ABB AC 31 User manual

Technical Manual Advant Controller 31
40 & 50 Series
1SBC 260400 R 1001-b

Summary
ABB Control - AC 31 Summary - Page 1
1SBC 260400 R1001-b 06.99
Chapter 1
Presentation / operation
1. Presentation 1-2
2. General setup rules 1-3
2.1. Central units with extensions 1-5
2.2. Central units with CS 31 bus 1-5
2.3. Cabling techniques 1-5
3. Operation of the 40 and 50 series central units 1-7
3.1. Functional diagram 1-7
3.2. Program execution 1-9
3.3. Bus transmission 1-9
3.4. Refresh times / reply times 1-10
3.4.1. Bus refresh times 1-10
3.4.2. Central unit reply times 1-10
3.5. Power on / program launch 1-11
3.6. Power cuts or drops 1-12
4. References 1-13
Chapter 2
Getting started
1. Required material 2-3
2. Cabling 2-3
3. Programming 2-5
3.1. Launching the AC31GRAF software 2-5
3.2. Project creation 2-5
3.3. Variable declarations 2-7
3.4. Program editing 2-7
3.4.1. Displaying the FBD (function blocks) toolbar 2-7
3.4.2. Selecting the OR function in the program editor window 2-7
3.4.3. Inserting variables 2-9
3.4.4. Links between the variables and the function block: 2-9
3.5. Saving 2-9
3.6. Compilation 2-9
3.7. Communication with the PLC 2-11
3.7.1. Configuration of the serial interface 2-11
3.7.2. Access to the control panel 2-11
3.7.3. Configuration of the central unit: 2-11
3.7.4. Initializing the central unit 2-13
3.7.5. Sending the program to the PLC 2-13
3.7.6. On-line program tests 2-13
3.8. Quitting AC31GRAF 2-15
Chapter 3
Technical specifications
1. General operating conditions 3-3
2. CS 31 bus technical specifications 3-5
3. Central units 3-7
3.1. The front of the central unit (see Figure 3-1) 3-7
3.2. Technical specification 3-8
4. Extensible remote units 3-13
4.1. The front (see Figure 3-3) 3-13
4.2. Technical specifications of the extensible remote units 3-14

Summary
Summary - Page 2 ABB Control - AC 31
1SBC 260400 R1001-b 06.99
5. Binary extensions 3-17
5.1. The front (see Figure 3-5 to Figure 3-9) 3-17
5.2. Binary extensions specifications 3-18
6. Analog extensions 3-21
6.1. The front (see Figure 3-10, Figure 3-11) 3-21
6.2. Analog display (see Figure 3-12) 3-21
6.3. Technical specifications of the analog extension 3-22
6.4. Analog inputs diagram: 3-24
6.4.1. Current 4-20mA: 3-24
6.4.2. Current 0-20mA: 3-24
6.4.3. PT100/PT1000: 3-24
6.5. Analog outputs diagrams: 3-25
6.5.1. Current 0-20mA: 3-25
6.5.2. Current 4-20mA: 3-25
7. Accessories 3-27
7.1. Programming cables: 07 SK 50 and 07 SK 52 3-27
7.1.1. 07 SK 50 connection diagram (see Figure 3-13): 3-27
7.1.2. 07 SK 52 connection diagram (see Figure 3-14): 3-29
7.2. ASCII/MODBUS®communication cables: 07 SK 51 and 07
SK 53 3-31
7.2.1. 07 SK 51 connection diagram (see Figure 3-15): 3-31
7.2.2. 07 SK 53 connection diagram (see Figure 3-16): 3-33
7.3. TC50 display cables: 07 SK 54 and 07 SK 55 3-35
7.4. Connectors (see Figure 3-17) 3-35
7.4.1. External dual connector: 07 ST 50 3-35
7.4.2. "Cage-clamp" type connectors 3-35
7.4.3. External dual connector: 07 ST 51 3-37
7.5. Stickers 3-38
8. TC50 Display 3-38
9. Dimensions (in mm) 3-39
Chapter 4
Installation
1. Implementation of an AC 31 system 4-3
1.1. Assembly conditions 4-3
1.2. Input/output cabling 4-3
1.3. Earthing 4-5
1.3.1. Basic earthing principles 4-5
1.3.2. Earthing principles for numerous cabinets 4-5
1.4. Cabling of the CS 31 bus 4-7
1.5. Different power supply types 4-9
2. Central unit and remote unit cabling 4-11
2.1. Power supply 4-11
2.2. Inputs/outputs cabling 4-11
2.3. Output protection 4-11
3. Cabling binary extensions 4-13
3.1. Extension XI 16 E1 (see Figure 4-18) 4-13
3.2. Extension XO 08 R1 (see Figure 4-20) 4-13
3.3. Extension XC 08 L1 (see Figure 4-22) 4-13
3.4. Extension XO 16 N1 (see Figure 4-19) 4-13
3.5. Extension XK 08 F1 (see Figure 4-21) 4-13
4. Cabling the analog extension 4-15
4.1. Extension XM 06 B5 4-15
4.2. Extension XE 08 B5 4-15

Summary
ABB Control - AC 31 Summary - Page 3
1SBC 260400 R1001-b 06.99
5. Addressing 4-17
5.1. Input/Output variables 4-17
5.2. Addressing CU masters or stand-alones with extensions 4-17
5.3. Addressing slave central units or remote extension units on
the CS 31 bus 4-21
5.3.1. Addressing extensible remote units 4-21
5.3.2. Addressing slave central units 4-23
5.3.3. Addressing example 4-24
5.4. Summary 4-25
Chapter 5
Programming
1. Software introduction 5-2
2. List of variables 5-4
3. Initialization 5-7
4. Configuration 5-9
4.1. AC31GRAF configuration tool 5-9
4.1.1. The central unit operative mode 5-10
4.1.2. Transmission/reception range of a slave central unit 5-11
4.1.3. Data initialization and backup 5-11
4.1.4. Initialization /Internal bits backup 5-12
4.1.5. Initialization / Internal words backup 5-12
4.1.6. Initialization / Internal double word backup 5-13
4.1.7. Initialization / Chain step backups 5-13
4.1.8. Initialization / Historical values backup 5-13
4.1.9. Central unit reaction to class 3 errors 5-14
4.1.10. Initialization of the CS 31 bus units 5-14
4.1.11. Communication mode of the COM1 serial interface 5-15
4.1.12. communication parameters: 5-17
4.1.13. The central unit cycle time 5-18
4.1.14. CS31 bus communication times 5-19
4.1.15. Clock 5-23
4.1.16. Password 5-25
4.2. CS31CO configuration function block 5-25
4.3. Analog configuration ( extension) 5-27
4.3.1. Hardware configuration 5-27
5. Programming examples 5-33
5.1. Practical advice 5-33
5.2. Operation AND 5-34
5.3. NAND operation 5-35
5.4. Operation OR 5-35
5.5. NOR operation 5-36
5.6. Combinations of Boolean functions 5-36
5.7. Timer functions 5-37
5.7.1. TON: on delay 5-38
5.7.2. TOF: off delay 5-38
5.7.3. TP: monostable (constant) 5-39
5.7.4. TIME_W: 5-39
5.7.5. W_TIME: 5-39
5.7.6. Oscillators 5-40
5.8. Detecting the first cycle with the M 255.15 variable 5-41
5.9. Up/Down counter function 5-42
5.10. Scaling an analog value 5-43
5.10.1. Using the potentiometers of the 40 and 50 series 5-43
5.10.2. Processing an analog input 5-44

Summary
Summary - Page 4 ABB Control - AC 31
1SBC 260400 R1001-b 06.99
Chapter 6
Program Optimization
1. Sub-program 6-3
1.1. Programming sub-programs 6-3
1.2. Calling a sub-program 6-4
1.3. Passing parameters 6-5
1.4. Limits 6-5
2. Interruptions 6-7
2.1. Programming interruptions 6-7
2.2. Validation of interruptions 6-8
2.3. Performances 6-8
3. Step motor command 6-9
4. High speed counter with value capture, zero reset and overflow
detection 6-11
5. Communication between central units on the CS 31 bus 6-13
5.1. CS 31 bus addressing 6-13
5.2. Communication type 6-13
5.3. Programming 6-14
5.3.1. Bit transmission 6-14
5.3.2. Transmission by word 6-15
5.3.3. Utilization of the function blocks 6-17
Chapter 7
Communication
1. Network communication with the incorporated MODBUS
interface 7-3
1.1. Protocol description 7-3
1.2. Communication configuration 7-5
1.3. Programming 7-6
1.3.1. MODBUS slave unit 7-6
1.3.2. MODBUS master unit 7-6
1.3.3. List of cross references 7-6
1.3.4. Example using the MODBUS function 7-9
1.4. Reply times for MODBUS communication 7-10
2. Point to point communication with the incorporated ASCII
interface 7-13
2.1. Protocol description 7-13
2.2. Configuration of the communication 7-13
2.2.1. Using the black 07 SK 51 or 07 SK 53 cable 7-13
2.2.2. Communication parameters 7-13
2.3. Programming 7-14
2.3.1. Sending messages 7-14
2.3.2. Receiving messages 7-14
2.3.3. Programming example 7-14
3. Point to point communication with the programming protocol 7-17

Summary
ABB Control - AC 31 Summary - Page 5
1SBC 260400 R1001-b 06.99
Chapter 8
Diagnosis
1. Types of errors detected 8-3
2. Detection of errors 8-3
3. Status through software 8-7
4. Error management through programming 8-7
4.1. Description of the diagnosis variables 8-7
4.2. Correspondence table between the error and the diagnosis
variable values 8-9
4.3. Class error descriptions: 8-10
4.3.1. Class 1 error descriptions 8-10
4.3.2. Class 2 error descriptions 8-10
4.3.3. Class 3 error descriptions 8-10
4.3.4. Class 4 error descriptions 8-11
4.4. Programming examples 8-12
4.4.1. Example of a reaction / command following a specific error 8-12
4.4.2. Example for saving numerous errors of the same class 8-13
Annexes
1. List of variables 2
2. List of functions 5
3. Mapping 9
4. Historical values 12
Index

AC 31 technical documentation
ABB Control - AC 31 Page 1-1
1SBC 260400 R1001-b 06.99
Chapter 1
Presentation / operation

Presentation / operation
Page 1-2 ABB Control - AC 31
1SBC 260400 R1001-b 06.99
This chapter gives you an introduction to the AC 31 automation, from the overall architecture
to the operational rules of the 40 and 50 series central units.
1. Presentation
The AC 31 brings accessibility to beginners and experienced automation users alike, for any
application with 14 to 1000 inputs / outputs and more, using the same set of basic
components.
From a compact machine fitted with a few automated functions to large installations spread
over hundreds of meter, and even kilometers, the AC 31 can fit your requirements.
It is therefore possible to realize distributed applications throughout a site, a workshop, or a
machine where each component (input / output unit, central unit) is close to the sensors /
actuators. The whole setup is connected by a single twisted pair over which all information
from the sensors is sent after processing by the central unit to the actuators, as well as
distributed intelligent units. The following communication interfaces are available, to extend the
AC 31’s possibilities and integration with the company's other automation systems:
MODBUS , ASCII, ARCNET , RCOM, AF100. The developments in this field are continual.
Many users on all the continents have realized numerous applications such as:
Machine control
Manufacture of floor boards
Assembly of electrical contactors
Manufacture of ceramic products
Metallic pipe welding, etc.
Controlling-commanding installations
Wharf cranes
Water treatment
Ski lifts
Wind power machines, etc.
Systems management
Climatic management
Building power management
Tunnel ventilation
Alarms in hospital environments
Greenhouse lighting / humidity, etc.

Presentation / operation
ABB Control - AC 31 Page 1-3
1SBC 260400 R1001-b 06.99
2. General setup rules
An ABB AC 31 system always includes an AC 31 central unit. There are three types of central
units:
- The 40 series central unit, with a local inputs / outputs extensions interface
- The 50 series central unit, with a local inputs / outputs extensions interface
and a CS 31 bus interface
- The 90 series central unit, with a CS 31 bus interface
Each central unit incorporates a specific number of binary inputs / outputs and occasionally
analog. It is possible, depending on the central unit, to increase the number of inputs / outputs,
to add input / output extensions connected directly to the central units or remote input / output
units via the CS 31 twisted pair.