Ascon tecnologic AC3 User manual

AC
3
System
User Manual
User Manual
M.U.
Code: ISTR-MU AC3ENG01A

Copyright © 2007, 2014 Ascon Tecnologic Srl
All rights reserved
No part of this document may be stored in a retrieval system, or transmitted in
any form, electronic or mechanical, without prior written permission of Ascon
Tecnologic Srl.
Ascon Tecnologic has used the best care and effort in preparing this manual and
believes that the information contained in this publication are accurate.
As Ascon Tecnologic continues to improve and develop products, the information
contained in this manual may also be subject to change.
Ascon Tecnologic reserves the right to change such information without notice.
Ascon Tecnologic makes no warranty of any kind, expressed or implied, with
regard to the documentation contained in this manual.
Ascon Tecnologic shall not be liable in any event - technical and publishing error
or omissions - for any incidental and consequential damages, in connection with,
or arising out of the use of this manual.
sigmadue
®
, gammadue
®
and deltadue
®
, are trademarks of Ascon Tecnologic Srl.
All other trade names or product names are trademarks or registered trademarks.
Ascon Tecnologic srl
Headquarters: viale Indipendenza 56,
27029 Vigevano (PV)
Phone: [phone]
Fax: [phone]
Internet Site: www.ascontecnologic.com
E-mail address: [email protected]

INDEX
iii
Chapter 1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1 Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1-1 AC3 System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1-2 P04 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-1-3 MP-02 CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-1-4 Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-2 Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-2-1 P04 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-2-2 MP-02 CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-2-3 AC3 System - AC Station Compatibility
I/O Assignment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-2-4 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1-2-5 Communication ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1-2-6 Communication cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1-3 Resident Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1-4 Function Block Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1-4-1 AT_AC3_Specific_Lib Description . . . . . . . . . . . . . . . . . . . . 12
1-4-2 AT_AC3_LAN_Mngt_Lib Description . . . . . . . . . . . . . . . . . . 13
1-4-3 AT_AC3_Panels_Lib Decription . . . . . . . . . . . . . . . . . . . . . . 13
1-4-4 Configuration Function Block Descriptions . . . . . . . . . . . . . . 15
1-4-5 Firmware Function Blocks List . . . . . . . . . . . . . . . . . . . . . . . 16
1-4-6 AT_Generic_Advanced_Lib . . . . . . . . . . . . . . . . . . . . . . . . . 18
1-4-7 AT_Process_Generic_Lib . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1-4-8 AT_Process_Control_Lib . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1-4-9 AT_Communications_Lib . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 2
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2-1 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-1-1 Pushbuttons, display areas and other
touch screen commands . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2-2-1 Custom Page Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2-2-2 Four Bargraph Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2-2-3 Two Bargraph Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2-2-4 One Bargraph Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2-2-5 Double Trend Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2-2-6 Alarm & Status Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2-2-7 Display Numericals Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2-2-8 Edit Numericals Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2-2-9 Edit Digitals Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2-2-10 SP Prog. Mngt Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2-3 Select a resident Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Index (continued)
iv
Chapter 3
PID, Tune and Communication . . . . . . . . . . . . . . . . . . . . . . . . . 43
3-1 Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3-2 Gain Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3-3 Two freedom degrees PID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3-4 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3-4-1 Programming port (LAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3-4-2 Communication port emulating the
ARCNET functionality (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Chapter 4
OpenPCS Programming Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4-1 Installing OpenPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4-1-1 Hardware and Software Requirements . . . . . . . . . . . . . . . . . 49
4-1-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4-1-3 Starting OpenPCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4-2 AT target .cab file Installation - Configuring OpenPCS . . . . . . . . . 50
4-3 PC Ethernet port configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4-4 OpenPCS Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4-4-1 OpenPCS connection Setup . . . . . . . . . . . . . . . . . . . . . . . . . 50
4-4-2 OpenPCS Target resource Setup . . . . . . . . . . . . . . . . . . . . . 51
Chapter 5
Advanced Function Block Libraries . . . . . . . . . . . . . . . . . . . . . 53
5-1 AT_AC3_Specific_Lib Description . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5-1-1 ALARM_ADV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5-1-2 MP_AI_MNGT_ADV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5-1-3 ANALOG MULTIPLEXER 2 CHANNELS . . . . . . . . . . . . . . . 57
5-1-4 RATIO TYPE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5-1-5 ANALOG SP SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5-2 AT_AC3_LAN_Mngt_Lib Description . . . . . . . . . . . . . . . . . . . . . . . . 61
5-2-1 LAN_MST_SYNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5-2-2 LAN_SLV_DIAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5-2-3 LAN_SLV_NODE_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5-3 AT_AC3_Panels_Lib Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5-3-1 PAGE_CUSTOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5-3-2 PAGE_4BARG_1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5-3-3 PAGE_2BARG_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5-3-4 PAGE_1BARG_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5-3-5 PAGE_2TRND_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5-3-6 PAGE_ALM_EVT_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5-3-7 PAGE_DSP_NUM_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5-3-8 PAGE_EDT_NUM_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5-3-9 PAGE_EDT_DIG_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5-3-10 SP_PROG_MNGT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5-4 Configuration Function Block Descriptions . . . . . . . . . . . . . . . . . . 99
5-4-1 SP_PROG_RECIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5-4-2 PAGE_CFG_PID_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5-4-3 PAGE_CFG_NUM_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5-4-4 PAGE_CFG_DIG_n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Index (continued)
v
Chapter 6
Password and Access Control . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6-2 Setting Access Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6-3 Password Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6-3-1 Password Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Chapter 7
Maintenance and Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7-1 TFTP Files Protocol Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7-2 P04 Operator Panel Brightness and Screensaver Adjustment . . . 112
7-3 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7-3-1 Setup Terminal Connection . . . . . . . . . . . . . . . . . . . . . . . . . 113
7-3-2 Starting the Setup Session . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7-3-3 CPU Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7-3-4 CPU Info Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7-4 Master Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7-5 Diagnostic Test and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7-5-1 Entering the Diagnostic Test session . . . . . . . . . . . . . . . . . . 116
7-5-2 I/O Watch Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7-5-3 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7-6 Faulty Components Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7-7 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Chapter 8
Expansion Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8-2 Technical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
8-2-1 MP-D1/08-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
8-2-2 MP-D1/16-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8-2-3 MP-D2/08-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8-2-4 MP-D4/08-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8-2-5 Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Chapter 9
Order Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Index (continued)
vi
Appendix A
Resident Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
A-1 How to implement a PID controller . . . . . . . . . . . . . . . . . . . . . . . . . 127
A-2 Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A-2-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A-2-2 Project Tasks (POU) Organization and Order . . . . . . . . . . . 129
A-2-3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
A-2-4 Graphic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
A-2-5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
A-2-6 Signals I/O Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
A-3 Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
A-3-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
A-3-2 Project Tasks (POU) Organization and Order . . . . . . . . . . . 136
A-3-3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
A-3-4 Graphic Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
A-3-5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
A-3-6 Signals I/O Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
A-4 Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
A-4-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
A-4-2 Project Tasks (POU) Organization and Order . . . . . . . . . . . 142
A-4-3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
A-4-4 Graphic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
A-4-5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
A-4-6 Signals I/O Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
A-5 4 Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
A-5-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
A-5-2 Project Tasks (POU) Organization and Order . . . . . . . . . . . 148
A-5-3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
A-5-4 Graphic Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
A-5-5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
A-5-6 Signals I/O Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

vii
Introduction
The products described in this manual should be installed, operated and main-
tained only by qualified personnel who is familiar with automation safetytopics and
applicable national standards.
Congratulation for having chosen an Ascon Tecnologic instruments.
This instruction manual is dedicated to the AC3System.
Notes: 1. Be sure this manual would be available to the instrument users.
2. The manual refers to a family of multifunction programmable systems supplied
with high innovative colours graphic display. This effective user interface
provides a huge amount of quality information.
3. The programing tool software for the AC3Systems, is tipically supplied on CD-
ROM, but can be also downloaded from internet. You should keep the original
disk in a safe place. The software is licensed to the company and you can
install it on any computer of the licensed company. It is not allowed to
redistribute or resell it. The use of the software is regulated by the licence
agreement provided by the Supplier.
4. When you open the package of an AC3System, check all the items and verify
the correspondance to the packing list below. If an item is missed or damaged,
you must contact the nearest Ascon Tecnologic sales office.
-AC
3System (P04 panel, MP-02 CPU);
- Mounting clamps;
- Installation manual.

Sigmadue Solutions - AC3System - User manual
viii
Using this manual
Specifications within the text of this manual are given in the International System
of Units (SI), with non SI equivalents in parentheses.
Fully Capitalized words within the text indicate markings found on the equipment.
Words in bold style within the text indicate markings found in the Configuration
Tools.
Warnings, Cautions and Notes are used to emphasize critical instructions:
DANGER!
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Caution
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury, or property damage.
Note: Highlights important information about an operating procedure or the equipment.
Current Documentation on the Internet
Make sure you are always working with the latest version of this document.
Ascon Tecnologic S.r.l. reserves the right to make changes to its products in the
name of technological advancement.
New manual revisions, when published, and can be found online at:
http://www.ascontecnologic.com

1
Chapter 1
General information
1-1 Technical specification
1-1-1 AC3 System Assembly
The AC3System is composed by a P04 Touch Screen Panel device and an MP-02
Control Unit. The system, optionally, can be installed as splitted version where the
P04 Panel can be installed remotely from the MP-02 Unit.
The data exchange between the two devices is performed through an Ethernet
Communcations.

Sigmadue Solutions - AC3System - User manual
2
1-1-2 P04 Operator Panel
Display
characteristics
Storage
characteristics
Communication
characteristics
Electrical
characteristics
Mechanical
characteristics
Environmental
characteristics
Item Description
LCD type TFT display
Screen dimension 4.3”
Screen format 16/9
Touch-screen Resistive
Resolution 480 x 272
Number of colours 262 k
Back light LED
Item Description
RAM 128 MB
Flash 128 MB (Operating System + Program +
16 MB user space)
Memory card MicroSD (max. capacity 8GB)
USB 2.0 full speed (max. distance <3 m)
Item Description
Ethernet 10/100Mb/s (max. distance <30 m)
RS485 Modbus RTU/CAN
Item Description
Power Supply 24VAC/DC, ±10%
Current consumption 300mA @ 24VDC
Internal fuse Not available
Item Description
Dimensions (H x L x W) 83 x 159 x 28 mm
Cutout 68 x 138 (P04 with front panel mounting adapter)
68 x 127 (panel only)
Weight 200 g
Item Description
Operating Temperature 0... 55°C
Storage Temperature -20... +60°C
Relative Humidity 85% RH
Protection degree Front panel: IP65, Rear side: IP20
CE standards EN61151-3, 61000-3-3:1995+A1:2001+A2:2005

Chapter 1 - General Information
3
1-1-3 MP-02 CPU
CPU
specifications
General and
environmental
specifications
High level
analogue
inputs
Universal
analogue
inputs
Item Description
Processor 32 bit ARM
Program memory 2 MB Flash
Dynamic memory 16 MB RAM
Retentive memory 64 kB redundant (32 kB + 32 kB)
Memory data retention 10 years (with replaceable battery)
Real Time Clock Available
Timer resolution 1 ms max.
Computing speed 70 Mips
Min. cycle time ≥5ms (typical 10ms)
Min. response time Inputs Acquisition + cycles execution time
Communications port Ethernet 10 Mb base T
Communications ports 1 RS485 + 1 RS232/485 selectable
Front LEDs
For digital I/Os, communication ports and CPU diagnostic
Item Description
Power supply voltage 24 VDC (-15... +25%)
Power consumption 10 W (+5 W with both the expansions)
Reverse polarity
protection Standard
Isolation class II (50 Vrms), EN61010-1
Vibration resistance 10... 57 Hz, 0.0375 mm, 57... 150 Hz, 0.5 g (3 axis)
Shock resistance 15 g
Operating temperature 0… 55°C; (humidity: 5... 95%)
Storage temperature -40… 70°C
Protection IP20
Item Description
6 configurable 0... 10 V, 0/1... 5 V, 0... 1 V - 0/4... 20 mA
2 optional configurable ±10 V, ±5 V, ±1 V - 0/4... 20 mA
Acquisition time Standard inputs: 170 ms, optional inputs: 40 ms
Resolution 16 bit
Accuracy 0.1%
Input impedance >100 kΩ(V); 300 Ω(mA)
Isolation 800 V between Power supply and logics
Item Description
2 optional configurable ±50 mV, ±100 mV, ±300 mV, ±1.25 V high impedance, TC (L, J, T, K, S, R, B, N, E, W3, W5), Pt100 (3 wire),
Pt1000 and potentiometer (0.1... 10 kΩ)
Acquisition time 60 ms
Resolution 16 bit
Accuracy 0.1%
Input inpedance 10 MΩ(V)

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4
Analogue
Outputs
Digital
Inputs
Digital
Outputs
Cold junction
compensation Isolation
≤1°C/20°C ambient temperature 800 V between
Power supply and logics 40 Vpp between the 2
channels (differential inputs)
Item Description
Item Description
0/2/4 optional
configurable ±10 V (±25 mA max.), 0/4... 20 mA
Update time 35 ms
Resolution 13 bit
Accuracy 0.1%
Isolation 800 V between Power supply and logics
Item Description
8... 40 with expansions 24 VDC (On: 5... 30 V, Off: 0... 3 V)
Max. input frequency 80 Hz
Type Sink
Protection Reverse polarity and overvoltage
Isolation 800 V between Power supply and logics
Compliance IEC/EN 61131-2 (type 2)
Item Description
8... 40 with expansions 24VDC, 0.5 A
Type Source (PNP)
Protection Overvoltage and short circuit
Isolation 800V between Power supply and logics

Chapter 1 - General Information
5
1-1-4 Installation Kit
The installation kit is a mandatory item when the AC3System is to be installed in
place of an AC Station or Front Panels mounted. It consists of some hardware
parts to allow the front panel installation:
• Front panel Adapter;
•2
Allen screws to install the P04 touch screen display in the front panel adapter;
• Mounting plate with a DIN rail that allows the installation of the MP-02;
• 4 conical head
Allen screws to assemble the mounting plate to the front panel
adapter;
• 2 clamps to fix the structure to the font panel.
Mechanical
characteristics
P04
Front panel
adapter
Mounting
plate
MP-02
Clamp
Clamp
DIN Rail
Item Description
Dimensions (H x L x W) 156 x 81 x 215 mm (short plate)
156 x 81 x 367 mm (long plate)
Cutout 68 x 138 (P04 with front panel mounting adapter)
68 x 127 (panel only)
Weight 730 g (short plate)
1200 g (long plate)

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6
1-2 Hardware Description
1-2-1 P04 Operator Panel
Touch
Screen
Panel
The P04 operator panel is operated directly from the Touch Screen Area.
Connections
and Ports
Power Supply connection
The power supply is to be provided to the operator panel via terminals 4 and 5 of
the terminal block. Since the power required can be both in alternate and in direct
current (AC/DC), the polarization of the terminals is not relevant.
Ethernet connection
The LAN Ethernet port (TCP/IP) is dedicated to interface the P04 Operator Panel
to the MP-02 Control Unit.
USB port
The USB port can be used to upload a startegy in the P04 Operator Panel.
AC
AC
3
Rear
USB
Ethernet
4-5 = Power
supply
24 VAC/VDC

Chapter 1 - General Information
7
1-2-2 MP-02 CPU
Integrated
I/Os The AC3system base MP-02 unit has up to 28 I/O ports:
6 AI 6 analogue inputs configurable for mA, V;
2 AI 2 optional universal or high level isolated analogue inputs configurable for:
-Thermocouples (L, J, T, K, S, R, B, N, E, W3, W5);
-RTD (PT100, PT1000);
-±mA, ±V linear inputs;
-Potentiometers.
4 AO 4 optional high level analogue outputs;
RS RUN/STOP program functionality;
8 DI General Purpose Digital Inputs;
8 DO
Isolated General Purpose Digital Outputs.
WARNING
The RESET button does not restart the CPU or the 1131 application, but resets
all the stored Setup parameters and restores the defaut parameters (as well
as those set by the user).
RS232/485
Communication/Configuration
Port Connector (X0)
RS485 Modbus
Connector (X1)
Ethernet 10 Base T
port (LAN) + 2 LAN
status LEDs
Run/Stop
terminal (A1)
and RS status
LED
Digital input
terminals
(A2...A4,
B2...B4)
Digital output
terminals
(A6...A9,
B6...B9)
Power Supply
Terminals
= +24 Vac/dc
(A10, A11)
= Ground (B10)
= 0V (B1, B11)
Diagnostics LEDs
•= ERR
•= RUN
•= BAT
•= PWR
Analogue
input
terminals
(E1...E6,
F1...F6)
Analogue
input
terminals
(E7...E10,
F6...F10)
Analogue
output
terminals
(E11...E14
F11...F14)
8 digital output
LEDs (red)
8 digital input
LEDs (yellow)
Expansion bus
connector
Serial ports
X0, X1 activity
LEDs (green)
RESET button
Serial ports
configuration
microswitches

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8
Terminal “A”
connections The “A” terminal block allows the connection of the +24V Power Supply, Run/Stop,
4 Digital Inputs and 4 Digital Outputs Signals.
The terminals are positioned as follows:
1 RS Run/Stop terminal, connecting this terminal to a 24V source, it is possible
to launch or stop the execution of the 1131 program loaded in the CPU;
2...5 1...4 4 Digital Inputs terminals , connecting this terminal to a 24V source, it is
possible to change the status of the input;
6...9 1...4 4 Digital Outputs terminals . Each source type (PNP) digital output can
manage a 24V 0.5A load;
10...11 L+ 24VDC power supply terminals.
Terminal “B”
connections The “B” terminal block allows the connection of the 0V Power Supply, 4 Digital
Inputs, 4 Digital Outputs Signals and the system hearth.
The terminals are positioned as follows:
1M- 0V power supply terminal.
2...5
5...8 4 Digital Inputs terminals , connecting this terminal to a 24V source, it is
possible to change the status of the input
6...9 5...8 4 Digital Outputs terminals . Each source type (PNP) digital output can
manage a 24V 0.5A load.
10 Frame ground.
11 M- 0V power supply terminal.
Pin 1 234567891011
Label RS 1 2 3 4 1 2 3 4 L+ L+
Function Run/Stop DI1 DI2 DI3 DI4 DO1 DO2 DO3 DO4 POWER
Signal INPUT INPUT INPUT INPUT INPUT OUT OUT OUT OUT +24V +24V
Power Supply
Digital Output
Digital Input
Run/Stop
Digital Input
Pin 1 2345678910 11
Label M- 5 6 7 8 5 6 7 8 M-
Function POWER DI1 DI2 DI3 DI4 DO1 DO2 DO3 DO4 Ground POWER
Signal 0V INPUT INPUT INPUT INPUT OUT OUT OUT OUT Ground 0V
PowerDigital OutputDigital InputPower Frame
supply ground supply

Chapter 1 - General Information
9
Terminal “E”
connections The “E” terminal block allows the connection of 6 Analogue Inputs, 2 optional Ana-
logue Inputs and 4 Analogue Outputs
.
The terminals are positioned as follows:
1...6 +6 configurable analogue (linear) inputpositive (+) poles. These inputs
can be configured as mA or V. The negative (-) poles are on
connector “F”;
7...10
A...B 2 universal/high level analogue (linear) inputs (No. 7, 8) (see the “MP-
02 Installation Manual” for details). The Input number (0... 2) and type
can be identified by the order code. The additional terminals of these
2 inputs are on connector “F”;
11...14 +
4 analogue output positive (+) poles. The outputs number (0, 2, 4) is
specified by the order code, the type can be set during the CPU
Setup phase
(see the “CPU Setup” chapter on the MP-02 User
manual)
. The negative (-) poles are on connector “ F ”.
Terminal “F”
connections The “F” terminal block allows to complete the connections of the I/Os present on
the “E” terminal block.
The connector “F” has 14 terminals:
1...6 -
6 configurable analogue (linear) input negative (-) poles;
7...10 P...b 2 universal/high level analogue (linear) inputs (No. 7, 8)(see the “AC3
System Installation Manual” for details);
11...14 -4 analogue output
negative (-) poles .
Pin 123456789101191011
Label + + + + + + A
V
B
mA
A
V
B
mA + + + +
Function AI1 AI2 AI3 AI4 AI5 AI6 Univ. AI1 Univ. AI2 AO1 AO2 AO3 AO4
Signal IN IN IN IN IN IN IN IN OUT OUT OUT OUT
Analogue input (mA, V) Analogue input (±mA, ±V) Analogue ouput (±mA, ±V)
Pin 1234567 8 91011121314
Name ------Pb
com
Pb
com - - - -
Function AI1 AI2 AI3 AI4 AI5 AI6 Univ. AI1 Univ. AI2 AO1 AO2 AO3 AO4
Signal IN IN IN IN IN IN IN IN OUT OUT OUT OUT
Analogue input (mA, V) Analogue input (±mA, ±V) Analogue ouput (±mA, ±V)

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10
1-2-3 AC3System - AC Station Compatibility I/O Assignment Table
Tag AC-Station
Terminals MP-02 Terminals Meaning
AI_1 1 + / 2 - E1 + / F1 - High Level Analogue Input_1
AI_2 3 + / 2 - E2 + / F2 - High Level Analogue Input_2
AI_3 4 + / 5 - E3 + / F3 - High Level Analogue Input_3
AI_4 6 + / 5 - E4 + / F4 - High Level Analogue Input_4
AI_5 7 + / 8 - E5 + / F5 - High Level Analogue Input_5
AI_6 9 + / 8 - E6 + / F6 - High Level Analogue Input_6
AI_7 10 + / 11 - E8 + / F8 - High Level Analogue Input_7
AI_8 12 + / 11 - E10 + / F10 - High Level Analogue Input_8
DI_1 13 / 14 A2 Digital Input_1
DI_2 15 / 14 A3 Digital Input_2
DI_3 16 / 17 A4 Digital Input_3
DI_4 18 / 17 A5 Digital Input_4
DI_5 19 / 20 B2 Digital Input_5
DI_6 21 / 20 B3 Digital Input_6
DI_7 22 / 23 B4 Digital Input_7
DI_8 24 / 23 B5 Digital Input_8
+24 VDC_1 25 + A11 + 24 VDC Power supply
+24 VDC_2 26 + - Not Present
AO_1 27 + / 28 - E11 + / F11 - Analogue Output_1
AO_2 29 + / 28 - E12 + / F12 - Analogue Output_2
AO_3 30 + / 31 - E13 + / F13 - Analogue Output_3
AO_4 32 + / 31 - E14 + / F14 - Analogue Output_4
DO_1 33 / 34 A6 Digital Output_1
DO_2 35 / 34 A7 Digital Output_2
DO_3 36 / 37 A8 Digital Output_3
DO_4 38 / 37 A9 Digital Output_4
DO_5 39 / 40 B6 Digital Output_5
DO_6 41 / 40 B7 Digital Output_6
DO_7 42 / 43 B8 Digital Output_7
DO_8 44 / 43 B9 Digital Output_8

Chapter 1 - General Information
11
1-2-4 Diagnostic LEDs
Referring to the image inserted at the previous page a description of the LEDs
functions is given in the table below.
Note: The ERR LED flashing sequence has a specific meaning which needs to be
acknowledged by the user as described on the dedicated MP-02 User manual.
1-2-5 Communication ports
The CPU has 3 communication ports (see paragraph “3-8 Communications
connections” in the MP-02 Installation Manual):
• The LAN Ethernet port (TCP/IP) is dedicated to interface the MP-02 Control
Unit to the P04 Operator Touch Screen Panel. Alternatively the LAN port can
be used to:
- CPU configuration (see the “CPU Setup” chapter on the MP-02 User manual);
- Programming, debuging and commissioning the application within the
OpenPCS tool.
• The X0 Service RS232/485 port is available and can be used as:
- Configuration port of the device with VT100 terminal;
- Standard ASCII serial port;
- Modbus RTU data exchange port.
• The X1 RS485 port is dedicated to emulate the original ARCNET network
available on the AC-Station units; alternatively:
- Modbus RTU data exchange port.
LED Colour Action (note 1) Description
RS Yellow ON RS input active (RUN program)
ERR Red
Flickering (10Hz) Checksum error in RETAIN data
Single flash
CRC error in the configuration file, reset to default
Double flash Problem during file system mount
Triple flash Checksum VAR % RETAIN error (NOTE 2)
RUN Green ON 1131 program running
OFF 1131 program stopped or not present
PWR Green ON Power Supply present
BAT Yellow ON Backup battery low
Sequence Meaning
Blinking The LED blinks at a frequence of 2.5 Hz (slow)
Flickering The LED blinks at a frequence of 10 Hz (fast)
Single flash The LED lits once for at least 200 ms
Double flash The LED lits twice with pulses of 200 ms each
Triple flash The LED lits three with pulses of 200 ms each

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12
X0/X1 Ports
DIP Switches The Communications Ports electrical settings can be selected through the micros-
witches located between the Serial Port connectors.
The following table describes the selectable options.
1-2-6 Communication cables
RS232/485
Serial Service/
Port
X0 connector
The connector X0 on the MP-02 unit is an RJ45 type, with the following pinout:
RS485 Port X1 connector
The connector X1 on the MP-02 unit is an RJ45 type, with the following pinout:
LAN Ethernet
10baseT LAN connector
The connector on the CPU module is an RJ45 type, with the following pinout:
For a more detailed explanation consult the “AC3Installation Manual”.
1-3 Resident Strategies
The AC3Systems are supplied with the following resident configurations, already
stored in the unit:
Ratio (1 Ratio Loop plus 1 simple Loop);
Cascade (Cascade loop with Remote Set Point and PV retransmission);
Override (2 Loops interconnected as override controllers);
4 Loops (4 simple Loops each other independent);
More information about this strategies are illustrated in Appendix A: Resident
configurations.
Aspect Switch Port Description ON OFF Default
1 X1 Termination Resistance (110Ω) Enabled Disabled OFF
2 X1 Pull-Down Line polarization Enabled Disabled OFF
3 X1 Pull-Up Line polarization Enabled Disabled OFF
4 X0 RS232 Selection Enabled Disabled ON
5 X0 RS485 Selection RS485 RS232 OFF
6 X0 Termination Resistance (110Ω) Enabled Disabled OFF
7 X0 Pull-Down Line polarization Enabled Disabled OFF
8 X0 Pull-Up Line polarization Enabled Disabled OFF
Pin 1 2 3 4 5 6 7 8
Signal D+
(RS485) D- (RS485) GND (RS485) GND (RS232) RX (RS232) TX (RS232) NC NC
Pin 1 2 3 4 5 6 7 8
Signal D+ (RS485) D- (RS485) GND (RS485) NC NC NC NC NC
Pin 1 2 3 4 5 6 7 8
Signal TX+ TX- RX+ NC NC RX- NC NC