3BDD010421R0401 A en S900 I O S - and N-System With SA920 Installation

S900 I/O
S- and N-System with SA920

Installation
Power and productivity

TM
for a better world
S900 I/O
S- and N-System with SA920
Installation
NOTICE
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TRADEMARKS
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tive owners.
Copyright © 2003-2010 by ABB.

All rights reserved.
Release: June 2010

Document number: 3BDD010421R0401 A
Table Of Contents
TABLE OF CONTENTS
NOTICE........................................................................................................4
TRADEMARKS ...........................................................................................4
Safety Summary ................................................................................. 13

Safe Operation .................................................................................................13
Qualified Personnel .........................................................................................14
About This Book ................................................................................ 15

General ............................................................................................................15
Document Conventions....................................................................................15
Warning, Caution, Information, Tip and Ex Icons ..........................................16
Related Documentation....................................................................................17
Section 1 Introduction ................................................................... 19

System Features ...............................................................................................19
System Limitations ..........................................................................................21
Section 2 S900 System Installation Sites .................................... 23

Hazardous Areas ..............................................................................................23
Classification of Hazardous Areas ...................................................................23
Zone 0 ..............................................................................................23
Zone 1 ..............................................................................................23
Zone 2 ..............................................................................................24
Non-hazardous Areas .......................................................................24
3BDD010421R0401 A 5
Table Of Contents
Installing the S900 I/O System in a Non-hazardous Area .............................. 25

Types ............................................................................................. 25
Fieldbus ........................................................................................... 25
Power Supply................................................................................... 26
Installing the S900 I/O System in Zone 2 ....................................................... 27
Types ............................................................................................. 27
Installation ....................................................................................... 27
Fieldbus ........................................................................................... 27
Installing the S900 I/O System in Zone 1 ....................................................... 29
Types ............................................................................................. 29
Installation ....................................................................................... 29
Fieldbus ........................................................................................... 29
Section 3 Fieldbus......................................................................... 31
Fieldbus Design with Electrical Lines ............................................................ 31
Fieldbus in S900 I/O System Applications Type N ................................... 31
Topology.......................................................................................... 31
Number of Bus Stations ................................................................... 31
Line Type......................................................................................... 33
Stub Lines ........................................................................................ 33
Connectors and Bus Termination .................................................... 34
Fieldbus in S900 I/O System Applications Type S and Type N ................ 35
Topology.......................................................................................... 35
Intrinsically Safe Fieldbus System .................................................. 36
Number of Bus Stations ................................................................... 36
Line Type......................................................................................... 37
Stub Lines ........................................................................................ 37
Connectors and Bus Termination .................................................... 38
Interconnection ................................................................................ 39
Procedure for Interconnecting the Components: ............................. 39
Example ........................................................................................... 40
6 3BDD010421R0401 A
Table Of Contents
Fieldbus Design with Fiber-optic Lines...........................................................41

General........................................................................................................41
Fiber Types and Ranges..............................................................................42
Optical Connectors .....................................................................................42
Application .................................................................................................42
Topologies ..................................................................................................42
Optical Ring .....................................................................................43
Redundancy in the Fieldbus System ................................................................44
Example 1 ...................................................................................................45
Example 2 ...................................................................................................46
Example 3 ...................................................................................................46
Powering Fieldbus Components ......................................................................47
Section 4 Environmental Capabilities and Power Consumption49

Environmental Capabilities..............................................................................49
Explosion Protection...................................................................................49
Ambient Temperature .................................................................................49
Mounting Orientation .................................................................................50
Atmosphere .................................................................................................50
Shock and Vibration ...................................................................................50
Power Details ...................................................................................................51
Power Limits...............................................................................................51
Power Details of Ex Modules (Type S) ......................................................53
Power Details of non-Ex Modules (Type N) ..............................................55
Power Details of the Field Housings ..........................................................57
Boundary Conditions: .................................................................................58
Procedure .........................................................................................................59
3BDD010421R0401 A 7
Table Of Contents
Section 5 Mounting and Connecting the System ....................... 61

Mounting the Termination Unit ...................................................................... 61
Connection Level Overview ........................................................................... 62
Power Supply .................................................................................................. 63
Terminal Cover and Terminal Assignment................................................ 63
Installation ................................................................................................. 64
Power Distribution, Power System Design ................................................ 64
Setup ............................................................................................. 65
Power ............................................................................................. 66
Fuse Protection ................................................................................ 68
Cable CSA and Length .................................................................... 68
Signal Circuits ................................................................................................. 69
Terminals ................................................................................................... 69
Markings/Designations .................................................................... 69
Cable CSA ....................................................................................... 69
Connecting/disconnecting terminals ................................................ 70
Installation ................................................................................................. 70
Fieldbus Connection ....................................................................................... 71
Connecting the Fieldbus to the Termination Unit ...................................... 71
Pin Assignment of the Fieldbus Connector ..................................... 71
Installation ................................................................................................. 72
Fieldbus Connector .................................................................................... 72
Unused Bus Connectors................................................................... 72
Marking the Fieldbus Cables ........................................................... 72
Field Housing .................................................................................................. 73
Using the Empty Housing FHxxx .............................................................. 73
Selection .......................................................................................... 73
Installing the S900 I/O System in the Housing ............................... 73
Additional Components ................................................................... 74
Wiring ............................................................................................. 74
8 3BDD010421R0401 A
Table Of Contents
Connecting the Power and Signal Lines ...........................................74

Cable Strain Relief ...........................................................................75
Mounting the Field Housing.............................................................75
Cleaning After Mounting .................................................................76
Verification and Approval ................................................................76
Maintenance and Dismounting .........................................................77
Using Cabinets ............................................................................................77
Section 6 Components Assembly and Commissioning ............. 79

Selecting and Combining Components............................................................79
Notes on Explosion Protection ...................................................................79
Power Units .....................................................................................................80
Power Units of Type S................................................................................80
Power Units of Type N ...............................................................................81
Replacing the SA910 with the SA920 ........................................................82
Mixed Operation...............................................................................82
Power Details ...................................................................................82
Power Requirements.........................................................................82
Power Supply Filter ..........................................................................82
How to Procede for Replacing the Power Supply Units ..................83
Modules ...........................................................................................................84
Selecting the Modules ................................................................................84
Replacing a Module ....................................................................................84
Field Circuits ..............................................................................................84
Number of Modules ....................................................................................84
Slot 84
Communication Interface ................................................................................85
Single Mode (No Redundancy) ..................................................................85
Redundancy Mode ......................................................................................85
Slot 85
Setting the Address .....................................................................................85
3BDD010421R0401 A 9
Table Of Contents
Unlocking and Encoding ................................................................................. 86

Unlocking the Modules and the Communication Interfaces ...................... 86
Encoding the Housings .............................................................................. 86
Using Hand-held Terminals (HART ) ............................................................ 88
Section 7 Shielding and Equipotential Bonding ........................ 91

Introduction ..................................................................................................... 91
Basic Requirements......................................................................................... 91
Overview ......................................................................................................... 92
Termination Unit........................................................................................ 93
Power Supply ............................................................................................. 93
Fieldbus...................................................................................................... 94
Signal Circuits............................................................................................ 96
Field Housing ............................................................................................. 96
Cable and Wire Layout ................................................................................... 97
General ....................................................................................................... 97
Power Cables ................................................................................... 97
Field Signal Lines ............................................................................ 98
FO Cables ........................................................................................ 98
Lightning and Overvoltage Protection ............................................................ 99
External Lightning Protectors .................................................................... 99
Internal Lightning Protectors ..................................................................... 99
Overvoltage Protection .............................................................................. 99
Protection Through Shield Grounding ....................................................... 99
Overvoltage Protection Equipment .......................................................... 100
Additional information .................................................................. 101
10 3BDD010421R0401 A
Table Of Contents
Section 8 Maintenance, Repair, Trouble-shooting ................... 103

Maintenance ...................................................................................................103
Trouble-shooting............................................................................................104
Repairing Ex-devices .....................................................................................105
Section 9 List of Tables, List of Figures .................................... 107

List of Tables .................................................................................................107
List of Figures ................................................................................................108
3BDD010421R0401 A 11
Table Of Contents
12 3BDD010421R0401 A
Safety Summary Safe Operation
Safety Summary
Safe Operation
Proper and safe operation of the S900 I/O System requires proper
transportation and storage, installation and commissioning by qualified
personnel, correct operation, proper use and careful maintenance.
The S900 I/O System must not be installed in hazardous areas of zone 0.
Observe the type of protection and the special conditions specified on the S900
system components.
The device must not be reconstructed or changed.
Prior to first use all foreign objects must be removed from the device.
Observe the national regulations for safety and for the prevention of accidents
when performing any work on the device.
Prior to commissioning check the S900 system for proper cabling/wiring and
functioning. Carefully check the wiring and markings of intrinsically safe
current circuits. Deliver the appropriate proof for the intrinsic safety of these
current circuits.
When a field housing is used, it must be closed properly after this check and
may only be re-opened for service.
The present manual does not supersede the relevant national regulations,
standards and directives. These must be observed and have to be applied
according to the national conditions.
3BDD010421R0401 A 13
Qualified Personnel Safety Summary
Qualified Personnel
Only personnel familiar with the installation, commissioning, operation and
maintenance of the electrical equipment and who have the required qualification
are authorized to work on the devices.
The regulations defining the qualification of supervisory staff in charge of
maintenance and repair in accordance with IEC/EN60079-17 must be observed.
14 3BDD010421R0401 A
About This Book General / Document Conventions
About This Book
General
This manual provides a description of mounting and installation procedures for
S900 I/O System type S and type N.
It provides instructions for S900 System installation sites, fieldbus, environmental
capabilities and power consumption, mounting and connecting the system,
components assembly and commissioning, shielding and equipotential bonding and
maintenance, repair, trouble-shooting.
For information on how to mount and install type B systems please refer to manual
No. 3BDD010432.
The information in this document related to Zone 1 and Zone 2 always refers to
the ATEX certificates applicable to the corresponding devices.
Strictly observe the conditions and specifications stipulated in these certificates.
The operating authorities in charge of the plants concerned must adhere to the
certificates and the national certificates derived from these to comply with the
local legal requirements and instrumentation regulations.
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.
3BDD010421R0401 A 15
Warning, Caution, Information, Tip and Ex Icons About This Book
Warning, Caution, Information, Tip and Ex 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.
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.
Ex icon indicates special conditions for meeting explosion protection

requirements.
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.
16 3BDD010421R0401 A
About This Book Related Documentation
Related Documentation
The following is a listing of manuals related to the S900 I/O system:
Table 1 Applicable reference manuals
Title Description
S900 I/O General Information and Installation Describes the general installation and
of Type S and Type N configuration information for the S900 I/O system
of type S and type N
Document number 3BDD010421
S900 I/O General Information and Installation Describes the general installation and
of Type B configuration information for the S900 I/O system
of type B
S900 I/O Fieldbus Communication Interface Describes the PROFIBUS-DP FCI in the S900 I/O
for PROFIBUS-DP/DPV1 system and the communication via PROFIBUS
CI920 Version 1.4 Document number 3BDD010422
S900 I/O Fieldbus Communication Interface Describes the PROFIBUS-DP FCI in the S900 I/O
for PROFIBUS-DP/DPV1 system and the communication via PROFIBUS
CI920 Version 1.5 Document number 3BDD015031
S900 Digital I/O Modules DO910 and DX910 Describes the field connection, module function,
communication and commissioning of the module.
S900 Digital I/O Module DP910 Describes the field connection, module function,
S900 Analog I/O Modules (HART) AI930, Describes the field connection, module function,
AI931, AO930 communication and commissioning of the module.
S900 Temperature Input AI950 Describes the field connection, module function,
Documentation will be delivered on separate CD with each Termination Unit,

Compact Box and Field Housing. It is also possible to order the CD type CD910
with the following Order No. 3KDE175839L9100. The CD includes GSD files,
certifications and additional related documentation, e.g. data sheets for the
Remote I/O S900.
3BDD010421R0401 A 17
Related Documentation About This Book
18 3BDD010421R0401 A
Section 1 Introduction System Features
Section 1 Introduction
System Features
The S900 I/O System is a remote I/O system for use in hazardous areas. Due to its
explosion protection certificates the S900 process I/O system can be installed in
both hazardous areas (ATEX zone 1 and zone 2) and safe areas. The system
provides bus-compatible local inputs and outputs (protection class IP20) for
connecting digital and analog field instruments.
The system consists of a termination unit accommodating the power units, the
Communication Interfaces, and the I/O modules. The passive termination unit
ensures power distribution and data transfer, and also provides the connection
platform. The power units reliably power the entire S900 I/O System station. One
power supply unit is sufficient for normal operation. However, as second
(redundant) power unit can be added to improve the system availability.
The Communication Interface handles and controls all data traffic between the I/O
modules and the supervisory open control system (OCS) or programmable logic
controllers (PLC). The Communication Interfaces (CIPB) can also be provided and
used redundantly (line redundancy and coupler redundancy).
Figure 1-1 S900 I/O System
3BDD010421R0401 A 19
System Features Section 1 Introduction
The termination unit can be installed in the field (when mounted in the appropriate
field housing), in a cabinet, or in a rack in the control room. Note that a certified
field housing approved for protection type 'Increased safety' (EEx e) must be used
when installing the termination unit in a hazardous area. The appropriate ready-
made field housings are available for the S900 I/O System. The system is powered
via special terminals with increased safety on the termination unit. The power
units, the Communication Interfaces, and the I/O modules are plugged into the
termination unit and locked automatically. The power units have a built-in shut-off
mechanism with automatic locking and can be plugged in/removed under power in
zone 1. The field housings may be opened for service and maintenance during
operation. The S900 I/O System does not require a pressurized or flameproof
enclosure and, therefore, is easy to install and to handle.
The termination unit and the power units ensure power supply of the
Communication Interfaces and up to 16 I/O modules. The termination unit provides
all necessary connections. Thus, only the field connections have to be made by the
user. Also, hot swapping of the Communication Interfaces and I/O modules is
possible, i.e. these units can be plugged in or removed under power. This ensures
good replaceability of all active components, and a high degree of flexibility and
user-friendliness.
Field instruments with a type of protection up to EEx ia IIC can be connected to the
I/O modules. At present, up to 16 I/O modules can be run on the same termination
unit. Each I/O module is designed for connecting 2, 4, 6 or 8 field instruments,
depending on the respective model. The I/O modules and the underlying field
instrument level are powered via the termination unit. All intrinsically safe
modules are self-feeding and short-circuit proof. No separate routing level with
additional power units is needed.
®
HART communication in the field with all analog S900 I/O modules is® possible
via a PC or hand-held terminal ®
(HHT). In addition, the special HART variants
allow for a consistent HART communication ®
with the process
®
control system
(PCS). Cyclic transmission of all HART variables, HART diagnostics and
®
(acyclic) configuration of all HART field instruments is possible.
The S900 I/O modules are slot-addressed and, therefore, do not require any
settings. The PROFIBUS address is usually set via three coding switches on the
termination unit. An address change will take effect upon restart of the
communication interface (e.g. by disconnecting the communication interface and
then plugging it in again).
®
The S900 communication interfaces, the I/O modules and the connected HART
field instruments are configured and parameterized via the fieldbus network. No
additional service bus is required. The communication interface and the I/O
modules have built-in LEDs allowing for on-site diagnostics. All diagnostic and
status indicator LEDs comply with DIN EN 60073 and NAMUR NE44.
Additionally, the PROFIBUS diagnostics down to the channel level are provided
via the bus.
20 3BDD010421R0401 A
Section 1 Introduction System Limitations
System Limitations
The S900 I/O System consists of various termination units which can
accommodate up to two power units and up to two Communication Interfaces. Up
to 16 I/O modules can be plugged onto one termination unit, depending on the
model. The I/O modules are 2-channel, 4-channel or 8-channel modules, depending
on the model. Every I/O module type can be plugged into any of the 16 available
slots. Refer to section Power Details of this manual for details about the maximum
configuration of the termination unit and the power limits of the power units.
When using 4-channel HART -modules, communication with up to 64 HART -
field devices is possible. Acyclic configuration and parameterization of all field
instruments is possible without any limitations. For cyclic data transfer of
secondary variables, however, there are limitations resulting from the maximum
length of the PROFIBUS datagram. Refer to the manual for analog HART
modules (see Related Documentation) for details.
3BDD010421R0401 A 21
System Limitation Section 1 Introduction
22 3BDD010421R0401 A
Section 2 S900 System Installation Sites Hazardous Areas
Section 2 S900 System Installation Sites
Hazardous Areas
The S900 I/O System is designed for applications requiring no explosion protection
and for installations in areas with potentially explosive atmosphere. In order to
facilitate the selection of the appropriate S900 I/O System components, the
individual scenarios are described in detail in the following sections.
Classification of Hazardous Areas

Hazardous areas are subdivided and classified in zones according to the occurrence
of potentially explosive atmospheres. The definitions of these zones comply with
IEC/EN60079 Part 10: 'Classification of hazardous areas'. A distinction is made
between the following zones:
Zone 0
Areas with a permanent, long-term, or frequent presence of an explosive

atmosphere consisting of a mixture of air and flammable substances such as gas,
vapors or mist (approximate value: more than 1000 hours / year).
Zone 1
Areas with a likelihood that an explosive atmosphere consisting of a mixture of air

and flammable substances such as gas, vapors or mist is present when the
equipment is operating (approximate value: between 10 and 1000 hours / year).
3BDD010421R0401 A 23
Classification of Hazardous Areas Section 2 S900 System Installation Sites
Zone 2
Areas with no or little likelihood that an explosive atmosphere consisting of a

mixture of air and flammable substances such as gas, vapors or mist is present i.e.
areas where such an atmosphere - if at all - only occurs for a very short time
(approximate value: between 0.1 and 10 hours / year)
Non-hazardous Areas
Areas where potentially explosive atmospheres are not likely to occur at all.
Figure 2-1 Classification of hazardous areas, example
24 3BDD010421R0401 A
Section 2 S900 System Installation Sites Installing S900 I/O System in a Non-hazardous Area
Installing the S900 I/O System in a Non-hazardous Area
Types
Depending on the application, S900 I/O Systems of type N, type B or type S are
suitable for installation in a non-hazardous area. Type N is used for processing
non-intrinsically safe signals, whereas type B and type S is used for intrinsically
safe signals of type "i". The S900 I/O system types are identified by their codes.
Example: termination unit with 16 analog input modules

Code for type N:
Termination unit TU921N
16 modules AI930N
Code for type B:
Termination unit TU921B
16 modules AI930B
Code for type S:
Termination unit TU921S
16 modules AI930S
Fieldbus
When selecting the S900 I/O System type pay special attention to the fieldbus
system instrumentation. The S900 I/O System type N is designed for connection to
a standard PROFIBUS DP in accordance with EN50170. An intrinsically safe
PROFIBUS DP has to be used with the S900 I/O System model S and B. Refer to
section Fieldbus for details about the structure of the two fieldbus systems.
When selecting the appropriate S900 I/O System (type N, type B or type S) pay
special attention to the fieldbus system instrumentation type.
3BDD010421R0401 A 25
Installing S900 I/O System in a Non-hazardous Area Section 2 S900 System Installation Sites
Power Supply
Refer to the data sheets of the S900 power units and to section Mounting and
Connecting the System for details about the power supply requirements. Observe
the applicable national standards and regulations (e.g. IEC60364: Standard for
Electrical Installations of Buildings) when designing and installing the system.
Non-hazardous area
Open control system
PROFIBUS DP Standard
I/O System S900

I/O System S900
Type N Isolating Type S
repeater
Intrinsically safe
Intrinsically safe
Non-intrinsically PROFIBUS DP
I/O signals
safe I/O signals
Zone 2
Non-intrinsically safe circuit,

installed with increased Zone 1
safety
Zone 0
Figure 2-2 Installing the S900 I/O System type N and type S in a non-hazardous area
26 3BDD010421R0401 A
Section 2 S900 System Installation Sites Installing the S900 I/O System in Zone 2
Installing the S900 I/O System in Zone 2
Types
If the S900 I/O System is installed in ATEX zone 2, type S or type B has to be
used. Exclusively connect intrinsically safe I/O signals to the S900 I/O System in
this case. Couplers are available for processing non-intrinsically safe signals.
Installation
When installing the system in zone 2, observe EN50021 and IEC/EN60079-14 and
use an IP 54 (IEC/EN60529) housing. No separate housing is required, if the
installation site (e.g. a cabinet) where the S900 I/O System is installed meets the
requirements of protection type IP 54. Observe the specifications in section Power
Details.
Fieldbus
If the S900 I/O System is installed in zone 2, always use an intrinsically safe
PROFIBUS DP. Refer to Section Fieldbus for details about the structure of the
fieldbus system. (For S900 I/O System type B installation in Zone 2 refer to S900
B-System manual installation guide 3BDD010432).
Power Supply
Connecting the System for details about the power supply requirements. The
installation must be in accordance with IEC/EN60079-14: Electrical Installations in
Hazardous Areas.
3BDD010421R0401 A 27
Installing the S900 I/O System in Zone 2 Section 2 S900 System Installation Sites
Non-hazardous area
Open control system
Isolating To other PROFIBUS DP

repeater devices
I/O System S900 Zone 2

Type S
Intrinsically safe
PROFIBUS DP
Processing of non-
intrinsically safe signals via
Intrinsically safe
couplers
I/O signals
Zone 1
Zone 0
Figure 2-3 Installing the S900 I/O System type S in a hazardous area, zone 2
28 3BDD010421R0401 A
Section 2 S900 System Installation Sites Installing the S900 I/O System in Zone 1
Installing the S900 I/O System in Zone 1
Types
If the S900 I/O System is installed in ATEX zone 1, the system type S has to be
used. Exclusively connect intrinsically safe I/O signals to the S900 I/O System in
this case. Couplers are available for processing non-intrinsically safe signals.
Installation
Exclusively use an approved field housing of protection type 'increased safety EEx
"e" ' in accordance with the EC Type Examination Certificate of the termination
unit, No. PTB 00 ATEX 2156 U (Item 17 b) for installing the system. Observe the
specifications in sections Power Details and Field Housing.
Special requirements have to be met when installing the S900 I/O System in
zone 1. Refer to Sections Power Detailsand Field Housing.
Fieldbus
If the S900 I/O System is installed in zone 1, always use an intrinsically safe
PROFIBUS DP. Refer to Section Fieldbus for details about the structure of the
fieldbus system.
Power Supply
Connecting the System for details about the power supply requirements. The
installation must be in accordance with IEC/EN60079-14: Electrical Installations in
Hazardous Areas.
3BDD010421R0401 A 29
Installing the S900 I/O System in Zone 1 Section 2 S900 System Installation Sites
Non-hazardous area
Open control system
Isolating To other PROFIBUS DP
repeater devices
I/O System S900 Zone 1

Type S A enclosure for hazardous
area is necessary
Intrinsically safe
PROFIBUS DP
Processing of non-
intrinsically safe signals via
couplers
Intrinsically safe
I/O signals
Zone 0
Figure 2-4 Installing the S900 I/O System type S in a hazardous area, zone 1
30 3BDD010421R0401 A
Section 3 Fieldbus Fieldbus Design with Electrical Lines
Section 3 Fieldbus
This chapter describes the fieldbus design for the S900 I/O system. Depending on
the specific application you can use an electrical or combined electrical/optical
fieldbus configuration. The selection criteria are to be matched to the application
(e. g. range, cost, number of bus stations, explosion protection application, etc.).
The chapter contains examples to aid in the selection.
When selecting the fieldbus system you must also consider the application location
of the S900 I/O system (refer to section S900 System Installation Sites).
Fieldbus Design with Electrical Lines
Fieldbus in S900 I/O System Applications Type N
Topology
The following page shows the design of the fieldbus for the type N version of the
S900 I/O system.
Number of Bus Stations
According to EN 50 170 the number of bus stations in the PROFIBUS standard can
be up to 127, if every bus segment is limited by repeaters to a maximum of 32 bus
stations. It must be observed that master units, repeaters, fiber-optic converters,
and operating/diagnostic devices are counted as bus stations. For instrumentation
of larger systems, repeaters can be used to:
increase the number of bus stations that can be connected
electrically isolate the bus stations
bridge longer distances
3BDD010421R0401 A 31
Fieldbus Design with Electrical Lines Section 3 Fieldbus
Non-hazardous area Profibus

DP
Master
More Profibus S900

Profibus DP I/O
DP slaves repeater System
type N
S900 S900
I/O I/O
System System
type N type N
Profibus DP
Bus station with

bus termination
Bus station without

bus termination
S900 S900
I/O I/O
System System
type N type N
Figure 3-1 Type N fieldbus topology
32 3BDD010421R0401 A
Line Type
The standard PROFIBUS line types according to EN 50 170 Part 8-2 are used as
line types for type N applications. Recommended use is line type A, the line type B
also described in EN 50 170 is obsolete and should no longer be used. The line
parameters according to the following table must be observed.
Table 3-1 Bus line parameters
Parameter Line type A
Cable construction Shielded twisted pair
Wire cross-section > 0.34 mm²
Wire diameter > 0.64 mm
Surge impedance 135 to 165 ohms at 3 to 20 MHz
Mutual capacitance < 30 pF/m
Loop resistance < 110 ohms/km
We recommend the use of ABB lines Type CDN110 as shown in list 10/63 in
section 06.46. With the specified line parameters of the standard line (line type A),
the bus segment lengths specified in the following table are determined for the
respective transmission speeds.
Table 3-2 Line lengths per segment
Transmission speed 9.6 19.2 45.45 93.75 187.5 500 1500
in kbit/s
Maximum segment 1200 1200 1200 1200 1000 400 200
length in m
Within a PROFIBUS-DP system only a transmission speed can be selected,

which is supported by all field devices. Depending on the selected transmission
speed, the segment lengths are determined as shown.
Stub Lines
Generally, passive stub lines are to be avoided.

Programming and diagnostic devices that are connected, for example, during
commissioning, are usually connected via own cables that act as stub lines. In such
cases you must use active connection variants (e. g. bus terminals, repeaters, active
lines, etc.).
3BDD010421R0401 A 33
Connectors and Bus Termination
To minimize line reflections and to ensure a defined steady level on the

transmission line, the transmission line must be fitted with a termination resistor
combination at both ends. When using SUB-D connectors for the bus connections,
the termination resistors integrated in the connectors can be used. For the N version
of the S900 I/O system we recommend SUB-D connectors from ABB list 10/63 in
chapter 6.44. The connector with order number BP910S is only provided for
intrinsically safe fieldbus installation of type S version and must not be used here.
It is recommended to use the connector with test jack at the master unit/process
control system, in order to facilitate the connection of diagnostic devices.
When designing the fieldbus system, observe also sections Shielding And
Equipotential Bonding and Redundancy in the Fieldbus System.
34 3BDD010421R0401 A
Fieldbus in S900 I/O System Applications Type S and Type N
Topology
Intrinsically safe
Profibus DP
Bus station with
standard bus termination
Profibus Non-hazardous
DP
Master area
Standard
Profibus DP Bus station without
bus termination
Bus station with

intrinsically safe
bus termination
Profibus More
DP Profibus
Repeater DP Slaves
Profibus Profibus Profibus
DP-Exi DP-Exi DP-Exi
Repeater Repeater Repeater
S900
I/O System
type N
Zone 2
S900
I/O System
type S
Zone 1
S900 S900 S900 S900

I/O System I/O System I/O System I/O System
type N type N type N type N
Figure 3-2 Type S and type N fieldbus topology
3BDD010421R0401 A 35
Intrinsically Safe Fieldbus System
An intrinsically safe PROFIBUS-DP fieldbus system can be realized by using the

appropriate certified components. When selecting the individual components you
must observe that all components fulfill the requirements of the EC Type
Examination Certificates (PTB 00 ATEX 2201 incl. 1st supplement) for RS485
fieldbus system listed for the S900 Process I/O module CI920S with respect to the
safety requirements. For this purpose, the following conditions must be guaranteed:
Maximum values:
Safety-relevant maximum voltage of each bus station: 4.2 V
Safety-relevant total current of all bus stations: 2.66 A
Concentrated capacitances and inductances are not permitted in the bus segment
length.
Other notes:
In intrinsically safe bus segments only those components must be installed that are
marked as intrinsically safe electrical resource or associated electrical resource
according to EN 50 020. The entire fieldbus must be electrically isolated from
other circuits and must be installed and operated in grounded condition. A ground
connection of either of the two conductors A or B along the fieldbus segment is not
permitted.
Number of Bus Stations
On the one hand, the maximum number of bus stations is limited by the explosion-
protection connection data of the individual bus stations. The top limit of the total
current must not be exceeded (refer to section Interconnection). From the
functional point of view, the maximum number of bus stations in a bus segment is
limited to a maximum of 11 (10 S900 Systems and one fieldbus isolating repeater).
36 3BDD010421R0401 A
Line Type
Line type A according to EN 50 039 is to be used with the following linear electric
constants:
L‘/R‘ 15 µH/
Capacitance per unit length 250 nF/km
Stranded wire diameter 0.2 mm
Furthermore, layout and routing of the bus lines must comply with explosion
protection regulations EN 50 014, EN 50 020, and IEC/EN 60 079-14.
We recommend the use of ABB lines with order number CDE110-Ex (color: blue)
as shown in list 10/63 in section 06.46.
With the recommended line the bus segment lengths specified in the following
table are determined for the respective transmission speeds
Table 3-3 Line lengths per segment
Transmission rate in 9.6 19.2 45.45 93.75 187.5 500 1500
kbit/s
Maximum segment 1200 1200 1200 1200 1000 400 200
length in m
Stub Lines
Generally, passive stub lines are to be avoided.
3BDD010421R0401 A 37
Connectors and Bus Termination

Only the certified ABB connector BP910S is permitted for the connection of
intrinsically safe bus segments to the S900 I/O System. Other connectors may
interfere with the explosion protection!
To minimize line reflections and to ensure a defined steady level on the
transmission line, the transmission line must be fitted with a termination resistor at
both ends. Connector BP910S contains an integrated switchable termination
resistor. However, it must be observed that the integrated termination resistor of the
connector is only used on one end of the intrinsically safe bus segment. The
termination resistance at the start of a bus segment must always be provided by a
fieldbus isolating repeater (e.g. BI912S or BI913S or BI914S).
On standard PROFIBUS-DP segments the same rules apply as for the type N
version of the S900 I/O system. Here, too, the use of a connector with test jack at
the master unit/process control system is recommendable for diagnostic purposes.
When designing the fieldbus system, observe also sections Shielding and
Equipotential Bonding and Redundancy in the Fieldbus System.
38 3BDD010421R0401 A
Interconnection
1
UO (1...n) ≤ UI (1...n) ≤ 4.2V
IO 1
∑i=1
IO i ≤ Imax ≤ 2.66A
UO/I 1
UO/I 2 UO/I 3 UO/I n
IO 2 IO 3 IO n
2 3 n
Figure 3-3 Interconnection of the intrinsically safe fieldbus
Procedure for Interconnecting the Components:
Checking the explosion protection:

Check whether all devices (field devices, repeaters/isolating repeaters, fiber-
optic components) comply with directive 94/9 EC Category 2 and to these
operating instructions.
Check the maximum possible total current of all bus stations in a fieldbus
segment: Io components 2.66 A
3BDD010421R0401 A 39
Check the maximum occurring output voltages of all bus stations Uo 4.2 V.
Check the maximum L/R ratio of the cable used. L/R cable 15 µH/ohms
(at minimum ambient temperature of the cable)
Check whether a potential equalization according to EN 60 079-14 12.2.2.3
section b) is present, if required.
Checking the functionality:
Check whether the number of stations per bus segment 11 (field devices and
repeaters/isolating repeaters).
Check whether the bus segment length matches the transfer rate used.
Check whether a termination resistor is fitted at the start and end of each bus
segment (connector BP910S contains an integrated switchable termination
resistor).
Example
The following components should be interconnected for application in explosion

protected areas:
- 1 x fieldbus isolating repeater BI913S
- 10 x S900 I/O system type S version
- line ABB CDE110-Ex
1. Checking the suitability
All components listed above comply with EC directive 94/9 and may only be used
in explosion hazard areas (refer to EC Type Acceptance Certificates).
2. Total current of all bus station 2.66 A
BI913S : Io = 144 mA
S900 CI920S : Io = 157 mA
Resulting total current: Io = 144 mA + 10 x 157 mA = 1.714 A < 2.66 A
3. Maximum output voltage of bus stations 4.2 V
BI913S : Uo = 4.1 V
S900 CI920S : Uo = 3.75 V
4. L/R ratio of the bus line 15 µH/ohms
The bus line used (ABB CDE110-Ex) fulfills this requirement.
40 3BDD010421R0401 A
Section 3 Fieldbus Fieldbus Design with Fiber-optic Lines
Fieldbus Design with Fiber-optic Lines
General
Features of optical transmission media include:
immunity against electromagnetic interference
no crosstalk between different fiber-optic signal lines
no noise injection from electrical lines
no interference through electromagnetic fields, such as occurring when
switching high electrical loads
electrical isolation between connected bus stations
no compensating currents between different ground potentials
no special lightning protection measures for the transmission line
ability to cover long distances at high transmission rates with fiber-optic lines
Substantial components of the optical transmission layer of a bus station are the
electro-optical converters forming the link between electrical part of the interface
module and the optical network. An optical transmitter converts electrical signals
into optical signals and feeds them into the optical network. Vice versa, an optical
receiver converts the received optical signals into electrical signals. The connection
between bus stations is established via fiber-optic lines (FO) within a topology
matched to the application (ring, star, line, or mixed topology).
3BDD010421R0401 A 41
Fieldbus Design with Fiber-optic Lines Section 3 Fieldbus
Fiber Types and Ranges
There are different fiber types with different characteristic features with respect to
range, price, and application area. The following table provides an overview.
Table 3-4 Characteristics of fiber-optic lines for PROFIBUS
Fiber type Characteristics
Glass fiber 62.5/125 µm Range approx. 2,600 m
Glass fiber 50/125 µm Range approx. 1,400 m
Plastic fiber 980/1000 µm Range approx. 50 m
PCS/HCS fiber 200/230 µm Range approx. 1,000 m
Optical Connectors
The FO converters available from ABB (BI923S, BI924S, BI933S) feature
connectors for D-SMA connectors with screw connections.
Application
All FO converters (BI923S, BI924S, BI933S) are suitable for application in
hazardous areas of zone 1 and 2 (see according EC-Type Examination Certificate).
Topologies
In the following, different topologies for designing FO fieldbus systems are shown.
Note that in the illustrations the fiber-optic links drawn as single lines are always
two physical fibers, one each for signal line and return line.
42 3BDD010421R0401 A
Section 3 Fieldbus Fieldbus Design with Fiber-optic Lines
Optical Ring
The optical ring is a special form of optical network. The optical ring is also used
for covering larger distances between several bus stations. For the number of bus
stations refer to the data sheets of the FO components. Unlike the optical network,
the function is still maintained in case of a failure of one fiber-optic link. Please
note, that Profibus Master devices are connected via the BI924S and Profibus Slave
devices are connected via the BI923S resp. BI933S with the optical ring.
Intrinsically safe Bus station with

Profibus Non-hazardous
DP
Profibus DP standard bus termination
Master area
Standard Bus station without
Profibus DP bus termination
Bus station with

FO links intrinsically safe
bus termination
More
Bus station with BI924S BI924S Profibus
FO connection DP Slaves
BI923S BI923S BI933S BI933S
S900
I/O
BI913S/ BI913S/ System
BI914S BI914S type S
S900 S900 S900

I/O I/O I/O
System System System
type S type S type S
Zone 1/2
Figure 3-4 Fieldbus system with an optical ring
3BDD010421R0401 A 43
Redundancy in the Fieldbus System Section 3 Fieldbus
Redundancy in the Fieldbus System

To increase the availability of fieldbus systems, different redundancy types are
used. A distinction is made between master, slave, and line redundancy. Master
redundancy is established independently of the connected bus stations and,
therefore, is not described here any further. The following section details the
physical design of the combined line/slave redundancy supported by the S900 I/O
System.
To design line redundancy, it is required that the two bus lines are coupled at or in
the master. This coupling must be made in such a way that an error on one bus line
does not interfere with the other, still functioning line. For masters not supporting
any corresponding line redundancy, the ABB redundancy link module RLM 01 can
be used (catalog number 72711-9450165V in list 10/63, section 6.41).
Line redundancy in connection with the S900 I/O system also requires the use of
two Communication Interfaces in one S900 I/O System station. To reduce the
space requirements and cost and to improve the energy balance (Ex), S900
Communication Interfaces have only one PROFIBUS connection. However,
through the use of two Communication Interfaces an additional slave redundancy is
established, i. e. the failure or replacement of a Communication Interface does not
affect the operation of the system. With respect to configuration and
commissioning of the system the corresponding documentation is available (refer
to Related Documentation).
44 3BDD010421R0401 A
Section 3 Fieldbus Redundancy in the Fieldbus System
I/O System I/O System

S900 S900
redundant redundant
type N. type S
BI912S/
BI913S/
Intrinsically safe
BI914S
Profibus Profibus DP
DP more S900
1 Master I/O Systems
BI912S/ Standard
BI913S/ Profibus DP
BI914S
FO link
I/O System
S900
redundant Bus station with
type S standard bus termination
BI912S/
BI913S/ Bus station without
BI914S bus termination
Profibus
DP RLM 01 more S900
2 Master I/O Systems Bus station with
BI912S/ intrinsically safe
BI913S/ bus termination
BI914S
Bus station with
FO connection
more fiber-optic
bus stations I/O System
S900
redundant
type S
BI924S BI933S
Profibus
DP more S900
3 Master I/O Systems
BI924S BI933S
more fiber-optic
bus stations
Figure 3-5 Examples for redundant configuration of a fieldbus system
Example 1
Here, line redundancy of the electrical fieldbus system with S900 I/O System
stations is shown with N type B type and S type versions. The master has
redundant fieldbus connections. Separation between the standard PROFIBUS-DP
and the intrinsically safe PROFIBUS-DP is implemented via isolating repeaters
(see also Fieldbus in S900 I/O System Applications Type S).
Diagnosing a faulty bus segment is done by the master. Here, the diagnostic
messages of slaves that switched to the redundant line can be analyzed.
3BDD010421R0401 A 45
Redundancy in the Fieldbus System Section 3 Fieldbus
Example 2
Other than in example 1, the master does not have any redundant fieldbus
connections. In order to establish line redundancy despite this fact, the ABB
redundancy link module RLM 01 can be used.
Diagnosing a faulty bus segment is again done by the master through analyzing the
diagnostic messages of the slaves. In addition, a signaling contact of the RLM 01
could be used.
For details refer to the operating instructions of the RLM 01.
Example 3
In this example the fiber-optic link is configured as a ring.
This arrangement provides extremely high availability. As the optical ring already
inherently tolerates a fault in the fiber-optic link (refer also to Optical Ring), an FO
converter may also fail in a redundant configuration, without affecting the fieldbus.
Diagnosing a defective line can be done again by analyzing the diagnostic
messages of the slaves. In addition, the FO converter provide a signal contact for
the optical ring for evaluating the availability (this allows diagnosing an interrupted
ring).
46 3BDD010421R0401 A
Section 3 Fieldbus Powering Fieldbus Components
Powering Fieldbus Components

The optical and electrical fieldbus components Bixxx described here require their
own power supply. Depending on the installation location, power can be preferably
derived from the power supply of the S900 I/O System or other fieldbus bus
stations. Refer to the data sheets and operating instructions of such components for
the power supply requirements.
When using these components in hazardous areas, the power supply must be
installed in explosion protection type “e” – Increased Safety.
3BDD010421R0401 A 47
Powering Fieldbus Components Section 3 Fieldbus
48 3BDD010421R0401 A
Section 4 Environmental Capabilities and Power Consumption Environmental Capabilities
Section 4 Environmental Capabilities and

Power Consumption
Environmental Capabilities
Explosion Protection
The S900 I/O System is designed to be installed and used in hazardous areas (zone
1 and zone 2) and safe areas. The intrinsically safe circuits of the input and output
modules meet the requirements of categories 1 and 2 (zone 0 and zone 1) in
accordance with IEC/EN60079-10. The operative range in accordance with
94/9/EC must be observed.
When the S900 I/O System is installed in hazardous areas, zone 2, it must be
accommodated in a subsidiary cabinet with protection class IP 54 or higher to
protect it against environmental influences.
When installing the system in zone 1, use a housing that is certified in accordance
with the local regulations for the installation of current circuits with increased
safety. For details about how to select the appropriate field housing refer to section
Power Details and to section Mounting and Connecting the System.
Ambient Temperature
The S900 I/O System components are designed for a maximum ambient
temperature range of –20…+60°C. Make sure that this temperature range is not
exceeded or fallen below, especially when installing the system in housings,
cabinets or racks. If necessary, the ambient temperature has to be monitored. The
maximum values specified here must be especially observed for applications where
explosion protection is required (system type S). Observe the instructions regarding
the determination of the power dissipation and the installation of the system in a
housing given in section Power Details.
The specified ambient temperature range must be observed under all operating
conditions to ensure explosion protection and system availability.
3BDD010421R0401 A 49
Environmental Capabilities Section 4 Environmental Capabilities and Power Consumption
When selecting the installation site, make sure that it is possible to observe the
necessary clearance from other heat sources. Do not expose the system to direct
sun light. Otherwise, the permissible ambient temperature may be exceeded. If
required, take the necessary measures to protect the system accordingly. The
appropriate covers, which at the same time protect the equipment from weather
impact, are available from ABB (catalog number type FR100 see field housing).
When designing/installing sun shields observe the different angles of incidence in
dependence of the season. Avoid heat accumulation under the sun shields.
Mounting Orientation
The S900 I/O System is designed for horizontal mounting orientation to ensure
optimal heat dissipation/ventilation. Other orientations are not intended.
Atmosphere
The parts of the S900 I/O System, including the external metal parts, are made of
high-quality materials and ensure protection against corrosion and resistance to
chemical substances that may occur in a "normal industrial environment". When
using the components in an unknown or aggressive environment, the chemical
resistance of the used materials has to be tested explicitly.
All S900 components are either completely sealed or protected through the
appropriate varnish. Water condensation due to temperature variations or after the
first system cold start is therefore negligible, provided that it only occurs for a short
time.
For detailed specifications regarding the operating environment and the system
capabilities (e.g. resistance to humidity or corrosive gases) refer to the data sheet of
the S900 I/O system.
Shock and Vibration

Refer to the S900 System data sheet for the maximum permissible shock and
vibration to which the system may be exposed.
50 3BDD010421R0401 A
Section 4 Environmental Capabilities and Power Consumption Power Details
Power Details
This section describes how to determine the S900 I/O System power consumption
and power dissipation. This is important to ensure that the specified operating
range is observed and the limit values are not exceeded. The section Procedure
contains the relevant instructions for systematic checks.
Power Limits
The S900 I/O System of type S is provided with a power unit (SA920S) with a
max. power output of 55 W. The efficiency is approximately 84 %. From this
results a maximum total power consumption of the termination unit of
approximately 65 watts. This specification is also valid for redundant power units,
i.e. a higher power consumption in redundancy mode is not permissible.
The system must be equipped in such a way that the total power consumption of
all S900 modules and S900 Communication Interfaces does not exceed 55
watts.
Compared to the previously used power supply SA910S (45 W) the SA920S
(55 W) has a 10 W higher output power.
With an output power of 45 W, the SA920S is specified for an ambient
temperature up to 70 °C. Due to temperature limitations of other S900
components, however, the maximum permissible ambient temperature of the
S900 I/O System is limited to 60 °C.
The S900 I/O System of type N is provided with a power unit (SA920N) with a
max. power output of 60 W. The total power consumption of the modules and the
Communication Interfaces must not exceed 60 watts, or 65 watts with the power
units.
3BDD010421R0401 A 51
Power Details Section 4 Environmental Capabilities and Power Consumption
With an S900 I/O System of type N, the total power consumption of the power
units SA920N in an S900 I/O System station must not exceed the power limit of
70 watts.
With an output power of 45 W, the SA920N is specified for an ambient
temperature up to 70 °C. Due to temperature limitations of other S900
components, however, the maximum permissible ambient temperature of the
S900 I/O System is limited to 60 °C.
When the S900 I/O System is used in a cabinet or field housing, the power output
to the field must be considered when determining the max. permissible ambient
temperature, in order to calculate the power dissipation within the field housing.
The evaluations and specifications in the following section are based on the
following maximum conditions: all channels under full load, no errors, and no
short circuits in the field circuit. Additionally, the load of the field devices can be
considered for optimization. If the load of the field devices is unknown, the
maximum values for which the most disadvantageous load has been taken into
account have to be used.
The maximum number of modules that can be run on a termination unit is given by
the available output power of the power unit.
The total power consumption of all I/O modules and Communication Interfaces
must always be smaller than the maximum output power provided by the power
unit.
The max. number of S900 components that can be run in a field housing is defined
by the maximum permissible power dissipation in the field housing at a given
ambient temperature.
The power specifications of the individual S900 components and field housings are
listed in the following tables.
52 3BDD010421R0401 A
Power Details of Ex Modules (Type S)

Table 4-1 Power details of Ex modules
Order No. Type Power Power Power Conditions
consumption output to dissipation Load of the Field current
[watts] the field [watts] field device [mA]
[watts] [ohms]
Power unit
SA920S SA920S
1 x SA920S 52.00 0.00 5.00 with 45 W output power
SA920S SA920S
Communication Interface
CI920S CIPB-Ex 2.50 0.00 2.50
Digital input/output
DX910S DIO8-Ex 1.10 0.00 1.10
DI920S DI920S 2,00 0,00 2,00
Valve control module
DO910S DO4-Ex 1.80 0.80 1.00 2500
2.00 0.90 1.10 2000
2.20 1.10 1.10 1500
2.30 1.10 1.20 1400
2.50 1.30 1.20 1200
2.90 1.30 1.60 1000
3.00 1.60 1.40 890
3.20 1.70 1.50 780
3.40 1.80 1.60 700
3.50 1.80 1.60 645
3.70 1.70 2.00 620
3.80 1.90 1.90 575
3.90 1.90 2.00 550
4.00 1.90 2.10 510
4.20 2.00 2.20 475
4.30 2.00 2.30 456
3BDD010421R0401 A 53

[watts] [ohms]
4.40 2.10 2.30 440
4.50 2.10 2.40 423
4.60 2.10 2.50 405
4.80 2.20 2.60 380
4.90 2.20 2.70 360
5.00 2.20 2.80 350
5.20 2.20 3.00 310
5.30 2.20 3.10 300
5.60 2.00 3.60 275
Frequency input
DP910S FI2-Ex 1.10 0.00 1.10
Analog input
AI910S AI4-Ex 2.50 1.20 1.30 20
AI920S AI4I-Ex 3.00 1.20 1.80 20
AI930S AI4H-Ex 2.50 1.20 1.30 20
AI931S AI4H-Ex 0.50 -0.40 0.90 20
Temperature input
AI950S TI4-Ex 0.70 0.00 0.70
Analog output
AO910S AO4-Ex 2.50 0.16 2.34 100 20
2.50 0.32 2.18 200 20
2.50 0.80 1.70 500 20
2.50 1.12 1.38 700 20
AO920S AO4I-Ex 3.30 0.16 3.14 100 20
3.30 0.32 2.98 200 20
3.30 0.80 2.50 500 20
3.30 1.12 2.18 700 20
AO930S AO4H- 2.50 0.16 2.34 100 20
Ex
2.50 0.32 2.18 200 20
2.50 0.80 1.70 500 20
2.50 1.12 1.38 700 20
Maximum values shown in bold characters, no closer examination of load required
54 3BDD010421R0401 A
Power Details of non-Ex Modules (Type N)

Table 4-2 Power details of non-Ex modules
[watts] [ohms]
Power unit
SA920N SA920N
1 x SA920N 52.00 0.00 5.00 with 45 W output power
SA920N SA920N
CI920N CIPB 2.70 0.00 2.70
Digital input/output
DX910N DIO8 1.10 0.00 1.10
DI920N DI920N 2.00 0.00 2.00
Valve control module
DO910N DO4 1.80 0.80 1.00 2500
2.00 0.90 1.10 2000
2.20 1.10 1.10 1500
2.30 1.10 1.20 1400
2.50 1.30 1.20 1200
2.90 1.30 1.60 1000
3.00 1.60 1.40 890
3.20 1.70 1.50 780
3.40 1.80 1.60 700
3.50 1.80 1.60 645
3.70 1.70 2.00 620
3.80 1.90 1.90 575
3.90 1.90 2.00 550
4.00 1.90 2.10 510
4.20 2.00 2.20 475
4.30 2.00 2.30 456
4.40 2.10 2.30 440
3BDD010421R0401 A 55

[watts] [ohms]
4.50 2.10 2.40 423
4.60 2.10 2.50 405
4.80 2.20 2.60 380
4.90 2.20 2.70 360
5.00 2.20 2.80 350
5.20 2.20 3.00 310
5.30 2.20 3.10 300
5.60 2.00 3.60 275
Frequency input
DP910N FI2 1.10 0.00 1.10
Analog input
AI910N AI4 2.50 1.20 1.30 20
AI920N AI4I 3.00 1.20 1.80 20
AI930N AI4H 2.50 1.20 1.30 20
AI931N AI4H 0.50 -0.40 0.90 20
Temperature input
AI950N TI4 0.70 0.00 0.70
Analog output
AO910N AO4 2.50 0.16 2.34 100 20
2.50 0.32 2.18 200 20
2.50 0.80 1.70 500 20
2.50 1.12 1.38 700 20
AO920N AO4I 3.30 0.16 3.14 100 20
3.30 0.32 2.98 200 20
3.30 0.80 2.50 500 20
3.30 1.12 2.18 700 20
AO930N AO4H 2.50 0.16 2.34 100 20
2.50 0.32 2.18 200 20
2.50 0.80 1.70 500 20
2.50 1.12 1.38 700 20
Maximum values shown in bold characters, no closer examination of load required
56 3BDD010421R0401 A
Power Details of the Field Housings

According to the specifications in the EC Type Examination Certificate the
maximum permissible ambient temperature of the S900 I/O modules and
components is 60°C. The average inherent heating of the module has been taken
into account for this value. The external ambient temperature at approximately 2
cm above the modules must not exceed 70°C. Otherwise, the permissible internal
module temperature may be exceeded. If the boundary conditions specified below
are not observed, adherence to this limit value must be monitored. The appropriate
equipment has to be provided by the customer.
The table seen below can be used as a guideline in the project planning phase. The
listed values were determined by measurement under observance of the maximum
internal module temperatures specified in the EC Type Examination Certificate.
The specifications are only valid if the stated boundary conditions are observed.
Table 4-3 Maximum permissible power dissipation in the field housing
Maximum ambient
temperature of the 30°C 35°C 40°C 45°C 50°C 55°C
field housing
Field housing type Maximum permissible power dissipation in the
WxHxD field housing
FH64*S
600x400x200, 41 W 37 W 32 W 27 W 21 W 16 W
Stainless steel
FH66*S
600x600x300 50 W 45 W 39 W 33 W 26 W 20 W
Stainless steel
FH68*S
600x800x300, 60 W 54 W 47 W 39 W 31 W 24 W
Stainless steel
* 0…9
3BDD010421R0401 A 57
Boundary Conditions:
The position and mounting orientation of the termination unit is given by the
field housing and must not be modified by the customer
The field housing must be mounted at a minimum spacing of 25 mm from the
fastening wall.
The maximum ambient temperature of the field housing of 55°C must not be
exceeded.
The maximum permissible power dissipation of the field housing (30°C value)
must not be exceeded.
The total power dissipation of additional devices installed in the field housing
(e.g. optical fieldbus isolators) must not exceed a maximum value of 5 watts.
This power dissipation must be handled in the same way as the power
dissipation of a module and has to taken into account when calculating the
power requirements.
The area right above the S900 system must be kept free of any objects.
The total power dissipation of the S900 components (modules, power units,
Communication Interfaces) must not exceed the maximum permissible power
dissipation of the field housing.
The actual internal temperature of the field housing depends on the local conditions
like external radiation (adjacent heat sources, sun light) or dirt accumulation on the
field housing. This must be taken into account. If required, the appropriate
measures have to be taken by the customer. Observance of the above-stated limit
values does not release the user of his duty to monitor the system and check to see
that the permissible ambient temperature is not exceeded.
58 3BDD010421R0401 A
Section 4 Environmental Capabilities and Power Consumption Procedure
Procedure
Follow the instructions below to evaluate/determine the power requirements:
Step 1:
Determine the configuration of every S900 I/O System station (number and
type of I/O modules, redundant Communication Interfaces, power units).
Step 2:
Determine the load parameters (load resistance for DO910, AO9xx).
Step 3:
Determine the total power consumption of all I/O modules and
Communication Interfaces; it must be smaller than the maximum output power
provided by the power unit.
Step 4:
Determine the total power dissipation (S900 I/O System and possible
additional components); it must be smaller than the maximum permissible
power dissipation of the selected field housing or smaller than the maximum
power dissipation that can be carried away under the respective installation
conditions (cabinet, switch room).
The S900 Engineering Tool can be used for performing the steps listed above.
3BDD010421R0401 A 59
Procedure Section 4 Environmental Capabilities and Power Consumption
60 3BDD010421R0401 A
Section 5 Mounting and Connecting the System Mounting the Termination Unit
Section 5 Mounting and Connecting

the System
Mounting the Termination Unit

The S900 I/O System termination unit is mounted on a stable rack or mounting
plate or in a field housing (depending on the application). Fasten the system with 4
screws (M5 to M6, galvanized or stainless steel) and spring washers. Secure the
screws against loosening. Note that this establishes at the same time the
equipotential bonding of the termination unit. Refer to the S900 I/O System data
sheet for the exact dimensions of the termination unit and the mounting slots.
3BDD010421R0401 A 61
Connection Level Overview Section 5 Mounting and Connecting the System
Connection Level Overview

The illustration below shows the connection levels of the S900 I/O System
termination unit.
ABB ABB
CIPB-1Ex CIPB-1Ex AI4H-Ex AI4H-Ex TI4-Ex TI4-Ex DIO8-Ex DIO8-Ex DIO8-Ex DIO8-Ex DIO8-Ex DIO8-Ex DIO8-Ex DIO8-Ex DIO8-Ex DIO8-Ex DIO8-Ex DIO8-Ex
PW PW
Power supply Fieldbus connection Signal circuits
Figure 5-1 Overview of the termination unit connection levels
62 3BDD010421R0401 A
Section 5 Mounting and Connecting the System Power Supply
Power Supply
Terminal Cover and Terminal Assignment

The power connectors on the termination unit of a type S S900 system are
protected by a special cover. Do not open this cover when the system is under
power. After having established the power connection, make sure that the cover is
closed and fastened properly and reliably.
The power connectors on a termination unit of a type N system are directly
accessible.
L+ N- PE L+ N- PE
Figure 5-2 Power terminals on a termination unit with redundancy capability
Use terminals L+, N- and PE for power connection. Two terminals are available
for each connection to enable through-connection. The second terminal block is
only available on termination units with redundancy capability and is used for
connecting a second, independent power source. If a power cable with a protective
ground wire is used, this wire must be connected to the PE terminal.
Wires with the following properties can be connected to the power terminals:
Table 5-1 Properties of the connectable power wires
Wire type Cross-sectional area
Rigid 0.2 – 2.5 mm²
Flexible 0.2 – 2.5 mm²
Flexible with end ferrules 0.25 – 1.5 mm²
3BDD010421R0401 A 63
Power Supply Section 5 Mounting and Connecting the System
Installation
When the S900 I/O System is used in a hazardous area, the electrical installation
must meet the requirements of the protection type "Increased safety".
The requirements defined in IEC/EN60079-14, especially Section 11 (additional
requirements for type of protection "e" – Increased safety) must be met. The
terminals are protected by an IP30 cover. Do not open the cover or disconnect the
terminals when the system is energized. An exception is only possible when a fire
permission is submitted by the plant operator.
Power Distribution, Power System Design
max. cable length
S900
F1 F3 S1
To other
S900 Process I/O
F2 F4 S2
Power supply To other

(power units, UPS) S900 Process I/O
Figure 5-3 S900 I/O System power distribution
64 3BDD010421R0401 A
Setup
The illustration above shows the setup of the power system in a schematic diagram.
Every S900 I/O System station is connected to the central power supply via a
separate line. Every line is fuse-protected (F3, F4) and can be switched on or off
(S1, S2). In redundancy mode, the two power connections of the S900 I/O System
must be realized via two separate, independent lines.
The SA920S and SA920N can bridge power failures on the power terminals (see
Fig. 5-2) for up to 5 ms. Mains power failures, however, must be bridged by the
power supply system.
Additional devices can be used to increase the power supply availability and
improve the bridging times in case of a mains power failure. Among these are
commercial power units, power supply systems, buffer modules and decoupler
modules. The setup and design of these components and devices are beyond the
scope of this manual.
3BDD010421R0401 A 65
Power
The power requirements and efficiency are important for selecting and
dimensioning the power units/UPS systems to be used for the S900 I/O System.
The minimum requirements are listed in the tables below:
Table 5-2 Minimum power requirements S900 I/O System, type S
S900 I/O System, type S

Mode Number of * Minimum Nominal power Nominal
S900 I/O peak output per SA920S power
Systeme power per for Pout=45 W per SA920S
SA920S for Pout=55 W
Single and 1 > 170 W > 70 W > 80 W
Redundancy 2 > 220 W > 130 W > 145 W
mode 3 > 270 W > 190 W > 210 W
4 > 320 W > 250 W > 275 W
5 > 370 W > 310 W > 340 W
*: The used power unit must be capable to deliver the peak output power permanently
without a decrease in the output voltage. In case of doubt this power must be considered as
the nominal power.
66 3BDD010421R0401 A
Table 5-3 Minimum power requirements S900 I/O System, type N
S900 I/O System, type N

Mode Number of S900 I/O * Minimum peak Nominal
Systems output power per power
SA920N per SA920N
for Pout=60 W
Single and 1 > 210 W > 80 W
Redundancy 2 > 275 W > 155 W
mode 3 > 340 W > 230 W
4 > 405 W > 305 W
5 > 470 W > 380 W
*: The used power unit must be capable to deliver the peak output power permanently
without a decrease in the output voltage. In case of doubt this power must be considered as
the nominal power.
The power specified in the table above must be available across the power
terminals of the S900 I/O System, independent of the power cable length. With the
above-specified power the voltage must not be inferior to the minimum supply
voltage of the S900 I/O System (see data sheet SA920S/N). If required, the output
voltage of the used power unit must be increased by adjustment. The series
resistance of the power feed equipment (cables, fuses, switches) must be
considered for this (see next section in this manual).
In redundancy mode, the specified power must be available for each of the two
power units of the S900 I/O System.
We recommend to use the appropriate power unit from ABB, ordering code
V17212-130 (adjustable to up to 28VDC) with 24VDC/10A/240W output.
3BDD010421R0401 A 67
Fuse Protection
Each power supply line should be protected separately (fuses F3 and F4 in the
illustration above). Use slow-blow fuses with a minimum nominal value of 4A.
The maximum value for fuse protection of the power supply to the S900 I/O
System is 10A.
Cable CSA and Length
The CSA and length of the used cables depends on the respective instrumentation
and can be determined by using the specifications above. –The following cross-
sectional areas are recommended under the proviso that the individual S900 I/O
Systems are connected to the external power supply in a star-type topology and that
the power supply is set in such a way that a voltage of at least 24VDC is available
across the power terminals under normal operating conditions.
For cables up to 50 m 2.5mm²
For cables of 50m…100m 4mm² *
For cables of 100m…200m 10mm² *
*: For cables with this cross-sectional area an additional terminal level must be inserted
before the S900 I/O System, or cable pins have to be used, since usually only CSAs up to
2.5mm² are supported.
68 3BDD010421R0401 A
Section 5 Mounting and Connecting the System Signal Circuits
Signal Circuits
Terminals
Markings/Designations
16 terminals are assigned to every module slot of the S900 I/O System.
11 12 13 14 Terminals with either blue (system type S) or black (system type

N) markings are used for the S900 I/O System termination unit.
21 22 23 24
The terminals are labeled as seen in the illustration.
The terminal assignment depends on the used I/O module. Refer
31 32 33 34 to the data sheets or rating plates on the modules for the
respective terminal assignment of a module.
41 42 43 44
Cable CSA
The terminals are designed for the following cable CSAs:

Table 5-4 Cable CSAs that can be connected to the signal terminals
Wire type Cross-sectional area
Rigid 0.5 – 2.5 mm²
Flexible 0.5 – 2.5 mm²
Flexible with end ferrules 0.5 – 1.5 mm²
3BDD010421R0401 A 69
Signal Circuits Section 5 Mounting and Connecting the System
Connecting/disconnecting terminals
Cage-mounted spring terminals are

Open/close clamping
used. The illustration shows the mechanism
opening through which the
clamping mechanism of the
terminal can be opened/closed, and
the opening where the wire is Insert wire
inserted. It is recommended to use a
screw driver with a 0.6 x 3.5 mm
blade in accordance with ISO 2380
/ DIN 5264 for this.
Installation
With an S900 I/O System type S the field current connections must meet the
requirements of protection type "i”. The requirements defined in IEC/EN60079-14,
especially Section 12 (additional requirements for type of protection "i" – Intrinsic
safety) must be met. Intrinsically safe and standard signal circuits must not be
connected to the same termination unit. Use different termination units to ensure
proper separation.
A separate shield bar or cable gland is to be provided for connecting the cable
shields of signal lines (also refer to section Field Housingand section Shielding and
Equipotential Bonding).
70 3BDD010421R0401 A
Section 5 Mounting and Connecting the System Fieldbus Connection
Fieldbus Connection
Connecting the Fieldbus to the Termination Unit

A SUB-D socket is used to connect the fieldbus to the termination unit of the S900
I/O System. For systems with redundancy capability two connectors are provided.
Figure 5-4 Connecting the fieldbus to the termination unit

(second connector only for redundant systems).
Pin Assignment of the Fieldbus Connector
Table 5-5 Pin assignment of the 9-pin D-SUB socket

Pin Signal Description
number
1 Shield Cable shield
2
3 RxD/TxD-P Receive/transmit data, positive, line B
4
5 DGND Bus termination, negative
6 VP Bus termination, positive
7
8 RxD/TxD-N Receive/transmit data, negative, line A
9
3BDD010421R0401 A 71
Fieldbus Connection Section 5 Mounting and Connecting the System
Installation
With an S900 I/O System type S the fieldbus connections on the termination unit
must meet the requirements of protection type "i”. The requirements defined in
IEC/EN60079-14, especially Section 12 (additional requirements for type of
protection "i" – Intrinsic safety) must be met.
Also observe the specifications in section Fieldbus of this manual.
Fieldbus Connector
Follow the instructions below to connect the fieldbus:
Connect the fieldbus cable to the fieldbus connector as specified in the
instruction leaflet delivered with the connector.
Plug the bus connector onto the appropriate D-SUB connector on the
termination unit.
Fasten the bus connector with the respective screws.
If the bus connector is located at the start or end of a bus segment, activate the
terminating resistor (switch position "ON").
Make sure that the bus stations where the terminating resistors are activated are
always under power when the system is starting up or is running.
Different connector types have to be used, depending on the S900 I/O system
type. Observe the specifications in section Fieldbus.
Unused Bus Connectors

If a bus connector is disconnected, it must be protected from getting into to contact
with other current circuits or with the equipotential bonding conductor. Either a
mechanical fixation or an insulation can be used for this purpose.
Marking the Fieldbus Cables

The following table shows the fieldbus markings. The two lines of a PROFIBUS
DP are used as an example. The markings may be different for other devices.
Table 5-6 Fieldbus cable markings
Cable Color Marking 1 Marking 2 Marking 3
Receive/transmit data, positive Red Line B P +
Receive/transmit data, negative Green Line A N -
72 3BDD010421R0401 A
Section 5 Mounting and Connecting the System Field Housing
Field Housing
S900 I/O Systems used in hazardous areas or in a rugged industrial environment
must be protected by field housings. The appropriate empty housings or complete,
approved field housings with the S900 I/O System already installed are available
from ABB.
Using the Empty Housing FHxxx

Various empty housings are listed in the data sheet for the S900 I/O System. These
housings are approved for use in hazardous areas and have a certificate of
conformity or EC Type Examination Certificate. The applicable instructions and
directives for using these housings are given in the following section.
Selection
The following facts are important for the selection of a field housing.
Housing size: The housing must be dimensioned in dependence of the
estimated power dissipation of the S900 I/O System and possible additional
components (also refer to Power Details of the Field Housings).
Configuration: The housings are available with different cable entry types.
This fact has to be considered when selecting the appropriate housing.
Material: e.g. Stainless steel 1.4301
Installing the S900 I/O System in the Housing
Install the S900 I/O system in the intended position in the empty field housing. Do
not install it in another position. Otherwise, proper heat dissipation is no longer
ensured. Fasten the system by using four stainless steel screws (M6) and spring
washers. Note that the equipotential bonding between the S900 I/O System and the
field housing is established at the same time. Observe the determined power limits
when selecting the S900 I/O System modules to be installed on the same
termination unit.
3BDD010421R0401 A 73
Field Housing Section 5 Mounting and Connecting the System
Additional Components
Additional components (e.g. FO converters, terminals, switches, overvoltage

protectors, etc.) may be installed in the field housing in the respective positions.
Observe the maximum permissible power dissipation in the field housing. Make
sure that the total power dissipation of all additional components and the S900 I/O
System does not exceed the limit values specified in section Power Details of the
Field Housings. If the equipment is to be used in hazardous areas, make sure to use
components that are designed for the application and meet the respective
requirements. Observe the specifications regarding the ambient conditions, and the
instructions in the operating manuals and the EC Type Examination Certificate of
the components.
Wiring
The internal wiring inside the field housing must be in accordance with the
applicable national standards, and with EN50019, EN50020 and IEC/EN60079-14
when the equipment is used in hazardous areas. Observe the instructions in the
operating manuals of the individual components for the connection of the
cables/wires. Do not lay intrinsically safe current circuits together with current
circuits that are not intrinsically safe. Preferably use cable ducts.
Intrinsically safe current circuits of equipment used in hazardous areas must be
marked accordingly. When using a color code, it is recommended to use blue color
to identify intrinsically safe circuits. Current circuits that are not intrinsically safe
must be protected with an IP30 (minimum requirement) cover according to
IEC/EN60529 and have to be provided with the appropriate warning.
Connecting the Power and Signal Lines
Follow the instructions in section Mounting and Connecting the System. Insert all
cables through the respective cable glands and strip off the cable sheath along the
specified length. Connect the cables/wires according to the terminal assignment.
Make sure that the diameter of the used cables does not exceed the permissible
cable diameters of the cable glands. After the installation is finished, the cable
glands have to be tightened thoroughly and checked for proper fitting of the cable.
Unused cable glands must be closed with the certified plugs with type of protection
"increased safety".
74 3BDD010421R0401 A
Connect the cable shields and integrate the field housing in the equipotential
bonding system as described in section Shielding and Equipotential Bonding of this
manual.
Observe the electrical specifications and the connection instructions given in the
operating manuals of the devices and components. Additionally observe the
applicable national standards and section Safety Summary of this manual.
Cable Strain Relief
The appropriate strain relief equipment must be provided under the housings for all
cables connected.
Mounting the Field Housing
The housings are delivered with mounting brackets. Use the appropriate screws to
fasten the housings to the mounting rack or wall. Select the appropriate screws and,
if necessary, wall plugs in dependence of the housing weight.
The mounting bracket is designed in such a way that a spacing between the housing
back and the wall is given. Use additional spacers to increase this air gap to at least
25 mm. Always keep this air gap on the housing back free from any objects like
covers or other material to ensure proper ventilation. Make sure that air can pass
freely. If possible, the housing should be mounted to a freely positioned rack
instead of the wall, where free air circulation on the back side is possible. Observe
the specified mounting orientation (S900 mounted horizontally, cables entered
from the bottom side).
When selecting the installation site observe the specified Environmental
Capabilities. See to it that the necessary spacing from heat sources is observed and
direct exposure to sun light is avoided. Otherwise the ambient temperature might
exceed the permissible range. If necessary, re-arrange the equipment. Use sun
shields to prevent direct exposure to sunlight. When designing/installing sun
shields observe the different angles of incidence in dependence of the season.
Avoid heat accumulation under the sun shields.
Additionally, it is recommended to protect the equipment against weather impact.
3BDD010421R0401 A 75
Cleaning After Mounting
Upon mounting and prior to commissioning the electrical equipment has to be

cleaned. Remove dust accumulation, cable pieces, insulating material, and
mounting material like screws, connectors, tie wraps, etc, that is not needed.
Remove all objects that may obstruct air vents. Check to see that the inlet of the air
conditioning system is clean. Clean if required.
Verification and Approval
The field housing and the installed components must be submitted to a verification
and approval. Only if the equipment passes this acceptance test it may be used in
hazardous areas. The test can be performed separately by an expert in accordance
with ElexV (regulation for electrical plants in hazardous areas) or during the final
acceptance test of the entire plant.
Upon installation and mounting, field housings must be submitted to the

relevant acceptance test for equipment to be used in hazardous areas.
As a rule, the following checks are performed on ABB installations and

documented in individual test reports.
Check if all used components are suitable for the intended application (marking
of electrical equipment).
Check if all instructions in the operating manuals and EC Type Examination
Certificates of the components have been observed.
Check if the Power Details for the S900 I/O system and the Power Details of
the Field Housings have been considered and the specified limits have been
observed.
Check if the installation complies with the regulations of EN 50014, EN50019,
EN50020, IEC/EN60079-14 and the instructions in this manual.
Check for complete and correct documentation (wiring diagrams, assembly
drawings, operating instructions for the components, EC Type Examination
Certificates, certificates of conformity for all components).
76 3BDD010421R0401 A
Maintenance and Dismounting
The housing may be opened for operation and maintenance during operation, even
in the hazardous area.
The S900 I/O System components (I/O modules, Communication Interfaces, power
units) may be removed/plugged in during operation under the proviso that the
instructions in section Components Assembly and Commissioning are observed.
Do not open current circuits that are not intrinsically safe while the system is
running. Do not remove the cover and warning on the respective terminals,
components and cables when the system is energized. When disconnecting fieldbus
links, be sure to consider all possible effects an other devices connected to the
fieldbus.
The field housing may only be dismounted when the power supply is switched off
and when no field signals are applied or when the plant is in a safe mode.
Using Cabinets
The appropriate, completely installed cabinets i.e. field housings with already
installed and wired components are available from ABB. The operating
instructions and documentation of these cabinets must be observed.
3BDD010421R0401 A 77
78 3BDD010421R0401 A
Section 6 Components Assembly and Commissioning Selecting and Combining Components
Section 6 Components Assembly and

Commissioning
This section describes the assembly and initial start of the S900 I/O System
components. For details about connecting the system to an open control system and
commissioning please refer to section Related Documentation or direct to
documentation of the used open control system.
Selecting and Combining Components

When selecting the components pay special attention to the type and the intended
use (see S900 System Installation Sites). For every type S component there is a
corresponding component of type N which has exactly the same functionality. On
the contrary, some components of type N do not have an equivalent of type S.
Refer to the data sheets for details.
Do not mix components of different types. All components (termination unit,

power units, Communication Interfaces and I/O modules) must be of the same
type (either N, B or S).
Notes on Explosion Protection

Every S900 I/O System module and termination unit has a separate EC Type
Examination Certificate. The certificates are matched with each other. It is not
necessary to deliver a special "Proof of intrinsic safety" for the internal connections
between the individual modules and the termination units, since this has already
bee evaluated by the verifying authorities and documented in the respective EC
Type Examination Certificates under item 15. The individual internal current
circuits are evaluated in the EC Type Examination Certificate PTB 00 ATEX
2156U for the termination units. As a result, all S900 I/O System components can
be used together without requiring further evaluations or tests on the customer side.
3BDD010421R0401 A 79
Power Units Section 6 Components Assembly and Commissioning
Power Units
Power Units of Type S

The power unit of type S (SA920S) has an automatic locking mechanism to ensure
explosion protection. The power unit is only switched on when all four fastening
screws are fixed. These locking screws must be fastened carefully and evenly.
The following procedure/step sequence must be observed when commissioning or
replacing a power unit:
Table 6-1 Commissioning/replacement procedure of type S power unit SA920S
Prerequisite The power supply has been installed according to
Chapter 5. Mounting and Connecting the System
Section Power Supply.
Action Procedure
Commissioning the power 1. Switch on the power.
unit 2. Plug the power unit SA920S onto the
termination unit.
3. Fasten the screws, the power unit is switched
on automatically -> PW LED lights up green.
Replacing a power unit 1. Undo the fastening screws.

2. Remove the power unit.
3. Plug in the new power unit.
Do not connect or disconnect supply cables under power. Make sure that the
IP30 terminal covers are mounted.
In redundancy mode the same order must be observed for commissioning or

replacement.
80 3BDD010421R0401 A
Section 6 Components Assembly and Commissioning Power Units
Power Units of Type N

The power unit of type N (SA920N) has an automatic locking mechanism to ensure
explosion protection. The power unit is only switched on when all four fastening
screws are fixed. These locking screws must be fastened carefully and evenly.
The following procedure/step sequence must be observed when commissioning or
replacing a power unit:
Table 6-2 Commissioning/replacement procedure of type N power unit SA920N
Prerequisite The power supply has been installed according to
Chapter 5. Mounting and Connecting the System
Section Power Supply.
Action Procedure
Commissioning the power 1. Switch on the power.
unit 2. Plug the power unit SA920N onto the
termination unit.
Replacing a power unit 1. Undo the fastening screws.

2. Remove the power unit.
3. Plug in the new power unit.
In redundancy mode the same order must be observed for commissioning or

replacement.
3BDD010421R0401 A 81
Power Units Section 6 Components Assembly and Commissioning
Replacing the SA910 with the SA920

The SA920 power supply unit (types S and N) replaces the SA910 (types S and N)
and can also be used in already existing plants, provided that the following basic
conditions are fulfilled:
Mixed Operation
Mixing SA920 and SA910 power supplies on the same termination unit is
impermissible.
Power Details
If the power details specified in the I/O System Mounting and Installation Manual
(3BDD010421R0201) have been observed when using the SA910, these details are
also valid for the SA920.
Power Requirements
It is not necessary to re-calculate the power requirements for SA920S if a

maximum output power of 45 W is not exceeded for supplying the bus couplers
and I/O modules on a termination unit.
Power Supply Filter
The power supply filter BP901S is no longer required for SA920S. Running the
SA920S with preceding power supply filter BP901S is nevertheless permissible.
82 3BDD010421R0401 A
Section 6 Components Assembly and Commissioning Power Units
How to Procede for Replacing the Power Supply Units
Order Comment
1. Switch off power supply. S1, S2 acc. to Fig 5-3:
Power distribution for the I/O System S900.
With redundant power supply units, both
SA910 modules on a backplane must be
switched off at the same time.
2. Remove the SA910. Undo the fastening screws and pull out the
power supply unit(s).
3. Switch on the power supply. Close S1, S2 acc. to Fig 5-3:
Power distribution for the I/O System S900
4. Install the SA920. Plug in the power supply unit(s) and fasten
the screws. The power supply unit is switched
on -> PW LED lights up green
For I/O System 900 backplanes with redundant power supply units a seamless
replacement of the SA910 with SA920 units is not possible. As a result, the
corresponding plant section must be switched off.
3BDD010421R0401 A 83
Modules Section 6 Components Assembly and Commissioning
Modules
Selecting the Modules
Observe the technical specifications in the applicable data sheets for the selection
of the modules. When using modules of type S or type B resp., observe the
regulations in IEC/EN60079-14, especially section 12 (additional requirements for
the type of protection "i” – Intrinsic safety).
Replacing a Module
The S900 Remote I/O System termination units are designed for accommodating
up to 16 I/O modules. The modules can be removed and plugged in while the
system is running. It must, however, be taken into account that the affected
channels generate a diagnostic message in the open control system and that, in case
of an output module, the field devices can no longer be triggered. Prior to removing
or plugging in a module, the user must make sure that no dangerous or unexpected
conditions or states of the plant may occur.
Field Circuits
A module should only be replaced with another module of the same type (check
catalog number). When using a different module type, the interconnection with the
field device must be checked and evaluated again. This is especially important for
modules of type S or type B resp.. In this case, the intrinsically safe interconnection
needs to be examined carefully.
Number of Modules
The maximum number of modules that can be plugged onto a termination unit is
limited by the maximum power output of the power units and by the maximum
permissible power dissipation which depends on the installation conditions.
Observe the specifications in section Power Details.
Slot
Exclusively plug the modules into the dedicated module slots. Plugging a module
into a Communication Interface slot is not permitted and may damage the module
and/or termination unit.
Special attention has to be paid when connecting/disconnecting feeding input
modules (DX910, AI910, AI930). If they are plugged in the wrong slot, they may
cause unwanted switching actions of the connected actors.
84 3BDD010421R0401 A
Section 6 Components Assembly and Commissioning Communication Interface
The appropriate Communication Interface has to be selected according to the used
S900 I/O system type (S, B or N). The Communication Interface can also be
removed/plugged in while the system is running. The following instructions have
to be observed.
Single Mode (No Redundancy)

In single mode fieldbus communication is no longer possible once the
Communication Interface has been removed. The output modules follow the
substitution value strategy defined before.
Redundancy Mode
In redundancy mode (i.e. two Communication Interfaces and two fieldbus links are
used, redundancy toggle from the open control system is possible) one of the
Communication Interfaces can be replaced. A diagnostic message related to the
missing Communication Interface is generated.
Slot
Exclusively plug the Communication Interfaces into the dedicated
Communication Interface slots. Plugging a Communication Interface into an
I/O module slot is not permitted and may damage the Communication Interface
and/or termination unit.
Setting the Address

Refer to the manual for the CI920 Communication Interface of the S900 I/O
System.
3BDD010421R0401 A 85
Unlocking and Encoding Section 6 Components Assembly and Commissioning
Unlocking and Encoding
Unlocking the Modules and the Communication Interfaces

The modules are fastened on the termination unit be simply plugging them in the
dedicated slots. When plugging in a module, make sure that the brackets of the
termination unit slide into the respective guides on the module top and bottom side.
Push in the modules until the brackets snap in (audibly and visibly) at the top and
bottom side of the module.
To undo this lock, slightly lift off the brackets at the top and bottom side of the
module and pull out the module. Pull out the module evenly and straight.
Encoding the Housings

The I/O module and Communication Interface housings are provided with an
optionally usable mechanical encoder. It can be used to identify the units clearly
and avoid that they are inadvertently plugged in a wrong slot.
The coding pins must be inserted on the module back and in the slots of the
termination unit (see the illustration below). They can be turned and set to 6
positions, each. The positions of the upper and lower coding pins on a module
should be identical. As a result, there are six possible codes (see illustration).
86 3BDD010421R0401 A
Section 6 Components Assembly and Commissioning Unlocking and Encoding
Coding position 1 Coding position 2
Figure 6-1 Encoding the module housing
The following table provides some suggestions for encoding the individual module
types
Table 6-3 Module type codes
Module type Coding position
Communication Interface Coding position 1
Analog input module AI…. Coding position 2
Analog output module AO… Coding position 3
Digital input module DIO…/FI… Coding position 4
Digital output module DO… Coding position 5
Temperature module TI… Coding position 6
3BDD010421R0401 A 87
Using Hand-held Terminals (HART ) Section 6 Components Assembly and Commissioning
Using Hand-held Terminals (HART )

The S900 I/O system permits to run a hand-held terminal (HHT) or another
HART operating terminal in parallel. The HART terminal can be directly
connected in parallel with the signal circuits. There is no need to connect an extra
resistance into the circuit. The following modules support the connection of a
HART terminal:
AI910/930/931 type S, B and N
AO910/920/930 type S, B and N
When using the HART terminal together with S-type modules (intrinsically safe
circuits), make sure that the intrinsic safety of the circuit is maintained when
circuits are interconnected. The Ex-specifications of the HART terminal must be
considered.
When using HART terminals together with an S900 I/O System type S and
type B, observe the standards and regulations pertaining to the interconnection
of intrinsically safe current circuits (see EN50039).
88 3BDD010421R0401 A
Section 6 Components Assembly and Commissioning Using Hand-held Terminals (HART )
Figure 6-2 Connecting a HART terminal to type S
When parameterizing and configuring field devices with the HART terminal,
make sure that no unintended or dangerous conditions or states of the plant may
occur.
Using a HART terminal may cause dangerous inconsistencies between the

database of the open control system and the field device's parameter data set.
It is therefore recommended to use the HART terminals for local monitoring,

only, or to avoid using them. The S900 I/O System permits to access all HART
data via the central Engineering Tool. This way is much easier and more
convenient. The risk of data inconsistencies implied by HART terminals is
reliably avoided by using the Engineering Tool.
3BDD010421R0401 A 89
Using Hand-held Terminals (HART ) Section 6 Components Assembly and Commissioning
90 3BDD010421R0401 A
Section 7 Shielding and Equipotential Bonding Introduction/Basic Requirements
Section 7 Shielding and Equipotential

Bonding
Introduction
The S900 I/O System S900 meets the EMC protection requirements for industrial
areas. Compliance with the respective directives is documented by the CE mark in
accordance with EC Directive 89/336/EC . Additionally, the S900 I/O System
meets the requirements of the NAMUR recommendation NE 21.
The ensure compliance with to the above-mentioned EMC requirements, the
following installation and commissioning instructions must be observed for the
entire automation system (open control system, S900 I/O System, field devices,
grounding, shielding, cabling and connecting equipment). When using the
equipment in hazardous areas, observe the instructions in the respective section of
the regulation IEC/EN60079-14: "Electrical Installations in Hazardous Areas".
Basic Requirements
Exclusively use devices with CE mark according to EC Directive 89/336/EC.
Ground cable shields in a sufficiently large area. Use shield clamps or cable
glands with shield rest.
Establish a connection to an equipotential bonding system
When connecting the cable shields, establish a low-impedance connection, to
reduce the effect of high interference frequencies. This also applies to the
grounding connection of the device. Usually, connections via long conductors
(e.g. grounding conductors, functional grounding conductors, equipotential
bonding conductors) do not meet these requirements.
3BDD010421R0401 A 91
Overview Section 7 Shielding and Equipotential Bonding
Overview
The illustration below shows a schematic diagram of the equipotential bonding.
2
1 ABB
PW
ABB
PW
8
24 V DC
7 6
5 3
PROFIBUS DP
ABB ABB
PW PW
5 3
Non hazardous area

Zone 1/2
Figure 7-1 Equipotential bonding
92 3BDD010421R0401 A
Section 7 Shielding and Equipotential Bonding Overview
Explanation:
1. Connection to functional ground/protective ground at a central point of the
switch room
2. Equipotential bonding system within the plant, including all metal parts
3. Connection of the signal cable shields to the field housing via shield cable
glands. Alternatively, a shield bar connected to the field housing can be used.
4. No connection of the signal cable shield on he field device side.
5. Connection of the fieldbus cable shield to the shield bar or cable entry through
shield cable gland Connection of the cable shield to the shield clamp integrated
in the fieldbus connector.
6. Connection of the field housings to the equipotential bonding system
7. Connection of the equipotential bonding system of the plant to the functional
ground/protective ground in the switch room (optional).
8. Direct connection of the functional ground/ shielding for the S900 power units
to the central power supply.
Termination Unit
Use a cable with the same cross-sectional area (at least 4 mm²) to connect the S900
I/O System termination unit to the equipotential bonding system. If field housings
are used, there is already a fixed electrical connection between the termination unit
and the field housing. With this, the field housing becomes a part of the
equipotential bonding system and must be connected to it with the same cross-
sectional area. If non-conducting field housings are used, the S900 termination unit
must be directly connected to the equipotential bonding system.
Power Supply
The power connector of the S900 termination unit is provided with a clamp for the
connection of functional ground. Preferably, the functional ground is derived from
the central power supply and then brought to the S900 I/O System as a PE wire
(marked green/yellow) in the supply line. No functional grounding is required for
the 24 V version of the S900 power unit. When using the equipment in hazardous
areas, make sure that the functional ground conductors are laid and connected in
accordance with the requirements of protection type "Increased Safety EExe".
3BDD010421R0401 A 93
Fieldbus
In order to ensure optimal shielding and grounding, the S900 I/O Systems and the
fieldbus cable shields must be connected to the equipotential bonding system
several times. This method yields optimal results regarding the electromagnetic
compatibility and may be used without any limitations in hazardous areas to
IEC/EN60079-14 Section 12.2.2.3 in plants with "a high degree of guaranteed"
equipotential bonding in the entire installation. It should be taken into account that
an equipotential bonding system is mandatory in hazardous areas to comply with
IEC/EN60079-14, Section 6.3. In addition to the measures specified in this
standard (e.g. integration of protective ground conductors, protective tubes, metal
cable shields, cable armors and metal parts in the equipotential bonding system) the
following measures can be used:
Laying fieldbus cables on metal platforms
Integrating the cable platforms in the equipotential bonding system
Establishing safe, current-carrying, low-impedance (seen under high-
frequency aspects) connections between the cable platforms and between
cable platforms and metal parts.
However, it must be ensured that the compensating currents do not damage the
fieldbus cable and, when used in hazardous areas, do not cause igniting sparks.
Refer to IEC60079-14 for details.
The fieldbus cable shields are connected to a shield bar linked with the
equipotential bonding system. Make sure that the shield is not interrupted and is
directly connected to the shield clamp integrated in the fieldbus connector (see also
section Fieldbus Connector).
94 3BDD010421R0401 A
Section 7 Shielding and Equipotential Bonding Overview
Open control Isolating

system / master transformer
S900 S900 S900

I/O System I/O System I/O System
Functional/ Equipotential bonding

protective ground
Non-hazardous area Hazardous area
Figure 7-2 Equipotential bonding of the fieldbus, detailed illustration

In order to avoid that impermissible energy potentials are transferred into the
hazardous area, either the equipotential bonding conductor must be continued until
reaching the start of the fieldbus segment in the non-hazardous area (see the
illustration above), or the cable shield must be connected "safely" (see illustration
below) at all transition points between the safe and the hazardous area. "Safe"
means that all wires of the cable shield are twisted and protected from being fanned
out by an end ferrule and are then connected to the respective screw terminal. The
cable shield connections within the hazardous area are not relevant for safety
issues. These connections ca be established by using standard shield clamps (bow
contacts).
Open control Isolating
system / Master transformer
S900 S900 S900

I/O System I/O System I/O System
Functional/ Equipotential bonding

protective ground
Non-hazardous area Hazardous area
Figure 7-3 Equipotential bonding at the transition point to the hazardous area
3BDD010421R0401 A 95
Signal Circuits
The S900 I/O System meet the requirements of the EC Directive 89/336/EC (CE
marking) and of the NAMUR recommendation NE21 even without using shielded
signal cables for connection to the field devices. This is sufficient for typical
industrial environments where only devices that meet the above-stated directives
are installed. If higher requirements regarding EMI/RFI shielding have to be met, it
is recommended to use shielded signal cables and to connect the cable shield on
one side to the shield bar integrated in the termination unit or provided separately
in the field housing. The shield bar must be connected to the equipotential bonding
system. If a metal field housing connected to the equipotential bonding system is
used, the signal cable shield can also be connected by using the appropriate cable
glands.
How the shields are connected to the field device depends on the field device
requirements and the plant design. If the shields need to be connected on both
sides, it is important to ensure proper equipotential bonding in hazardous areas. It
is not permissible to directly connect the cable shield on both sides in a hazardous
area if sufficient equipotential bonding is not ensured. In these cases capacitive
connection of the shield is a possible solution for increasing the electromagnetic
compatibility.
Field Housing
If a metal field housing is used, it has to be integrated in the equipotential bonding
system. If nonmetallic housings are used, the built-in components (termination
unit, shield bars, etc.) must be connected separately to the equipotential bonding
system.
96 3BDD010421R0401 A
Section 7 Shielding and Equipotential Bonding Cable and Wire Layout
Cable and Wire Layout
General
Although current circuits laid in parallel in the same metal transmission line may
be independent of each other, there is nevertheless a capacitive and/or inductive
coupling between them, due to the line geometry and the material properties. The
intensity of this coupling and, thus, the intensity of possible interference depends
on the spacing between and the overall length of the conductors laid together. As a
rule, it is recommended to lay signal lines not too close to power lines.
In order to avoid unwanted effects, it is useful to plan the cable layout in

dependence of the electrical properties and the current circuits to be connected. The
cables/lines of current circuits with similar operating levels, terminating impedance
and interference properties should be grouped in tightly packed cable bunches.
These cable bunches should be laid with a spacing of approximately 20 cm.

Usually, the interference between them is already sufficiently low with this
spacing. According to EC/EN60079-14 intrinsically safe and not intrinsically safe
circuits may be realized in the same cable bunch if the cables are protected by
grounded shields that are separated from each other or if the cable insulation of the
intrinsically safe circuits meet special requirements.
Power Cables
Inside and outside the cabinets and racks the power cables must always be laid
separately from other metal transmission lines. The local standards and regulations
for the installation must be observed. For power cables laid in hazardous areas the
requirements defined in IEC/EN60079-14:, Section 11 (Additional requirements
for the type of protection "e” – Increased safety) must be observed additionally.
3BDD010421R0401 A 97
Cable and Wire Layout Section 7 Shielding and Equipotential Bonding
Field Signal Lines
It is recommended to consider the following criteria for the field signal line layout:
The following current circuit should not be realized in the same cable trunks:
Input circuits and output circuits
Analog/digital circuits with static switches and digital circuits with mechanical
contacts.
Circuits with type of protection "Intrinsic safety" and circuits that are not
intrinsically safe.
Note that the feed and return lines of the current circuits should always be laid in
the same cables. The wire pairs should be twisted, to reduce the surface of the
circuit loops.
Additionally, the electrical specifications and connecting instructions given in the
manuals of the respective devices and the applicable national standards and
regulations must be observed.
FO Cables
To avoid mechanical damage, FO cables must always be laid separately from other,
metal-type transmission cables. Due to the different physical transmission method
and interference properties no minimum spacing has to be observed. It must,
however, be noticed that FO cables are only flexible to a certain extent. They may
be bent slightly, but not kinked. The bending radius specified by the FO cable
vendor must be observed. A protecting tube must be used to protect underground
FO cables from decay and mechanical damage.
98 3BDD010421R0401 A
Section 7 Shielding and Equipotential Bonding Lightning and Overvoltage Protection
Lightning and Overvoltage Protection

In accordance with IEC61312 lightning protectors are further subdivided in:
External Lightning Protectors

e.g. capturing equipment and lightning arresters in the open-air area and the
corresponding grounding equipment
Internal Lightning Protectors

e.g. potential equalizers and charge eliminators, building shields
Overvoltage Protection
e.g. room shields, cable shields, and overvoltage arresters
External and internal lightning protectors are part of the buildings at the
customer site and are, therefore, not included in the ABB product range. The
measures listed below, however, assume that the appropriate internal and
external lightning protection equipment is present and functioning.
Protection Through Shield Grounding

It is possible to reduce transient overvoltage by limiting the cable length that might
be affected by partial lightning current. The cable shield should be connected on
both sides - and possible directly at the transition points between protected and
unprotected areas or directly at the sensors and actors in the unprotected area - to
the equipotential bonding system. The distance between the two grounding points
defines the influenced line length.
3BDD010421R0401 A 99
Lightning and Overvoltage Protection Section 7 Shielding and Equipotential Bonding
Overvoltage Protection Equipment

Generally, overvoltage protectors must be inserted in the line between the
unprotected areas and the components to be protected. To ensure proper protection
of the S900 I/O System components, the overvoltage protectors should be placed at
the point where the cable enters the building. If the sensors or actors in the field are
to be protected as well, additional overvoltage protectors are required. These
should be installed close to the actors/sensors.
The following overvoltage protection equipment is available from the listed
suppliers.
Table 7-1 Overvoltage protectors
S900 I/O System, type N

Protection of… Overvoltage protector Catalog number *
Communication Basic part BAS 919 506
Interface CI920N Lightning ductor CT Type MD 919 570
PROFIBUS-DP, HF 5
standard version Shield fastener for bus cable 919 508
EFK BCT
All I/O module signal Basic part BAS 919 506
circuits Lightning ductor CT Type MD 919 544
30
S900 I/O System, type S

Protection of… Overvoltage protector Catalog number *
Communication Basic part BAS EX 919 507
Interface CI920S Lightning ductor CT Type MD 919 583
PROFIBUS-DP, HFD 6 919 508
intrinsically safe Shield fastener for bus cable
EFK BCT
All I/O module signal Basic part BAS EX 919 507
circuits Lightning ductor CT Type MD 919 581
intrinsically safe EX 30
* These components are available from :

DEHN + SÖHNE GmbH & Co. KG
Elektrotechnische Fabrik
Hans-Dehn-Strasse 1
D-92306 Neumarkt
http://www.dehn.de
100 3BDD010421R0401 A
Section 7 Shielding and Equipotential Bonding Lightning and Overvoltage Protection
Additional information
All connections to the equipotential bonding system should be made by using the
shortest path and with a big contact surface. Metal cable clamps which
concentrically press the shield onto the (grounded) surfaces are suitable.
All lightning and overvoltage protection measures must be in accordance with
IEC/EN60079-14.
3BDD010421R0401 A 101
Lightning and Overvoltage Protection Section 7 Shielding and Equipotential Bonding
102 3BDD010421R0401 A
Section 8 Maintenance, Repair, Trouble-shooting Maintenance
Section 8 Maintenance, Repair,

Trouble-shooting
Maintenance
All S900 I/O System components are virtually maintenance-free. Maintenance and
repair are therefore reduced to periodic checks for damage and the replacement of
individual modules.
Devices and components that are defective or suspect to be defective must not be
used any longer.
Do not use intrinsically safe components in intrinsically safe current circuits once
they have been connected to a circuit that is not intrinsically safe.
The operator of electrical equipment that is used in hazardous areas is obliged to
commission a qualified electrician to inspect and examine the equipment at defined
intervals for a proper condition, e.g. to check the housings for cracks or other
damage, the gaskets for leakage or damage, and the terminals and plugs to see if
they are seated properly.
When replacing the S900 I/O System components, observe the instructions in
section Components Assembly and Commissioning.
Prior to replacing or dismounting parts that cannot be plugged in / removed under
power disconnect the respective equipment from power. Use ABB genuine spare
parts, only.
3BDD010421R0401 A 103
Trouble-shooting Section 8 Maintenance, Repair, Trouble-shooting
Trouble-shooting
Under the proviso that the S900 I/O System modules are used as intended and
according to the instructions in this manual, the only trouble-shooting actions that
may be required are checks for fieldbus and signal transmission errors (wire break,
etc.). The S900 I/O System is provided with indicator lamps (LEDs) which allow
for quick error localization and debugging.
A distinction is made between power supply errors, module errors, communication
errors, parameterization errors, and channel errors.
All errors indicated locally by the LEDs are also reported by a PROFIBUS
diagnostic message.
Additionally, the S900 I/O System is provided with a simulation (forcing) option
allowing to perform important service and commissioning tasks. The simulation
function serves for
testing the applications in the PLC or OCS
simulating the outputs and testing the actors e.g. for checking how the system
responds to the violation of limit values, without actually affecting the control
loop
avoiding unwanted error messages in the case of signal failures that may occur
when a defective module is replaced.
For details about diagnostics and forcing refer to the Communication Interface
manual.
104 3BDD010421R0401 A
Section 8 Maintenance, Repair, Trouble-shooting Repairing Ex-devices
Repairing Ex-devices
If a part of the S900 I/O System that is relevant for explosion protection is repaired,
it may only be put back into service after being checked by an expert for
fulfillment of the explosion protection requirements. The expert has to confirm that
the part has passed the acceptance test by issuing a certificate or attaching a test
badge to the electrical equipment. This check is not required if the electrical
equipment is submitted to a routine check test by the manufacturer before being put
into operation again, and if the respective test badge is attached to the equipment,
indicating that the routine check test has been passed successfully.
3BDD010421R0401 A 105
Repairing Ex-devices Section 8 Maintenance, Repair, Trouble-shooting
106 3BDD010421R0401 A
Section 9 List of Tables, List of Figures List of Tables
Section 9 List of Tables, List of Figures
List of Tables
Table 1 Applicable reference manuals 17
Table 3-1 Bus line parameters 33
Table 3-2 Line lengths per segment 33
Table 3-3 Line lengths per segment 37
Table 3-4 Characteristics of fiber-optic lines for PROFIBUS 42
Table 4-1 Power details of Ex modules 53
Table 4-2 Power details of non-Ex modules 55
Table 4-3 Maximum permissible power dissipation in the field housing 57
Table 5-1 Properties of the connectable power wires 63
Table 5-2 Minimum power requirements S900 I/O System, type S 66
Table 5-3 Minimum power requirements S900 I/O System, type N 67
Table 5-4 Cable CSAs that can be connected to the signal terminals 69
Table 5-5 Pin assignment of the 9-pin D-SUB socket 71
Table 5-6 Fieldbus cable markings 72
Table 6-1 Commissioning/replacement procedure of type SA920S power unit 80
Table 6-2 Commissioning/replacement procedure of type SA920N power unit 81
Table 6-3 Module type codes 87
Table 7-1 Overvoltage protectors 100
3BDD010421R0401 A 107
List of Figures Section 9 List of Tables, List of Figures
List of Figures
Figure 1-1 S900 I/O System 19
Figure 2-1 Classification of hazardous areas, example 24
Figure 2-2 Installing the S900 I/O System type N and type S in a non-hazardous
area 26
Figure 2-3 Installing the S900 I/O System type S in a hazardous area, zone 2 28
Figure 2-4 Installing the S900 I/O System type S in a hazardous area, zone 1 30
Figure 3-1 Type N fieldbus topology 32
Figure 3-2 Type S and type N fieldbus topology 35
Figure 3-3 Interconnection of the intrinsically safe fieldbus 39
Figure 3-5 Examples for redundant configuration of a fieldbus system 45
Figure 5-1 Overview of the termination unit connection levels 62
Figure 5-2 Power terminals on a termination unit with redundancy capability 63
Figure 5-3 S900 I/O System power distribution 64
Figure 5-4 Connecting the fieldbus to the termination unit 71
Figure 6-1 Encoding the module housing 87
Figure 6-2 Connecting a HART terminal to type S 89
Figure 7-1 Equipotential bonding 92
Figure 7-2 Equipotential bonding of the fieldbus, detailed illustration 95
Figure 7-3 Equipotential bonding at the transition point to the hazardous area 95
108 3BDD010421R0401 A
Contact us
3BDD010421R0401 A
ABB AB Copyright © 2003-2010 by ABB.
Control Systems All Rights Reserved
Västerås, Sweden
Phone: +46 (0) 21 32 50 00
Fax: +46 (0) 21 13 78 45
E-Mail: processautomation@se.abb.com
www.abb.com/controlsystems
ABB Inc.
Control Systems
Wickliffe, Ohio, USA
Phone: +1 440 585 8500
Fax: +1 440 585 8756
E-Mail: industrialitsolutions@us.abb.com
ABB Industry Pte Ltd

Control Systems
Singapore
Phone: +65 6776 5711
Fax: +65 6778 0222
E-Mail: processautomation@sg.abb.com
ABB Automation GmbH

Control Systems
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
Power and productivity

TM
for a better world

3BDD010421R0401 A en S900 I O S - and N-System With SA920 Installation

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3BDD010421R0401 A en S900 I O S - and N-System With SA920 Installation

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S900 I/O

S- and N-System with SA920

Power and productivity

Copyright © 2003-2010 by ABB.

Release: June 2010

Safety Summary ................................................................................. 13

About This Book ................................................................................ 15

Section 1 Introduction ................................................................... 19

Section 2 S900 System Installation Sites .................................... 23

Installing the S900 I/O System in a Non-hazardous Area .............................. 25

Fieldbus Design with Fiber-optic Lines...........................................................41

Section 4 Environmental Capabilities and Power Consumption49

Section 5 Mounting and Connecting the System ....................... 61

Connecting the Power and Signal Lines ...........................................74

Section 6 Components Assembly and Commissioning ............. 79

Unlocking and Encoding ................................................................................. 86

Section 7 Shielding and Equipotential Bonding ........................ 91

Section 8 Maintenance, Repair, Trouble-shooting ................... 103

Section 9 List of Tables, List of Figures .................................... 107

About This Book

Warning, Caution, Information, Tip and Ex Icons

Caution icon indicates important information or warning related to the concept

Information icon alerts the reader to pertinent facts and conditions.

Ex icon indicates special conditions for meeting explosion protection

Documentation will be delivered on separate CD with each Termination Unit,

Figure 1-1 S900 I/O System

Section 2 S900 System Installation Sites

Classification of Hazardous Areas

Areas with a permanent, long-term, or frequent presence of an explosive

Areas with a likelihood that an explosive atmosphere consisting of a mixture of air

Areas with no or little likelihood that an explosive atmosphere consisting of a

Figure 2-1 Classification of hazardous areas, example

Installing the S900 I/O System in a Non-hazardous Area

Example: termination unit with 16 analog input modules

I/O System S900

Non-intrinsically safe circuit,

Installing the S900 I/O System in Zone 2

Isolating To other PROFIBUS DP

I/O System S900 Zone 2

Installing the S900 I/O System in Zone 1

I/O System S900 Zone 1

Fieldbus Design with Electrical Lines

Fieldbus in S900 I/O System Applications Type N

Number of Bus Stations

Non-hazardous area Profibus

More Profibus S900

Bus station with

Bus station without

Figure 3-1 Type N fieldbus topology

Within a PROFIBUS-DP system only a transmission speed can be selected,

Generally, passive stub lines are to be avoided.

Connectors and Bus Termination

To minimize line reflections and to ensure a defined steady level on the

Fieldbus in S900 I/O System Applications Type S and Type N

Bus station with

S900 S900 S900 S900

Figure 3-2 Type S and type N fieldbus topology

Intrinsically Safe Fieldbus System

An intrinsically safe PROFIBUS-DP fieldbus system can be realized by using the

Number of Bus Stations

Generally, passive stub lines are to be avoided.

Connectors and Bus Termination

UO/I 2 UO/I 3 UO/I n