The Module Termination Units (MTU) are passive base units used to house the
S800 I/O modules. They contain the process wiring terminals.
Refer to specifications in S800 I/O Modules and Termination Units (3BSE020924*)
and S800 I/O Modules and Termination Units with Intrinsic Safety Interface
(3BSE020927*) for more information.

I/O Modules
There are two different types of I/O modules; S800 modules and S800L modules.
S800 modules are designed to be put into a MTU.

3BSE020923-510 A

53

S800 I/O Modules

Section 1 Introduction

S800L modules are designed to be put direct on a standard DIN rail and contain also
process connections and part of the ModuleBus.

S800 I/O Modules

The I/O modules have open ventilated plastic enclosures. On the front of each I/O
module there are three LEDs (FAULT, RUN and WARNING) indicating the module
status and digital I/O modules have a status LED for each channel, some even two.
One additional LED (OSP) is included on analog output and digital output modules.
I/O modules may be replaced in a fully operational I/O station. Mechanical keying
on modules and MTUs protect I/O modules from being inserted in positions where
they could be damaged by excessive voltage or current. An electronic type
designation ID in each module keeps the I/O module from being taken into
operation by the ModuleBus master, if a modules ID does not match the configured
module type definition in the data base.

S800L I/O Modules

The I/O modules have open vertical plastic enclosures and a bottom of sheet-metal.
On the front of each I/O modules there is a LED (STATUS) indicating the module
status (run or fault) and digital I/O modules have a status LED for each channel.
Refer to specifications in S800 I/O Modules and Termination Units (3BSE020924*)
and S800 I/O Modules and Termination Units with Intrinsic Safety Interface
3BSE020927*) for more information.

Power Supply
The SD82x and SD83x are switch-mode power supply units which convert the
mains voltage to 24 volts d.c. These power supplies can be utilized for nonredundant and redundant applications. Redundant applications require diode voting
units SS822, SS823 or SS832.
Please refer to specifications in Appendix C Specifications SD82x Power Supply
Modules, 24 V d.c.and Power Supply Units Types SD83x for more information.
The S800 I/O station/cluster can be powered by a single or redundant supply voltage
of 24 V d.c., see Figure 18 and Figure 19. Power supplies with 100-240 V a.c. or
110-300 V d.c. inputs and 24 V d.c. outputs are available to supply the I/O station

54

3BSE020923-510 A

Section 1 Introduction

Power Supply

and its field circuits. It is recommended to feed the I/O station/cluster and the field
circuits from different power supplies.

Power
Supply

24 V
A
B
FCI
or ModuleBus Modem

I/O station

24 V power supply
I/O modules

Figure 18. Installation Using Single Power Supply Unit

The ModuleBus master and ModuleBus Modem are able to supervise the redundant
voltage supply. The supervision function is individually configurable for power
supervision of each I/O station.

FCI
or ModuleBus Modem
Power
Supply
A
Power
Supply
B

Voting
Unit

24 V
A
B
I/O station
24 V d.c. power supply
Supervision 24V A, 24V B
I/O modules

Figure 19. Installation Using Redundant Power Supply Units

3BSE020923-510 A

55

G3 Compliant Modules

Section 1 Introduction

G3 Compliant Modules
In general, all S800 units are G3 compliant (for exceptions, see Product Overview
on page 24).
G3 is a severity level in the standard ISA-S71.04 Environmental Conditions for
Process Measurement and Control Systems: Airborne Contaminants, for further
information about the environment turn to the standard ISA-S71.04.
During transport, storage and installation special caution must be taken:

56

Dividable connectors/terminals must not be left unconnected/open in G3

environment if the are intended to be used later.

Module must not be stored in G3 environment due to unprotected

connectors/terminals, also valid for modules in packaging.

3BSE020923-510 A

Section 1 Introduction

Example of Enclosure Configurations

Example of Enclosure Configurations

In Figure 20 a layout example are shown for an I/O station in an RE820 cabinet
which could house the I/O station with power supplies for the I/O system as well as
for the field powering, and space for marshalling terminals.

POW POW

1000 mm (39.4")

FCI

800 mm (31.5")

Figure 20. RE820 Cabinet with 12 I/O Modules and Redundant Station Power
Supplies

3BSE020923-510 A

57

Support for External Intrinsic Safety System

Section 1 Introduction

Support for External Intrinsic Safety System

Beside S800 I/O modules with Intrinsic Safety Interfaces, Intrinsic Safety Systems
can be connected to the S800 I/O.
Intrinsic Safety System from Pepperl+Fuchs Elcon (manufacturer outside ABB) is
supported via S800 I/O module and a special MTU.
Supported Intrinsic Safety System is the HiD Series 2000.
The S800 I/O modules are connected via MTU TU812/TU812V1, a standard cable
and a specific adapter board, one for each I/O module types.
For further information refer to Elcon Instruments Manuals.
The following I/O modules are supported:
AI810, AO810/AO810V2, DI810 and DO810.
See Figure 21 for an example of a connection between S800 I/O and Intrinsic Safety
System.
S800 I/0

Intrinsic Safety System

Figure 21. Example of Connection between S800 I/O and Intrinsic Safety System
from Pepperl+Fuchs Elcon

58

3BSE020923-510 A

Section 1 Introduction

Support for External HART Communication

Support for External HART Communication

Beside S800 I/O modules with HART interface, Pepperl+Fuchs Elcon provides a
HART protocol connection to I/O modules integrated with the Intrinsic Safety
System, see Figure 22.
For further information refer to Pepperl+Fuchs Elcon.
To PC
RS485

S800 I/O

HART Multiplexer Connection

Intrinsic Safety System

Figure 22. Example of Connection between S800 I/O and Intrinsic Safety System
from Pepperl+Fuchs Elcon and HART Multiplexer Interface from HART

Redundancy
Figure 2 shows the basic construction of I/O Stations without any redundancy. To
increase the up-time, a number of component can be set up with redundancy:

Power Supply

I/O Module

Fieldbus Communication Interface (FCI)

Fieldbus

Electrical ModuleBus

3BSE020923-510 A

59

Redundancy

Section 1 Introduction

An example of a system using redundancy for all these components is shown in

Figure 23.
Redundant
Controller

ModuleBus
Optical Port

FCI

I/O Module

Electrical
ModuleBus

Optical ModuleBus Modem

I/O Cluster

Fieldbus
Optical
ModuleBus

I/O Cluster

Figure 23. I/O Station Overview with Maximum Redundancy and Additional Single
I/O Modules
It is not necessary to implement redundancy on all components, but there are some
dependencies:

60

Redundant power supply requires no other redundancy.

Redundant Advant Fieldbus 100 requires no other redundancy.

3BSE020923-510 A

Section 1 Introduction

Redundancy

Redundant PROFIBUS requires redundant FCIs

Redundant FCI requires:

redundant fieldbus

Redundant I/O Module (only in base cluster and on PROFIBUS) requires:

double electrical ModuleBus
redundant FCI
redundant fieldbus

Redundancy Functionality
Fieldbus Communication Interface (FCI). When using redundant FCI, one is

primary and one is secondary. The FCI will diagnose itself, and when the primary
FCI fails it will hand over to the secondary FCI.
If using redundant FCI and redundant electrical ModuleBuses only on PROFIBUS,
the primary FCI will control both electrical ModuleBuses. When the primary FCI
fails, the secondary FCI will take control of both electrical ModuleBuses.
Input Modules. When using redundant input modules, all reading is done from the

primary input module. The input module will diagnose itself, and when the primary
input module fails the reading will be done from the secondary input module.
The secondary AI module is checked for error status at a lower cycle rate than the
primary.
Analogue Output Modules. When using redundant AO modules, half the output
current is generated from each AO module. The AO module will diagnose itself, and
when one fails, it disconnects and a direct communication between the two
redundant AO modules will ensure that the second AO module quickly doubles its
output current.
Digital Output Module. When using redundant DO modules, they both work

parallel to each other. They give the same output.

When one DO module fails it will give output signals set to low. The DO module
that still work will override by setting active signals to high.

3BSE020923-510 A

61

Redundancy

62

Section 1 Introduction

3BSE020923-510 A

Section 2 Installation
This section contains guidelines for planning the installation of the S800 I/O
equipment.
This section does not give the complete list of measures to be taken with respect to
environment and other conditions on site. The equipment should be adapted to the
actual application by thorough system definition and design.
Since each system is designed to meet a specific requirement, there is no standard
configuration that describes every system. Therefore, certain areas of the following
instructions are meant only as a guide for planning a specific installation.
However, some of the information covers specific requirements for proper system
and equipment operation, and is not subject to modification.
All information given in this section relates to standard equipment.
For installation of Advant Fieldbus 100 and Advant Fieldbus 100 modems, see S800
I/O Fieldbus Communication Interface for Advant Fieldbus 100 (3BSE020925*)
manual.
For installation of PROFIBUS, see PROFIBUS DP Wiring and Installation
(3BDS009029*) manual.
For installations of S800 I/O modules with Intrinsic Safety Interface see S800 I/O
Modules and Termination Units with Intrinsic Safety Interface (3BSE020927*)
manual.

3BSE020923-510 A

63

Site Planning

Section 2 Installation

Site Planning
Site Selection and Preparation
When planning an S800 I/O installation, consider the following:

Surrounding environment and atmosphere.

The temperature in the room where the equipment is to be located.

This should include an estimation of the resulting temperature rise with respect
to the power dissipation from the planned equipment.

Proximity of the equipment to the process.

Size of the cabinets to accommodate all the required equipment.

Minimum distances from a cabinet to walls and ceiling to obtain satisfactory

results from different aspects.

Ease of access for moving equipment in and out of area.

Free space in front of cabinets. Also consider the need of space to fully open a
cabinet door either left hand or right hand hinged.

Spare area for future expansion of the system.

Grounding by an effective connection to the grounding plane.

Cable routing with respect to installation rules.

Availability of power and other utilities.

The following sections examine some of these factors in detail and provide
recommendations and requirements as necessary.

Environmental Considerations
General

S800 I/O equipment can be installed in a designated control room, or located in the
process area when housed in a suitable enclosure. The S800 I/O is designed for a
demanding industrial environment.

64

3BSE020923-510 A

Section 2 Installation

Environmental Considerations

Temperature
I/O Module Factors. The maximum ambient air temperature around S800 modules
is 55C (131F) for I/O modules mounted on Extended MTUs on vertical or
horizontal orientated DIN-rails, or I/O modules mounted on compact MTUs on
horizontal oriented DIN-rails. I/O modules mounted in Compact MTUs on a vertical
DIN-rail allows operation at 40C (104F).

The maximum ambient air temperature around S800L modules is 55C (131F) for
I/O modules mounted on horizontal orientated DIN-rails. It is 40C (104F) for I/O
modules mounted on vertical oriented DIN-rails.
The ambient temperature de rating which applies for vertical DIN rail and Compact
MTUs is due to the reduced air flow through an I/O module due to the orientation.
The different hardware modules in the S800 I/O have different outputs of heat.
Accurate calculation of the heat produced by the system requires knowledge of the
modules and the work cycle. Power supplies with regulated outputs are highly
recommended to minimize heat in cabinets. Use of such devices will reduce the
power loss of resistive loads and current outputs, for example, digital inputs and
analog outputs. Refer to Power and Cooling on page 165 for more information.
Cabinets Factors. The temperature within cabinets and in the surrounding

environment and atmosphere must be considered, especially when using sealed

cabinets (IP65/IP54) or tropicalized cabinets (IP41) with considerable equipment
and outside ambient temperatures at levels approaching 40C (104F). The
frequency of faults is estimated to double for each 20C (36F) increase in
temperature. Thus, it is important to maintain as low ambient temperature outside
the cabinets (typical operating range 5 - 40C (41 - 104F)) as possible where the
equipment is installed. Design considerations are given in Heat Dissipation
Permitted in Cabinets on page 162.
Vibration

The cabinets are to be located on a stable floor, wall, deck or supporting structure,
free from vibrations.
If the system equipment is installed in a control room adjacent to large machinery
such as shakers or large presses, where frequent major vibrations occur, shock

3BSE020923-510 A

65

Electromagnetic Compatibility and CE Marking

Section 2 Installation

absorbers or an isolation pad may be required to protect the system equipment.

Shock absorbers normally protect the equipment from sustained low level vibrations
(vibrations that are perceptible, but not excessive). If vibrations or shock is a major
problem, more extreme measures must be considered to alleviate the problem, such
as fasten the MTUs with extra screws.

Electromagnetic Compatibility and CE Marking

Grounding, cable selection and cable routing must be considered for
electromagnetic interference-free operation. Planning considerations are discussed
in the following sections. Instructions for implementing these plans are provided in
Installation Procedures on page 105.
The S800 I/O meets requirements specified in EMC Directive 2004/108/EC.

Layout of I/O Stations

I/O Station with S800 I/O

The S800 I/O is mounted on a standard DIN-rail according to EN 50022 NS35/7,5.

The DIN-rail is mounted in a cabinet or on an enclosure wall to a metal sheet with
fastening screws every 100 mm to ensure a good ground connection in the cabinet or
an open rack. The ModuleBus master, ModuleBus Modem, MTUs and S800L I/O
modules are mounted to the DIN rail. In environments with major vibrations, the
MTUs shall also be screwed on the metal sheet. The FCI, ModuleBus Modem and
MTUs have a snap locking device that attaches it to the mounting rail.
It is possible to mount the FCI, ModuleBus Modem, MTUs and S800L I/O modules
both vertically and horizontally.
To mount the FCI, ModuleBus Modem, MTU or S800L, place it on the top edge of
the DIN rail, release the rail latch with a flat blade screw driver and snap the bottom
mechanism into place. When the unit is in place on the DIN rail and in position, take
away the screw driver and the rail latch will fix the unit in position on the DIN rail.
Release the unit from the DIN rail in a similar way.
S800L module has screw locking device that attaches it to the mounting rail.

66

3BSE020923-510 A

Section 2 Installation

Layout of I/O Stations

Mounting Procedure for S800L I/O

Use a screwdriver with a 1 mm (0.03 inch) tick flat blade that fits the locking screw.
This is the only tool you need for the mounting. See Figure 24 and Figure 25.
1.

Turn the locking device to open position (1) and hook the lip at the rear of the
unit onto the DIN rail and snap the unit into position.

2.

Turn the screw to the slide position (2). Now you can slide the unit along the
rail to desired position and join it to another unit. Make sure that the connector
pins and sockets are in line. Do not use excessive force!

3.

Turn the screw clockwise to locked position (3). The unit is now locked and
has good earth connection to the DIN rail.It is essential that the locking device
is in locked position to avoid problems due to vibration and inadequate
grounding.

1. Open

2. Slide

3. Locked

Figure 24. Mounting Procedure

3BSE020923-510 A

67

Layout of I/O Stations

Section 2 Installation

DO801

Turn the screw counterclockwise to

release the locking device

Figure 25. Unlocking the S800L I/O Module

68

3BSE020923-510 A

Section 2 Installation

Layout of I/O Stations

A flat blade screw driver can be used to release the latch to allow easier movement
along the DIN rail or removal of the unit (Figure 26).

DIN-rail

I/O Module
Lock/Switch
To

E
F

Lock

A
E
F

B
C

Ground
Clip Spring

B
C

L1+ C1 2

Move up to
release rail
latch

L1+ B1 2
L1- A1 2

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

A8 L2-

Pry down to
release rail
latch

Figure 26. MTU Latching System

Snapping the FCI, ModuleBus Modem or MTU to the DIN-rail makes contact by a
grounding spring with the chassis.

3BSE020923-510 A

69

Layout of I/O Stations

Section 2 Installation

Connection of the MTU, or S800L module, ModuleBus connector to the FCI,

ModuleBus Modem, next MTU or S800L module is made by sliding the MTU or
the S800L module along the mounting rail and then locking it in place (Figure 27).

R
P

T1

E
F

E
F

B
C

AF100
1

A
B
C

SWX.X/Y
L+ L+ SA
L- L- SB

A
B
C

STN. ADDR.
4 56
3
7 x 10
2
8
109
4 56
3
7x1
2
8
109

CI810

B
C

SERVICE

E
F

E
F

T2

Tx Rx
2

SH
SH

Tx

L1+ B1 2

SH
SH

L1+ C1 2

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

L1+ C1 2
L1+ B1 2

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

Rx
L1- A1 2

A8 L2-

L1- A1 2

A8 L2-

Figure 27. I/O Station Installation Diagram

70

3BSE020923-510 A

Section 2 Installation

Layout of I/O Stations

The MTU and S800L module (locking screw in position) can be disconnected from
the FCI, ModuleBus Modem, another MTU or S800L module by using a screw
driver and pressing it between the two items.

T1

T2

E
F

D
D

AF100
1

A
B
C

SWX.X/Y
L+ L+ SA
L- L- SB

DO801

E
F

STN. ADDR.
4 56
3
7 x 10
2
8
109
4 56
3
7x1
2
8
109

CI810

A
B
C

SERVICE

Tx Rx
2

SH
SH

SH
SH

Tx

L1+ C1 2

L1+ B1

5 6 7

C8 L2+

B8 L2+

Rx
L1- A1

A8 L2-

Figure 28. Module Release

Redundant FCI Installation AF100

Installation of an I/O Station with redundant FCIs requires two CI820/CI820V1

FCIs and a TB815 Interconnection Unit (Figure 29). They are connected to the I/O
modules of the base cluster by an electrical ModuleBus extension cable. From the

3BSE020923-510 A

71

Layout of I/O Stations

Section 2 Installation

TB815 ModuleBus connector, a TK801V0xx cable is connected to the first MTU

via a TB806 Cable Adapter-in module.

T1

T2

PR

DU

M
O
D
U
L
E
B
U
S

SERVICE

CI820

T1

P
DU

SERVICE

STN. ADDR

TB815

CI820

4 56
3
7 x 10
2
8
109
4 56
3
7x1
2
8
109

SWX.X/Y

SWX.X/Y

L+ L+ SA
L- L- SB

R
T2

PR

STN. ADDR

4 56
3
7 x 10
2
8
109
4 56
3
7x1
2
8
109

L+ L+ SA
L- L- SB

AF100
+
SH
SH

Tx

Rx

AF100
+
SH
SH

Figure 29. Redundant CI820 FCIs and TB815 Interconnection Unit Layout
The redundant FCIs can either be mounted on a separate DIN rail or the same one as
the I/O modules. Room must be allowed to the left and right of the FCIs for
disconnection from the TB815 for removal (Figure 30).
The total length of the ModuleBus extension, from the TB815, and ModuleBus
segments of the I/O modules must not exceed 2.5 meters (8.2 feet).

72

3BSE020923-510 A

Section 2 Installation

Layout of I/O Stations

11
12
13
14
15
16

E
F

DI810
24V

DI810
24V

11
12
13
14
15
16

A
E
F

E
F

11
12
13
14
15
16

STN. ADDR
4 56
3
7
2
8 x 10
109
4 56
3
7
2
8 x1
109

E
F

5
6
7
8
9
10

E
F

5
6
7
8
9
10

Rx

5
6
7
8
9
10

Tx

1
2
3
4

A
B
C

+
SH
SH

1
2
3
4

B
C

L+ L+ SA
L- L- SB

AF100

1
2
3
4

B
C

CI820

F
R
W

B
C

TB815

F
R
W

B
C

L+ L+ SA
L- L- SB

SERVICE

F
R
W

B
C

CI820

STN. ADDR
4 56
3
7
2
8 x 10
109
4 56
3
7
8 x1
2
109

R
P
T2
DU

SERVICE

T1
PR

F
M
O
D
U
L
E
B
U
S

R
P
T2
DU

F
T1
PR

E
F

Optical ModuleBus Extension can be connected to the TB815 via the TB810
ModuleBus Optical Port unit for connection of 1 to 7 additional I/O clusters.

DI810
24V

AF100
+
-

TB806

SH
SH

L1+C1 2 3 4 5 6

7 C8 L2+

L1+B1 2 3 4 5 6 7 B8 L2+
L1- A1 2 3 4 5 6 7 A8 L2-

L1+C1 2 3 4 5 6 7 C8 L2+
L1+B1 2 3 4 5 6 7 B8 L2+
L1- A1 2 3 4 5 6 7 A8 L2-

L1+C1 2 3 4 5 6 7 C8 L2+
L1+B1 2 3 4 5 6 7 B8 L2+
L1- A1 2 3 4 5 6 7 A8 L2-

TK801V003
(300 mm)
(1 ft.)

Figure 30. Connection of Redundant FCIs to I/O Modules

Redundant FCI Installation Profibus

Installation of an I/O Station with redundant FCIs requires two CI840 FCIs and one
TU846 or TU847 (Figure 31). They are direct connected to the I/O modules of the
base cluster.
TU846 are used with redundant I/O modules and TU847 with single I/O modules.

3BSE020923-510 A

73

Layout of I/O Stations

Section 2 Installation

CI840

Connection to
Electrical ModuleBus

F
R
P
Rx/Tx
PRIM
DUAL

F
R
P
Rx/Tx
PRIM
DUAL

CI840

Service
ports

Address Switches

Figure 31. Redundant CI840 FCIs on TU847

The total length of the electrical ModuleBus, must not exceed 2.5 meters (8.2 feet).
ModuleBus Extension (Electrical)

When the next MTU or S800L module is located away from the previous MTU,
S800L module, then a TK801V0xx ModuleBus Extension cable must be used. The
previous MTU or S800L module will require a TB805 Cable Adapter-out to be
plugged into the ModuleBus-out connector. The TK801V0xx cable is then

74

3BSE020923-510 A

Section 2 Installation

Layout of I/O Stations

connected to the TB805 adapter. The next MTU will have a TB806 Cable Adapterin plugged into the ModuleBus-in connector and then connected to the other end of
the ModuleBus Extension cable. See Figure 32.
In case of redundant I/O two TK801V0xx ModuleBus Extension cables, a Cable
Adapter-out TB845 instead of TB805 and a Cable Adapter-in TB846 instead of
TB806 are needed. See Figure 33.
The TB805/TB806 ModuleBus Cable Adapter-Out/In adapters mount on the DINrail. Each has a latch that locks it to the rail. There is also a grounding spring that
connects it to the DIN-rail. The latch can be released with a screw driver and the
adaptor moved toward or away (for removal) from the MTU or S800L module.
The ModuleBus Extension cable comes in three standard lengths:

TK801V003 - 300 mm (1 ft.)

TK801V006 - 600 mm (2 ft.)

TK801V012 - 1.2 meters (4 ft.).

3BSE020923-510 A

75

Layout of I/O Stations

Section 2 Installation

ModuleBus length must not exceed 2.5 meters (8.2 feet) from FCI, TB815
Interconnection Unit, or ModuleBus Modem to the last MTU or S800L module
including extension cables.
TB805

Latch Release

E
F

D
4
4

5
5

Female Cable
Connector

7 C8 L2+

7 A8 L2-

E
F

DI810
24 V

Male Cable
Connector

L1+ C1 2

7 B8 L2+

B
C

B
C

L1- A1 2

3
3

E
F

E
F

B
C

DI810
24 V

L1+ C1 2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

B
C

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

L1+ B1 2

F
R
W

TB806

F
R
W

L1+ B1 2

TK801V003
(300 mm)
(1 ft.)

L1- A1 2

3
3

4
4

5
5

7 C8 L2+
7 B8 L2+

6
6

7 A8 L2-

Figure 32. ModuleBus Extension Cable Connections, single I/O

76

3BSE020923-510 A

Section 2 Installation

Layout of I/O Stations

TB84x

TB84x
TB845
TB846

I/O

I/O

TK801V0xx

Figure 33. ModuleBus Extension Cable Connections, Redundant I/O

Optical ModuleBus Expansion Single Configuration

The FCI (Fieldbus Communication Interface) provides fiber optic expansion of the
ModuleBus for up to 7 additional I/O clusters or to drive equipment. The
TB810/TB811 ModuleBus Optical Port must be inserted in to the CI810 or CI830
FCI or TB815 Interconnect unit (redundant CI820/CI820V1) to provide optical
ModuleBus expansion. See Figure 34 for location of the TB810/TB811 on the
CI810/CI830 FCI and Figure 35 for location in the TB815 Interconnection Unit.

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Layout of I/O Stations

Section 2 Installation

4
3
2
1
4
3
2
1

CI810

AF100
L+ L+ SA
L- L- SB

56
09
56
09

7 x 10
8
7x1
8

TB810

Tx Rx
2

SH
SH

SH

Tx

SH

Rx

Figure 34. Location of TB810/TB811 ModuleBus Optical Port in CI810 FCI

SERVICE

SERVICE

STN. ADDR

CI820

L+ L+ SA
L- L- SB

4 56
3
7 x 10
8
2
109
4 56
3
7x1
8
2
109

STN. ADDR

CI820

TB815

L+ L+ SA
L- L- SB

AF100
+
SH
SH

4 56
3
7 x 10
8
2
109
4 56
3
7x1
8
2
109

AF100
+
-

Tx

SH
SH

Rx

TB810

Figure 35. Location of TB810/TB811 ModuleBus Optical Port on the TB815

78

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Layout of I/O Stations

The TB842 ModuleBus Optical Port must be connected to CI840 via TB806 or
TB846 and TU846 or TU847. TB806 and TU847 for single I/O, see Figure 36, and
TB846 and TU846 for redundant I/O, see Figure 37.
TB810 and TB842 has 10 Mbit drivers and is used with the TB820/TB820V2 (S800
I/O) and ABB drives equipment. TB811 has 5 Mbit drivers and is used with ABB
drives equipment. The TB811 can only use up to 10 meters (33 ft) plastic optic fiber.
A ModuleBus must have the same type of drivers on each node

CI801 or
CI840/TU847

TB806

TB842
1

Figure 36. TB842 and TB806 Connected to CI801 or Redundant CI840 FCIs
Through TU847

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Layout of I/O Stations

Section 2 Installation

TU846

CI840
TB846

TB842

Figure 37. TB842 and TB846 Connected to Redundant CI840 FCIs Through TU846
After optical expansion of the Modulebus, only single I/O configurations can be
used.
Each I/O cluster can have a maximum of 12 S800 I/O modules. The maximum
number of S800 I/O modules or other units connected to one FCI is 24. The optical
ring connection or duplex connection allows for a maximum distribution of 15m
(49 ft.) (plastic fiber) or 200m (667 ft.) (HCS fiber) between each I/O cluster, see
example in Figure 38.

80

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Layout of I/O Stations

FCI

FCI

Simplex optical cable (TK812Vxxx)

15m (49 ft.)Max. (plastic fiber)

Duplex optical cable (TK811Vxxx)

15m (49 ft.) Max. (plastic fiber

ModuleBus Optical Port TB810

ModuleBus Modem TB820/TB820V2

TB807 ModuleBus Terminator

Fiber Optic Simplex Configuration

Fiber Optic Duplex Configuration

Figure 38. Optical ModuleBus Expansion, Simplex and Duplex Configurations

The TB820/TB820V2 can be used in both a simplex optical configuration as well as
in a duplex optical configuration. In a simplex optical configuration, the optical
ModuleBus nodes are connected in a ring. In a duplex optical configuration,
the optical ModuleBus nodes are connected in a row.

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Layout of I/O Stations

Section 2 Installation

The optical ModuleBus Extension fiber optic (plastic fiber) cable comes in three
standard lengths:

TK811V015 (duplex), TK812V015 (simplex) - 1.5 meters (5 ft.)

TK811V050 (duplex), TK812V050 (simplex) - 5 meters (16 ft.)

TK811V150 (duplex), TK812V150 (simplex) - 15 meters (49 ft.)

As with the FCI (base cluster), the electrical ModuleBus length must not exceed
2.5 meters from the ModuleBus Modem to the last MTU or S800L module of each
cluster. Each cluster requires a TB807 ModuleBus Terminator plugged into the last
MTU or S800L module.
Optical ModuleBus Expansion Redundant Configuration

Redundant Optical ModuleBus Expansion can only be used with redundant

AC 800M Controller. Redundant Optical modem TB840/TB840A and TU840 for
redundant I/O and TB840 and TU841 for single I/O. See Figure 39.
Redundant AC 800M

TB840/TB840A
I/O Cluster

Figure 39. Optical Module Expansion Redundant Configuration

I/O Module Installation

Connection of the I/O module to the MTU is made by setting the I/O Module Keys
#1 and #2 to the correct setting, place the I/O Module Lock/Switch to the unlock
position and then push the I/O module straight onto the MTU. The I/O module is
locked and electrically connected to the MTU by the I/O Module Lock/Switch.

82

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Layout of I/O Stations

R
W

I/O Module Lock/Switch

(shown locked)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

I/O Module Lock/Switch

(shown unlocked)

E
F

E
F

Turn clockwise
to lock I/O Module

E
F

I/O Module
Key #1

B
C

B
C

D
E
F

B
C

DI810
24V

B
C

I/O Module
Key #2

Figure 40. MTU Mechanical Keys for I/O Module and Module Lock

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Layout of I/O Stations

Section 2 Installation

Figure 41. Mounting of I/O module on MTU

At the mounting of a S800 I/O Box on a Termination Unit the following should
be observed:
Press the Box straight and right on to stop into the Termination Unit. Above
shown angle shall be 0.
Turn the Locking Device clockwise to its end position. Above shown state with
the Locking Device in a position before end position shall not exist for an active
module.
Do not turn the I/O Module Lock/Switch counter-clockwise from the unlocked
position. This will cause it to break and will make the MTU and the I/O module
inoperative.

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Layout of I/O Stations

After all the MTUs or S800L module are connected, the TB807 ModuleBus
Terminator connects to the ModuleBus connector of the last MTU or S800L module
of the I/O cluster. The TB807 has a snap latch (Figure 42) that holds it in place. To
release the terminator, the latch has to be squeezed to allow removal.

Top View
F
R
W
TB807
1
2
3
4
5
6
7

ModuleBus
Terminator
Latch

Figure 42. TB807 ModuleBus Terminator Installation

The I/O cluster configuration can be as shown in Figure 43 and/or as presented in
S800 I/O Modules and Termination Units and Example of Enclosure Configurations
on page 57.
The space between the I/O modules or FCIs are ca 0.8 mm (0.03)

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Layout of I/O Stations

Section 2 Installation

826 mm (32.5")

End Stop

End Stop

DIN-rail
mm
(inches)

10
(0.4)

84
(3.3)

20
(0.8)

58.5
(2.3)

Figure 43. I/O Station Layout with FCI and S800 I/O Modules

443,8 mm (17.5")
ModuleBus Modem TB820/TB820V2

Fiber Optic
ModuleBus Cables
10
58
(0.4) (2.2)

58.5
(2.3)

20
(0.8)

mm
(inches)

Figure 44. I/O Station Layout with ModuleBus Modem and S800 I/O Modules

In all installations, two end stops must be mounted on the DIN-rail, one at each
end of the cluster, to prevent the modules from moving along the rail, see
Figure 43.

86

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Layout of I/O Stations

The installation rules should be followed as much as possible. The flexibility of the
system allows both horizontal and vertical mounting of the rail and mixing of MTU
types as shown in Figure 45.

Status

S1 2 34 5 6 7 89 10 1112 1314 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

S 12 3 4 5 67 8 9 10 1112 13 1415 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Status

Figure 45. Compact, Extended MTU and S800L Modules showing Horizontal and
Vertical Mounting
Mounting Kit for CI801/CI840/CI840A/TB840/TB840A

The Mounting Kit is used for horizontal mounting of CI801/CI840/CI840A and

TB840/TB840A on a vertical DIN-rail.

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Layout of I/O Stations

Section 2 Installation

The Mounting Kit is locked to the vertical DIN-rail by a DIN rail lock, which is
screwed and tightened to the Mounting Kit by two M4 screws, see Figure 46.
Tighten with M4 screws
Torque = 2Nm

DIN-rail lock
Below DIN-rail

Below DIN-rail

Figure 46. Locking of Mounting Kit to the vertical DIN-rail

88

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Mechanical Installation

The modules will be placed on the Mounting Kit, locked by the locking device, and
screwed with M4 screws into the Mounting Kit, see Figure 47.

M4 screws

Figure 47. Mounting of modules on the Mounting Kit

Mechanical Installation
There are two ways of mounting AC 800M and S800 I/O in cabinets, open rack, or
other types of installations:

Mounting on DIN rail attached to a metal sheet

Mounting on prefabricated aluminium profile

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Mechanical Installation

Section 2 Installation

All cabinet structure components must be bonded together with good and permanent
ground connections. The connections should preferably be made with
self-tapping Taptite screws with cutting head. Where self-tapping Taptite screws
cannot be used on painted components, the paint must be removed under the head of
the screw and the nut and the surface must be smeared with conductive grease.
The metallic parts in the cabinet shall be properly connected to plant ground.
Prefabricated Aluminium Profile

There are aluminum profiles for horizontal and vertical mounting. The aluminum
profile gives an excellent grounding and rigid mounting of products concerned. The
aluminum profile shall be fastened to the cabinet with at least 4 fastening screws.
The profile has grooves for self-tapping screws (ST 4.89.5) that can be used for
fastening the modules in an environment with high vibrations.
The aluminum profiles have one DIN-rail and one cable duct and are available in
different sizes, see Figure 48.
Horizontal mounting:

482 mm (19) ordering number 3BSE022255R1

609 mm (24) ordering number 3BSE022256R1
736 mm (29) ordering number 3BSE022257R1

Vertical mounting:

1806 mm (71") ordering number 3BSE049768R1

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Grooves for self-tapping screws

ST 4.8x9.5, used for fastening in
environments with high vibrations

Mechanical Installation

End support
3BSE022471R1

Fasten with
self-tapping screws
Taptite M6x10

Figure 48. MTU mounted on aluminium profile

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Mechanical Installation

Section 2 Installation

Figure 49. Cabinet with Controller on prefabricated aluminium profiles

Mounting on Metal Sheet

The DIN-rail shall be mounted on an unpainted metal sheet with fastening screws
every 100 mm to ensure good mechanical stability and a good chassis ground
connection in the cabinet or an open rack, see Figure 2.
The metal sheet shall at least be 2.5 mm thick and at least 178 mm (4U) high,
preferably with at least one long edge bent 90 degrees to increase the stability. The
metal sheet shall be mechanically fastened at least every 500 mm to the cabinet or
rack, nevertheless with a minimum of four screws. The fastening to the cabinet
frame shall be performed with fastening screws to get a good grounding connection.
DIN-rail type with height 7.5 mm shall be used. Refer to type NS 35/7.5 according
to standard EN50022.

92

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Mechanical Installation

Fasten with self-tapping

screws Taptite M6x10

DIN-rail (height 7.5mm) mounted

with self-tapping screws Taptite M6x10

For all bolted joints,

ensure good
electrical contact
to chassis

Figure 50. Mounting on unpainted metal sheet

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Grounding

Section 2 Installation

Figure 51. Cabinet with Controller and I/O on metal sheet

Grounding
General

The plant ground potential must be stable and well defined, even in the event of a
low ground fault caused by high voltage equipment or a lightning strike. The
interference suppression for external signals, are normally directly grounded to
plant ground.
For interference free operation, the S800 I/O system need to be connected properly
to plant ground.

94

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Grounding

Each S800 I/O module's grounding spring connects to the metallic DIN-rail which
serves as the module electronics ground conductor between the inter-connected
devices. This is to ensure a good ground connection both for the internal logic and
for the EMI immunity and RF emission of the modules.
The DIN mounting rail must therefore have a good bond to the cabinet structure
which shall be connected to plant ground. How to get a good bond from DIN-rail to
cabinet structure is described in the mechanical installation section.
The ground wire which joins the grounding systems and connects to the cabinet to
plant ground should be 35 mm2 (2 AWG) copper (Cu), see Figure 52. The ground
wire should be fastened firmly to a unpainted surface of the cabinet structure.
Cabinets
or enclosure

Shield bar

Connection to
ground plane
Ground Plane
> 35 mm2

(> 2 AWG)

Figure 52. Grounding of Electronic Equipment

Protective Earth (PE)

Cabinets supplied with 120/230 V a.c. always must be connected to protective earth
(PE) grounding.

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Signal Cable Considerations

Section 2 Installation

Grounding of Signals and Voltage Supply

For minimum interference and maximum accuracy, it is normally most effective to

ground supply voltages for transducers, sensing voltage for contacts, load supply
voltage and so on at the same location. Since all I/O modules have galvanic isolation
from ground, different groups of channels can be grounded in different locations.
All channels within a group shall have a common ground reference.
In the event that the above recommendations (because of measurement techniques
or safety regulations) cannot be complied with, be sure to use these methods:

Signal isolation for analog input signals.

Digital inputs and outputs are divided into groups at the MTUs and I/O
modules, with supply voltage distribution and grounding common for each
single groups.

Local grounding of a signal at the transducer location may be a requirement in some

cases. This normally hinders the use of MTUs for voltage distribution. A
distribution bar with the terminal block and fuse equipment required by the
application can be used in such cases.
If the transmitter/transducer has galvanic isolation of the supply, its signal zero can
be grounded where most suitable for measurement accuracy.

Signal Cable Considerations

When planning for the cable routing in the plant and when selecting suitable cables
to be used, the following should be considered:

Routing of communication cables with regard to a.c. power wiring.

Mixing of signals and signal types within cables.

Need of shielded or un-shielded cables.

Recommendations for Signal and Process Cable

For use in a typical industrial environment according to the basic protection:

1.

96

Unshielded lines are adequate for binary signals and high level (0...20 mA,
10 V...) analog signals.

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Section 2 Installation

Signal Cable Considerations

2.

Shielded cables should be used for low level (RTDs, TC...) analog signals,
HART1 signals, pulse transducer signals and High Integrity I/O modules.

3.

Minimize the loop area formed between the cable and earth (environment
ground), for example by laying the cable on metallic trays that are earthed at
several points. Closed cable conduits provide an additional
attenuation of up to 30 dB.

4.

Usage of binary and analog signals in a multi-core cable works fine, if the
following conditions are fulfilled:

All binary signals are 24 V d.c. or slow varying analog signals.

Field power supply is earthed to S800 earth.

All multi-core cable signals are earthed to S800 earth (same earth as the
field power supply).

Binary signals are suppressed. (S800 semiconductor binary outputs have

built-in free-wheel diodes for smooth inductive load switching.)

If cable shield, it should be connected to S800 earth.

Three wire analog transducers with voltage outputs should have individual
power return wires to avoid voltage drop caused by binary loads return
current.

In other cases use separate cables for analog, binary and heavy current lines.
Lay the cables separately sorted according to type.
The signal cables and heavy current cables (power supply cables > 600V)
should be in separate conduits or at least 30 cm apart from each other.
5.

The return-conductor should be in the same cable as the signal.

6.

The field cables must be wired according to the recommendations of Table 5.

7.

Advant Fieldbus cable installed per S800 I/O Fieldbus Communication

Interface for Advant Fieldbus 100 (3BSE020925*).

8.

PROFIBUS-DP cable installed. Refer to PROFIBUS DP Wiring and

Installation 3BDS009029* manual.

1.

Shielded twisted pair cables should be used for HART signals.

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Power Requirements

Section 2 Installation

Power Requirements
General

Power supplied to ABB systems power supply units and for external supply to I/O
can normally be obtained from the plant a.c. or d.c. supply sources.
A.C. Supply

A power source can be rated as Installation Category II or III with respect to level of
disturbances, voltage variations and so on, according to IEC standards. Standard
voltage range is 100 - 240 V a.c. Installation Category II denotes a higher quality
than III mains. The S800 I/O power supplies SD82x and SD83x are rated for
Overvoltage Category II on the secondary side and Overvoltage Category III on
primary side.
D.C. Supply

Table 4. Requirements for d.c. Supply Sources

Device

Voltage Range

FCI/ModuleBus Modem

19.2 - 30

SD821/SD822

225-250

SD823

250

SD831/SD834

110-300

Hazardous Location North American Approval (cULus)

If indicated on the label the unit is suitable for use in Class 1 Zone 2 and in Class 1
Division 2 Groups A, B, C or D hazardous locations (or in nonhazardous locations).
Units must be installed in an enclosure providing at least IP54, according to
IEC 60529.
Provision shall be made to prevent transient disturbances of more than 40% of rated
voltage at the power supply terminals.

98

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Hazardous Location European Approval (ATEX)

Please notice that the following restrictions must be followed when equipment are
installed in hazardous locations:
Explosion hazard!
Do not disconnect equipment unless power has been removed or the area is
known to be non-hazardous.
Explosion hazard!
Substitution of components may impair suitability for Class 1 Zone 2 and
Class 1 Division 2.
Explosion hazard!
Do not replace batteries unless power has been switched off or the area is known
to be non-hazardous.
Explosion hazard!
Do not remove fuses unless the area is known to be non-hazardous.
Marking: Class 1 Zone 2 AEx nC (or nA) IIC T4 and CL 1 DIV 2 GP A B C D T4

Hazardous Location European Approval (ATEX)

If indicated on the label or by documentation the unit is suitable for use in
potentially explosive atmospheres according to the EU directive 94/9/EC, the
installation is allowed in Zone 2 or in safe area. For more information, refer to the
Users Guide 3BSE020927*.
Marking: ATEX (Ex / EEx)

High Voltage Switch-gear Applications

The I/O modules are not designed for direct connection to high voltage switch-gear.
Interposing relays are used for digital input and output signals as a connecting link.
For analog signals, special transmitters/converters are used.

Lightning Strike Protection

Industrial installations and power plants are normally provided with well-integrated
grounding networks installed together with the power distribution system.
In installations with such grounding systems, it is not necessary to install lightning
strike protection unless overhead wiring or suspended cables are used outdoors.

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Inductive Load Suppression

Section 2 Installation

Large plants (water supply installations, refineries and so on) can however have an
inadequate grounding system and signal cables can be routed above ground. In such
cases lightning strike protection must be used.
Cables outside the grounding system (even for short distances such as 10 m) always
require lightning strike protection.

Inductive Load Suppression

Inductive loads, such as relays and contactors, connected directly to products, do not
require suppression. The necessary suppression components (varistors or snubbers RC units) are installed on the circuit boards.

Mounting Dimensions
When placing a control cabinet, specified minimum distances to walls and ceiling
must be kept to ensure satisfactory performance.

(6)

Min 150 mm

Overhead Clearances

Figure 53. Minimum Distance to Cabinets

To ensure adequate ventilation, there should be a free space, 150 mm (6") high,
between the top of the cabinet and the ceiling, the underside of any beam, duct or
similar object over the cabinet. When cables enter the cabinet from above, the space
available should be at least 1000 mm (40") high to provide working space, see
Figure 53.

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Mounting Dimensions

Standoffs for Wall

Mounted Enclosures

Min 40 mm
(1.6 inches)

Rear and Side Clearance

Min 40 mm
(1.6 inches)

Figure 54. Minimum Distance from Rear and Side of Cabinet to a Wall
The distance between the rear and the sides of the cabinet and an adjacent wall
should be no less than 40 mm (1.6 inches), see Figure 54. This will ensure good
ventilation. The free space in front of the cabinet should be the width of the door
plus aisle width.
Wall mounted enclosures should use standoffs equal to the clearance requirements.
Clearances within an Enclosure

Clearances within an enclosure with horizontally mounted I/O modules are

described in Figure 55.

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Mounting Dimensions

Section 2 Installation

800 mm (31.5")
Min
100 mm (3.9)

Min
8 mm (0,03)

FCI

Min
8 mm (0,03)

Min
8 mm
(0,03)
Min
8 mm (0,03)

Min
100 mm (3,9)

1000 mm (39.4")

Min
100 mm (3.9)

SD SD
822 822

I/O

Min 40 mm (1.6)
Min 100 mm (3.9)

Cable channel
Min 25 mm (1) if the cable channel is higher than 40 mm (1.6)

I/O

Figure 55. Enclosure with 12 Modules mounted horizontally and Redundant Station
Power Supplies

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Electrical Installation Overview

Clearances within an enclosure with vertically mounted I/O modules are described
in Figure 56.

Min
100 mm (3.9)
Min
100 mm (3.9)

800 mm (31.5")

Min
100 mm (3.9)

SD SD
822 822

Min
100 mm (3.9) Min
100 mm (3,9)

FCI

Min
100 mm (3.9)

Min
100 mm
(3.9)
1000 mm (39.4")

Figure 56. Enclosure with 12 I/O modules mounted vertically

Electrical Installation Overview

The electrical environment on a site is shown in Figure 57. In the figure, different
Overvoltage categories are shown.

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Electrical Installation Overview

Section 2 Installation

Figure 57. Electrical installation showing Overvoltage categories

Overvoltage Categories

Overvoltage categories are based on magnitude of surges caused by lightning strikes

and overvoltage generated by circuit components, primary hard contacts breaking
inductive load circuits. Spacings, creepage distances and clearances given by
product standards are based on Overvoltage categories.
Overvoltage Category IV
Public mains, voltage >600 V a.c, and all over head lines.

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Installation Procedures

Overvoltage Category III

Factory mains, isolated by transformer from the Public mains normal,
120/480 V a.c.
Overvoltage Category II
Local power distribution, I/O signals, no un-suppressed inductive loads are
allowed. For example 120/230 V a.c., 24/48/110/220 V d.c., 4 to 20 mA, 0 to
10 V signals, and temperature signals.
All digital output modules in the S800 I/O family have integrated components
to suppress inductive loads.
External components can be used to suppress inductive loads, if:

S800 output circuit can be disconnected from the inductive load by other
contacts.

The inductive loads are not directly driven by a S800 I/O module (relay
between load and S800 I/O output).

The inductive loads are driven by other type of equipment without

components to suppress inductive loads.

Installation Procedures
After some general information in the following section, you will find individual
setup descriptions for different parts of the system.

Safety Regulations
The following instructions are to be followed when installing and operating an S800
I/O system to minimize the risks of injury to personnel and damage to the
equipment. Local statutory regulations, to the degree that they are more strict than
the following are to take precedence.

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Grounding in Enclosures

Section 2 Installation

Personnel Safety

The following are to be observed:

Voltage supply of a cabinet shall never be switched on during installation work.

Work with care when supply voltage is applied to the system. Voltages
within the cabinet can cause serious injury or death.

All who work on the installation must know the location of the main power
supply switch to the equipment and how it is operated.

When the subsections of the process are checked and a test run has been
performed, interlocking links are to be checked by a responsible engineer.
All assembly personnel must be informed about test runs to be performed.

Process technicians are to be present when testing and operating the process
device.

Equipment Safety

Observe the following safety rules:

Avoid direct contact with the bus connector of the I/O modules.

Always switch off the voltage before extracting a module which cannot to be
exchanged with power applied, for example, processor units, extension cable
adaptors and extension cables, see Section 5, Maintenance. Wait for a sufficient
time for the capacitors to discharge before removing a power sensitive module.

Grounding in Enclosures
This section describes where and how grounding is to be done in a cabinet or small
enclosures.
General

The plant ground potential must be stable and well defined, even in the event of a
low ground fault caused by high voltage equipment or a lightning strike.

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Grounding in Enclosures

The interference suppression for external signals, are normally directly grounded to
plant ground. For interference-free operation, the S800 I/O system need to be
connected properly to plant ground.
Each S800 I/O module's grounding spring connects to the metallic DIN-rail, which
serves as the module electronics ground conductor between the inter-connected
devices.
This ensures a good ground connection both for the internal logic and for the EMI
immunity and RF emission of the modules. The DIN mounting rail must therefore
have a good bond to the cabinet structure which shall be connected to plant ground.
For details on how to obtain a good bond from DIN-rail to cabinet structure, see
Mechanical Installation on page 89.
Protective Earth

Cabinets supplied with 120/230 V a.c. always must be connected to protective earth
(PE) grounding. The main power source distribution normally includes a protective
ground wire. This shall be connected to the protected earth (PE) terminal block on
the power supply. Use cable lug connectors when connecting on the ground screw.
Ground Line

The cabinet is to be grounded with a copper lead (35 mm2, 2 AWG) to the plant
ground line. Cabinets in a row shall be individually connected to the plant ground
plane. To form an even stronger ground plane, cabinets placed next to each other
should be connected together.
Grounding of Process Cable Shields

Process cable shields are, as applicable, attached directly to the cabinet ground. It is
recommended to use a shield bar (or similar grounding termination) that is
connected to the cabinet structure. This gives a firm connection to plant ground.

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Cable Routing

Section 2 Installation

Grounding of Communication Cable Shields

The shields of communication cables are to be connected directly to the modem or

FCI module in an I/O station. Please refer to S800 I/O Fieldbus Communication
Interface for Advant Fieldbus 100 (3BSE020925*) and PROFIBUS DP Wiring and
Installation (3BDS009029*) manual for more information.
Grounding of Process Signals

There are three applications of signal grounding directly to chassis. (High frequency
grounding by capacitors is always provided and not discussed in this context).

Signals can be commonly grounded by connecting the reference 0 V of the

power supply for loads and sensing to plant ground.

Individual grounding of a signal in the I/O cabinet is possible (if applicable

with respect to I/O module type). The requirement for such an application, is
when the signal is not grounded elsewhere, for example, not locally grounded
at load/sensor or not grounded via a power supply grounding.
Do not ground the same circuit at different points in the plant.

Grounding of Additional Equipment

Additional power supply units of different types used by loads or sensor, and
modems and so on, and are located in the controller or I/O cabinet, shall be
connected to the installation protective earth terminal or directly to cabinet ground:

Cable Routing
There are some restrictions in mixing cables within a cabinet due to the risk of
interference.To describe the simple rules applicable at site installation, cables are
divided in categories. See Table 5 and the following rules for custom cabinet
installations:

108

Within a category cables can be arbitrary mixed.

The distance between cables belonging to different categories shall be as

described in Table 5.

3BSE020923-510 A

Section 2 Installation

I/O Station with S800 I/O

Table 5. Separation between cables of category X and category Y

Cable
category X
[OVC =
Overvoltage
category]

Cable
category Y
[OVC =
Overvoltage
category]

Separation
for standard
installation

Separation for
installation with
shielded cables

Separation for
installation in cable
duct with grounded
conducting barrier

OVC IV

OVC III

300 mm

No separation
required

No separation
required

OVC IV

OVC II

350 mm

No separation
required

No separation
required

OVC IV

Modulebus
extension

350 mm

No separation
required

No separation
required

OVC III

OVC II

50 mm

No separation
required

No separation
required

OVC III

Modulebus
extension

50 mm

No separation
required

No separation
required

OVC II

Modulebus
extension

No separation No separation
required
required

No separation
required

I/O Station with S800 I/O

Assembly

Information regarding location of equipment may be found in the documentation

delivered with the equipment. Some general I/O Station information is presented
below.

3BSE020923-510 A

Install a DIN-rail sized to allow installation of the FCI, ModuleBus Modem,

MTUs, and S800L modules, terminator and power supplies. Some extra DINrail should be allowed for expansion or the moving of the FCI, ModuleBus
Modem, MTUs or S800L modules during maintenance.

109

I/O Station with S800 I/O

Section 2 Installation

Install the FCI, ModuleBus Modem on the left end of the DIN-rail leaving
some room to the left to allow removable from the first MTU or S800L
modules. If vertical mounting is used, leave room to the top of the FCI for
removal.

Install the first MTU or S800L modules to the right (below) of the FCI or
ModuleBus Modem and all other MTUs or S800L modules to the right (below)
of the preceding MTU or S800L module.

The last MTU or S800L module (12 max.) connected to the FCI or ModuleBus
Modem will have the TB807 Terminator installed in the ModuleBus connector.

Set each MTU mechanical keys to the correct setting for the I/O module that
will be located there.

The power supply modules may be located on the same DIN-rail as the FCI or
ModuleBus Modem and the I/O modules, but should be always located on a
horizontal DIN-rail.

Install an end stop before the first module and after the last one on the DIN-rail.

Then proceed with the electrical connections as necessary.

Electric Installation
Advant Fieldbus 100 Fieldbus Connection

The AF100 Fieldbus is connected to the terminals of a CI810 or a CI820/CI820V1.

The incoming fieldbus twisted pair cable is connected to a plug connector with four
terminals, two for the signal wires and two for the shield. The incoming and out
going fieldbus signal + conductors are terminated in the + terminal.
The - conductors are both terminated in the - terminal. The cable shield drain wires
are terminated in the two SH terminals and they must be bridged to ensure a
continuous shield connection in case the fieldbus plug is removed from the FCI.
Keep the drain wires as short as possible (< 50mm). If the unit is at the end of the
bus, a terminator (TK501Vxxx) must be connected. Please refer to the Advant
Fieldbus 100 Users Guide for complete details.

110

3BSE020923-510 A

Section 2 Installation

I/O Station with S800 I/O

PROFIBUS Fieldbus Connection

The PROFIBUS fieldbus is connected to the terminals of a CI830/CI840. The

incoming fieldbus cable is connected to a 9 pin D-sub connector. If the unit is at the
end of the bus, a connector with termination must be used. Please refer to relevant
PROFIBUS documentation.
I/O Clusters (1-7)

The TB820/TB820V2/TB840/TB840A ModuleBus Modem of an I/O cluster is

connected to the CI810/CI830/CI840/CI801 FCI or TB815 Interconnection Unit by
Optical Expansion cables. The optical ModuleBus can be a simplex, duplex or
mixed design, CI840 only duplex.
Optical cable length between each cluster must not exceed 15 meters with plastic
fiber cable and 200 meters with HCS glass fiber cable.
Refer to TB820/TB820V2 and TB840/TB840A ModuleBus Modem on page 139
for optical ModuleBus configurations.
Distributed MTUs and S800L Modules

An MTU or a S800L module can be extended to another MTU or S800L module by

using a ModuleBus extension cable. The following instructions apply:
Cable length and ModuleBus length must not exceed 2.5 meters.
Cable routing in cabinets, see Cable Routing on page 108.
Process Signals

Process signals are connected to the MTUs or S800L modules according to site
installation drawings.
The following instructions also should apply:

Cable routing in cabinets, see Cable Routing on page 108.

Grounding of cable shields and Process signals, see Grounding in Enclosures

on page 106.

A carefully done electrical installation is the basis for future interference-free

operation.

3BSE020923-510 A

111

I/O Station with S800 I/O

Section 2 Installation

Address Setting

All S800 I/O modules are automatically set to the correct addresses by the
ModuleBus interconnection scheme.
The FCI module station address should be set to the assigned PROFIBUS address or
Advant Fieldbus 100 station set by the station address switches. Refer to S800 I/O
Fieldbus Communication Interface for PROFIBUS-DP/DPV1 (3BSE020926*) or
S800 I/O Fieldbus Communication Interface for Advant Fieldbus 100
(3BSE020925*) as to location of address switches.
The ModuleBus Modem cluster address should be set to the assigned cluster
number by the cluster address switch. Refer to TB820/TB820V2 ModuleBus
Modem on page 43.
Check of the External Wiring

The level of workmanship must be judged case by case, and the results will
determine the need for a check of all connections before the system is powered up. It
is possible to check, with a buzzer, that the external wiring to the process equipment
is correct and that all conductors are intact. The check of the field wiring should be
done before the I/O modules are installed. It is also possible, without activating the
control equipment, to check that transmitters, transducers and actuators (including
all process wiring) to see if they function correctly. This makes it necessary to
connect voltage to these units and develop suitable checking methods.
An alternative method, is to make an integrated check of the process equipment,
wiring and the corresponding controller functions. This should be done on a point
by point basis. Preferably the controller should be loaded with the application data
base. The data base is then used as one check-point. Status / values can be read and
control signals to process devices can be simulated.
Be aware of the risk of accidents. Short-circuit and over-voltage can damage
the equipment, for example, a process I/O board or field element.

112

3BSE020923-510 A

Section 2 Installation

Checklists

Checklists
The following checklists, Table 6 to Table 12, are a summary of important
information that should be checked for the installation.

3BSE020923-510 A

113

Checklists

Section 2 Installation

Grounding Philosophy, Ground Plane System

Table 6. Grounding Philosophy, Grounding System

Item
Grounding
philosophy

Concerning
Ground system

Check
Grounding to PE network only. Only
one ground system. No exceptions.

Process Cabling, Shielding, Grounding, Max. Length

Table 7. Process Cabling, Shielding, Grounding, Max. Length

Item
Cables

Concerning
Prescribed type

Check
Communication cables
Pulse transducer cables
Shielded for low level AI (RTD,
thermocouple, and so on).
Signal wire and return wire in same cable

Shielding: Single
shield

Multi-core signal
cable

Grounding

Should be grounded directly as it comes

into the cabinet

Grounding:
Communications

For AF 100, see S800 I/O Fieldbus

Communication Interface for Advant
Fieldbus 100 (3BSE020925*) manual.
For PROFIBUS, see PROFIBUS DP
Wiring and Installation (3BDS009029*)
manual.

Grounding

All signals in a multi-core cable shall

refer to a common ground

A.C. digital inputs Max. cable length

120 V and 230 V

114

Approximately 200 m (656 ft.)

3BSE020923-510 A

Section 2 Installation

Checklists

Power Supply

Table 8. Power Supply

Item

Concerning

Check

Connection in
cabinet

Protective ground is connected.

No unsuppressed
load

No unsuppressed load on same finale

circuit from distribution box

Internal distribution

Incoming power supply (120, 230 V)

must be separated from other cables.
See Table 5.

D.C. (floating
supply)

Grounding, supply

Floating supply is permitted if supply

voltage to S800 ground is not >50 V
(Voltage between 24V minus and DIN
rail must be < 50V). If >50V, use an
isolating d.c./d.c. converter.

D.C. (grounded
supply)

Connection

The D.C. supply shall be grounded to

the same ground plane as S800.

Note: There must be no breaks in the

protective ground conductor to the PE
terminal.

A.C. Power Mains

Lightning Protection

Table 9. Lightning Protection

Item
Lightning
protection

Concerning

Check
Protections are compulsory for all circuits in:
Overhead lines
Cables that leave the general ground line
network

3BSE020923-510 A

115

Checklists

Section 2 Installation

MTU, I/O Module

Table 10. MTU, I/O Module

Item
Mounting rail

Concerning

Check

(for MTUs)

Ground connection See Mechanical Installation on page 89.

to cabinet via DIN
rail mounting screws

MTU

Ground connection

DIN rail type with height 7.5 mm shall be

used. See Mechanical Installation on
page 89.

Cabinet, Internal Cables

Table 11. Cabinets, Internal Cables

Item

116

Concerning

Check

Row of cabinets

Electrical connection Through 35 mm2 (2 AWG) copper

(grounding)
conductors in each cabinet.

Cabinet parts
(plates)

All parts electrically

connected to each
other and to the PE
bar

Grounding in
cabinet

Design

Temperature in
cabinet

Max. permitted
temperature for
continued operation

Bonded together.

Only one grounding system.

The only exception is if non-isolated IS
barriers are used in the same cabinet.
Max. permitted temperature for
continued operation in cabinet is
0 to +55C (32 to 131F)(1).
Measured just below the I/O module.
Modules on compact MTUs or S800L
modules on a vertical DIN rail allow
0 to +40C (32 to 104F)(1) ambient
temperature. See Table 24.

3BSE020923-510 A

Section 2 Installation

Checklists

Table 11. Cabinets, Internal Cables (Continued)

Item

Concerning

Check

Radio emission

Emission

S800 equipment does not require radio

proof enclosures.

Shielded cable

Design

Communication, pulse transducers,

S800 I/O High Integrity and analog
circuits for Low Level (RTD,
thermocouples) must be shielded.
Please refer to module documentation
for details.

Internal cables

Routing

See Cable Routing on page 108.

Check that there is no tension in the
wiring.

(1) Non-condensing

Environmental Data

See Appendix A, General Specifications.

Airborne Contaminants

See Appendix A, General Specifications.

3BSE020923-510 A

117

Final Procedure Before Start-up

Section 2 Installation

Miscellaneous

Table 12. Miscellaneous

Item

Concerning

Action

Non suppressed
inductive loads

Cable routing

Cabling to non-suppressed inductive

loads in cabinets must be kept more
than 100 mm (4") away from internal
cables

Non suppressed
inductive loads

Power supply

Use separate power supply

Thermocouples

Position of AI835
CJC RTD Cold
Junction
Compensation)

CJC RTD should be placed where the

TCs compensation cable is terminated

Analog inputs

External grounded
transmitters

Use analog input modules with

differential or isolated channels.

Analog outputs

External grounded
receivers

Use analog output modules with isolated

channels.

External Cables

When selecting cables that are to be used in the plant environment, you should know
that there are some restrictions and rules to follow:

Routing of communication cables.

Mixing of signals and signal types within cables.

Need of shielded cables.

Final Procedure Before Start-up

Remove all debris from the work performed and clean off all grease and dirt. Check
that no tools or assembly material are left in the cabinets. Vacuum clean the
cabinets.

118

3BSE020923-510 A

Section 2 Installation

Start-up and Shut-down Procedures

Start-up and Shut-down Procedures

Start-up Procedures
This section includes power up for the very first definition/configuration of the
system resources. A visible result of the start-up procedures, are that all red LED on
module fronts are turned off and all green LED are turned on.
Safety Regulations

The instructions given in Safety Regulations on page 105 are applicable in all
situations when working with S800 I/O and associated equipment. Please read the
instructions carefully.
Work with care when supply voltage is applied in the system. The voltage in the
cabinet can cause serious injury or death.
Controller and I/O

When the set-up activities are finished and after using Checklists on page 113,
the equipment will be ready for start-up, but first read the following security
guidelines before proceeding.
Security Guidelines

During the power up of S800 I/O there is always a risk of spurious output signals to
the process due to a faulty hardware module.
Critical process devices should always be identified and isolated in some way if the
process is energized. Examples of different methods are:

Disconnected output power supply.

Disconnect the process cables from outputs.

Remove output S800 I/O modules.

Succeeding operations after power up, including necessary tests, must be performed
carefully.

3BSE020923-510 A

119

Shut-down Procedures

Section 2 Installation

Shut-down Procedures
Before power is switched on, and start-up of the equipment, it is important to know
how to shut-down in different situations. This is described below.
Safety Regulations

The instructions given in Safety Regulations on page 105 are applicable in all
situations when working with a Controller and associated equipment. Please read
the instructions carefully.
Work with care when supply voltage is applied in the system. The voltage in the
cabinet can cause serious injury or death.
Emergency Shut Down

An emergency stop should always be available. It shall be controlled by local

regulations. This is a responsibility of the plant design and construction. The
controller system does not supply this special function.
Check the Location of the Emergency Stop and use it in an Emergency Situation
From the electrical and functional point of view, an emergency stop will have the
same consequences to the controller and associated equipment as a safety shut
down.
Safety Shut Down

The controller and its S800 I/O may be mounted in a row of joined cabinets and are
connected as a single unit to the mains power source. The I/O Station with S800 I/O
may also be located remotely in the process area and have its own power source.
Safety shut down, by disconnecting the controller or remote enclosure from the
mains, can be carried out in two ways:

120

As prescribed in the site planning Power Requirements on page 98, there

should be a common safety switch installed within 3 m (10 feet) of the
cabinets.

Check the Location of the Safety Switch and use it when working with the
equipment.

3BSE020923-510 A

Section 2 Installation

Product Verification

The safety switch should be arranged to shut down the power of not only the
electronics system but also transmitters, transducers and other process devices. In
other words, a total power shut down for the plant section controlled.
Since the safety switch is a plant component this document can not stipulate and
describe the design exactly. Please check the plant documentation in this respect
carefully. Instructions, as to the extent of the power shut down, should preferably
be attached to the safety switch.
Regardless of the way, the results and consequences of a shut down will be:

Zero output to the process devices (S800 I/O).

De-energized output relays (S800 I/O). Not for normally closed contacts.

The system is ready for a restart. Restart can be performed when the
reason for the shut down is cleared away.

Manual Stop

Beyond the most drastic way of shut down, by disconnecting power, there is an
other way to stop the S800 I/O:

Stop program execution in the controller

Disconnect the I/O station from the fieldbus.

The results of the manual stop method:

Output modules goes to the OSP state.

The system is ready for a restart. Restart can be performed by starting the
execution in the controller or connecting the fieldbus.

After necessary measures, a restart can take place.

Product Verification
As the test requirements vary considerably between different installations,
the system engineer is responsible for determining the functional requirements
which apply.

3BSE020923-510 A

121

General

Section 2 Installation

Equipment Required

The following equipment is a minimum requirement:

Necessary parts of the documentation listed in Related Documentation on page

20.

Specific documentation enclosed with the equipment.

In more complex installations which include closed loop control some additional
test equipment can be necessary/practical at tuning:

Access to an operator station for loop tuning.

General
A general description of how to set the controller in operation and start the
execution of application program is presented in the controller manuals. Once the
system is started and ready for operation the I/O can be checked.
General information for some functional tests, which can be made to verify the
S800 I/O are presented in the following sections.
Check of Process Input/Output Systems

With the application program running in the controller, the inputs and outputs can be
checked. This should be done by using a signal by signal procedure.
It may be necessary to simulate digital and analog input signals which are normally
generated by the process. Suitable methods are:

122

Digital inputs: Activate the input by connecting a voltage which corresponds to

the nominal value of the input. The 1 and 0 status is simulated by opening
and closing the terminal connections. Activate the input as close to the process
transducer as possible to test the process wiring as far as possible. Manual
operation of transducers, for example, limit switches can also give the required
change for the input signals.

Analog input signals: Use a signal generator for analog signals. A simple test
coupling can be used as a voltage source. This can consist of a potentiometer
across a suitable voltage source which gives +/- voltage. A current source,
which can give sufficient current, for example, 20 mA, is required for current

3BSE020923-510 A

Section 2 Installation

General

signals. Analog input test signals should be entered as close to the

transmitter/transducer as possible to test the process wiring.
Digital and analog output signals are obtained by setting the required values from
the overlaying controller.
Input Signals

Figure 58 shows where an input signal can be checked in an S800 I/O application.
DI modules provide a field input connector and DI channel LEDs, and AI modules
provide a field input connector.

Engineering Tool

Process

Controller

Process
Device

Input
Module

FCI
Fieldbus
Interface

Application

DI ch.

Figure 58. Block Diagram of S800 I/O Input Channel, Test Points

Digital Input Signals

A digital input signal can be checked as shown in Figure 58. Use the following
procedure as a guide:

3BSE020923-510 A

Simulate the digital input signal as close to the process transducer as

possible or activate the transducer itself.

123

General

Section 2 Installation

Check that the corresponding yellow LED on the input module concerned
illuminates and that the change is shown accordingly in the overlaying
controller

Change the input signal to a low level. Check that the yellow LED on the
input board extinguishes and that the display value has changed.

Analog Input Signals

Figure 58 shows where an analog input signal of an input channel can be
checked. Proceed as follows to check an analog input channel:

Simulate the analog input signal as close to the process

transmitter/transducer as possible.

Check that the simulated signal is available at the screw terminal of the
corresponding connection.

Check that the value shown on the display screen corresponds to the
simulated value set in the field. Check the complete signal range.

Output Signals

Figure 59 shows where an output signal can be checked in an S800 I/O application.
DO Modules provide a field output connector and DO channel LEDs.
AO Modules provide a field output connector.

124

3BSE020923-510 A

Section 2 Installation

General

Engineering Tool

Controller

Application

Process
FCI
Fieldbus
Interface

Process
Device

Output
Module

DO ch.

Figure 59. Block Diagram of S800 I/O Output Channel, Test Points

Digital Output Signals

Typical digital output channels and where the signals can be tested are shown
in Figure 59. Digital output signals in a specific plant are shown in the terminal
diagrams for the plant.
Proceed as follows to check digital channels:

Check that the corresponding output shows that it is set to on.

Check that the corresponding yellow LED on the digital output module
illuminates.

Check the value on the screw terminal block, and if practical also at the
process device.

Analog Output Signals

When checking analog output signals, use a multimeter to test for an output signal
over the complete signal range.

3BSE020923-510 A

125

Final Check

Section 2 Installation

Typical analog output channels and where the signals can be tested are shown
in Figure 59. Analog output signals in a specific plant are shown in the
connection diagrams for the plant.
Proceed as follows to check analog channels:

Set the output value, and check that the corresponding output shows this
value.

Measure the value on the screw terminal block, and if practical also at the
process.

When checking analog output signals use a multimeter to test that an

output signal is obtained over the complete signal range.

Final Check
When the test of the control system is complete, and the plant functions
satisfactorily, the following actions should be taken:

126

Check that all S800 I/O modules are properly inserted in the MTUs.

Check that the I/O module lock/switch is in its locked position.

Check that all terminal screws on MTUs and S800L modules are properly
tightened and that all grounds are good.

Check that all cable connectors are properly mated.

Check that all cable coverings or tie wraps are installed properly to avoid cable
wear.

Check that no tools or debris from installation remain in the cubicle. Clean the
cabinet.

3BSE020923-510 A

Section 3 Configuration
Design Considerations
This section provides guidelines and other information that you need to know before
designing and configuring the S800 I/O. This information includes an overview of
the hardware and database configuration guidelines.

I/O Station Layout Hardware Configuration Guidelines

The S800 I/O is DIN rail mounted. The rail can be any practical length to fit the
needs of that particular I/O Station. A S800 I/O cluster can have a maximum length
of the ModuleBus from the ModuleBus master, TB815 Interconnection Unit, or
ModuleBus Modem to the ModuleBus terminator of 2,5 meters (8.2 feet). See
Figure 60 for maximum layout of station using Compact MTUs.

3BSE020923-510 A

127

I/O Station Layout Hardware Configuration Guidelines

Cable Adaptor, out

TB805

84 mm
(3.3)
123 mm*
(4.84)

58.5 mm
(2.3)

Section 3 Configuration

Terminator
TB807

Cable Adaptor, in
TB806

TK801V0xx
Bus Cable
20 mm
(0.8)

22 mm
(0.86)

(6.4)

162 mm

Maximum 2.5 meters (98.4)

816 mm (32.1)
855 mm (33.6) *
* Measurements for TU847 and CI840

Figure 60. Maximum Layout of I/O Cluster with Compact MTUs

128

3BSE020923-510 A

Section 3 Configuration

I/O Station Layout Hardware Configuration Guidelines

See Figure 61 for maximum layout of I/O cluster using Extended MTUs.
469 mm (18.5)
508 mm (20) *
84 (3.3)
84
123*

120
(4.74)

120

22 mm
(0.86)

162 mm
(6.37)

123 (8.44)*

Bus Cable
Length = 300 mm
(11.8)

1554 mm
(61,2)
1593 mm
(62.7)*

1129 mm
(44.5)

mm
(inches)

109 mm
(4.3)
20
(0.8)

* Measurements for TU847 and CI840

Figure 61. Maximum Layout of I/O Cluster with Extended MTUs

3BSE020923-510 A

129

S12345678910111213141516

(3.4)

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

85.8 mm
S12345678910111213141516

S12345678910111213141516

Status

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516

S12345678910111213141516
Status

mm
(inch)

1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 1011 12131415 16

Status
Status

Status

Status

Status

(6.38)
162 mm
S12345678910111213141516

Status

1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 1011 1213141516 1 2 3 4 5 6 7 8 9 1011 12131415 16 1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 1011 1213141516

Status

S12345678910111213141516

Status
Status

3BSE020923-510 A

130

Status
Status

(0.8)
(0.8)

Status

1143 mm (45)
1182 mm (46.5)*

20 mm

110 mm
(4.3)
20 mm

Status

Status

22 mm
(0.87)
Status

821 mm
(32.3)
Status

Status

S12345678910111213141516

Status

Status

1 2 3 4 5 6 7 8 9 10 11 12131415 16 1 2 3 4 5 6 7 8 9 10 11 1213141516 1 2 3 4 5 6 7 8 9 10 11 1213141516

Status

Bus Cable
Length = 300 mm
(11.8)
Status

S12345678910111213141516

85.8 mm
(3.4)

85.8
123 mm (8.43)*

S12345678910111213141516
Status

22 mm
(0.87)
84
123*
84 mm (3.3)

Section 3 Configuration
I/O Station Layout Hardware Configuration Guidelines

See Figure 62 for maximum layout of I/O cluster using S800L.

406 mm (16)*
367mm (14.4)

* Measurements for TU847 and CI840

Figure 62. Maximum Layout of I/O Cluster with S800L

Section 3 Configuration

I/O Station Layout Hardware Configuration Guidelines

An I/O cluster may be divided into smaller parts to fit a particular requirement, but
the 2.5 meter (8.2 feet) maximum must be observed at all times. The cluster may be
distributed because of space limitations or to keep signal types together.
See Figure 63 for a example of an I/O cluster divided up into four groups.

Analog Inputs

Digital Inputs

Terminator
TB807

TK801V0xx

Cable Adaptor, out

TB805

Status

S 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Cable Adaptor, in
TB806

Analog Outputs

Digital Outputs

Figure 63. I/O Cluster in Small Groups

The first unit of the I/O Station is the Fieldbus Communications Interface (FCI).
It connects to the fieldbus and is the communications interface to the I/O modules.
The FCI controls the ModuleBus and provides power to the logic-side of the I/O
modules. The FCI is a station on the fieldbus and must be set to the correct address.
Refer to respective FCI manual for more information.
The FCI connects to the first MTU or S800L module. Additional MTUs or S800L
modules connect to each other or through the ModuleBus Extension cable, up to a
maximum of 12. The ModuleBus is terminated by the TB807 Bus Terminator
module. The I/O Modules are installed onto the MTUs and connected to the process
in the field.

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Redundant FCIs for Advant Fieldbus 100

Section 3 Configuration

Redundant FCIs for Advant Fieldbus 100

An I/O Station with redundant CI820/CI820V1 FCIs requires that the ModuleBus
Extension cable be connected to the TB815 Interconnection Unit and then to the
first I/O Module. The maximum ModuleBus length from the TB815 to the
ModuleBus terminator is 2.5 meters. See Figure 64 for layout of a station.
Terminator
TB807

CI820 FCI

TK801V0xx
TB815
Interconnection
Unit

Cable adaptor, in
TB806

Cable adaptor, out

TB805

Figure 64. I/O Station with Redundant CI820 FCIs

Redundant FCIs and I/O Modules for PROFIBUS

An I/O Station with redundant CI840 FCIs can have the first I/O module connected
direct to the MTU TU846. ModuleBus Extension cables can be connected via a
ModuleBus Cable Adaptor-Out TB845 and a ModuleBus Cable Adaptor-In TB846.

132

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I/O Clusters

The maximum ModuleBus length from the TU846 to the ModuleBus terminator is
2.5 meters. See Figure 65 for layout of a station.
CI840 FCI
Cable adaptor, out
TB845

Terminator
TB807

MTU
TU846

Cable adaptor, in
TB846

Figure 65. I/O Station with Redundant CI840 FCIs and Redundant I/O Modules

I/O Clusters
I/O clusters 1-7 connect to the Optical ModuleBus port on the FCI or TB815
Interconnection Unit by Optical Expansion cables. Each I/O station can have up to
24 I/O modules and each I/O cluster can have up to 12 I/O modules.

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I/O Clusters

Section 3 Configuration

The 24 V power supply has to be connected to each cluster. See Figure 66 to

Figure 70 for an example of optical ModuleBus Expansion cabling.

Status

CI801 Base I/O Cluster

I/O Cluster 1

I/O Cluster 2

ModuleBus Modem TB820/TB820V2

I/O Cluster 3

Figure 66. Optical ModuleBus Extension non-redundant, CI801

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Section 3 Configuration

I/O Clusters

CI810/CI830 FCI

CI820 FCI

Base I/O Cluster

Optical ModuleBus
Port TB810

I/O Cluster 1
ModuleBus Modem TB820/TB820V2

TB815
Interconnection
Unit

Base I/O Cluster

Optical ModuleBus
Port TB810

I/O Cluster 1
ModuleBus Modem TB820/TB820V2

I/O Cluster 2

I/O Cluster 2

I/O Cluster 3

I/O Cluster 3

Figure 67. Optical ModuleBus Extension non-redundant, CI810, CI820, CI830

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I/O Clusters

Section 3 Configuration

CI840

Base I/O Cluster

I/O Cluster 1

I/O Cluster 2

ModuleBus Modem TB820/TB820V2

I/O Cluster 3

Figure 68. Optical ModuleBus Extension non-redundant, CI840 with single I/O

136

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Section 3 Configuration

TB846

I/O Clusters

CI840

Redundant I/O

TB842
I/O Cluster 1

I/O Cluster 2

ModuleBus Modem TB820/TB820V2

I/O Cluster 3

Figure 69. Optical ModuleBus Extension non-redundant, CI840 with redundant I/O

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CI801/CI810/CI820/CI820V1/CI830/CI840 FCI

Redundant AC 800M

Section 3 Configuration

TB840/TB840A
I/O Cluster (single I/O)

I/O Cluster (redundant I/O)

Figure 70. Redundant Optical ModuleBus Extension with Redundant

TB840/TB840A

CI801/CI810/CI820/CI820V1/CI830/CI840 FCI
The FCI needs to be connected to a fieldbus and have an address selected. It is also
connected to a 24 V d.c. power source to provide power to the I/O Station. Also,
refer to appropriate FCI manual for information on how to estimate the fieldbus and
power loading of each I/O station configuration.

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Section 3 Configuration

TB820/TB820V2 and TB840/TB840A ModuleBus Modem

TB820/TB820V2 and TB840/TB840A ModuleBus Modem

The TB820/TB820V2 ModuleBus Modem needs to be connected to the Optical
ModuleBus, and have an I/O cluster address selected. It is also connected to a 24 V
d.c. power source to provide power to the I/O modules of the cluster.

R
P

ORx1

ORx2
ERx

CLUSTER
4 56
3
7
2
1

Cluster Address
Switch
(Address 4 shown)

TB820 V2

L+
LSA
SB

X5
X4
Rx Rx
Tx
Tx

Optical ModuleBus
Interface Connector (X4, X5)

Figure 71. Front Panel of the TB820/TB820V2 ModuleBus Modem

The TB840/TB840A ModuleBus Modem must be mounted on a TU841 Module
Termination Unit and needs to be connected to the Optical ModuleBus, and have an
I/O cluster address selected. It is also connected to a 24 V d.c. power source to
provide power to the I/O modules of the cluster.

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TB820/TB820V2 and TB840/TB840A ModuleBus Modem

Section 3 Configuration

CLUSTER ADDR.

Figure 72. TB840/TB840A ModuleBus Modem mounted on TU841

Cluster Address Switch

The TB820/TB820V2 is equipped with a rotary switch used as the I/O cluster
address selector for the I/O cluster. The address switch for TB840/TB840A is
placed on TU841. The I/O cluster address is in the range of 1 to 7. The FCI is base

140

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Section 3 Configuration

TB820/TB820V2 and TB840/TB840A ModuleBus Modem

cluster address 0 (zero). Figure 71 shows the front panel of the TB820/TB820V2
and Figure 72 the front panel of the TB840/TB840A.
Care must be taken that no I/O clusters have the same address setting. This could
result in output modules in the same ModuleBus position but in different I/O
clusters putting out the same value.
On TB820/TB820V2, a new cluster address should not be set during operation. If
the address changes are done during operation, the cluster is disconnected from
the ModuleBus, and no communications is possible with the I/O modules on that
cluster address.
The new address is set at reset or power up. If the address changes are done on
TB840 during operation, the cluster will get a warning signal and the new address
will not be set until reset or power up.
TB820/TB820V2 can not handle High Integrity I/O modules (AI880/AI880A,
DI880 and DO880).
Optical ModuleBus Connections

The TB820/TB820V2/TB840/TB840A has a connection to the optical ModuleBus

by the optical ports on its side. The fiber optic cable(s) connect to the X4 (Tx and Rx
ports) and X5 (Tx and Rx ports) connectors of the
TB820/TB820V2/TB840/TB840A.
The optical ModuleBuses can be connected to duplex or simplex fiber optic cables.
See Figure 73 for connection details.

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TB820/TB820V2 and TB840/TB840A ModuleBus Modem

Section 3 Configuration

TB820

L+ L+ SA
L- L- SB
X4 X5
Rx Rx
Tx
Tx

Rx
X4
Tx

Optical ModuleBus
Interface Connectors
(X4, X5)

Tx2
X4
Rx2
Duplex Fiber Optic Cable Connector
Tx1
X5
Rx1

Rx
X5
Tx
Front View

Simplex Fiber Optic Cable Connector

Front View

Figure 73. TB820/TB820V2 and TB840 Optical ModuleBus Connections

The connector style, either simplex or duplex, all provide snap-in action when
mated to the X4/X5 ports. Simplex connectors are color coded to facilitate
identification of transmitter (Tx) or receiver (Rx) connections. Duplex connectors
are keyed so that proper orientation is ensured during insertion.
Figure 74 shows a duplex, simplex and mixed configuration of the optical
ModuleBus. Duplex (two-way) is normally the best communication design, but may
not apply to all requirements. Duplex design allows additional TB820/TB820V2s
or TB840/TB840As to be added down-stream on-line.
Simplex (one-way) connections provide a ring configuration from the FCI to the
first TB820/TB820V2/TB840/TB840A, then to the next and so on and then back to
the FCI. Simplex designs will require that the home-run cable from the last
TB820/TB820V2/TB840/TB840A back to the FCI, or another
TB820/TB820V2/TB840/TB840A, is limited to the 15 meter (49 ft.) plastic fiber or
200 meter (667 ft.) HCS fiber cable length. The 15 meter (49 ft.) cable length or 200

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Section 3 Configuration

TB820/TB820V2 and TB840/TB840A ModuleBus Modem

meter (667 ft.) maximum applies from FCI to TB820/TB820V2/TB840/TB840A, to

the next TB820/TB820V2/TB840/TB840A, etc. and back to the FCI. Also, duplex
and simplex configurations can be mixed in the same optical ModuleBus if required.

FCI/
Controller
Rx

Example of a duplex connection of the optical ring.

Tx
X5-Rx
X5-Tx

TB820/
X4-Tx
TB820V2/
TB840/
X4-Rx
TB840A *

X5-Rx

TB820/
X4-Tx
TB820V2/
TB840/
X4-Rx
TB840A *

X5-Tx

X5-Rx

TB820/
X4-Tx
TB820V2/
TB840/
X4-Rx
TB840A *

X5-Rx

TB820/
TB820V2/
TB840/
TB840A *

X5-Tx

X5-Tx

max. 15 m (49 ft.)

or 200 m (667 ft.)

FCI/
Controller
Rx

Tx

Example of a simplex connection of the optical ring.

TB820/
X5-Rx TB820V2/ X4-Tx
TB840/
TB840A *

X5-Rx

TB820/
TB820V2/
X4-Tx
TB840/
TB840A *

X5-Rx

TB820/
TB820V2/
X4-Tx
TB840/
TB840A *

X5-Rx

TB820/
TB820V2/ X4-Tx
TB840/
TB840A *

max. 15 m (49 ft.)

or 200 m (667 ft.)

FCI/
Controller
Rx

Example of a mixed simplex/duplex connection of the optical ring.

Tx
X5-Rx
X5-Tx

TB820/
X4-Tx
TB820V2/
TB840/
X4-Rx
TB840A *

X5-Rx

TB820/
X4-Tx
TB820V2/
TB840/
TB840A *

X5-Rx

TB820/
X4-Tx
TB820V2/
TB840/
X4-Rx
TB840A *

X5-Tx

* TB840/TB840A not together with FCI

X5-Rx

TB820/
TB820V2/
TB840/
TB840A *

X5-Tx

max. 15 m (49 ft.)

or 200 m (667 ft.)

Figure 74. Typical Optical ModuleBus Designs

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TB820/TB820V2 and TB840/TB840A ModuleBus Modem

Section 3 Configuration

In a duplex connection a cable break or loss of a TB820/TB820V2, TB840 or

TB840A will only affect the clusters down-stream of the break. In a simplex
connection a cable break or loss of a TB820/TB820V2, TB840 or TB840A will
affect all I/O expansion clusters on the ModuleBus.
Power Supply Connections

The TB820/TB820V2/TB840/TB840A requires 24 V d.c. (19.2 - 30 V) with a

maximum current requirement of 1,7 Ampere. The module can be powered by either
a single or redundant power supply. If a redundant power supply is used, the
TB820/TB820V2/TB840/TB840A can monitor the status of each supply and send
the status back to the FCI of the I/O Station.
See Figure 75 for the latest layout of power supply connections and Figure 76 for
the previous layout.

TB840

TB840

TB820 V2

From
Power Supply
X5
X4
Rx Rx
Tx
Tx

0 V d.c.
Power Supply A
Monitor
Power Supply B
Monitor

L+ L -- SA SB

+24 V d.c.

Terminal
Headers

Figure 75. TB820/TB820V2/TB840/TB840A Power Supply Connections Latest

Layout

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Section 3 Configuration

TB820/TB820V2 and TB840/TB840A ModuleBus Modem

Table 13. TB820/TB820V2 Power Connection Terminal valid for Figure 75.
Pin

Designation

Description

L+

L+

+ 24 V d.c. Supply

L-

L-

0 V d.c. Supply

SA

SA

Redundant Power Supply Monitoring Input

SB

SB

Redundant Power Supply Monitoring Input

TB820

L+ L+ SA
L- L- SB
X5
X4
Rx Rx
Tx
Tx

X1B
X1A

Terminal
Headers
Power Supply B
Monitor

Power Supply A
Monitor

3
1 2

+24 V d.c.

+24 V d.c.
From Power Supply
0 V d.c.

0 V d.c.

3
1 2

To MTUs
(I/O Modules)

Jumper

Figure 76. TB820/TB820V2 Power Supply Connections Previous Layout

Power connections can accept up to 0.2 - 2.5 mm2 (24 - 14 AWG) wire size.

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TB825 Optical Media Converter

Section 3 Configuration

Table 14. TB820/TB820V2/TB840/TB840A Power Connection Terminal valid

for Figure 76.
Pin

Designation

Description

X1A1

L-

0 V d.c. Supply (can be jumpered to pin 2)

X1A2

L-

0 V d.c. Supply

X1A3

SB

Redundant Power Supply Monitoring Input

X1B1

L+

+24 V d.c. Supply (can be jumpered to pin 2)

X1B2

L+

+24 V d.c. Supply

X1B3

SA

Redundant Power Supply Monitoring Input

TB825 Optical Media Converter

Optical ModuleBus Connections

TB825 can be used for star connections or where long distance optical fiber is
required, see Figure 78. Signal routing is done according to Table 15 and in
Figure 77.
The modem is powered by 24 V d.c.

Table 15. TB825 Signal Routing

Receiving Port

146

Regeneration Port

Rx1

Tx2, Tx3

Rx2

Tx1

Rx3

Tx1

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Section 3 Configuration

TB825 Optical Media Converter

Figure 77. TB825 Signal Routing

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147

TB825 Optical Media Converter

Section 3 Configuration

Figure 78. ModuleBus configuration with Optical Media Converter TB825

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Section 3 Configuration

TB825 Optical Media Converter

Power Supply Connections

The TB825 requires 24 V d.c. (19.2 - 30 V) with a maximum current requirement of

0.1 Ampere.
Table 16. TB825 Power Connection Terminal
Pin

Designation

Description

L+

L+

+ 24 V d.c. Supply

L-

L-

0 V d.c. Supply

Optical Fiber Connection

Table 17. TB825 Optical Port Description

Connection

Description

Tx1

Transmitting port local fiber 1

Rx1

Receiving port local fiber 1

Tx2

Transmitting port field fiber

Rx2

Receiving port field fiber

Tx3

Transmitting port local fiber 2

Rx3

Receiving port local fiber 2

Calculation of Maximum Optical ModuleBus Configuration

The maximum signal delay should be calculated in a configuration using Optical

Media Converter. This is calculated using the signal path from the controller to the
point in the configuration that has the longest delay. The maximum delay in a
optical ModuleBus configuration must be 42 s.

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TB825 Optical Media Converter

Section 3 Configuration

The delay values in Table 18 can be used to calculate the maximum delay in an
optical ModuleBus configuration.
Table 18. Delay Values Optical ModuleBus Components
Opto-to-opto delay in TB825(1)

2.4 s

Opto-to-opto delay in TB820/TB820V2(1)

4.0 s

Opto-to-electrical delay in TB820/TB820V2(1)

6.5 s

Opto-to-opto delay in TB840/TB840A(1)

2.0 s

Opto-to-electrical delay in TB840/TB840A

(1)

5.5 s

Delay in optical fiber(1)(2)

(0.01 x length) s

(1) Notice that the delays in the table is the sum of the communication delay in both directions, i.e.
(delay of master frame) + (delay of slave frame).
(2) Total fiber length = total local fiber length + field fiber length

Maximum fiber length between two modems is 15 m for plastic fiber, 200 m for
HCS fiber and 1000 m for glass fiber.

AC800

LF
15 m

TB820

I/O

TB820

I/O

TB820

I/O

LF
15 m
LF
15 m
LF = Local fiber
FF = Field fiber
E = Electrical Modulebus

LF
15 m
TB820

I/O

TB820

I/O

LF
1.5 m
LF
1.5 m

LF
1.5 m

FF
TB825

TB825

TB820

I/O

1000 m

Figure 79. Example of worst case delay configuration

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Section 3 Configuration

TB826 Optical Media Converter

Calculation of the ModuleBus delay for the configuration in Figure 79:

ModuleBus delay = (total delay in optical fiber) + 5 x (opto-to-opto delay in
TB820/TB820V2) + 2 x (delay in TB825) + (opto-to electrical delay in
TB820/TB820V2) = (4 x 15 + 3 x 1.5 + 1000) x 0.01 + 5 x 4 + 2 x 2.4 + 6.5 = 42 s.

TB826 Optical Media Converter

Optical ModuleBus Connections

TB826 can be used for duplex fiber configurations. Also, it is possible to connect
TB826 in a mixed duplex/simple configuration. TB826 is always connected with
duplex fibers, see Figure 81. Signal routing is done according to Table 19 and in
Figure 80.
The modem is powered by 24 V d.c.

Table 19. TB826 Signal Routing

Receiving Port

3BSE020923-510 A

Regeneration Port

Rx1

Tx2, Tx3

Rx2

Tx1

Rx3

Tx1

151

TB826 Optical Media Converter

Section 3 Configuration

Figure 80. TB826 Signal Routing

152

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Section 3 Configuration

TB826 Optical Media Converter

Figure 81. ModuleBus configuration with Optical Media Converter TB826

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Calculation of Maximum Optical ModuleBus Configuration

Section 3 Configuration

Power Supply Connections

The TB826 requires 24 V d.c. (19.2 - 30 V) with a maximum current requirement of

0.1 Ampere.
Table 20. TB826 Power Connection Terminal
Pin

Designation

Description

L+

L+

+24 V d.c. Supply

L-

L-

0 V d.c. Supply

Optical Fiber Connection

Table 21. TB826 Optical Port Description

Connection

Description

Tx1

Transmitting port local fiber 1

Rx1

Receiving port local fiber 1

Tx2

Transmitting port field fiber

Rx2

Receiving port field fiber

Tx3

Transmitting port local fiber 2

Rx3

Receiving port local fiber 2

Calculation of Maximum Optical ModuleBus Configuration

Calculation of Maximum Fiber length

The maximum signal delay in a configuration is calculated using Optical Media

Converter. This is calculated using the signal path from the controller to the point in
the configuration that has the longest delay. The maximum delay in a optical
ModuleBus configuration must be 100s (less than 250s for
S800 I/O HI).

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Calculation of Maximum Optical ModuleBus Configuration

The delay values in Table 22 can be used to calculate the maximum delay in an
optical ModuleBus configuration.
Table 22. Delay Values Optical ModuleBus Components
Opto-to-opto delay in TB826(1)

2.0 s

Opto-to-opto delay in TB820(1)

4.0 s

Opto-to-electrical delay in TB820(1)

6.5 s

Opto-to-opto delay in TB840(1)

2.0 s
(1)

Opto-to-electrical delay in TB840

5.5 s

Delay in optical fiber(1)(2)

(0.01 x length) s

(1) Notice that the delays in the table is the sum of the communication delay in both directions, i.e.
(delay of master frame) + (delay of slave frame).
(2) Total fiber length = total local fiber length + field fiber length

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Power Supply System

Section 3 Configuration

Maximum fiber length between two modems is 15m for plastic fiber, 200m for HCS
fiber and up to 5000m (20000m for S800 I/O HI) for Glass Optical Fiber.

Figure 82. Example of worst case delay configuration TB826

Calculation of the Communication link delay

For the configuration in Figure 82 the Communication link delay is calculated as:
(Total delay in FF) + (Total delay in LF) + 6*(Opto-to-opto delay in
TB820/TB820V2) + 2*(Delay in TB826) + (Opto-to-electrical delay in TB820)
= 5000*0.01 + ((7 * 200)+100)*0.01 + 6*4 + 2*2.0 + 6.5
= 50 + 1500*0.01 + 24 + 4 + 6.5
= 99.5 s

Power Supply System

The power supply system for an S800 I/O system is very straightforward.
With the Type SD8xx series power supply modules, there is no requirement for
the installation of a mains filter. Should other types of non-ABB power supply units

156

3BSE020923-510 A

Section 3 Configuration

Powering S800 I/O System

be used, it may be necessary to install mains filters. For confirmation, refer to the
relevant manufacturers documentation.

Powering S800 I/O System

Figure 83 shows a series of simple circuit diagrams to indicate the various
possibilities for connecting the incoming mains power supply, via the mains
breaker, the power supply modules and the SS822, SS823 or SS832 voting devices,
to the 24 V d.c. distribution terminals of the S800 I/O System.

Powering Field Equipment

Interference
Powering field equipment from a power supply located close to the S800 I/O system
often requires the use of long 24 V d.c. cables which can easily pick up local
interference and direct it straight back to the power supply modules.

Short-circuit at the output

The SD8xx series power supply has only a little extra energy reservoir at their
outputs. In case of a short-circuit the output voltage of the power supply will fall
rapidly.
Short-circuits, (even if fuses are installed in the 24 V d.c. distribution system), can
produce unwanted voltage dips in the power supply. To avoid any influences on the
S800 I/O system from any of the field equipment, it is strongly recommended that
independent power supply modules for both the S800 I/O system and the field
equipment are installed.

Sectioning the field equipment

If the field equipment connected to an S800 I/O system are to be sectioned into
groups so that a power fail in one group is not allowed to influence the power to
other groups then it is recommended to use one power supply for each group of field
equipment.

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157

Cable protection

Section 3 Configuration

It is not safe to use fuses for sectioning in the 24 V d.c. distribution system. If a
short-circuit occurs in one group the power supply voltage will most likely drop
before any fuse is blown and consequently all groups will have a voltage drop in
their supply. To work fairly the power supply must have a spare capacity of at least
3-4 times the rated current value of the largest fuse connected to the power supply.
The resistance of long cables can lead to problems.

Cable protection
Fuses in the 24 V d.c. distribution system for cable protection only can be used.

Connection alternatives
It is recommended to power the S800 I/O system and field equipment from different
power supplies; however, the power supply for field equipment can be connected in
the same manner as that used for connecting and powering the S800 I/O system, see
Figure 83.
It should be pointed out however, that the same Mains Breaker Unit can be used to
control and isolate both power supplies or, alternatively, independent Mains
Breakers can be used on each spur, see the examples shown in Figure 84.

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Section 3 Configuration

Connection alternatives

To
S800 I/O

Single Power Supply

system

SD
8xx

Mains
Mains Breaker

24 V dc
Distribution
Terminals

Power
Supply

Redundant Power Supplies

SD
8xx

Mains

SS
832

To
S800 I/O

SS
832

24 V dc
Distribution
Terminals

system

Mains Breaker

SD
8xx
Power
Supplies

Voting
Device

Redundant Mains Power Supplies

Mains 1

SD
8xx

SS
832(1)

SD
8xx

SS
832(1)

To
S800 I/O
system

Mains Breaker

Mains 2

24 V dc
Distribution
Terminals

Mains Breaker
Power
Supplies

Voting
Device

(1)

or SS823.
If the individual power supplies are
5A or lower, only one SS832 is required.

Figure 83. Power Supply Options for S800 I/O System

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159

Connection alternatives

Section 3 Configuration

To
S800 I/O
system

Mains

SD
8xx
24 V dc
Distribution

Mains Breaker
Independent
Power Supply
Modules

To
Field
equipment

SD
8xx
24 V dc
Distribution

To
S800 I/O
system

SD
8xx

Mains
Mains Breaker

Independent Power
Supply Modules

24 V dc
Distribution
To Field Equipment

SD
8xx
Mains Breaker

24 V dc
Distribution

Independent Mains
Breaker Units

Figure 84. Powering Field Equipments

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Section 3 Configuration

Power Supply Load Calculation

Power Supply Load Calculation

Appropriate Hardware
Different power supply systems are available for the S800 I/O Station. The number
of power supply units is calculated with respect to actual number of S800 I/O
modules supported by the Station, see Power Supply Requirements on page 164 for
details.
Normally you dont have to deal with current consumption calculations, however
there are occasions with special requirements, or designs when detailed information
regarding current consumption is valuable. Please find a description of special
power supply usage under the guidelines below.

Guidelines

A summary of the main requirements of the plant supply, from a planning point
of view, is found in Section 2, Installation.

Auxiliary equipment in the controlled system is normally powered separately

from the S800 I/O power supplies.

If field devices are grounded, be sure to use galvanic isolation.

Heavy current on/off loads are always powered separately

It is possible to use the system power supply for transmitters/transducers:

3BSE020923-510 A

There is idle capacity in the available power supply units.

The transducer is grounded directly in the control system chassis.

161

Heat Dissipation

Section 3 Configuration

Heat Dissipation
Cabinet Ventilation
To avoid overheating, when ambient temperatures are high, the heat dissipated in
the electronics cabinet must be taken into consideration. This is particularly the case
with sealed cabinets (IP54) or tropicalized cabinets (IP41).
The frequency of faults is estimated to be doubled for each 20C increase in
temperature. It is therefore important to maintain a low temperature where the
equipment is installed.
The different hardware modules in the controller and the I/O system have different
outputs of heat. Accurate calculation of the heat produced by the system requires
knowledge of the modules and the work cycle.

Heat Dissipation Permitted in Cabinets

The maximum permitted temperature below the I/O station in the cabinet is 55 C.
The permissible amount of heat generated depends on the type of cabinet and its
location.
In critical applications with an I/O station fully equipped and cabinets arranged in
groups, it may be necessary to make a calculation of the actual power dissipation
and an estimation of the temperature rise within the cabinet. It is recommended that
you re-calculate when you expand the system as well.

Calculation of Heat Generated in a Cabinet

When calculating the heat generated in a cabinet, the heat generated by the different
I/O modules must be summed, and then added to the heat generated by the power
supply units and other equipment such as an extra modem, extra unit for supply of
power to transmitters etc.
Power and Cooling on page 165 gives the power dissipated as heat by hardware
modules in the S800 I/O system.
The total power dissipated in the cabinet can thus be written:
PFCI = Power of the FCI Module
PIO = Power of each S800 I/O Module

162

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Section 3 Configuration

Maintenance and Repair

P Total = P FCI + P IO + P Voltagesupplyunit + P Sundry

PVoltagesupplyunit = Power loss of the power supply unit(s)

PSundry = Miscellaneous power using equipment installed in the cabinet.

Maintenance and Repair

From the maintenance point of view, use as few module types as possible in the
hardware disposition of a control system. This is most relevant with the process I/O
design. Standardization of I/O signal types and other electrical qualities is important
to minimize the spare part stock.
Your solutions must make sense to the maintenance people in the event of
disturbances and following trouble-shooting.

Expansion Considerations
A new S800 I/O station can be connected to an existing fieldbus without affecting
other stations and controllers. The new I/O is automatically incorporated in the
communication system. Spare connections must be pre-installed as to not disturb
the existing bus.
The system fieldbus can be expanded in the following ways:

Process I/O or MTU unit

New I/O modules can be added on line. It is recommended to have approximately

10 - 20% of total capacity as spare channels, and spare space.
Spare MTUs need to be pre-mounted to add I/O modules on-line.

3BSE020923-510 A

163

Power Supply Requirements

Section 3 Configuration

Power Supply Requirements

A quick guide for power consumption to be used in a preliminary phase of a project
work or whenever you need estimated figures is provided in Table 23.
Table 23. Estimated System Power Consumption
I/O Station

24 V d.c. Power
Consumption

Base Cluster (single FCI) and 6 I/O Modules

0.5 A

Base Cluster (single FCI) and 12 I/O Modules

1.0 A

Redundant FCIs (2) and 6 I/O Modules

1.0 A

Redundant FCIs (2) and 12 I/O Modules

1.5 A

Additional I/O Clusters and 6 I/O Modules

0.5 A

Additional I/O Clusters and 12 I/O Modules

1.0 A

The above estimates are based on an I/O Station with a mixed configuration of
AI/AO and DI/DO. Only power consumption on the 24 V d.c. distributed via the
ModuleBus are included. External 24 V connected directly to the I/O modules,
for external loads and transmitters, are not included. When using large quantities
of AO820s, DI885s, DO815s and/or DO820/DO821s, these load figures may be
exceeded.

Power Supply for DO880

To ensure bumpless performance of the I/O system including DO880, the power
supply for the I/O field power should be able to support at least short circuit on one
DO880 channel in addition to the total nominal load. Short circuit current for
DO880 see technical data in S800 I/O Modules and Termination Units.
The following rules must be considered if ABB power supply units are being used
together with DO880.

164

Single DO880 and SD833: The basic load must not exceed 10 A, with voting
unit 8 A.

3BSE020923-510 A

Section 3 Configuration

Power and Cooling

Single DO880 and SD834: The basic load must not exceed 20 A, with voting
unit 20 A.

Redundant DO880 and SD833: The basic load must not exceed 4 A, with
voting unit 4 A, if the power supply voltage >26 V

Redundant DO880 and SD834: The basic load must not exceed 20 A, with
voting unit 20 A.

Single DO880 and voting unit SS823: The basic load must not exceed 20 A.

Redundant DO880 and voting unit SS823: The basic load must not exceed
16A.

Power and Cooling

Table 24 shows the typical power and cooling values that can be used when
designing the S800 I/O.
Table 24. I/O Station Power and Cooling (Typical) Values

Device

5 Volts
24 Volts
ModuleBus ModuleBus

24 Volts
External

Power
Dissipation
(Watts)

Cooling
Load (1)
(BTU/H
Typical)

Maximum Ambient
Temperature

AI801

70 mA

30 mA

1.1

3.7

55/40C
(131/104F)(2)

AI810

70 mA

40 mA

1.5

5.1

55/40C
(131/104F)(2)

AI815

100 mA

50 mA

22 mA +
sensor
current

3.5

12

55/40C
(131/104F)(2)

AI820

80 mA

70 mA

1.7

5.8

55/40C
(131/104F)(2)

AI825

100 mA

110 mA

3.2

11

55/40C
(131/104F)(2)

3BSE020923-510 A

165

Power and Cooling

Section 3 Configuration

Table 24. I/O Station Power and Cooling (Typical) Values (Continued)

Device

5 Volts
24 Volts
ModuleBus ModuleBus

24 Volts
External

Power
Dissipation
(Watts)

Cooling
Load (1)
(BTU/H
Typical)

Maximum Ambient
Temperature

AI830/
AI830A

70 mA

50 mA

1.6

5.4

55/40C
(131/104F)(2)

AI835/
AI835A

75 mA

50 mA

1.6

5.4

55/40C
(131/104F)(2)

AI843

60 mA

50 mA

1.5

5.1

55/40C
(131/104F)(2)

AI845

100 mA

50 mA

22 mA +
sensor
current

3.5

12

55/40C
(131/104F)(2)

AI880/
AI880A

45 mA

50 mA

4 mA +
sensor
current

2.4

8.2

55/40C
(131/104F)(2)

AI890

150 mA

300 mA
including
sensor
current

3.3

11

55/40C
(131/104F)(2)

AI893

125 mA

0.6

2.0

55/40C
(131/104F)(2)

AI895

130 mA

370 mA
including
sensor
current

4.75

16

55/40C
(131/104F)(2)

AO801

70 mA

200 mA
including
load
current

3.8

13

55/40C
(131/104F)(2)

166

3BSE020923-510 A

Section 3 Configuration

Power and Cooling

Table 24. I/O Station Power and Cooling (Typical) Values (Continued)

Device

5 Volts
24 Volts
ModuleBus ModuleBus

24 Volts
External

Power
Dissipation
(Watts)

Cooling
Load (1)
(BTU/H
Typical)

Maximum Ambient
Temperature

70 mA

200 mA
including
load
current

3.0

10

55/40C
(131/104F)(2)

AO810V2 70 mA

245 mA
including
load
current

2.3

7.8

55/40C
(131/104F)(2)

AO810

(3)

AO815

125 mA

165 mA
including
load
current

3.5

12

55/40C
(131/104F)(2)

AO820

100 mA

260 mA

6.0

20

55/40C
(131/104F)(2)

AO845/
AO845A

125 mA

165 mA
including
load
current

3.5

12

55/40C
(131/104F)(2)

AO890

150 mA

300 mA
including
load
current

3.5

12

55/40C
(131/104F)(2)

AO895

130 mA

330 mA
including
output
current

4.25

14.5

55/40C
(131/104F)(2)

CI801

140 mA

5.4 W(4)

19

55/40C
(131/104F)(2)

3BSE020923-510 A

167

Power and Cooling

Section 3 Configuration

Table 24. I/O Station Power and Cooling (Typical) Values (Continued)

Device

5 Volts
24 Volts
ModuleBus ModuleBus

24 Volts
External

Power
Dissipation
(Watts)

Cooling
Load (1)
(BTU/H
Typical)

Maximum Ambient
Temperature

CI810

110 mA

2.6

8.9

55C/(131F)

CI820/
CI820V1

250 mA (5) 6.0

20

55C/(131F)

CI830

110 mA

2.6

8.9

55C/(131F)

7.7

26

55/40C
(131/104F)(2)

(5)

CI840/
CI840A

190 mA

DI801

70 mA

2.2

7.5

55/40C
(131/104F)(2)

DI802

50 mA

2.8

9.6

55/40C
(131/104F)(2)

DI803

50 mA

2.8

9.6

55/40C
(131/104F)(2)

DI810

50 mA

1.8

6.1

55/40C
(131/104F)(2)

DI811

50 mA

2.7

9.2

55/40C
(131/104F)(2)

DI814

50 mA

1.8

6.1

55/40C
(131/104F)(2)

DI820

50 mA

2.8

9.6

55/40C
(131/104F)(2)

DI821

50 mA

2.8

9.6

55/40C
(131/104F)(2)

DI825

90 mA

4.9

15

55/40C
(131/104F)(2)

168

3BSE020923-510 A

Section 3 Configuration

Power and Cooling

Table 24. I/O Station Power and Cooling (Typical) Values (Continued)

Device

5 Volts
24 Volts
ModuleBus ModuleBus

24 Volts
External

Power
Dissipation
(Watts)

Cooling
Load (1)
(BTU/H
Typical)

Maximum Ambient
Temperature

DI830

120 mA

2.3

7.8

55/40C
(131/104F)(2)

DI831

120 mA

3.2

11

55/40C
(131/104F)(2)

DI840

100 mA

15 mA +
sensor
current

2.7

9.0

55/40C
(131/104F)(2)

DI880

125 mA

15 mA +
sensor
current

2.4

8.2

55/40C
(131/104F)(2)

DI885

160 mA

91 mA(6)

91 mA(6)

3.0

10

55/40C
(131/104F)(2)

DI890

150 mA

70 mA
including
sensor
current

1.6

5.4

55/40C
(131/104F)(2)

DO801

80 mA

(7)

2.1

7.2

55/40C
(131/104F)(2)

DO802

70 mA

80 mA

2.2

7.5

55/40C
(131/104F)(2)

DO810

80 mA

(7)

2.1

7.2

55/40C
(131/104F)(2)

DO814

80 mA

(7)

2.1

7.2

55/40C
(131/104F)(2)

DO815

120 mA

(8)

4.0

14

55/40C
(131/104F)(2)

3BSE020923-510 A

169

Power and Cooling

Section 3 Configuration

Table 24. I/O Station Power and Cooling (Typical) Values (Continued)

Device

5 Volts
24 Volts
ModuleBus ModuleBus

24 Volts
External

Power
Dissipation
(Watts)

Cooling
Load (1)
(BTU/H
Typical)

Maximum Ambient
Temperature

DO820

60 mA

140 mA

2.9

9.9

55/40C
(131/104F)(2)

DO821

60 mA

140 mA

2.9

9.9

55/40C
(131/104F)(2)

DO840

130 mA

200 mA (7) 4.3

+ channel

14

55/40C
(131/104F)(2)

19

55/40C
(131/104F)(2)

load

DO880

45 mA

55 mA

10 mA (7)
+ channel

5.6(9)

load

DO890

150 mA

360 mA @ 4.4
300 ohms
load/
channel

15

55/40C
(131/104F)(2)

DP820

120 mA

(7)

2.5

8.5

55/40C
(131/104F)(2)

DP840

115 mA

(10)

4.0

14

55/40C
(131/104F)(2)

TB810

100 mA

20 mA

0.5

1.7

55C/(131F)

TB811

100 mA

20 mA

0.5

1.7

55C/(131F)

TB820/
TB820V2

100 mA

6.0

20

55C/(131F)

TB825

96 mA

2.3

7.8

55C/(131F)

92 mA

2.2

7.8

55C/(131F)

120 mA(5) 6.0

20

55/40C
(131/104F)(11)

TB826
TB840/
TB840A

170

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Section 3 Configuration

Power and Cooling

Table 24. I/O Station Power and Cooling (Typical) Values (Continued)

Device

5 Volts
24 Volts
ModuleBus ModuleBus

24 Volts
External

Power
Dissipation
(Watts)

Cooling
Load (1)
(BTU/H
Typical)

Maximum Ambient
Temperature

TB842

100 mA

20 mA

0.5

1.7

55C/(131F)

SD821

8.6

29

55C/(131F)(12)

SD822

13.3

45

55C/(131F)(12)

SD823

26.7

90

55C/(131F)(12)

SD831

10/8(13)

34/27

55C/(131F)(12)

SD832

14/13(13)

47/44

55C/(131F)(12)

SD833

24/22(13)

81/75

55C/(131F)(12)

SD834

40/31(13)

136/105

55C/(131F)(12)

SS822

2.5(14)

8.5

55C/(131F)(12)

SS823

24

82

55C/(131F)(12)

SS832

7,9

27

55C/(131F)(12)

(1) Cooling load is the heat (BTU/H) produced by the equipment that may be required to meet room or enclosure cooling
specifications.
(2) 40C(104F) applies to Compact MTUs with I/O modules, S800L, CI801 or CI840 mounted on a vertical DIN rail.
(3) AO810V2 replaces AO810
(4) With maximum load at ModuleBus 24 V and 5V
(5) In redundant configuration twice
(6) 24 V from ModuleBus (91 mA) or 24 V external (91 mA) or 48 V external (22 mA).
(7) 500 mA per channel with maximum load per channel.
(8) 2 A per channel with maximum load per channel.
(9) With maximum channel load
(10) Sensor power
NAMUR: 56 + 0.5 x external load [mA]
12 V: 89 + 0.7 x external load [mA]
24 V: 97 + external load [mA]
(11) 40C(104F) mounter on a vertical DIN rail.
(12) Horizontal mounting only.
(13) a.c. 120/230V.
(14) 2,5 W at 5A, for calculation use W=0,5 V x Output current.

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171

Calculation of 24 V d.c. Power Consumption

Section 3 Configuration

Calculation of 24 V d.c. Power Consumption

Total 24 V d.c. power consumption = V load ModuleBus + V load
ModuleBus*0.3 + V external load.
The calculated 24 V ModuleBus load should not exceed 1.4 A.
If too many of the modules: AO820, DO820 and DO821 are used, the maximum
24 V ModuleBus load could be exceeded. See Table 24 for exact data.
The calculated 5 V ModuleBus load should not exceed 1.5 A.
If too many of the modules: AI890, AI895, AO890, AO895, DI830, DI831,
DI885, DI890, DO815, DO890 or DP820 are used, the maximum 5 v load could
be exceeded. See table Table 24 for exact data.

172

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Section 4 Operation
Operating Overview
An I/O station is an autonomous station, which is normally not handled by an
operator. Of course, it is started and sometimes stopped manually. This is done in
specific situations, for example during installation work and maintenance.
Consequently, operating instructions are spread out in this manual and will be
discussed in the appropriate section.
For specific instructions, see Section 2, Installation and Section 5, Maintenance.
For more information regarding operation, refer to the controller manual or the
S800 I/O Fieldbus Communication Interface for PROFIBUS-DP/DPV1
(3BSE020926*) or the S800 I/O Fieldbus Communication Interface for Advant
Fieldbus 100 (3BSE020925*) manuals.

3BSE020923-510 A

173

Operating Overview

Section 4 Operation

174

3BSE020923-510 A

Section 5 Maintenance
Preventive Maintenance
This section describes routine maintenance, replacement and installation procedures
necessary to maintain the operation of the S800 I/O equipment. The S800 I/O
modules do not need special adjustments such as zero and span of analog I/O
modules.
Analog I/O modules are factory calibrated and have calibration parameters for all
ranges stored in memory on the module. The ModuleBus master uses those
calibration parameters for calculations of the correct input and output signals.
Thermocouple and RTD modules use internal references for calibrations of the
measured values.

Hardware Indicators
Various visual indications (LEDs) are used in the I/O-system for showing module
status and for digital I/O modules also channel status.
These indications serve the purpose of informing the user about status or fault in the
system or in the process. They are intended to be a simple and easy to use help.
They should allow to spot faults in the station easily.

Color
A fixed meaning is assigned to the colors red, yellow and green:
RED

Danger or alarmWarning of potential danger or a situation which

requires immediate action

YELLOW

Caution

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Change or impending change of condition, warning

175

Location

Section 5 Maintenance

GREEN

Safety

Indication of a normal situation or authorization to

proceed, clear way.

For digital I/O on-states a definite meaning can not be assigned. For them the color
yellow is chosen. The Table 25 shows the meaning and colors of LED's.
Table 25. Meaning and Colors of LEDs
Meaning/Purpose
Fault; Error

Color
Red

Warning, I/O State Indications

and OSP (Outputs
Set as Predetermined)

Yellow

Normal Operation

Green

Examples
"FAULT
OSP, Process error,
Digital I/O on-state,
Process voltage low, Traffic.
RUN, Normal operation,
Power OK.

Location
For the location of LEDs the following rules are applied:
S800 I/O Modules (except S800L)

Indications having the same meaning on every I/O module (for example,
FAULT, RUN, WARNING, OSP) are at the same position.

The standard indications FAULT, RUN, WARNING and OSP (only output
modules), are always on the topmost position on every device (top: FAULT,
RUN, then WARNING, OSP).

S800L I/O Modules

Have one LED S for module status showing FAULT (Red) or RUN (Green).

FCI

On the FCI: FAULT, RUN, POWER OK, TRAFFIC and for redundant FCI also
PRIMARY and DUAL.

Optical ModuleBus Modem

176

On TB820/TB820V2: FAULT, RUN, POWER OK, ORx1, ORx2 and ERx.

3BSE020923-510 A

Section 5 Maintenance

Identification

On TB840: STATUS, POWER OK, Rx1, Rx2, ERx1 and ERx2.

Identification
LED's shall be identified by an appropriate symbol or abbreviation of an English
term. For the standard indications the abbreviation is as follows:

Fault in the moduleFAULT or F

Device is in operationRUN or R

External fault or minor fault in the moduleWARNING or W

Output Set as Predetermined, OSP or O

Digital I/O on-state1, 2,... (channel number)

Digital I/O channel FAULT or F

Power supply ok internal and/or external okPOWER OK or P

Module status (S800L modules and Optical

ModuleBus Modem TB840)STATUS or S

Traffic on FieldbusTRAFFIC, T1, T2 or Rx/Tx

Primary in redundant FCI configurationPRIMARY, PR or PRIM

Both FCI in a redundant pair are in operationDUAL or DU

Traffic on the Optical ModuleBusORx1, ORx2, Rx1 or Rx2

Traffic on the electrical ModuleBus.ERx, ERx1 or ERx2

Error Messages
Not applicable.

Fault Finding and User Repair

Introduction
Diagnostics are available in different forms for rapid localization of the source of
the equipment malfunction. Hardware error is usually corrected by replacing the

3BSE020923-510 A

177

Diagnostics and Fault Indications

Section 5 Maintenance

faulty module which is returned to ABB Service for repairs. The smallest
replaceable unit is normally a module or an apparatus like a power supply unit.
Disturbances and system halt caused by software error is commonly solved by a
manual system restart.
External faults in process wiring and transducers can also affect the function of the
S800 I/O system. However, this type of fault is not discussed in this manual.

Diagnostics and Fault Indications

Hardware and software in a S800 I/O system is provided with supervision against
system faults.
LED indicators on modules:

Green LED, RUN, indicates normal function.

Yellow LED indicates an active signal, for example, status of digital input
(DI) or digital output (DO), OSP and Warning.

Red LED, FAULT, indicates malfunction.

Red/Green LED indicates module status (S800L modules)

Red = FAULT, Green = RUN normal function.

List of General Fault Finding Procedures and Hints

Location of Malfunction

Sometimes, you lack the information from the controller diagnostics, that tells you
where the fault is located. Suspicion about a fault is raised by the process behavior.
Experience indicates that approximately 85% of all faults occur in the process, 10%
in the control program and 5% in the control system hardware.
It is always advisable to localize the malfunction with these figures in mind to
minimize the down-time.

178

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Section 5 Maintenance

List of General Fault Finding Procedures and Hints

External Factors

In an electronics system which has given satisfactory service, most malfunctions

have external causes. It is therefore important, when tracing a fault, to determine if
any external factor such as incorrect handling of the equipment, short circuits,
welding work, lightning strike and/or power failure has caused the malfunction.
Safety at Start/Stop

Voltage failure, component fault or manual restart usually affect the control system
function. I/O system failure affects the process in different ways:

In a system which is monitoring the process only, changes in the process status
are not registered but there is no immediate danger to the process operation.

In a system which is controlling a continuous processes (rolling mills and paper

manufacture) demands a high degree of continuity of the control system
functions.
A restart of the I/O system or controller can have very serious consequences. It is
important to be aware of the local requirements for safety when starting and
stopping the I/O system or controller.

Check of Non-redundant Power Supply

The CI801/CI810/CI820/CI820V1/CI830/CI840 Fieldbus Communications

Interface (FCI), or TB820/TB820V2/TB840/TB840A status LED - P is illuminated
when 24 V d.c. is supplied to the FCI or TB820/TB820V2/TB840/TB840A, and 5 V
(from the FCI or TB820/TB820V2/TB840/TB840A) is supplied to the rest of the
I/O Station.
The supply system consists at least of one power supply.
Power can be checked at the FCI or TB820/TB820V2/TB840/TB840A on terminals
L+ and L- with a voltmeter. The value should be 24 V d.c. (19.2 to 30). Power can
also be checked at the power supply or on the distribution strip.
Check of Redundant Power Supply

The CI801/CI810/CI820/CI820V1/CI830/CI840 Fieldbus Communications

Interface (FCI), or TB820/TB820V2/TB840/TB840A status LED - P is illuminated

3BSE020923-510 A

179

User Repair

Section 5 Maintenance

when 24 V d.c. is supplied to the FCI/TB820/TB820V2/TB840/TB840A, and 5 V

(from the FCI/TB820/TB820V2/TB840/TB840A) is supplied to the rest of the I/O
Station.
The supply system consists of at least two power supplies.
Power can be checked at the FCI or TB820/TB820V2/TB840/TB840A on terminals
L+ and L- with a voltmeter. The value should be 24 V d.c. (19.2 to 30). Power can
also be checked at the power supplies, diode unit or on the distribution strip.
To do a complete check each power supply has to be run as single.

User Repair
I/O Module Replacement

All S800 I/O modules, except for the S800L modules or relay output modules with
normally closed contacts, can be exchanged on-line with the process power supply
connected. This is possible because the module deactivates when the I/O module
lock switch is turned to unlock.
Switch off the process voltage before removal of the module, if the plastic cover
for the I/O modules DI802, DI803, DI820, DI821, DO802, DO820 or DO821 is
damaged, and there is risk for contact with live parts.
It is important to understand the consequences of a module exchange on-line and
how it affects the process. Replacement of an S800 I/O module affects all channels
on the module. It also sometimes indirectly affects the outputs via some application
function, on another module.
To exchange a S800L module or MTU the power supply must be switched off.
The system software in the ModuleBus master checks automatically that all I/O
modules function correctly. In the event of module fault, and module exchange, the
module and associated signals are marked as faulty.
The system software checks that the module is inserted and correct. If this is the
case, the Fault-indicator (LED) extinguishes (after 10 seconds).

180

3BSE020923-510 A

Section 5 Maintenance

User Repair

At exchange of faulty I/O modules, it is important to check that the new modules
start up correctly. If the module does not start up correctly within about one minute
the module is faulty or of wrong type and should be taken out from the system and
changed to a correct module.
Power Supply Module Replacement

In single or parallel operation of power supplies, there will always be a disturbance

of the function when a power supply must be replaced; the station will not have
power.
In a redundant power supply configuration, it is possible to replace a power supply
module without disturbance of the function. To achieve that installation, see
Figure 83 and Figure 84 and the correct replacement procedure that follows.
Practical Execution. Replace faulty or suspect power supply module in the
following way:
For single or parallel operation do steps 1, 2 and 4 to13.
For redundant configuration do steps 1 to 14.

1.

Read Section 2, Installation.

2.

Check that the new module can replace the old.

3.

Switch off the output from the module (only redundant configuration).

4.

Switch off input power to the module.

5.

Disconnect the wires.

6.

Dismount the module by loosening the module locking.

7.

Mount the new module.

8.

Connect the input wires.

9.

Switch on input power to the module.

10. Perform a function test on the new module.

11. Switch off input power to the module.
12. Connect the output wires.

3BSE020923-510 A

181

User Repair

Section 5 Maintenance

13. Switch on input power to the module.

14. Switch on the output from the module (only redundant configuration).
Communication Module Replacement

Normally communications modules cannot be exchanged on-line, the only

exception are the CI820/CI820V1/CI840/TB840/TB840A in a redundant
configuration.
It is important to understand the consequences of a module exchange and how it
affects the process.

Replacement of a communication module type

CI801/CI810/CI820/CI820V1/CI830 or a CI840 in a single configuration
affects all channels on all the modules in an I/O station. The station will loose
power.

Replacement of a single communication module type CI820/CI820V1/CI840

in a redundant configuration has no affects on channels in an I/O station.

Replacement of a communication module type TB810/TB811/TB842 affects

all channels on all the modules in all clusters except cluster 0. The
communication will be broken to all clusters except for cluster 0.
If TB842 should be replaced in a running system the carrier (TB806 or TB846)
of TB842 have to be disconnected from the FCI first.

182

Replacement of a communication module type TB815 affects all channels on

all the modules in an I/O station. The station will loose power.

Replacement of a communication module type TB820/TB820V2, TB840 or

TB840A in a single configuration, connected via a simplex optical cable,
affects all channels on all the modules in all clusters except cluster 0. The
communication will be broken to all clusters except for cluster 0. The cluster
where the TB820/TB820V2/TB840/TB840A should be replaced will be power
less.

Replacement of a communication module type TB820/TB820V2, TB840 or

TB840A in a single configuration, connected via a duplex optical cable, affects
all channels on all the modules in all clusters after and including the cluster
where the replaced TB820/TB820V2/TB840/TB840A is located.

3BSE020923-510 A

Section 5 Maintenance

User Repair

The communication will be broken to all clusters after where the replaced
TB820/TB820V2/TB840/TB840A is located. The cluster where
TB820/TB820V2/TB840/TB840A should be replaced will be power less.

Replacement of a communication module type TB840/TB840A in a redundant

configuration has no affects on channels in an I/O station.

Table 26. Replacement Aspects of S800 I/O Modules

Module Type - Settings
TB810/811 No settings

TB820/
TB820V2
ModuleBus
Modem

Optical ModuleBus cable can be removed by

pulling the connector(s) out of the unit. Can not
be replaced with power applied.

Switch setting for I/O Cluster

address
F
ORx1

R
P
ORx2
ERx

CLUSTER
4 56
3
7
2
1
TB820

Comments

Cluster Address
Switch

L+ L+ SA
L- L- SB
X4 X5
Rx TxRx Tx

Can not be replaced with power applied.

Needs room to the left of an MTU in order to be
removed.
In normal operation mode, before a
TB820/TB820V2 is replaced, the supply to the
S800 I/O is to be switched off. Power
connections can be removed by pulling the
header terminals out of the unit.
Optical ModuleBus connections can be removed
by pulling the connector(s) out of the unit.
TB840/TB840A: Can be replaced with power
applied.

TB840/
TB840A
and TU841

In redundancy applications, one TB840/TB840A

can be replaced, without any affects on
channels in an I/O station.

Cluster Address
Switch

3BSE020923-510 A

TU841:Needs room to the left of an MTU in

order to be removed. Can not be replaced with
power applied.

183

User Repair

Section 5 Maintenance

Table 26. Replacement Aspects of S800 I/O Modules (Continued)

Module Type - Settings
TB842

No settings

Comments
Optical ModuleBus cable can be removed by
pulling the connector(s) out of the unit. Can be
replaced with power applied.
If TB842 should be replaced in a
running system the carrier (TB806 or
TB846) of TB842 have to be
disconnected from the FCI first.

TU841

184

See TB840

3BSE020923-510 A

Appendix A General Specifications

Directives
EMC Directive
All products, mentioned in this document, that bares the CE marking, meet the
requirement of the EMC Directive EMCD 2004/108/EC. The following standards
have been applied:

EN 61000-6-4 (2007) EMC, Emission

EN 61000-6-2 (2005) EMC, Immunity

Low Voltage Directive

All products, mentioned in this document, that bares the CE marking, meet the
requirement of the Low Voltage Directive LVD 2006/95/EC. The following standard
has been applied:

EN 61131-2 (2007) Clause 11, 12, 13 and 14.

ATEX directive
All products, mentioned in this document, that bares the Ex symbol, meet the
requirement of the ATEX Directive ATEX 94/9/EC. For more information, see
Certifications on page 194.

3BSE020923-510 A

185

Standards and Approvals

Appendix A General Specifications

Standards and Approvals

Check how the approvals are applicable for each module.

Electrical Safety
Table 27. Electrical Safety
EN 50178

Electronic Equipment for Use in Power Installations

IEC/EN 61131-2
Programmable Controllers Part 2: Equipment
(Clause 11, 12, 13 and 14) Requirements and Tests
UL 508

Industrial Control Equipment.

CSA 22.2 No.142-M1987

Process Control Equipment. Industrial Products

Hazardous Classified Locations

Table 28. Hazardous Locations
CSA 22.2 No.213-M1987
CAN/CSA-E60079-15:02

Non-Incendive Electrical Equipment for use in

Class 1, Division 2 Hazardous Locations

FM 3600

Electrical Equipment for use in Hazardous

(Classified) locations

FM 3611

Non-Incendive Electrical Equipment for use in

Class 1, Division 2 Hazardous Locations

UL 60079-15

Electrical Apparatus for Explosive Gas Atmospheres

- Part 15: Electrical Apparatus with Type of Protection
"n".

IEC/EN 60079-15

Electrical apparatus for explosive gas atmospheres

Part 15: Construction, test and marking of type of
protection n electrical apparatus.

EN 50020

Electrical apparatus for potentially explosive

atmospheres - Intrinsic safety "i"

See Certifications on page 194 for each module type certification details.

186

3BSE020923-510 A

Appendix A General Specifications

CE-marking

CE-marking
S800 products fulfill the requirements of EU-directives 2004/108/EC
"Electromagnetic Compatibility" (EMC Directive) and 2006/95/EC "Electrical
Equipment Designed for Use between Certain Voltage Limits" (Low Voltage
Directive). Declarations of conformity are available on request.
See Certifications on page 194 for each module type certification details.

G3 Compliant
G3 compliant modules fulfills the severity level in the standard ISA-S71.04
Environmental Conditions for Process Measurement and Control Systems: Airborne
Contaminants.
G3 compliant modules shall not be stored in more severe environment than G2 if the
contacts are unconnected.

Transport and Storage Conditions

S800 modules should be transported and stored in their original packaging.
Table 29. S800 Storage Conditions
Condition

Range

Standard

Temperature

-40 to +70C

Humidity

RH = 5 to 95%, no condensation

Altitude

-500 to +3000 m

Pollution degree

Degree 2

IEC 60664-1

Corrosive
atmosphere

< 1000 Angstrom copper corrosion over

28 days

ISA-71.04
Severity level G2

3BSE020923-510 A

IEC/EN 61131-2

187

Transport and Storage Conditions

Appendix A General Specifications

Table 29. S800 Storage Conditions

Condition
Fall in package

Range
< 10 kg: 300 mm
10 - 40 kg: 300 mm
> 40 kg: 250 mm

Standard
IEC/EN 61131-2

Free-fall drop height in original product

package.
Shock

188

150 m/s2, 11 ms

3BSE020923-510 A

Appendix A General Specifications

Climatic operating conditions

Climatic operating conditions

Table 30. Climatic Operating Conditions
Condition

Temperature(1)

Operative range
0 to +55C non-condensing
0 to +40C compact MTUs or S800L
modules on vertical DIN-rail, see
Table 24, non-condensing

Standard
IEC/EN 61131-2

Temperature
change

3 C/min

Humidity

RH = 5 to 95%, no condensation

Altitude

2000 m

Pollution degree

Degree 2

IEC 60664-1

<1000 Angstrom copper corrosion over

28 days

ISA-71.04
Severity level G2

<2000 Angstrom copper corrosion over

28 days

ISA-71.04
Severity level G3

Corrosive
atmosphere

(1) Approvals are issued for +5 to +55C.

Mechanical operating conditions

Table 31. Mechanical Operating Conditions
Operative range
Vibration Test

59 Hz, amplitude 3,5 mm

Sinusoidal

9-150 Hz, acceleration 1,0g

Operational

1 octave/min

Shock

150 m/s2, 11 ms

Emitted noise

<55 dB (A)

3BSE020923-510 A

Standard
IEC/EN 61131-2

IEC/EN 61131-2

189

EMC

Appendix A General Specifications

EMC
Table 32. Radiated Radio Frequency Emission IEC/EN 61000-6-4 (Class A),
IEC/EN 61131-2
Radiated Radio Frequency Emission IEC/EN 61000-6-4 (Class A),
IEC/EN 61131-2
Test

Limits

30 MHz -230 MHz

40 dB (V/m) quasi peak measured at

10m

230 MHz - 1000

MHz

47 dB (V/m) quasi peak measured at

10m

Generic
standards
EN/IEC 61000-6-4,
EN/IEC 61131-2

Table 33. Conducted Radio Frequency Emission, AC mains port IEC 61000-6-4
(Class A), IEC/EN 61131-2
Conducted Radio Frequency Emission, AC mains port IEC 61000-6-4 (Class
A), IEC/EN 61131-2
Test
0,15 MHz -0,50
MHz

Limits
79 dB (V/m) quasi peak
66 dB (V/m) average

Generic
standards
EN/IEC 61000-6-4,
EN/IEC 61131-2

0,50 MHz - 30 MHz 73 dB (V) quasi peak

60 dB (V/m) average

190

3BSE020923-510 A

Appendix A General Specifications

EMC

Table 34. Immunity IEC/EN 61000-6-2, IEC/EN 61131-2

Immunity IEC/EN 61000-6-2, IEC/EN 61131-2 Continuous...
Test
Radiated RF field

Severity
80MHz 1.0GHz, 10 V/m
1.4GHz 2.0GHz, 3 V/m

Generic
standards
EN/IEC 61000-6-2,
EN/IEC 61131-2

2.0GHz 2.7GHz, 1 V/m

Conducted RF field 0.15MHz-80MHz, 10V

EN/IEC 61000-6-2,
EN/IEC 61131-2

Table 35. Transients Immunity

Transients immunity
Electrostatic
discharge

4 kV contact discharge
8 kV air discharge

IEC 61000-6-2,
IEC 61131-2

Electrical fast
transient/Burst

2 kV, AC/DC, process I/O AC

1 kV, Process I/O DC, analog I/O and
com

IEC 61000-6-2,
IEC 61131-2

Surge

2 kV common mode, AC/DC power ports, IEC 61000-6-2,

IEC 61131-2
process I/O AC
1 kV differential mode, Process I/O DC,
analog I/O and com

3BSE020923-510 A

191

Overvoltage Categories

Appendix A General Specifications

Overvoltage Categories
Table 36. Overvoltage
Installation type

Category

Equipment permanently
connected to low voltage
mains

Overvoltage categories III

Equipment not energized

directly from the low voltage
mains

Overvoltage categories II

Standards
IEC/EN 60664-1

AC mains power supplies are compliant with Overvoltage Category III networks
(industrial mains). All I/O signals are overvoltage II compliant.

Equipment Class and Insulation Voltages

Equipment Class
S800 equipment class is Class 1 according to IEC 60536. Class 1 means protection
of electric shock by protective earth connection (PE). In this case this means a PEconnection must be made to the DIN rail.

Insulation Voltage
All accessible ports on S800 modules are galvanically isolated from ground and
system. For actual module isolation configuration, please consult module data
sheets.

192

3BSE020923-510 A

Appendix A General Specifications

Insulation Test Voltage

Insulation Test Voltage

Type test, insulation test voltage

500 V a.c. or 700 V d.c. 1 minute for RIV 50V1 modules

2000 V a.c. 1 minute for RIV 250V modules
Routine Test, insulation test voltage

850 V d.c. 1 second for RIV 50V modules

2000 V a.c. 1 second for RIV 250V modules

1.

Modules with a working voltage of less than 50 V have RIV 50 V. RIV 250 V applies to all modules having a
working voltage greater than 50 V. It should be noted that insulation test voltage specifications, according to
electrical safety standards, do not imply that permanent connection to circuits with voltages greater than the
specified Rated Insulation Voltage is allowed. Connection to voltages higher than specified RIV violates
electrical safety codes and may expose users to electric shock.

3BSE020923-510 A

193

Certifications

Appendix A General Specifications

Certifications
The S800 I/O system is continuously enhanced with additional certificates. The
table below describes the situation at the printing of this manual.
Table 37. Current Certifications for S800 Modules

Module
Type

CE

cULus
CSA
FM
El. safety
El. safety El. safety
Haz loc
Haz loc
Haz loc
C1 Zone
C1, Div 2 C1, Div 2
(1)
2

ATEX
Zone 2
Category
3 (1) G (2)

ATEX Zone
cULus
2 Category SIL1-3
El. safety
(3)
3G

Analog Input Modules

AI801

AI810

AI820

AI815

AI825

AI830

AI830A

AI835

AI835A

AI843

AI845

AI880/
AI880A

AI890

AI893

AI895

194

X
X(4)

X(4)

X(4)

X(4)

X
X
X

3BSE020923-510 A

Appendix A General Specifications

Certifications

Table 37. Current Certifications for S800 Modules (Continued)

Module
Type

CE

cULus
CSA
FM
El. safety
El. safety El. safety
Haz loc
Haz loc
Haz loc
C1 Zone
C1, Div 2 C1, Div 2
(1)
2

ATEX
Zone 2
Category
3 (1) G (2)

ATEX Zone
cULus
2 Category SIL1-3
El. safety
(3)
3G

Analog Output Modules

AO801

AO810

AO810V2

AO815

AO820

AO845

AO845A

AO890

X(4)

X(4)

AO895

X(4)

X(4)

Field Communication Interface

CI801

CI810B

CI820V1

CI830

CI840

CI840A

TB815

3BSE020923-510 A

195

Certifications

Appendix A General Specifications

Table 37. Current Certifications for S800 Modules (Continued)

Module
Type

CE

cULus
CSA
FM
El. safety
El. safety El. safety
Haz loc
Haz loc
Haz loc
C1 Zone
C1, Div 2 C1, Div 2
(1)
2

ATEX
Zone 2
Category
3 (1) G (2)

ATEX Zone
cULus
2 Category SIL1-3
El. safety
(3)
3G

Advant Fieldbus 100

TC501V150

TC506

TC513V1

TC514V2

TC515V2

Digital Input Modules

DI801

DI802

DI803

DI810

DI811

DI814

DI820

DI821

DI825

DI830

DI831

DI840

196

3BSE020923-510 A

Appendix A General Specifications

Certifications

Table 37. Current Certifications for S800 Modules (Continued)

Module
Type

CE

cULus
CSA
FM
El. safety
El. safety El. safety
Haz loc
Haz loc
Haz loc
C1 Zone
C1, Div 2 C1, Div 2
(1)
2

DI880

DI885

DI890

ATEX
Zone 2
Category
3 (1) G (2)

ATEX Zone
cULus
2 Category SIL1-3
El. safety
(3)
3G
X

X(4)

X(4)

Digital Output Modules

DO801

DO802

DO810

DO814

DO815

DO820

DO821

DO840

DO880

DO890

SD821(5)

SD822(5)

SD823(5)

SS822(5)

SD832

3BSE020923-510 A

X
X(4)

X(4)

197

Certifications

Appendix A General Specifications

Table 37. Current Certifications for S800 Modules (Continued)

Module
Type

CE

cULus
CSA
FM
El. safety
El. safety El. safety
Haz loc
Haz loc
Haz loc
C1 Zone
C1, Div 2 C1, Div 2
(1)
2

SD833

SD834

SS823

SS832

ATEX
Zone 2
Category
3 (1) G (2)

ATEX Zone
cULus
2 Category SIL1-3
El. safety
(3)
3G
X
X
X

X
X

Pulse Counting Modules

DP820

DP840

Module Termination Units

TU801

TU807

TU810V1

TU811V1

TU812V1

TU813

TU814V1

TU830V1

TU831V1

TU833

198

3BSE020923-510 A

Appendix A General Specifications

Certifications

Table 37. Current Certifications for S800 Modules (Continued)

Module
Type

CE

cULus
CSA
FM
El. safety
El. safety El. safety
Haz loc
Haz loc
Haz loc
C1 Zone
C1, Div 2 C1, Div 2
(1)
2

ATEX
Zone 2
Category
3 (1) G (2)

ATEX Zone
cULus
2 Category SIL1-3
El. safety
(3)
3G

TU834

TU835V1

TU836V1

TU837V1

TU838

TU839

TU840

TU841

TU842

TU843

TU844

TU845

TU846

TU847

TU848

TU849

TU890

TU891

TY801

TY804

3BSE020923-510 A

X
X
X

X(4)

X(4)

199

Certifications

Appendix A General Specifications

Table 37. Current Certifications for S800 Modules (Continued)

Module
Type

CE

cULus
CSA
FM
El. safety
El. safety El. safety
Haz loc
Haz loc
Haz loc
C1 Zone
C1, Div 2 C1, Div 2
(1)
2

ATEX
Zone 2
Category
3 (1) G (2)

ATEX Zone
cULus
2 Category SIL1-3
El. safety
(3)
3G

ModuleBus Communication Parts

TB805

TB806

TK801V003

TK801V006

TK801V0012

TB807

TB810

TB811

TB820V2

TB825

TB826

TB840/
TB840A

TB842

TB845

TB846

(1) Marking for mounting and interface: Class 1 Zone 2 AEx nC (or nA) IIC T4 and CL 1 DIV 2 GP A B C D T4
(2) Marking for mounting: Ex II 3G EEx nA [ia] IIC T4
Marking for interface: Ex II (1)G [EEx ia] IIC
(3) Marking for mounting and interface: Ex II 3G Ex nA IIC T5 Gc
(4) Provides Intrinsically safe circuit for Cl. I, Div 1; Cl. II, Div. 1; Cl. III, Div 1 or Cl. I, Zone 0 group IIc
(5) cULus; UL508, UL1950, CSA 22.2 No 950

200

3BSE020923-510 A

Appendix B Specifications
SD82x Power Supply Modules, 24 V d.c.
Key Features

Simple DIN-rail mounting

Input a.c. or d.c.

Class I Equipment, (when connected to Protective Earth, (PE))

Over-voltage Category III for connection to primary main TN network of

Installation Category III

Protective separation of secondary circuit from primary circuit.

Secondary outputs;

SD823 = 24 Volts d.c. regulated @ 10 A

SD822 = 24 Volts d.c. regulated @ 5 A

SD821 = 24 Volts d.c. regulated @ 2.5 A

Accepted for SELV and PELV applications

Equipment Class
The Power Supply Units, (PSU), are designed to meet all the applicable electrical
safety data stated by the EN 50178 harmonized European Standard Publication and
the additional safety and function data required by EN 61131-2 and UL 508.
The secondary output circuitry is accepted for SELV or PELV applications.
SELV according to EN 50178, EN 60950 and VDE 0100 Part 410.
For PELV applications; in accordance with EN 50178.

3BSE020923-510 A

201

Ingress Protection

Appendix B Specifications

Ingress Protection
IP20 according to EN 60529, IEC 60529
Protective Class I according to EN 50718; 3.56

110
50

103
97

L+ L+ L- LOK

125

SD821
N

44

L PE

230

Mains Voltage
Selection Switch
(115 / 230)

Figure 85. SD821 Connections for 2.5 A Power Supply

202

3BSE020923-510 A

Appendix B Specifications

Ingress Protection

110
65

103
97

L+ L+ L- LOK

125

SD822
N

230

L PE

44

Mains Voltage
Selection Switch
(115 / 230)

Figure 86. SD822 Connections for 5 A Power Supply

3BSE020923-510 A

203

Power Supply Units Types SD821 / 822 / 823 - Description

Appendix B Specifications

110mm (4.3")
120mm (4.7")

103mm (4.1")

125mm
(4.9")

97mm (3.8")

SD823
N

L PE

OK

L+ L+ L- L-

44mm
(1.7")

115V
230V

Figure 87. SD823 Connections for 10 A Power Supply

Power Supply Units Types SD821 / 822 / 823 - Description

ABB recommend the use of these robust and reliable power supply units, (PSUs),
for providing power to the S800I/O system, when connected to an industrial mains
network of installation category III. PSUs can be used for both non-redundant and
redundant applications.
The three PSUs were designed as switch mode power converters, that is, converting
a.c. mains supply voltage to a regulated 24 V d.c. output. The three converters have
rated output capacities as follows:

204

SD823 = 24 Volts d.c. regulated @ 10 A

SD822 = 24 Volts d.c. regulated @ 5 A

SD821 = 24 Volts d.c. regulated @ 2.5 A

3BSE020923-510 A

Appendix B Specifications

Power Supply Units Types SD821 / 822 / 823 - Description

The mains input voltage is set to either 115 V or 230 V by means of a switch
mounted on the front face of the module. The factory default for this switch is in the
230 V position.
The output voltage of all three PSUs is, as stated, a regulated, low noise, 24 V d.c. A
green LED, mounted on the PSU front panel, indicates that the output circuit is
providing the correct output voltage level. The double connectors, provided on the
24 V d.c. output terminals, allow for the connection of more than one equipment.
A surge current limiter within the PSU circuit, provides a soft-start feature. The
controlled power-on of a PSU therefore, will not trip fuses or earth-fault circuit
breakers. In addition, the normal disturbances that occur within an industrial main
network will not cause any transient fault conditions or trips to occur.
This means that the surge current limiter will effectively reduce the peak inrush
current, caused by a power disruption, to a level that the PSU can tolerate.
This soft-start, surge current limiter facility provides ease of design for the system
power distribution circuits.
X1

X2
Fuse
L+
LED

L+
LL-

PE

Chopper

Figure 88. PSUs SD821, 822 and 823 - Block Diagram

3BSE020923-510 A

205

Insulation of Power Supply Units (PSU)

Appendix B Specifications

Insulation of Power Supply Units (PSU)

Basic with protective conductor. The primary circuit is separated from all other live
circuits by reinforced insulation.
Rated insulation voltage Primary to Secondary 300 V a.c.
Dielectric test voltage 3000 V a.c. (EN 60950).

Fuses and Protective Devices

Internal primary main fuses are arranged to meet the requirements of electrical
safety publications for connection to the Phase - Neutral terminals of primary main
network; TN network, 1 (one) fuse. Recommended primary external fuse:

Micro Circuit Breaker (MCB) 10 Amperes, characteristic B.

Table 38. Power Supply Units - Fuses and Protective Devices
Fuse

SD821

SD822

SD823

Primary: Internal fuse

3.15 AT

4 AT

6.3 AT

Primary: Recommended external fuse (1)

10 A (1)

10 A (1)

10 A (1)

Secondary: Short circuit

<5 A

<10 A

<20 A

Secondary: Over-load protection

3 A> I
I <5 A

6 A< I
I< 10 A

12 A< I
I < 20 A

Secondary: Over-Voltage protection

32 V typ

29 V typ

35 V typ

(1) Microcircuit Breaker (MCB), Characteristic B

206

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Appendix B Specifications

Technical Data

Technical Data
Table 39. PSUs SD821, 822 and 823 - Technical Data
Parameter

SD821
Converter

SD822(1)
Converter

SD823
Converter

Rated output current (A)

2.5 A

5A

10 A

Rated output power

60 W

120 W

240 W

Rated output voltage

24 V

24 V

24 V

Rated input power

160 VA
70 W

280 VA
135 W

690 VA
265 W

Mains/input voltage, nominal

115/230 V a.c. 115/230 V a.c. 115/230 V

225-250 V d.c. 225-250 V d.c. a.c.
250 V d.c.

Mains voltage variation allowed

85 - 110%

Mains/input voltage,
max. (a.c.= 45-65 Hz)

138/275 V a.c. 138/275 V a.c. 138/275 V

375 V d.c.(2)
375 V d.c.(2)
a.c.375 V
d.c.(2)

Surge; Primary peak current at

power on

25 A

15 A

30 A

Power Factor (at rated output

power)

0.47 typ

0.5 typ

0.5 typ

Heat dissipation

8.6 W

13.3 W

26.7 W

Efficiency factor

87% typ

90% typ

90% typ

Output voltage regulation at max.

current

+-2%

+-2%

+-2%

Ripple (peak to peak)

25 mV

25 mV

30 mV

Secondary voltage holdup time at

mains blackout

>20 ms

>20 ms

>20 ms

Maximum output current

5A

10 A

20 A

3BSE020923-510 A

85 - 110%

85 - 110%

207

Technical Data

Appendix B Specifications

Table 39. PSUs SD821, 822 and 823 - Technical Data (Continued)
Parameter
Maximum ambient temperature

SD821
Converter
55oC(3)

SD822(1)
Converter
55oC(3)

SD823
Converter
55oC(3)

Acceptable wire sizes:

0.5 - 0.6 mm2

Solid
Stranded

0.5 - 4mm

Recommended Torque

0.5 - 0.6 mm2

0.5 - 4mm

0.5 - 0.6 mm2

0.5 - 4mm2

22 - 14 AWG

22 - 14 AWG

22 - 14 AWG

0.8 Nm

0.8 Nm

0.8 Nm

(1) SD822Z is G3 compliant version according to ISA-S71.04.

(2) At d.c. input, always leave the mains voltage switch in position 230 V. Connect d.c. + to terminal L
and d.c. - to terminal N
(3) Mounting on a horizontal DIN rail

Table 40. PSUs SD821, 822 and 823 - Mounting Dimensions

Parameter
Dimensions, Width

208

SD821
Converter

SD822
Converter

SD823
Converter

HxD = 125 x 110 mm (4.9 x 4.3)

50 mm (1.97) 65 mm (2.56) 120 mm

(4.72)

Mounting spacing W mm

10 mm (0.39) 15 mm (0.59) 15 mm (0.59)

Mounting spacing H mm

25 mm (0.98) 25 mm (0.98) 25 mm (0.98)

Weight (lbs.)

460 g
(1.0 lbs.)

620 g
(1.4 lbs.)

980 g
(2.2 lbs.)

3BSE020923-510 A

Appendix B Specifications

SD83x Power Supply Modules, 24 V d.c.

SD83x Power Supply Modules, 24 V d.c.

Key Features

Simple DIN-rail mounting.

Class I Equipment, (when connected to Protective Earth, (PE)).

Over-voltage Category III for connection to primary main TN network of

Installation Category III.

Protective separation of secondary circuit from primary circuit.

Accepted for SELV and PELV applications.

The output of the units is protected against over current (current limit) and over
voltage (OVP).

SD834 can be connected in parallel to increase output power.

Both a.c. and d.c. input at SD831 and SD834.

Floating DC-OK relay contact at SD834.

Equipment Class
The Power Supply Units, (PSU), are designed to meet all the applicable electrical
safety data stated by the EN 50178 harmonized European Standard Publication and
the additional safety and function data required by EN 61131-2 and UL 508.
The secondary output circuitry is accepted for SELV or PELV applications.
SELV according to EN 50178, EN 60950 and VDE 0100 Part 410.
For PELV applications; in accordance with EN 50178.
UL 508, listed E 198865.

Ingress Protection
IP20 according to EN 60529, IEC 60529
Protective Class I according to EN 50718; 3.56

3BSE020923-510 A

209

Dimensions and Connections

Appendix B Specifications

Dimensions and Connections

Figure 89. SD831 Dimension and Connections for 3 A Power Supply

Figure 90. SD832 Dimensions and Connections for 5 A Power Supply

210

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Appendix B Specifications

Dimensions and Connections

Figure 91. SD833 Connections for 10 A Power Supply

Figure 92. SD834 Connections for 20 A Power Supply

3BSE020923-510 A

211

Power Supply Units Types SD831 / 832 / 833 / 834- Description

Appendix B Specifications

Power Supply Units Types SD831 / 832 / 833 / 834- Description

ABB recommend the use of robust and reliable power supply units, (PSUs), for
providing power to the AC800 and S800I/O system, when connected to an industrial
mains network of installation category III. PSUs can be used for both non-redundant
and redundant applications.
The four PSUs are designed as switch mode power converters. They converting a.c.
or d.c. mains supply voltage to a regulated d.c. 24 V output. The four PSUs have
data as follows:

SD831 = Input a.c. 100-240 V or d.c. 110-300 V.

Output d.c. 24 Volts regulated @ 3 A.

SD832 = Input a.c. 100-120 or 200-240 V.

Output d.c. 24 Volts regulated @ 5 A

SD833 = Input a.c. 100-120 or 200-240 V.

Output d.c. 24 Volts regulated @ 10 A

SD834 = Input a.c. 100-240 V or d.c. 110-300 V.

Output d.c. 24 Volts regulated @ 20 A

The output voltage of the four PSUs is, as stated, a regulated, low noise, d.c. 24 V. A
LED, mounted on the PSU front panel indicates that the output voltage is within
range.
The PCSs provide a soft start feature. The controlled power-on of a PSU therefore,
will not trip fuses or earth-fault circuit breakers. In addition, the normal

212

3BSE020923-510 A

Appendix B Specifications

Power Supply Units Types SD831 / 832 / 833 / 834- Description

disturbances that occur within an industrial main network will not cause any
transient fault conditions or trips to occur.

Figure 93. Functional Diagram SD831 for a 3 A Power Supply

3BSE020923-510 A

213

Power Supply Units Types SD831 / 832 / 833 / 834- Description

Appendix B Specifications

Figure 94. Functional Diagram SD832/SD833 for a 5 A/ 10 A Power Supply

214

3BSE020923-510 A

Appendix B Specifications

Power Supply Units Types SD831 / 832 / 833 / 834- Description

Figure 95. Functional Diagram SD834 for a 20 A Power Supply

3BSE020923-510 A

215

Dielectric strength

Appendix B Specifications

Dielectric strength
Basic with protective conductor. The primary circuit is separated from all other live
circuits by reinforced insulation.
Table 41. Dielectric Strength
A
Dielectric test

a.c. 2500V

a.c. 3000V

a.c. 500V

a.c. 2000V

a.c. 2000V

a.c. 500V

voltage
Field test
Rules for Field test:
Use appropriate test equipment which applies the voltage with a
slow ramp. Connect L and N together as well as all output poles.

DC-OK relay contact (SD834 only)

This feature monitors the output voltage, which is produced by the power supply
itself. It is independent of a back fed voltage from a unit that is connected in parallel
to the power supply output.
Short dips will be extended to a signal length of 250ms. Dips shorter than 1ms will
be ignored.
Contact closes: for output voltage > 90% of the adjusted output voltage.
Contact opens: for output voltage dips > 10% below the adjusted output voltage.
Contact ratings: max 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load
Min. >1mA, >5 V over open contact.
Isolation voltage:Field test: a.c. 2000 V to input. a.c. 500 V to output.

216

3BSE020923-510 A

Appendix B Specifications

SD834 in parallel to increase output power

SD834 in parallel to increase output power

Table 42. SD834 Schematic and Instructions for parallel use.
Schematic for parallel operation

Instructions for parallel use

a) Only SD834 can be used in parallel connection.
b) Adjust the output voltages of all power supplies to
approximately the same value (500mV). Otherwise,
the DC-OK signal might not work properly.
c) A fuse (or diode) on the output is only required if
more than three units are connected in parallel.
d) Do not continuously load the terminals with more
than 25A. Keep an installation clearance of 15mm
(left/right) between two power supplies and avoid
installing the power supplies on top of each other.

Installation, Fuses and Protective Devices

The PSUs should be mounted horizontally at a DIN rail. The PSUs have to be used
in non-hazardous locations only.
Internal primary main fuses are arranged to meet the requirements of electrical
safety publications for connection to the Phase - Neutral terminals of primary main
network; TN network, 1 (one) fuse. When SD831 and SD834 are used with d.c.
input, connect + terminal to L and - terminal to N.
Recommended primary external fuse:
Table 43. Power Supply Units - Fuses and Protective Devices Power Supply Units Types SD83x
Fuse
Primary: Recommended external fuse

SD831
(1)

min/max 6 - 20A

SD832

SD833

SD834

6 - 20A

6 - 20A

10 - 20A

Secondary: Short circuit

<8 A

<14 A

<18 A

<40 A

Secondary: Over-Voltage protection

<39 V

<39 V

<39 V

<37 V

(1) Microcircuit Breaker (MCB), Characteristic C or a delayed action fuse.

3BSE020923-510 A

217

Technical Data

Appendix B Specifications

Table 44. PSUs SD831, 832, 833, 834 - Mounting space and weight.
SD831
Converter

SD832
Converter

SD833
Converter

SD834
Converter

Mounting spacing top(1)

40 mm

40 mm

40 mm

40 mm

Mounting spacing
bottom(2)

20 mm

20 mm

20 mm

20 mm

Mounting spacing side

15 mm

15 mm

15 mm

15 mm

Weight

430 g

500 g

700 g

1200 g

Parameter

(1) Do not place temperature sensitive units above the PSU.

(2) Do not place units with high power dissipation below the PSU.

Technical Data
Table 45. Technical Data PSUs SD831, 832, 833 and 834
Parameter

SD831
Converter

SD832
Converter

SD833
Converter

SD834
Converter

Rated output current (A)

3A

5A

10 A

20 A

Rated power output

72 W

120 W

240 W

480 W

Rated output voltage

d.c. 24 V

d.c. 24 V

d.c. 24 V

d.c. 24 V

Rated input power

134/143 VA

240/283 VA

447/514 VA

547/568 VA

a.c. 120/230 V

82/80 W

134/133 W

264/262 W

519/511 W

Mains/input voltage,
nominal. a.c. 47-63Hz

a.c. 100-240 V a.c. 100-120 V a.c. 100-120 V a.c. 100-240 V

d.c. 110-300 V a.c. 200-240 V a.c. 200-240 V d.c. 110-300 V
Auto-select

Auto-select

input

input
a.c. 90-132 V

Mains voltage variation

allowed

a.c. 90-264 V

a.c. 90-132 V

d.c. 88-375 V

a.c. 180-264 V a.c. 180-264 V d.c. 88-375 V

Max input voltage <0.5s

a.c. 264-300 V a.c. 264-300 V a.c. 264-300 V a.c. 276-300 V

Primary peak current at

<28/<54 A

<10 A

<10 A

a.c. 85-276 V

<13 A

power on at a.c.120/230V

218

3BSE020923-510 A

Appendix B Specifications

Technical Data

Table 45. Technical Data PSUs SD831, 832, 833 and 834 (Continued)
Parameter
Power Factor (at rated
output power)

SD831
Converter

SD832
Converter

SD833
Converter

SD834
Converter

0.61/0.56

0.56/0.47

0.59/0.51

0.95/0.90

10/8 W

14/13 W

24/22 W

39.6/31.4 W

88/89.8%

89.4/90.2%

91/91.6%

92.4/93.9%

Line/load regulation

< 50 mV /<
100 mV

< 70 mV /<
100 mV

< 70 mV /< 100 < 10mV /< 100mV

mV

Ripple (peak to peak)

< 50 mV

< 50 mV

< 50 mV

< 100mV

Holdup time at mains

blackout a.c. 120/230 V
typ

29/120 ms

80/78 ms

46/47 ms

32/51 ms

Maximum output current

3.3 A

6A

12 A

30 A < 4 s

At ambient
temp < 45 oC

At ambient
temp < 45 oC

55 oC

55 oC

a.c. 120/230V typ

Heat dissipation
a.c. 120/230 V
Efficiency factor
a.c. 120/230 V typ

Maximum ambient
temperature(1)

55 oC

Acceptable wire sizes

Power connection
terminals

Solid: 0.5 6 mm2

55 oC

Stranded wire: 0.5 4 mm2, 20 10 AWG

Recommended torque: 0.8 Nm

Acceptable wire sizes

DC-OK-signal terminals

Solid: 0.3 - 4 mm2

Stranded wire:
0.3 - 2.5 mm2,
26 - 12 AWG

(1) Mounting on a horizontal DIN rail.

3BSE020923-510 A

219

Voting Unit - (for Redundant Power Supply)

Appendix B Specifications

Voting Unit - (for Redundant Power Supply)

The Voting Unit has been specifically designed to be employed as a control unit
within a redundant power supply configuration. The output connections from two
Power Supply Units, (PSUs), are connected to the Voting Unit.
The Voting Unit separates the redundant PSUs, supervises the voltage supplied,
and generates supervision signals to be connected to the computer system. Green
LEDs, mounted on the front panel of the voting unit, provide a visual indication
that the correct output voltage is being delivered. Simultaneously with the green
LED illuminating, a voltage free contact closes the path to the corresponding OK
connector. Voting Unit trip levels, are factory preset. Three different types of
voting units are available:
SS822 up to 20 A.
SS823 up to 20 A, with over voltage protections and enlarge diagnostics.
SS832 up to 10A.
See Table 46 for the selection of voting unit based on the type of power supply.
Table 46. Selection of Voting Unit
SS822

SS832

SS823

SD831

(x1)

x1

x2

SD832

(x1)

x1

x2

SD833

(x1)

x2

x2

SD834

(x2)

x2

x2

(x#) not preferred solution, x2 it needs two in parallel.

SS822
For SS822 Block diagram and Dimensions see Figure 96 and Figure 97.Table 47
and Table 48 shows the supervision data and the technical data respectively. For
connection of SS822 in a redundant configuration see Figure 98.

220

3BSE020923-510 A

Appendix B Specifications

SS822

X1

X2

A+

OK

B+

F
L+

A+
OK

L+

F
B+
L-

Figure 96. SS822 Block Diagram

3BSE020923-510 A

221

SS822

Appendix B Specifications

110
103

50

97

OK+ F OK+ F
A
B

125

SS822

44

A+B+L+L+L-

Figure 97. SS822 Voting Unit Connections

Table 47. SS822 Voting Unit - Supervision Data
SS822(1)

Supervision Data
Voltage, low trip level (for decreasing
voltage)

22 V

Voltage, low trip hysteresis

0.7 V

Voltage, high trip level for rising voltage 30 V

High trip hysteresis

0.7 V

Contact rating a.c.

Max. 120 V and max. 0.5 A

Contact rating d.c.

Max. 28 V and max. 1 A;

min. 1 mA, recommended min. 5 mA

(1) SS822Z is G3 compliant version according to ISA-S71.04.

222

3BSE020923-510 A

Appendix B Specifications

SS822

Table 48. SS822 - Technical Data and Mounting Dimensions

Parameter

SS822 Voter

Rated output current (A)

20 A

Rated output voltage

35 V

Rated input power

500 W

Mains/input voltage, nominal

2 x 24 V d.c.

Rated/input voltage

35 V d.c.

Heat dissipation

10 W at 20 A and 2,5 W at 5 A

Output voltage regulation at max.

current

0,5 V lower than input

Maximum output current

35 A (Overload)

Ingress Protection

IP20 according to EN60529, IEC 60529.

Max ambient temperature

55oC(1)

Acceptable wire sizes

Solid: 0.5 - 6 mm2

Input/output terminals

Stranded: 0.5 - 4mm2, 20 - 10 AWG

Recommended torque: 0.8 Nm

Acceptable wire sizes

Solid: 0.2 - 1.5 mm2

Supervision output terminals

Stranded: 0.2 - 1.5 mm2, 22 - 14 AWG

Recommended torque: 0.8 Nm

Dimensions, Width

50 mm (1.97)

HxD = 125 x 110 mm

(4.9 x 4.3 inches)
Mounting spacing W mm

10 mm (0.39)

Mounting spacing H mm

25 mm (0.98)

Weight (lbs.)

630 g (1.4 lbs.)

(1) Mounting on a horizontal DIN rail

3BSE020923-510 A

223

SS823

Appendix B Specifications

SA
SB

L+ L+ LOK

L-

L+ L+ LOK

SD821
N

PE

L-

SD821
N

PE

Supervision
signals to
CI8X0/TB8X0

OK+ F OK + F
A

SS822
A+ B+ L+ L+ L-

L+

Mains
Input
L-

Protective Earth

+24V

0V

Figure 98. SS822 - Used in Redundant SD821 Configuration

SS823
The SS823 Voting Unit has double overvoltage protection circuit on both inputs. It
is also able to detect both short and open circuit in the voting element. For details
see Table 50.
Two SS823 can never be configured in parallel to achieve more current.
Block diagram and dimensions for SS823 see Figure 99 and Figure 100. Table 49
and Table 50 shows supervision data and technical data for SS823. For connection
of SS823 in a redundant configuration see Figure 101.

224

3BSE020923-510 A

Appendix B Specifications

SS823

Figure 99. SS823 Block Diagram

3BSE020923-510 A

225

SS823

Appendix B Specifications

Figure 100. SS823 Power Voter Unit Connections

Table 49. SS823 Power Voter Unit - Supervision Data
Supervision Data

SS823

Voltage, low trip level (for decreasing

voltage)

22 V

Voltage, low trip hysteresis

0.7 V

Voltage, high trip level for rising voltage 30 V

226

High trip hysteresis

0.7 V

Contact rating a.c.

Max. 120 V and max. 0.5 A

Contact rating d.c.

Max. 28 V and max. 1 A;

min. 1 mA, recommended min. 5 mA

3BSE020923-510 A

Appendix B Specifications

SS823

Table 50. SS823 - Technical Data and Mounting Dimensions

Parameter

SS823 Voter

Rated output current (A)

20 A

Rated output voltage

24 V

Rated input power

500 W

Mains/input voltage, nominal

24 V d.c.

Mains/input voltage, max

30 V d.c.(1)

Dual level OVP (Overvoltage

protection)

Trip 32.0 V nominal

Return 31.5 V nominal

Heat dissipation

24 W max

Output voltage regulation at max. 1.2 V lower than input

current
Maximum output current

Static 35 A typical, dynamic 150 A for 100 s

typical

Ingress Protection

IP20 according to EN60529, IEC 60529.

Max ambient temperature

55oC(2)

Acceptable wire sizes

0.2 - 2.5 mm2, 24 - 12 AWG

Connector X1 and OK+F

Recommended torque: 0.5 - 0.6 Nm

Acceptable wire sizes

0.2 - 6 mm2, 24 - 10 AWG

Connector A+, L+, L-

Recommended torque: 0.7 - 0.8 Nm

Mounting spacing W mm

15 mm (0.59)

Mounting spacing H mm

25 mm (0.98)

Width

140 mm (5.51)

Depth

144 mm (5.67

Height

174 mm (6.85)

Weight

800 g (1.8 lbs.)

(1) Electronically limited by OVP, voltage between 32 V and 60 V will result in 0 V output
(2) Mounting on a horizontal DIN rail

3BSE020923-510 A

227

SS823

Appendix B Specifications

SA
SB

From Mains
Breaker

L+
L-

From Mains
Breaker

Figure 101. SS823 - Used in Redundant SD821 Configuration

228

3BSE020923-510 A

Appendix B Specifications

SS832

SS832
SS832 is can be used directly for load up to 10 A and for loads up to 20 A two
SS832 modules must be used. See Figure 103 and Figure 104.
For Block diagram and connections of SS832 see Figure 102 and Figure 105.
Table 51 and Table 52 shows supervision data and technical data respectively.
Figure 106 shows connection of SS832 in redundant configuration with maximum
10 A load, see Figure 107 for load up to 20 A.

Alarm
Relay

Input
Voltage
Monitor

Input 1
ok

VIN 1

+
-

VIN 2

+
-

Input 1
Alarm
contact

+
-

VOUT
Chassis
Ground

Input
Voltage
Monitor

Input 2
ok

Alarm
Relay

Input 2
Alarm
contact

Figure 102. SS832 Block Diagram

AC

AC
DC

DC

IN 1 IN 2

OUT

Load

Figure 103. SS832 up to 10 A

3BSE020923-510 A

229

SS832

Appendix B Specifications

AC

AC
DC

DC

IN 1 IN 2

OUT

OUT

IN 1 IN 2

Load

Figure 104. SS832 up to 20 A

230

3BSE020923-510 A

Appendix B Specifications

SS832

Figure 105. SS832 Voting Unit Dimensions and Connections

Table 51. SS832 Voting Unit - Supervision Data
Supervision Data

SS832

Voltage, low trip level (for decreasing

voltage)

21.5 +- 0.5V

Voltage, low trip hysteresis

0.7 V

High trip hysteresis

0.7 V

3BSE020923-510 A

231

SS832

Appendix B Specifications

Table 51. SS832 Voting Unit - Supervision Data (Continued)

Supervision Data

SS832

Contact rating a.c.

Max. 30 V and max. 0.5 A, resistive load

Contact rating d.c.

Max. 60 V and max 0.3 A, 30 V max 0.5

A
resistive load
min. 1 mA at 5 V d.c.

Acceptable wire sizes

0.2 -1.5 mm2, 22 - 14 AWG

Recommended torque: 0.4 Nm

Table 52. Technical Data and Mounting Dimensions

Parameter

SS832 Voter

Input current

10A per input

Rated output current

20 A

Mains/input voltage, nominal

2 x 24 V d.c.

Rated/input voltage

60 V d.c.

Heat dissipation

8.9 W at 10 A and 4.6 W at 5 A

Input to output voltage drop at max.

current

0,85 V

Maximum output current

25 A (Overload)

Ingress Protection

IP20 according to EN60529, IEC 60529.

Max ambient temperature

55oC(1)

Acceptable wire sizes

Solid: 0.5 - 6 mm2, 20 - 10 AWG

Stranded: 0.5 - 4 mm2, 20 - 10 AWG
Recommended torque: 0.8 Nm

232

3BSE020923-510 A

Appendix B Specifications

SS832

Table 52. Technical Data and Mounting Dimensions (Continued)

Parameter
Dimensions
Width
Depth
Height

SS832 Voter
32 mm (1.26)
117 mm (4.6")
124 mm (4.9")

Mounting spacing W

5 mm (0.2"), In case the adjacent device

is a heat source 15 mm (0.59")

Mounting spacing H

40 mm (1.57") on the top, 20 mm (0.79")

on the bottom

Weight

350 g (0.77 lbs.)

(1) Mounting on a horizontal DIN rail

Figure 106. SS832 Redundant Configuration up to 10 A

3BSE020923-510 A

233

SS832

Appendix B Specifications

Figure 107. SS832 Redundant Configuration up to 20 A

234

3BSE020923-510 A

Appendix B Specifications

TB805/TB806 ModuleBus Cable Adapter-Out/In

TB805/TB806 ModuleBus Cable Adapter-Out/In

Features

Passive unit used for connection

and extension of the ModuleBus.

DIN rail mounting.

TB805 ModuleBus
Connector (X1)

Latch Release

Description
1

The TB805 ModuleBus Cable AdaptorOut and TB806 ModuleBus Cable

Adaptor-In with the ModuleBus
Extension Cables, TK801V0xx, are used
to extend the ModuleBus.

14

DB25 Female
Connector (X2)

Using the TB805 and TB806, I/O

modules on the same electrical
ModuleBus of an I/O cluster, can be
mounted on different DIN rails. This
makes the installation of I/O Modules
more flexible when laying out an
enclosure design. Please refer to Section
2, Installation for details on layouts.

25

13

TB806 ModuleBus
Connector (X1)

The ModuleBus extension cables used

with the TB805/TB806 come in 3
standard lengths:

TK801V003 - 300 mm

TK801V006 - 600 mm

TK801V012 - 1.2 meters.

Overall ModuleBus length must not

exceed 2.5 meters including all cables
and MTUs.

3BSE020923-510 A

DB25 Male
Connector (X2)

13

25

14

235

Technical Data

Appendix B Specifications

TB806 is also used for connection of the optical port TB842 to CI801 or TU847
(CI840).
The TB805/TB806 mounts on the standard DIN rail. It has a mechanical latch that
locks it to the rail. It is grounded to the DIN-rail through a metallic spring connector.
The latch can be released with a screwdriver.

Technical Data

Table 53. TB805/TB806 ModuleBus Cable Adaptor Specifications

Item

TB805

TB806

Direction

Out

In

Connections

2
DIN41612 Type R/4 (X1)
DB25 Female (X2)

2
DIN41612 Type R/4 (X1)
DB25 Male (X2)

1.5 A
1.5 A

1.5 A
1.5 A

Module catch

Locks module to previous

device

Locks module to previous

device

Module DIN rail lock

Locks module and provide

ground connection

Locks module and provide

ground connection

Equipment Class

Class I according to IEC 60536; Class I according to IEC 60536;

(earth protected)
(earth protected)

Ingress Protection

IP20 according to IEC 60529

IP20 according to IEC 60529

Rated Insulation Voltage

50 V

50 V

Dielectric test voltage

500 V a.c.

500 V a.c.

Width

22 mm (0.87)

22 mm (0.87)

ModuleBus:
Maximum 5 V
current distribution
Maximum 24 V current
distribution

236

3BSE020923-510 A

Appendix B Specifications

Block Diagram TB805

Table 53. TB805/TB806 ModuleBus Cable Adaptor Specifications (Continued)

Item

TB805

TB806

Depth

25 mm (0.98)

25 mm (0.98)

Height

109 mm (4.29)

109 mm (4.29)

Weight

46 g (0.10 lbs.)

46 g (0.10 lbs.)

Block Diagram TB805

X1

X2

7
/

POWOK
DAT, DAT-N
+24 V, 0 V24
+5 V
0V
CLK+, CLK-

2
/
2
/
5
/
/
/

4
2
Shield

ModuleBus Connector DB25 Female

ModuleBus Connector R/4 Female

POS 0 - 6

EM

3BSE020923-510 A

237

Block Diagram TB806

Appendix B Specifications

Block Diagram TB806

X2
POS 0 - 6

+24 V, 0 V24

2
/
2
/
5

+5 V

0V

CLK+, CLKShield

4
2

ModuleBus Connector R/4 Male

ModuleBus Connector DB25 Male

POWOK
DAT, DAT-N

X1

EM

238

3BSE020923-510 A

Appendix B Specifications

TB807 ModuleBus Terminator

TB807 ModuleBus Terminator

Features

ModuleBus
Connector (X1)

Passive unit used for

termination of the electrical
ModuleBus.

Top View

Description
TB807

The TB807 ModuleBus

Terminator is used to terminate
the electrical ModuleBus.

ModuleBus Terminator
Latch

E
F

Use the TB807 to terminate the

electrical ModuleBus of an I/O
cluster. The ModuleBus
terminator connects to the outlet
ModuleBus connector of the last
MTU.

A
B
C

E
F

MTU Assembly

A
B
C

L1+ C1 2
L1+ B1 2
L1- A1 2

3BSE020923-510 A

3
3

4
4

5
5

6
6

7
7

C8 L2+
B8 L2+

A8 L2-

239

Technical Data

Appendix B Specifications

Technical Data
Table 54. TB807 ModuleBus Terminator Specifications
Item

240

Value

Connections

1
DIN41612 Type R/4 (X1)

Module catch

Attaches module MTU

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Rated Insulation Voltage

50 V

Dielectric test voltage

500 V a.c.

Width

13 mm (0.51)

Depth

19 mm (0.75)

Height

24 mm (0.94)
module projects 17 mm (0.67)

Weight

10 g (0.022 lbs.)

3BSE020923-510 A

Appendix B Specifications

Block Diagram TB807

Block Diagram TB807

ModuleBus Connector R/4 Female

X1

3BSE020923-510 A

DAT

DAT-N

CLK+

CLK-

241

TB810/TB811 ModuleBus Optical Port

Appendix B Specifications

TB810/TB811 ModuleBus Optical Port

Features

1 fiber optic port for the Optical ModuleBus expansion.

Connection to the CI810/CI830, FCI and TB815

(CI820/CI820V1).

Description TB810
The TB810 ModuleBus Optical Port is a communication
interface between the CI810 FCI electrical ModuleBus and
the TB820/TB820V2 ModuleBus Modem of an I/O cluster or
ABB drives units via the Optical ModuleBus.
The TB810 can be used in both a simplex optical
configuration as well as in a duplex optical configuration. In a
simplex configuration, the optical ModuleBus nodes are
connected in a ring. In a duplex configuration, the optical
ModuleBus nodes are connected in a row.
The TB810 has two connectors for fiber optic connections and
a connection to the communication interface module. The
module is equipped with Transmitter/Receiver for up to 10
Mbit/s. Both plastic and HCS (Hard Clad Silica) optic fiber
with connectors (Agilents, former Hewlett-Packard, Versatile
Link) can be used with the TB810.

Tx

Rx

Rx

Tx

Description TB811
The TB811 ModuleBus Optical Port is a communication interface between the FCI
electrical ModuleBus and the ABB drives units via the Optical ModuleBus.
The TB811 can be used in a simplex optical ring configuration.
The TB811 has two connectors for fiber optic connections and a connection to the
communication interface module. The module is equipped with
Transmitter/Receiver for up to 5 Mbit/s. Plastic and optic fiber with connectors
(Agilents, former Hewlett-Packard, Versatile Link) can be used with the TB811.

242

3BSE020923-510 A

Appendix B Specifications

Technical Data

Technical Data
Table 55. TB810 ModuleBus Optical Port Specifications
Item

TB810

TB811

Application

S800 I/O clusters and ABB

variable drives

ABB variable drives

Configuration

Simplex and duplex

Simplex

Fibers

Plastic and HCS (Hard Clad

Silica)

Plastic

Connector

Agilents, former HewlettPackard, Versatile Link

Agilents, former HewlettPackard, Versatile Link

Optical ModuleBus

Fiber optic interface, one

transmit and one receive
connection for max. 10 Mbit/s.

Fiber optic interface, one

transmit and one receive
connection for max. 5 Mbit/s.

Wavelength 650 nm

Wavelength 650 nm

Tx LED: Yellow indicates

transmitting of data on the
optical ModuleBus

Tx LED: Yellow indicates

transmitting of data on the
optical ModuleBus

Rx LED: Yellow indicates

receiving of data on the optical
ModuleBus

Rx LED: Yellow indicates

receiving of data on the optical
ModuleBus

Current consumption +5 V

100 mA

100 mA

Current consumption +24 V

20 mA

20 mA

Power dissipation

0.5 W

0.5 W

Equipment Class

Class I according to IEC 60536; Class I according to IEC 60536;

(earth protected)
(earth protected)

Ingress Protection

IP20 according to IEC 60529

IP20 according to IEC 60529

Rated insulation voltage

50 V

50 V

Dielectric test voltage

500 V a.c.

500 V a.c.

Width

20 mm (0.79)

20 mm (0.79)

Indicators

3BSE020923-510 A

243

Connections

Appendix B Specifications

Table 55. TB810 ModuleBus Optical Port Specifications (Continued)

Item

TB810

TB811

Depth

39.6 mm (1.56)

39.6 mm (1.56)

Height

39.6 mm (1.56)

39.6 mm (1.56)

Weight

19 g (0.042 lbs.)

19 g (0.042 lbs.)

Connections
Table 56. Optical ModuleBus Connections (X2)
Port

Duplex Signals

Simplex Signals

Tx

Transmit data to down-stream

device

Transmit data to next device

Rx

Receive data from up-stream

device

Receive data from last device

Opto Cable for TB810 according to HP

Plastic Optical Fiber (POF) (TK811V... or TK812V...) up to 15 meters.

Extra low loss attenuation.

Simplex or duplex cable.

Latching simplex or duplex connector.

Cable attenuation maximum 4 dB.

Hard Clad Silica (HCS) fiber up to 200 meters.

244

Riser or plenum.

Simplex or duplex cable.

Latching simplex or duplex connector.

Cable attenuation maximum 2 dB.

3BSE020923-510 A

Appendix B Specifications

Opto Cable for TB811 according to HP

Opto Cable for TB811 according to HP

Plastic Optical Fiber (POF) (TK811V... or TK812V...) up to 10 meters.

Extra low loss attenuation

Simplex cable

Latching simplex connector.

Block Diagram TB810/TB811

X1
E
O

X2

3BSE020923-510 A

RX
TX

245

TB820/TB820V2 ModuleBus Modem

Appendix B Specifications

TB820/TB820V2 ModuleBus Modem

Features

2 fiber optic ports to optical ModuleBus.

ModuleBus (electrical) to the I/O Modules.

Supervisory functions of I/O ModuleBus

and power supply.

Isolated power supply to I/O modules.

DIN rail mounting.

F
Rx1

R
P
Rx2
ERx

Description
The TB820/TB820V2 ModuleBus Modem is a
communication interface for connection of S800
I/O modules via the optical and electrical
ModuleBus.

CLUSTER
4 56
3
7
2
1
TB820 V2

The module can not handle High Integrity I/O

modules (AI880/AI880A, DI880 and DO880).
The TB820/TB820V2 can be used in both a
simplex optical configuration as well as in a
duplex optical configuration. In a simplex
configuration, the optical ModuleBus nodes are
connected in a ring. In a duplex configuration,
the optical ModuleBus nodes are connected in a
row.

L+
LSA
SB

X4 X5
Rx2 Rx1
Tx2 Tx1

TB820/TB820V2 has two basic parts: Module termination board and the power
supply/communications board (see block diagram).
The termination board is a unit where most of the connections to the outside takes
place. It is grounded to the DIN rail through a metallic spring connector. The board
carries screw terminals for power supply and redundant power supply monitoring,
connector for the electrical ModuleBus, a current limit fuse for the +24 V supply
of the I/O modules and the electrical ModuleBus.

246

3BSE020923-510 A

Appendix B Specifications

Description

The power supply board has an isolated power converter that generates a short
circuit proof +5 V supply for the TB820/TB820V2 and connected I/O modules.
This board also contains the ModuleBus interfaces, LED indicators and one
screwdriver maneuvered rotary switch for the ModuleBus I/O cluster address. The
ModuleBus I/O cluster address (1-7) is set by a rotary decimal code switch, any
other value than 1-7 is not allowed and will turn the Run LED off.
The ModuleBus has an electrical and an optical interface which are logically the
same bus. A maximum of twelve I/O modules can be connected to the electrical
ModuleBus and up to seven clusters can be connected to the fiber optic ModuleBus
expansion. The fiber-optical interface is intended for local distribution of I/O
clusters and where more than 12 I/O modules per station are required. Any
distribution of I/O modules across the base cluster and the remote cluster(s) is
allowed, however not more than 24 I/O modules per station can be used.
The module is equipped with optical Transmitter/Receiver for up to 10 Mbit/s. Both
plastic and HCS (Hard Clad Silica) optic fiber with connectors (Agilents, former
Hewlett-Packard, Versatile Link) can be used with TB820/TB820V2.

3BSE020923-510 A

247

Technical Data

Appendix B Specifications

Technical Data
Table 57. TB820/TB820V2 ModuleBus Modem Specifications
Item

Value

Power input

24 V d.c. (19.2 - 30)

Power consumption at 24V d.c.

100 mA

Power dissipation

6.0 W

Power supply monitoring inputs

Max. input voltage: 30V

Min. input voltage for high level: 15 V
Max. input voltage for low level: 8 V

Power output (ModuleBus)

24 V max. = 1.4 A
5 V max. = 1.5 A

Electrical ModuleBus

Maximum of 12 I/O modules

Optical ModuleBus

Maximum of 7 I/O clusters

Fiber optic interface, two transmitters

and two receivers for
Max. 10 Mbit/s
Wavelength 650 nm
Maximum ambient temperature

248

55oC/(131F)

3BSE020923-510 A

Appendix B Specifications

Technical Data

Table 57. TB820/TB820V2 ModuleBus Modem Specifications (Continued)

Item
Indicators

Value
R(un) LED: Green indicates that the
TB820/TB820V2 is operational
F(ault) LED: Red indicates a fault condition;
Reset and communications errors on the
electrical ModuleBus turns the LED on.
P(owok) LED: Green indicates that the
d.c./d.c. converter generates a valid
+5 V d.c.
ORx1 and ORx2 traffic LEDs: Yellow
(blinking) indicates that the
TB820/TB820V2 is receiving data on the
two optical ModuleBus channels
respectively.
ERx traffic LED: Yellow (blinking) indicates
the TB820/TB820V2 is receiving data on
the electrical ModuleBus.

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Rated insulation voltage

50 V

Dielectric test voltage

500 V a.c.

Acceptable wire sizes

Solid: 0.2 - 2.5 mm2

Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm

Width

58 mm (2.28)

Depth

122 mm (4.80)

Height

170 mm (6.69) including latch

Weight

0.3 kg (0.66 lbs.)

3BSE020923-510 A

249

Connections

Appendix B Specifications

58 mm (2.3)

122 mm (4.8)

R
P

ORx1

ORx2

170 mm (6.7)

ERx

CLUSTER
4 5 6
3
7
2

TB820

L L+L- + - SAB
L+
SA
SB

Figure 108. TB820/TB820V2 Module

Connections
Table 58. Power Supply Connections TB820/TB820V2/TB820V1
Designation

250

Description

L+

+24 V d.c. Supply In

L+

+24 V d.c. Supply Out

SA

Redundant Power Supply A Monitoring

Input

L-

0 V d.c. Supply In

3BSE020923-510 A

Appendix B Specifications

Connections

Table 58. Power Supply Connections TB820/TB820V2/TB820V1 (Continued)

Designation

Description

L-

0 V d.c. Supply Out

SB

Redundant Power Supply B Monitoring

Input

Table 59. Power Supply Connections TB820V2

Designation

3BSE020923-510 A

Description

L+

+24 V d.c. Supply

L-

0 V d.c. Supply

SA

Redundant Power Supply A Monitoring

Input

SB

Redundant Power Supply B Monitoring

Input

251

Opto Cable according to HP

Appendix B Specifications

Table 60. Optical ModuleBus Connections (X4, X5)

Port

Duplex Signals

Simplex Signals

X4 - Tx

Transmit data to down-stream

device

Transmit data to next device

X4 - Rx

Receive data from downstream device

Not used

X5 - Tx

Transmit data to up-stream

device

Not used

X5 - Rx

Receive data from up-stream

device

Receive data from last device

Opto connectors type Agilents, former Hewlett-Packard, Versatile Link can handle
both plastic and HCS optic fiber.

Opto Cable according to HP

Plastic Optical Fiber (POF) up to 15 meters.

Extra low loss attenuation.

Simplex or duplex cable.

Latching simplex or duplex connector.

Cable attenuation maximum 4 dB.

Hard Clad Silica (HCS) fiber up to 200 meters.

252

Riser or plenum.

Simplex or duplex cable.

Latching simplex or duplex connector.

Cable attenuation maximum 2 dB.

3BSE020923-510 A

Appendix B Specifications

Block Diagram TB820/TB820V2

Block Diagram TB820/TB820V2

RS-485
RS-485

X2

TB820-1
F(ault)

Reset logic,
+5 V Supervision

MBI-4

P(owok)
ORx1

Electrical ModuleBus
Connector

POS(9:0)
MB +5 V

R(un)

X3
POWOK
D+,DCLK+,CLK-

MB +5 V
+5 V

0V

MB+5 V
0V
LMB+24 V

MB +5 V

+5 V

+5 V

0V

0V

0V

ORx2
ERx

Current
Limit

DC

DIN-rail

DC
SB

X1A
3
2

L-

SA

X1B
3

POS(9:7)

2
L+

E
O
X4

3BSE020923-510 A

E
O

E
O

TB820-2

X5

253

TB825 Optical Media Converter

Appendix B Specifications

TB825 Optical Media Converter

Features

Converts between plastic or HCS opto

fiber and glass optical fiber.

DIN rail mounted.

S800L mechanics.

Description
ModuleBus Optical media converter, converts
between plastic opto fiber or HCS fiber with
Versatile link connectors and glass optical
fiber with ST connectors.
Signal routing between Tx1/Rx1 and
Tx2/Rx2 and between Tx1/Rx1 and Tx3/Rx3.

Technical Data

Table 61. TB825 Optical Media Converter Specifications

Item
Power input

24 V (19.2 - 30)

Power consumption at 24V d.c.

96 mA

Power input fuse

2A

Power dissipation

2.3 W

Optical ModuleBus

Local Optical ModuleBus 1, 2 and Field

Optical ModuleBus

Fiber optic interface, three

transmitters and three receivers for

254

Value

3BSE020923-510 A

Appendix B Specifications

Technical Data

Table 61. TB825 Optical Media Converter Specifications (Continued)

Item
Indicators

Value
(S) Status LED: Red indicates module fault.
Green indicates Module OK (FPGA
configuration).
Rx1 LED: Yellow indicates data received on
opto port 1.
Tx1 LED: Yellow indicates data transmitted
on opto port 1.
Rx2 LED: Yellow indicates data received on
opto port 2.
Tx2 LED: Yellow indicates data transmitted
on opto port 2.
Rx3 LED: Yellow indicates data received on
opto port 3.
Tx3 LED: Yellow indicates data transmitted
on opto port 3.

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Acceptable wire sizes

Solid: 0.2 - 2.5 mm2

Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm

Rated insulation voltage

50 V

Dielectric test voltage

500 V a.c.

Width

85.6 mm (3.37)

Depth

58.5 mm (2.30)

Height

136 mm (5.35) including latch

Weight

0.21 kg (0.46 lbs.)

3BSE020923-510 A

255

Opto Connection

Appendix B Specifications

136 mm (5.35")

114 mm (4.49")

67.5 mm (2.66")

85.6 mm (3.37")

5 mm
(0.20")

14.2 mm
(0.56")
57.2 mm (2.25")

58.5 mm (2.30")

Figure 109. TB825 Optical Media Converter

Opto Connection
Local Optical Cable

Opto connectors type Agilents, former Hewlett-Packard, Versatile Link can handle
both plastic and HCS optic fibre.
Plastic Optical Fiber (POF) (TK811V... or TK812V...) up to 15 meters

256

Extra low loss attenuation

Simplex or duplex cable

Latching simplex or duplex connector.

3BSE020923-510 A

Appendix B Specifications

Opto Connection

Cable attenuation maximum 4 dB

Hard Clad Silica (HCS) fiber up to 200 meters.

Riser or plenum

Simplex or duplex cable

Latching simplex or duplex connector

Cable attenuation maximum 2 dB

Field Optical Cable

Glass Optical Fiber, multimode up to 1000 m

Fiber dimensions: 62.5/125 m

Connector type: ST, bayonet

Wave length: 820 nm

Max cable attenuation: 3.5 dB (1000 m of unspliced cable)

3BSE020923-510 A

257

Block Diagram TB825

Appendix B Specifications

LOCAL FIBER
INTERFACE
O
E
O

INTERFACE

E
O

INTERFACE

Tx3

Rx3

Rx2

FPGA
RX1

SIGNAL
SYNC

TX1

SIGNAL
ROUTING

Tx2

FPGA
PROM

Rx1

LOAD OF FPGA
CONFIGURATION DATA

Tx1

X2

Status

Block Diagram TB825

RX3

FIELD FIBER
INTERFACE

SIGNAL
SYNC

TX2

TX3

SIGNAL
SYNC

RX2

E
INTERFACE

O
E
O

5.0V
X1

258

L+ FUSE

5V

3.3V

L-

0V

2.5V

3BSE020923-510 A

Appendix B Specifications

TB826 Optical Media Converter

TB826 Optical Media Converter

Features

Converts between plastic or HCS opto fiber

and glass optical fiber.

DIN rail mounted.

S800L mechanics.

Description
ModuleBus Optical media converter, converts
between plastic opto fiber or HCS fiber with
Versatile link connectors and glass optical fiber
with SC connectors.

Technical Data

Table 62. TB826 Optical Media Converter Specifications

Item
Power input

Value
24 V (19.2 - 30)

Power consumption at 24V d.c. 92 mA

Power input fuse

2A

Power dissipation

2.2 W

Optical ModuleBus

Local Optical ModuleBus 1, 2 and Field

Optical ModuleBus

Fiber optic interface, three

transmitters and three
receivers for

3BSE020923-510 A

259

Technical Data

Appendix B Specifications

Table 62. TB826 Optical Media Converter Specifications (Continued)

Item
Indicators

Value
(S) Status LED: Red indicates module fault.
Green indicates Module OK (FPGA
configuration).
Rx1 LED: Yellow indicates data received on
opto port 1.
Tx1 LED: Yellow indicates data transmitted
on opto port 1.
Rx2 LED: Yellow indicates data received on
opto port 2.
Tx2 LED: Yellow indicates data transmitted
on opto port 2.
Rx3 LED: Yellow indicates data received on
opto port 3.
Tx3 LED: Yellow indicates data transmitted
on opto port 3.

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Acceptable wire sizes

Solid: 0.2 - 2.5 mm2

Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm

260

Rated insulation voltage

50 V

Dielectric test voltage

500 V a.c.

Width

85.6 mm (3.37)

Depth

58.5 mm (2.30)

Height

136 mm (5.35) including latch

Weight

0.21 kg (0.46 lbs.)

3BSE020923-510 A

Appendix B Specifications

Opto Connection

67.5 mm (2.66")

114 mm (4.49")

136 mm (5.35")

85.6 mm (3.37")

57.2 mm (2.25")

58.5 mm (2.30")

Figure 110. TB826Optical Media Converter

Opto Connection
Local Optical Cable

Opto connectors type Agilents, former Hewlett-Packard, Versatile Link can handle
both plastic and HCS optic fibre.
Plastic Optical Fiber (POF) (TK811V... or TK812V...) up to 15 meters

Extra low loss attenuation

Simplex or duplex cable

Latching simplex or duplex connector.

3BSE020923-510 A

261

Opto Connection

Appendix B Specifications

Cable attenuation maximum 4 dB

Hard Clad Silica (HCS) fiber up to 200 meters.

Riser or plenum

Simplex or duplex cable

Latching simplex or duplex connector

Cable attenuation maximum 2 dB

Field Optical Cable

Glass Optical Fiber, single mode up to 5000m (20000m for S800 I/O HI)

262

Fiber dimensions: 9/125 m

Connector type: SC

Wave length: 1310 nm

Max cable attenuation: 20 dB

3BSE020923-510 A

Appendix B Specifications

Block Diagram TB826

Block Diagram TB826

3BSE020923-510 A

263

TB840/TB840A ModuleBus Modem

Appendix B Specifications

TB840/TB840A ModuleBus Modem

Features

2 fiber optic ports to optical ModuleBus

ModuleBus (electrical) to the I/O

Modules

Supervisory functions of I/O ModuleBus

and power supply

Isolated power supply to I/O modules

Input power fused

S
P
Rx1
Rx2
ERx1
ERx2

Description
The TB840/TB840A ModuleBus Modem is a
communication interface for connection of
S800 I/O modules via the optical and
electrical ModuleBus.
TB840/TB840A is designed to be used in 1+1
redundant applications.
TB840/TB840A can be used in both a
simplex optical configuration as well as in a
duplex optical configuration. In a simplex
configuration, the optical ModuleBus nodes
are connected in a ring. In a duplex
configuration, the optical ModuleBus nodes
are connected in a daisy-chain.

TB840

TB840/TB840A must be mounted on a Module Termination Unit TU807, TU840,

TU841, TU848 or TU849.
The Module Termination Unit carries screw terminals for power supply and power
supply monitoring, connector for the electrical ModuleBus and a rotary switch for
setting of the cluster address.

264

3BSE020923-510 A

Appendix B Specifications

Description

TB840/TB840A has isolated power converters that generates internal power for
TB840/TB840A and short circuit proof +5 V supply for two electrical
ModuleBuses. It also contains two ModuleBus interfaces and LED indicators. The
ModuleBus I/O cluster address (1-7) is set by a rotary decimal code switch, on the
Module Terminal Unit TU841.
TB840/TB840A has two electrical and one Optical ModuleBus Interface which are
logically the same bus. Only one electrical ModuleBus is connected if
TB840/TB840A is mounted on TU841, TU849 or TU807. A maximum of twelve
I/O modules can be connected to the electrical ModuleBus and up to seven clusters
can be connected to the fiber optic ModuleBus expansion. The fiber-optical
interface is intended for local distribution of I/O clusters and where more than 12
I/O modules per station are required. Any distribution of I/O modules across the
base cluster and the remote cluster(s) is allowed, however not more than 24 I/O
modules per I/O station can be used.
Both plastic and HCS (Hard Clad Silica) optic fiber with connectors (Agilents,
former Hewlett-Packard, Versatile Link) can be used with TB840/TB840A.

3BSE020923-510 A

265

Technical Data

Appendix B Specifications

Technical Data
Table 63. TB840/TB840A ModuleBus Modem Specifications
Item

Value

Power input

24 V d.c. (19.2 - 30)

Power consumption at 24V d.c.

120 mA

Power input fuse

2 AF

Power dissipation

6W

Power supply monitoring inputs

Max. input voltage: 30V

Min. input voltage for high level: 15 V
Max. input voltage for low level: 8 V

Power output (ModuleBus)

24 V max. = 1.4 A
5 V max. = 1.5 A

Electrical ModuleBus

Maximum of 12 I/O modules

Optical ModuleBus

Maximum of 7 I/O clusters

Fiber optic interface, two transmitters

and two receivers for
Max. 10 Mbit/s
Wavelength 650 nm

266

3BSE020923-510 A

Appendix B Specifications

Technical Data

Table 63. TB840/TB840A ModuleBus Modem Specifications (Continued)

Item
Indicators

Value
S(tatus) LED: Green indicates that the
TB840 is operational.
Red indicates a fault condition; Reset and
communications errors on the electrical
ModuleBus turns the LED on.
P(owok) LED: Green indicates that the
d.c./d.c. converter generates valid internal
power and +5 V d.c. on the electrical
ModuleBus.
Rx1 and Rx2 traffic LEDs: Yellow (blinking)
indicates that the TB840 is receiving data
on the two optical ModuleBus channels
respectively.
ERx1 traffic LED: Yellow (blinking) indicates
the TB840 is receiving data on the electrical
ModuleBus A.
ERx2 traffic LED: Yellow blinking, indicates
that the TB840 is receiving data on the
electrical ModuleBus B.

MTU Keying code

AB

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Rated insulation voltage

50 V

Dielectric test voltage

500 V a.c.

Width

54 mm (2.13)

Depth

96 mm (3.78)

Height

119 mm (4.69) including latch

Weight

0.2 kg (0.44 lbs.)

3BSE020923-510 A

267

Connections

Appendix B Specifications

54 mm (2.13)

X4
119 mm
(4.69)

96 mm
(3.78)

X5

Figure 111. TB840/TB840A Module

Connections
Opto connectors type Agilents, former Hewlett-Packard, Versatile Link can handle
both plastic and HCS optic fiber.

Opto Cable according to HP

Plastic Optical Fiber (POF) (TK811V... or TK812V...) up to 15 meters.

Extra low loss attenuation.

Simplex or duplex cable.

Latching simplex or duplex connector.

Cable attenuation maximum 4 dB.

Hard Clad Silica (HCS) fiber up to 200 meters.

268

3BSE020923-510 A

Appendix B Specifications

Opto Cable according to HP

Riser or plenum.

Simplex or duplex cable.

Latching simplex or duplex connector.

Cable attenuation maximum 2 dB .

Table 64. Optical ModuleBus Connections (X4, X5)

3BSE020923-510 A

Port

Duplex Signals

Simplex Signals

X4 - Tx

Transmit data to down-stream

device

Transmit data to next device

X4 - Rx

Receive data from downstream device

Not used

X5 - Tx

Transmit data to up-stream

device

Not used

X5 - Rx

Receive data from up-stream

device

Receive data from last device

269

270

4
3
2
1

Rx1

Tx1

Rx2

Tx2

Rx1

Tx1

Rx2

Tx2

L+
LSA
SB

x5

x4

x5

x4

ERx2

ERx1

Rx2

ModuleBus Optical Modem

TB840/TB840A

KEY CODE:AB

CLUSTER ADDRESS

4 5 6
7
3
8
2
1 0 9

KEY CODE:AB

Rx1= Receive from upstream

Rx2= Receive from downstream (duplex only)
ERx1= Receive from electrical ModuleBus A
ERx2= Receive from electrical ModuleBus B

P(OWER)
Rx1

ModuleBus Optical Modem

TB840/TB840A

Rx1= Receive from upstream

Rx2= Receive from downstream (duplex only)
ERx1= Receive from electrical ModuleBus A
ERx2= Receive from electrical ModuleBus B

S(TATUS)

ERx2

ERx1

Rx2

Rx1

P(OWER)

S(TATUS)

Termination Unit for Redundant TB840/TB840A

ModuleBus

TU841

Connection Diagram TB840/TB840A

Appendix B Specifications

Connection Diagram TB840/TB840A

3BSE020923-510 A

Appendix B Specifications

TB842 ModuleBus Optical Port

TB842 ModuleBus Optical Port

Features

1 fiber optic port for the Optical ModuleBus

expansion

Connection to CI801 and CI840

Description TB842
TB842 ModuleBus Optical Port is a communication
interface between the CI801 or CI840 FCI and the
TB820/TB820V2 ModuleBus Modem of an I/O
cluster or ABB drives units via the Optical
ModuleBus.
TB842 connects to CI801 via TB806 or CI840 via
TU847 and TB806.
TB842 can be used in both a simplex optical
configuration as well as in a duplex optical
configuration. In a simplex configuration, the optical
ModuleBus nodes are connected in a ring. In a
duplex configuration, the optical ModuleBus nodes
are connected in a row.
TB842 has two connectors for fiber optic
connections and a connection to the communication
interface module. The module is equipped with
Transmitter/Receiver for up to 10 Mbit/s. Both
plastic and HCS (Hard Clad Silica) optic fiber with
connectors (Agilents, former Hewlett-Packard,
Versatile Link) can be used with the TB842.

3BSE020923-510 A

271

Technical Data

Appendix B Specifications

Technical Data
Table 65. Technical Data TB824
Item

TB842

Application

S800 I/O clusters and ABB variable drives

Configuration

Simplex and duplex optical fiber

Fibers

Plastic and HCS (Hard Clad Silica)

Connector

Agilents, former Hewlett-Packard, Versatile

Link

Optical ModuleBus

Fiber optic interface, one transmit and one

receive connection for max. 10 Mbit/s.
Wavelength 650 nm

Indicators

Tx LED: Yellow indicates transmitting of

data on the optical ModuleBus
Rx LED: Yellow indicates receiving of data
on the optical ModuleBus

272

Current consumption +5 V

100 mA

Current consumption +24 V

20 mA

Power dissipation

0.5 W

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Width

17.6 mm (0.69)

Depth

42.3 mm (1.67)

Height

56.7 mm (2.23)

Weight

40 g (0.088 lbs.)

3BSE020923-510 A

Appendix B Specifications

Connections

Connections
Table 66. Optical ModuleBus Connections (X2)
Port

Duplex Signals

Simplex Signals

Tx

Transmit data to down-stream

device

Transmit data to first device

Rx

Receive data from up-stream

device

Receive data from last device

Opto Cable for TB842 according to HP

Plastic Optical Fiber (POF) (TK811V... or TK812V...) up to 15 meters.

Extra low loss attenuation

Simplex or duplex cable

Latching simplex or duplex connector.

Cable attenuation maximum 4 dB

Hard Clad Silica (HCS) fiber up to 200 meters.

Riser or plenum

Simplex or duplex cable

Latching simplex or duplex connector

Cable attenuation maximum 2 dB

3BSE020923-510 A

273

Block Diagram TB842

Appendix B Specifications

Block Diagram TB842

X1
E
O

X2

274

RX
TX

3BSE020923-510 A

Appendix B Specifications

TB845/TB846 ModuleBus Cable Adapter-Out/In

TB845/TB846 ModuleBus Cable Adapter-Out/In

Features

TB845 ModuleBus
Connector (X1A)

Passive unit used for connection

and extension of the ModuleBus

DIN rail mounting.

TB845 ModuleBus
Connector (X1B)

Description
The TB845 ModuleBus Cable AdaptorOut and TB846 ModuleBus Cable
Adaptor-In with the ModuleBus
Extension Cables, TK801V0xx, are used
to extend the ModuleBus.

DB25 Female
Connector (X2A)

Using the TB845 and TB846, I/O

modules on the same electrical
ModuleBus of an I/O cluster, can be
mounted on different DIN rails. This
makes the installation of I/O Modules
more flexible when laying out an
enclosure design. Please refer to Section
2, Installation for details on layouts.

TB846 ModuleBus
Connector (X1A)

TB846 ModuleBus
Connector (X1B)

The ModuleBus extension cables used

with the TB845/TB846 comes in 3
standard lengths:

VTK801V003 - 300 mm

TK801V006 - 600 mm

TK801V012 - 1.2 meters.

DB25 Female
Connector (X2B)

DB25 Male
Connector (X2A)

DB25 Male
Connector (X2B)

Overall ModuleBus length must not

exceed 2.5 meters including all cables
and MTUs.
TB846 is also used for connection of the
optical port TB842 to TU846 (CI840).

3BSE020923-510 A

275

Technical Data

Appendix B Specifications

The TB845/TB846 mounts on the standard DIN rail. It has a mechanical latch that
locks it to the rail. It is grounded to the DIN-rail through a metallic spring connector.
The latch can be released with a screwdriver.

Technical Data

Table 67. TB845/TB846 ModuleBus Cable Adaptor Specifications

Item

TB845

TB846

Direction

Out

In

Connections

4
2 DIN41612 Type R/4 (X1)
2 DB25 Female (X2)

4
2 DIN41612 Type R/4 (X1)
2 DB25 Male (X2)

1.5 A
1.5 A

1.5 A
1.5 A

Module catch

Locks module to previous

device

Locks module to previous

device

Module DIN rail lock

Locks module and provide

ground connection

Locks module and provide

ground connection

Equipment Class

Class I according to IEC 60536; Class I according to IEC 60536;

(earth protected)
(earth protected)

Ingress Protection

IP20 according to IEC 60529

IP20 according to IEC 60529

Rated Insulation Voltage

50 V

50 V

Dielectric test voltage

500 V a.c.

500 V a.c.

Width

49.8 mm (1.96) incl. connectors 43 mm (1.69)

Depth

31.5 mm (1.24)

ModuleBus:
Maximum 5 V
current distribution
Maximum 24 V current
distribution

276

31.5 mm (1.24)

3BSE020923-510 A

Appendix B Specifications

Block Diagram TB845

Table 67. TB845/TB846 ModuleBus Cable Adaptor Specifications (Continued)

Item

TB845

TB846

Height

186 mm (7.32) incl. latch

186 mm (7.32) incl. latch

Weight

180 g (0.4 lbs.)

180 g (0.4 lbs.)

Block Diagram TB845

X1

X2

7
/

POWOK
DAT, DAT-N
+24 V, 0 V24
+5 V
0V
CLK+, CLK-

2
/
2
/
5
/
/
/

4
2
Shield

ModuleBus Connector DB25 Female

ModuleBus Connector R/4 Female

POS 0 - 6

EM

3BSE020923-510 A

277

Block Diagram TB846

Appendix B Specifications

Block Diagram TB846

X2
POS 0 - 6

+24 V, 0 V24

2
/
2
/
5

+5 V

0V

CLK+, CLKShield

4
2

ModuleBus Connector R/4 Male

ModuleBus Connector DB25 Male

POWOK
DAT, DAT-N

X1

EM

278

3BSE020923-510 A

Appendix B Specifications

TU807, MTU for TB840/TB840A

TU807, MTU for TB840/TB840A

Features

A rotary switch for cluster address setting

Mechanical keying prevents insertion of wrong

module type

Single ModuleBus connection

Latching device to DIN rail for locking and

grounding

DIN rail mounted.

Description
The TU807 is a module termination unit (MTU) for
single configuration of Optical ModuleBus Modem
TB840/TB840A.
The MTU is a passive unit having connections for
power supply, a single electrical ModuleBus, one
TB840/TB840A and a rotary switch for cluster
address (1 to 7) setting.
Two mechanical keys are used to configured the MTU for the right types of
modules. Each key has six positions, which gives a total number of 36 different
configurations. The configurations can be changed with a screwdriver.
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has a BLOCK signal that keeps the module in its INIT state until it is
locked in its position.

3BSE020923-510 A

279

Technical Data

Appendix B Specifications

Technical Data
Table 68. TU807 Single MTU for TB840/TB840A
Item

Value

Power input

24 V d.c. (19.2 - 30 V)

ModuleBus current distribution

Maximum 5 V
24 V

1.5 A
1.5 A

Mechanical keys (2)

36 different combinations

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Acceptable wire sizes

Solid:

0.2 - 2.5 mm2

Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG

Recommended torque: 0.5 Nm

280

Rated insulation voltage

50 V

Dielectric test voltage

500 V a.c.

Width

59 mm (1.57)

Depth

47 mm (1.85)

Height

186.5 mm (7.34) including latch

Weight

0.45 kg (0.99 lbs.)

3BSE020923-510 A

Appendix B Specifications

Dimensions

Center of
DIN-rail

99.5 mm (3.92")

162.9 mm (6.41")

167.4 mm (6.59")

186.5 mm (7.34")

Dimensions

5 mm (0.20")
31.5 mm
(1.24")

9.5 mm (0.37")
40 mm
(1.57")

47 mm (1.85")

59 mm (2.32")

Figure 112. Dimensions TU807

Connections
Table 69. TU807 Power Supply Connections
Designation

3BSE020923-510 A

Description

L+

+24 V d.c. Supply In

L-

0 V d.c. Supply In

SA

Redundant Power Supply A Monitoring Input

SB

Redundant Power Supply B Monitoring Input

281

Block Diagram TU807

Appendix B Specifications

Block Diagram TU807

CLUSTER
ADDRESS
3
2

4 5 6

TU807

TB840A
+24V_A
+24V_B

7
BLOCK-N

ADDR
L+
LSA
SB

X6

0V24
+5V_A
+5V_B
0V
POWOK_A
POWOK_B

&

DATA

MTU_SEL

0V

CLK

0V

X1

CLK
POSx
POSy

+24V
0V24
+5V
0V
POWOK
DAT

LSA
SB

L+

+5V

0V

X3

Figure 113. Block Diagram TU807

282

3BSE020923-510 A

Appendix B Specifications

TU840, MTU for Redundant TB840/TB840A with Dual ModuleBus

TU840, MTU for Redundant TB840/TB840A with

Dual ModuleBus
Features

A rotary switch for cluster

address setting

Mechanical keying prevents

insertion of wrong module type

Double ModuleBus connection

Latching device to DIN rail for

locking and grounding

DIN rail mounted.

Description
The TU840 is a module termination
unit (MTU) for redundant
configuration of Optical ModuleBus
Modem TB840.

CLUSTER ADDR.

The MTU is a passive unit having

connections for power supply, double
electrical ModuleBus, two TB840/TB840A and a rotary switch for cluster address
(1 to 7) setting.
Four mechanical keys, two for each position, are used to configured the MTU for
the right types of modules. Each key has six positions, which gives a total number of
36 different configurations. The configurations can be changed with a screwdriver.
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has two BLOCK signals, one for each module position, that keeps the
modules in its INIT state until it is locked in its position.

3BSE020923-510 A

283

Technical Data

Appendix B Specifications

Technical Data
Table 70. TU840 Redundant MTU for TB840/TB840A
Item

Value

Power input

24 V d.c. (19.2 - 30 V)

ModuleBus current distribution

Maximum 5 V
24 V

1.5 A
1.5 A

Mechanical keys (2)

36 different combinations

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Acceptable wire sizes

Solid: 0.2 - 2.5 mm2

Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm

284

Rated insulation voltage

50 V

Dielectric test voltage

500 V a.c.

Width

124 mm (4.88)

Depth

47 mm (1.85)

Height

186 mm (7.32) including latch

Weight

0.45 kg (0.99 lbs.)

3BSE020923-510 A

Appendix B Specifications

Dimensions

Dimensions
39 mm (1.54)

124 mm (4.88)

162.9 mm
(6.41)
Center of
DIN rail

99.5 mm
(3.92)

186.9 mm
(7.36)

CLUSTER ADDR.

17 mm
(0.67)

5mm
(0.2)

47 mm (1.85)
90 mm (3.54)

Figure 114. Dimensions TU840

3BSE020923-510 A

285

Connections

Appendix B Specifications

Connections
Table 71. TU840 Power Supply Connections
Designation

286

Description

L+

+24 V d.c. Supply In

L-

0 V d.c. Supply In

SA

Redundant Power Supply A Monitoring Input

SB

Redundant Power Supply B Monitoring Input

3BSE020923-510 A

Appendix B Specifications

Block Diagram TU840

Block Diagram TU840

CLUSTER
4 5 6
3
7
2
1

TB840
Pos A
BLOCK_A-N

POS

POS
L+
LSA
SB

X6A

SL

+24V_A
+24V_B
0V24
+5V_A
+5V_B
0V
POWOK_A
POWOK_B
DAT_A
DAT_B
CLK_A
CLK_B

TB840
SL
Pos B
BLOCK_B-N
POS
L+
LSA
SB

+24V_A
+24V_B
0V24
+5V_A
+5V_B

X6B

0V
POWOK_A
POWOK_B
DAT_A
DAT_B
CLK_A
CLK_B
+5V_B

X3A

X1

0V
POWOK_B
DAT_B
CLK_B
POSx_B
POSy_B

0V

+24V_B
0V24
+5V_B

0V
POWOK_A
DAT_A
CLK_A
POSx_A
POSy_A

L+
LSA
SB

+24V_A
0V24
+5V_A

+5V_A

0V

X3B

Figure 115. Block Diagram TU840

3BSE020923-510 A

287

TU841, MTU for Redundant TB840/TB840A with Single ModuleBus

Appendix B Specifications

TU841, MTU for Redundant TB840/TB840A with Single

ModuleBus
Features

A rotary switch for cluster

address setting

Mechanical keying prevents

insertion of wrong module type

Single ModuleBus connection

Latching device to DIN rail for

locking and grounding

DIN rail mounted.

Description
The TU841 is a module termination
unit (MTU) for redundant
configuration of Optical ModuleBus
Modem TB840/TB840A.

CLUSTER ADDR.

The MTU is a passive unit having

connections for power supply, a
single electrical ModuleBus, two TB840/TB840A and a rotary switch for cluster
address (1 to 7) setting.
Four mechanical keys, two for each position, are used to configured the MTU for
the right types of modules. Each key has six positions, which gives a total number of
36 different configurations. The configurations can be changed with a screwdriver.
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has two BLOCK signals, one for each module position, that keeps the
modules in its INIT state until it is locked in its position.

288

3BSE020923-510 A

Appendix B Specifications

Technical Data

Technical Data
Table 72. TU841 Redundant MTU for TB840/TB840A
Item

Value

Power input

24 V d.c. (19.2 - 30 V)

ModuleBus current distribution

Maximum 5 V
24 V

1.5 A
1.5 A

Mechanical keys (2)

36 different combinations

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Acceptable wire sizes

Solid: 0.2 - 2.5 mm2

Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm

Rated insulation voltage

50 V

Dielectric test voltage

500 V a.c.

Width

124 mm (4.88)

Depth

47 mm (1.85)

Height

186 mm (7.32) including latch

Weight

0.45 kg (0.99 lbs.)

3BSE020923-510 A

289

Dimensions

Appendix B Specifications

Dimensions
39 mm (1.54)

124 mm (4.88)

162.9 mm
(6.41)
Center of
DIN rail

99.5 mm
(3.92)

186.5 mm
(7.34)

CLUSTER ADDR.

17 mm
(0.67)

5mm
(0.2)

47 mm (1.85)
90 mm (3.54)

Figure 116. Dimensions TU841

290

3BSE020923-510 A

Appendix B Specifications

Connections

Connections
Table 73. TU841 Power Supply Connections
Designation

3BSE020923-510 A

Description

L+

+24 V d.c. Supply In

L-

0 V d.c. Supply In

SA

Redundant Power Supply A Monitoring Input

SB

Redundant Power Supply B Monitoring Input

291

Block Diagram TU841

Appendix B Specifications

Block Diagram TU841

CLUSTER
4 5 6
3
7
2
1

TB840
+24V_A
Pos A
BLOCK_A-N

POS

POS
L+
LSA
SB

0V24
+5V_A
X6A

0V
POWOK_A
DAT_A
CLK_A

SL

TB840
+24V_A

SL
Pos B
BLOCK_B-N
POS
L+
LSA
SB

0V24
+5V_A
X6B

0V
POWOK_A
DAT_A
CLK_A

X1

0V
POWOK_A
DAT_A
CLK_A
POSx_A
POSy_A

+24V_A
0V24
+5V_A

L+
LSA
SB

+5V_A

0V

X3A

Figure 117. Block Diagram TU841

292

3BSE020923-510 A

Appendix B Specifications

TU848, MTU for Redundant TB840/TB840A with Dual ModuleBus and

TU848, MTU for Redundant TB840/TB840A with

Dual ModuleBus and Dual Power Supply Connections
Features

Dual power supply connection

A rotary switch for cluster address

setting

Mechanical keying prevents

insertion of wrong module type

Double ModuleBus connection

Latching device to DIN rail for

locking and grounding

DIN rail mounted.

Description
The TU848 is a module termination
unit (MTU) for redundant configuration
of Optical ModuleBus Modem
TB840/TB840A.
The MTU is a passive unit having connections for double power supply (one for
each modem), double electrical ModuleBus, two TB840/TB840A and a rotary
switch for cluster address (1 to 7) setting.
Two mechanical keys are used to configured the MTU for the right types of
modules. Each key has six positions, which gives a total number of 36 different
configurations. The configurations can be changed with a screwdriver.
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has a BLOCK signal that keeps the modules in its INIT state until it is
locked in its position.

3BSE020923-510 A

293

Technical Data

Appendix B Specifications

Technical Data
Table 74. TU848 Redundant MTU for TB840/TB840A
Item

Value

Power input

24 V d.c. (19.2 - 30 V)

ModuleBus current distribution

Maximum 5 V
24 V

1.5 A
1.5 A

Mechanical keys (2)

36 different combinations

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Acceptable wire sizes

Solid: 0.2 - 2.5 mm2

Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm

294

Rated insulation voltage

50 V

Dielectric test voltage

500 V a.c.

Width

124 mm (4.88)

Depth

47 mm (1.85)

Height

186.5 mm (7.34) including latch

Weight

0.45 kg (0.99 lbs.)

3BSE020923-510 A

Appendix B Specifications

Dimensions

Center of
DIN-rail

99.5 mm (3.92")

162.9 mm (6.41")

167.4 mm (6.59")

186.5 mm (7.34")

Dimensions

5 mm (0.20")

17 mm (0.67")

90 mm (3.54")

31.5 mm
(1.24")

124 mm (4.88")

47 mm (1.85")

Figure 118. Dimensions TU848

Connections
Table 75. TU848 Power Supply Connections
Designation

3BSE020923-510 A

Description

L+

+24 V d.c. Supply In

L-

0 V d.c. Supply In

SA

Redundant Power Supply A Monitoring Input

SB

Redundant Power Supply B Monitoring Input

295

Block Diagram TU848

Appendix B Specifications

Block Diagram TU848

CLUSTER
4

TB840

+24V_A

+24V_B

BLOCK_A-N
POS

0V24
+5V_A

POS

+5V_B

L+
L-

X1A

SA

X6A

0V
POWOK_A

X3A

POWOK_B

SB

DAT_A
DAT_B
CLK_A
CLK_B

+5V_A

LINK

POSx_A
POSy_A

0V
TB840
+24V_A
+24V_B

BLOCK_B-N

0V24
+5V_A

POS

+5V_B

L+
L-

X1B

SA
SB

X6B

0V
POWOK_A

X3B

POWOK_B
DAT_A
DAT_B
CLK_A
CLK_B

+5V_A
POSx_B
POSy_B

0V

Figure 119. Block Diagram TU848

296

3BSE020923-510 A

Appendix B Specifications TU849, MTU for Redundant TB840/TB840A with Single ModuleBus and

TU849, MTU for Redundant TB840/TB840A with Single

ModuleBus and Dual Power Supply Connection
Features

Dual power supply connection

A rotary switch for cluster address

setting

Mechanical keying prevents insertion

of wrong module type

Single ModuleBus connection

Latching device to DIN rail for

locking and grounding

DIN rail mounted.

Description
The TU849 is a module termination unit
(MTU) for redundant configuration of
Optical ModuleBus Modem
TB840/TB840A.
The MTU is a passive unit having connections for double power supply, one for
each modem, a single electrical ModuleBus, two TB840/TB840A and a rotary
switch for cluster address (1 to 7) setting.
Four mechanical keys, two for each position, are used to configured the MTU for
the right types of modules. Each key has six positions, which gives a total number of
36 different configurations. The configurations can be changed with a screwdriver.
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has two BLOCK signals, one for each module position, that keeps the
modules in its INIT state until it is locked in its position.

3BSE020923-510 A

297

Technical Data

Appendix B Specifications

Technical Data
Table 76. TU849 Redundant MTU for TB840/TB840A
Item

Value

Power input

24 V d.c. (19.2 - 30 V)

ModuleBus current distribution

Maximum 5 V
24 V

1.5 A
1.5 A

Mechanical keys (2)

36 different combinations

Equipment Class

Class I according to IEC 60536; (earth

protected)

Ingress Protection

IP20 according to IEC 60529

Acceptable wire sizes

Solid: 0.2 - 2.5 mm2

Stranded: 0.2 - 2.5 mm2, 24 - 12 AWG
Recommended torque: 0.5 Nm

298

Rated insulation voltage

50 V

Dielectric test voltage

500 V a.c.

Width

124 mm (4.88)

Depth

47 mm (1.85)

Height

186.5 mm (7.34) including latch

Weight

0.45 kg (0.99 lbs.)

3BSE020923-510 A

Appendix B Specifications

Dimensions

Center of
DIN-rail

99.5 mm (3.92")

162.9 mm (6.41")

167.4 mm (6.59")

186.5 mm (7.34")

Dimensions

5 mm (0.20")

17 mm (0.67")

90 mm (3.54")

31.5 mm
(1.24")

124 mm (4.88")

47 mm (1.85")

Figure 120. Dimensions TU849

Connections
Table 77. TU849 Power Supply Connections
Designation

3BSE020923-510 A

Description

L+

+24 V d.c. Supply In

L-

0 V d.c. Supply In

SA

Redundant Power Supply A Monitoring Input

SB

Redundant Power Supply B Monitoring Input

299

Block Diagram TU849

Appendix B Specifications

Block Diagram TU849

CLUSTER
4

TB840

+24V_A

+24V_B
BLOCK_A-N

POS

0V24
+5V_A

POS

+5V_B

L+
L-

X1A

SA

0V

X6A

POWOK_A
POWOK_B

SB

X3A

&

DAT_A
DAT_B
CLK_A
CLK_B

0V

+5V_A

LINK

POSx_A
POSy_A

0V
TB840
+24V_A
+24V_B

BLOCK_B-N

0V24
+5V_A

POS
L+

LX1B

SA
SB

+5V_B

X6B

0V
POWOK_A
POWOK_B
DAT_A
DAT_B
CLK_A
CLK_B

Figure 121. Block Diagram TU849

300

3BSE020923-510 A

Appendix B Specifications

TK811 Opto Cable, Duplex Plastic Fibre

TK811 Opto Cable, Duplex Plastic Fibre

Figure 122.

Features

Available in lengths of 1.5, 5 and 15 m.

LSZH (Low Smoke Zero Halogene) plastic fiber.

Classified according to UL1581.

Classified according to AWM VW-1.

Opto connectors type Agilents, former Hewlett-Packard, Versatile Link

Latching connector.

Extra low loss attenuation.

3BSE020923-510 A

301

TK812 Opto Cable, Simplex Plastic Fibre

Appendix B Specifications

TK812 Opto Cable, Simplex Plastic Fibre

Figure 123.

Features

302

Available in lengths of 1.5, 5 and 15 m.

LSZH (Low Smoke Zero Halogene) plastic fiber

Classified according to UL1581

Classified according to AWM VW-1

Opto connectors type Agilents, former Hewlett-Packard, Versatile Link

Latching connector

Extra low loss attenuation

3BSE020923-510 A

Appendix B Specifications

Mounting Kit

Mounting Kit
Features

Prepared for 9 different

configurations

DIN rail locking

mechanism

Description
The Mounting Kit is used for
horizontal mounting of CI801,
CI840/CI840A and
TB840/TB840A on a vertical
DIN rail.
ModuleBus cable adapters can be mounted on the Mounting Kit together with
communication modules.

Technical Data
Table 78. Mounting Kit
Item

Value

Width

200 mm (7.87)

Depth

170 mm (6.69)

Height

17 mm (0.67)

Weight

0.5 kg (1.10 lbs.)

3BSE020923-510 A

303

Configuration

Appendix B Specifications

Configuration
There are 9 different configurations for mounting of MTU:s on the Mounting Kit,
see Figure 124.

TU840/TU848 TB845

TB846

TU846

TU841/TU849 TB805

TB845

TB806 CI801 TB805

TB806 TU847

TU846

TB805

TB845

TU847

TB805

TU807 TB805

CI801 TB805

Figure 124. Configurations for mounting of MTU:s on the Mounting Kit

304

3BSE020923-510 A

Appendix B Specifications

Horizontal and Vertical Mounting Profile

Horizontal and Vertical Mounting Profile

Features

Good mechanical stability

Good chassis ground connection

Provided with groove for additional screw fastening of the modules

Description
On the horizontal aluminium profile are mounted:

one DIN-rail with height 7.5 mm type NS 35/7.5 according to EN 50022

one cable duct u-profile

The profile are available in three different lengths; 465 mm (19), 592 mm (24) and
719 mm (28.31).
On the vertical aluminium profile are mounted:

two DIN-rail, one vertical and one horizontal, with height 7.5 mm type NS
35/7.5 according to EN 50022

one cable duct u-profile

The profile are available in lengths; 1800 mm (70.87). The profile can be mounted
to left, centered or to right in a cabinet.

3BSE020923-510 A

305

Dimensions

Appendix B Specifications

Dimensions

40 mm (1.57")

253.3 mm (9.97")

465 mm (18.31")

44.45 mm
(1.75")

7.73 mm
(0.29")

482 mm (19")

76 mm
(2.99")

Figure 125. Horizontal Mounting Profile Dimensions

Figure 126. Vertical Mounting Profile Dimensions

306

3BSE020923-510 A

Appendix C Power Up
Power Up on S800 I/O
S800 I/O will start under four different conditions.
1.

Without configuration and without communication with the controller. Start the
first time or after a long power off.

2.

Without configuration but with communication with the controller. Start the
first time or after a long power off.

3.

With configuration but without communication with the controller. Start after a
short power off.

4.

With configuration and with communication with the controller. Start after a
short power off.

Below follows a description how to start and how S800 behaves during start-up
under different conditions.
1.

Check that the circuit breakers on the power switch units are switched off.

2.

Switch on the mains power, and check for correct mains voltage with a
multimeter.

3.

Switch on the circuit breaker on the power switch unit(s).

Without configuration and without communications with the controller:

See timing diagram Figure 127.
Indications on FCI
F (fault)
R (run)
P (pow ok)
T1

3BSE020923-510 A

on at power up and off after self-test ok

off
on if power supply ok
off

307

Power Up on S800 I/O

T2
PR
DU

Appendix C Power Up

off
on (only primary FCI in a redundant configuration)
off (both FCI in a redundant configuration).

Indications on I/O Modules

F (fault)
R (run)
W (warning)
O (osp only outputs)

on
off
off
off

Without configuration but with communications with the controller:

See timing diagram Figure 128.
Indications on FCI
F (fault)
R (run)

P (pow ok)
T1
T2
PR
DU

on at power up and off after self-test ok

off at power up and on after configuration ok
and commanded operational from the controller
(can take about 1 to 4 minutes)
on if power supply ok
on if cable 1 ok
on if cable 2 ok
on (only primary FCI in a redundant configuration)
off (both FCI in a redundant configuration)

The backup will be started up after the I/O. When the backup has started
PR
DU

on (only primary FCI in a redundant configuration)

on (both FCI in a redundant configuration)

Indications on I/O Modules

F (fault
R (run)

W (warning
O (outputs only)

308

on at power up and off after the first access

from the FCI
off at power up and on for AI, DI after
configuration and for AO, DO after configuration and
commanded operational from the controller
off at power up and after module operational
updated from the module
off at power up and after module operational
updated from the module

3BSE020923-510 A

Appendix C Power Up

Power Up on S800 I/O

With configuration but without communications with the controller:

See timing diagram Figure 129.
Indications on FCI
F (fault)
R (run)
P (pow ok)
T1
T2
PR
DU

on at power up and off after self-test ok

off
on if power supply ok
off
off
on (only primary FCI in a redundant configuration)
off (both FCI in a redundant configuration)

Indications on I/O Modules

F (fault)
R (run)

W (warning)
O (osp only outputs)

on at power up and off after the first access from

the FCI
off at power up and on for AI, DI after
configuration from the FCI. AO and DO
remains in off
off at power up and after module operational
updated from the module
off

With configuration and communications with the controller:

See timing diagram Figure 130.
Indications on FCI
F (fault)
R (run)

P (pow ok)
T1
T2

on at power up and off after self-test ok

off at power up and on after configuration and
commanded operational from the controller.
(can take about 1 to 4 minutes)
on if power supply ok
on if cable 1 ok
on if cable 2 ok

The backup will be started up after the I/O. When the backup has started
PR
DU

3BSE020923-510 A

on (only primary FCI in a redundant configuration)

on (both FCI in a redundant configuration)

309

Power Up on S800 I/O

Appendix C Power Up

Indications on I/O Modules

F (fault)
R (run)

W (warning)
O (osp only outputs)

on at power up and off after the first access from

the FCI
off at power up and on for AI, DI after
configuration and for AO,DO after configuration and
commanded operational from the controller
off at power up and after the module operational
updated from the module
off at power up and after module is operational
it is handled by the module

Power up of backup FCI in a running system:

See timing diagram Figure 131.
Indications on FCI

310

Primary
F (fault)
R (run)
P (pow ok)
T1
T2
PR
DU

off
on
on
on
on
on
off (on when the backup is running)

Backup
F (fault)
R (run)
P (pow ok)
T1
T2
PR
DU

off
off (on when the backup is running)
on
on
on
off
off (on when the backup is running)

3BSE020923-510 A

Appendix C Power Up

Power Up on S800 I/O

FCI
F
R
P
T1/T2
DU (both)
PR (primary)
PR (backup)
I/O module
F
R
W
OSP

Power up INIT in
S800 I/O FCI

Figure 127. Power-up Timing Diagram, no Configuration and no Communications

to Controller

3BSE020923-510 A

311

Power Up on S800 I/O

FCI

Appendix C Power Up

FCI operational

F
R
P
T1
T2
PR (primary)
DU (both)

PR (backup)
R (backup)
I/O module
F
R (AI, DI)
R (AO, DO)
W (AI, DI)
W, OSP (AO, DO)
Start of I/O
Power up
S800 I/O

INIT
in FCI

INIT
backup

Figure 128. Power-up Timing Diagram, no Configuration and Communications to

Controller

312

3BSE020923-510 A

Appendix C Power Up

Power Up on S800 I/O

FCI
F
R
P
T1/T2
DU (both)
PR (primary)
PR (backup)
I/O module
F
R (AI, DI)
R (AO, DO)
W (AI, DI)
W (AO, DO)

Power up
S800 I/O

INIT
in FCI

Start of I/O

Figure 129. Power-up Timing Diagram, with Configuration and no

Communications to Controller

3BSE020923-510 A

313

Power Up on S800 I/O

FCI

Appendix C Power Up

FCI operational

F
R
P
T1
T2
PR (primary)
DU (both)

PR (backup)
R (backup)
I/O module
F
R (AI, DI)
R (AO, DO)
W (AI, DI)
W, OSP (AO, DO)

Power up
S800 I/O

Start of I/O
INIT

INIT
backup

Figure 130. Power-up Timing Diagram, with Configuration and Communications to

Controller

314

3BSE020923-510 A

Appendix C Power Up

Power Up on S800 I/O

FCI
Primary
F
R
P
T1/T2
PR
DU
Backup
F
R
P
T1/T2
PR
DU

Power-up
backup

INIT
backup

Figure 131. Power-up Timing Diagram, Power-up of Backup in a Running System

3BSE020923-510 A

315

Power Up on S800 I/O

316

Appendix C Power Up

3BSE020923-510 A

INDEX
A
A.C. supply 98
Address setting 112
Advant Fieldbus 100 110
AI801 25
AI810 25
AI820 25
AI825 25
AI830 25
AI830A 25
AI835 25
AI843 26
AI845 26
AI880 26
AI880A 26
AI890 26
AI893 26
AI895 26
AO801 26
AO810 26
AO810V2 26
AO820 26
AO845 26
AO845A 26
AO890 26
AO895 26

C
Cable adaptor 29 to 30
Cable considerations 96
Check of non-redundant power supply 179
Check of redundant power supply 179
CI801 26
CI810/CI810A/CI810B 27, 36
CI820 27, 37

3BSE020923-510 A

CI830 27, 37, 111

CI840 27
Cooling load 165

D
D.C. supply 98
DI801 27
DI802 27
DI803 27
DI810 27
DI811 27
DI814 27
DI820 27
DI821 27
DI825 27
DI830 27
DI831 27
DI840 28
DI880 28
DI885 28
DI890 28
DIN-rail 66
Dissipation permitted in cabinets 162
Distributed MTUs 111
DO801 28
DO802 28
DO810 28
DO814 28
DO815 28
DO820 28
DO821 28
DO840 28
DO880 28
DO890 28
DP820 28

317

Index

DP840 29

E
Environmental considerations 64
Extension cables 34

F
FCI 18, 36 to 37
CI801 138
CI810 138
CI810A 138
CI820 138
CI830 138
CI840 138
Fieldbus connection 110

L
LED
Location 176
LEDs 175
Lightning strike protection 99

G
G3 compliant 19
Ground contact 69
Grounding 94, 106
Process signals 108
Protective ground 95
Signals and voltage supply 96

H
Hardware configuration 127
Hazardous Location - North American
Approval 98
Heat dissipation 162
High voltage switch-gear applications 99

I
I/O clusters (1-7) 111
I/O module installation 82
I/O module replacement 180
I/O modules 54
I/O Station
Assembly 109
I/O station 19, 66

318

Industrial environments 96
Installation
Checklists 113

Maximum ambient temperature 165

Module termination units 53
ModuleBus extension 30
ModuleBus extension cable 75
ModuleBus modem 183, 246, 264
ModuleBus optical port 77
TB810 77
ModuleBus terminator 85
Mounting Kit 33, 87, 303

O
Optical ModuleBus expansion 77

P
Personnel safety 106
Power
A.C. supply 98
D.C. supply 98
Requirements 98
Power and cooling 165
Power consumption 164
Power Dissipation 165
Power supply 54
Load calculation 161
Procedure
Power up 307
Process signals 111
PROFIBUS-DP 19, 27, 37
PROFIBUS-DPV1 19, 27, 36, 38

3BSE020923-510 A

Index

R
Redundant FCI installation 71

S
S800 I/O
Assembly 109
Installation 64
Safety regulations 105
SD821 29
SD822 29
SD823 29
Shut down
Emergency 120
Manual stop 121
Safety 120
SS822 29
SS823 29

T
TB805 29
TB806 29
TB807 29, 85
TB810 29, 77
TB810/811 183
TB811 30
TB815 30
TB820 30, 183
TB825 30
TB826 30
TB840 30
TB842 30
TB845 30
TB846 30
TC501V150 30
TC505 30
Temperature 65
Cabinetry factors 65
I/O module factors 65
Terminator 30
TK801V003 30

3BSE020923-510 A

TK801V006 30
TK801V012 30
TK811V015 30
TK811V050 31
TK811V150 31
TK812V015 31
TK812V050 31
TK812V150 31
TU805 31
TU807 31, 279
TU810 31
TU811 31
TU813 31
TU814 31
TU830 31
TU831 31
TU833 31
TU834 31
TU835 32
TU836 32
TU837 32
TU838 32
TU840 32
TU841 32
TU842 32
TU843 32
TU844 32
TU845 32
TU846 32
TU847 32
TU848 32, 293
TU849 32
TU890 33
TU891 33
TY801 33
TY804 33

V
Ventilation 162
Vibration 65

319

Index

320

3BSE020923-510 A

Revision History
Introduction
This section provides information on the revision history of this User Manual.
The revision index of this User Manual is not related to the 800xA 5.1 System
Revision.

Revision History
The following table lists the revision history of this User Manual.
Revision
Index

Description

Date

First version published for 800xA 5.1

June 2010

Added contents for new TB826 and corrected

contents in few other sections.

December 2011

3BSE020923-510 A

321

Updates in Revision Index A

Updates in Revision Index A

The following table shows the updates made in this User Manual for
Revision Index A.
Updated Section/Sub-section

Description of Update

Section 1, Introduction

Added a sub-section TB826 Optical Media Converter.

Section 3, Configuration

Added a sub-section TB826 Optical Media

Converter.

Updated Table 24 I/O Station Power and Cooling

(Typical) Values.

Appendix A, General Specification

Appendix B, Specifications

322

In Table 37 Current Certifications for S800 Modules:

Updated values for SD82X, SD83X, SS823, and

SS832.

Added new row for TB826.

Updated table footnote.

Added a sub-section TB826 Optical Media

Converter.

Updated description of TB840/TB840A

ModuleBus Modem.

3BSE020923-510 A

ABB AB
Control Technologies
Vsters, Sweden
Phone: +46 (0) 21 32 50 00
Fax:
+46 (0) 21 13 78 45
E-Mail: processautomation@se.abb.com

Copyright 2003-2011 by ABB.

All Rights Reserved

www.abb.com/controlsystems
ABB Inc.
Control Technologies
Wickliffe, Ohio, USA
Phone: +1 440 585 8500
Fax:
+1 440 585 8756
E-Mail: industrialitsolutions@us.abb.com
www.abb.com/controlsystems
ABB Pte Ltd
Control Technologies
Singapore
Phone: +65 6776 5711
Fax:
+65 6778 0222
E-Mail: processautomation@sg.abb.com
www.abb.com/controlsystems
ABB Automation GmbH
Control Technologies
Mannheim, Germany
Phone: +49 1805 26 67 76
Fax:
+49 1805 77 63 29
E-Mail: marketing.control-products@de.abb.com
www.abb.de/controlsystems
ABB Automation LLC
Control Technologies
Abu Dhabi, United Arab Emirates
Phone: +971 (0) 2 4938 000
Fax:
+971 (0) 2 5570 145
E-Mail: processautomation@ae.abb.com
www.abb.com/controlsystems

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for a better world

3BSE020923-510 A

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