Ascon Tecnologic SAT1 Open case customizable Multifunction Controller Installation Manual

mod.

SAT1

23/10 - Code: ISTR_ I _SAT1_E_00_--

Installation

Manual

Integrated system,

CPU module with on-board I/O

SAT1

model

Ascon Tecnologic S.r.l. a socio unico via Indipendenza 56,

27029 - Vigevano (PV)

Tel.: +39 0381 69871,

Fax: +39 0381 698730 www.ascontecnologic.com

E

Contents

- General description

- Accessories

- Installation

- Electrical connections

- Electric safety

1

21 20

General description

19 10 11 6 5

15

14

13

12

7

8

9

Dimensions (mm)

Installation

Operating conditions

1 X5

1 X12

1 X4

1 X8

X2 1

203

X1

70

Environmental condition

B

Operating conditions

T

%Rh

Temperature

0...+50°C

Umidity:

5... 95% Rh non condensing

Suggestion

T Temperature

> 50°C

Use forced ventilation

Special conditions

%Rh

> 95% RH Warm up

Forbidden conditions

P

C

Conducting atmosphere

Corrosive atmosphere

Use filter

E Explosive atmosphere

18 17 16 4 3 2

1 DIN RAIL 35 x 7.5 (EN50022);

2 X1 : 2 poles plug to connect the power supply;

3 X2 : 5 poles plug to connect DI5... DI8 High Voltage Digital Inputs;

4 X3 : 4 poles plug to connect OP9... OP11 SPST-NO 5 A output relays;

5 X4 : 6 poles plug to connect DI1... DI4 Digital Inputs;

6 X5 : 5 poles plug to connect OP4, OP5 (SPST-NO 5 A) and OP6 (SPDT 8 A) output relays;

7 X6 : 5 poles plug to connect AO1... AO4 analogue outputs (0/4... 20 mA,

PWM and Hz);

8 X7 : 5 poles plug to connect CN1... CN4 High speed Digital Inputs;

9 X8 : 10 poles plug to connect AI1... AI4 Analogue Inputs (mA, TC, PT100,

PT1000, NTC)

10 X10 : USB type A receptacle to connect a flash drive;

11 X11 : RJ45 plug to connect the Ethernet TCP/IP network for programming purposes or for the MODBUS through the TCP port;

12 X12 : 3 poles plug to connect COM1 serial port (RS485);

13 4 switches to configure the serial port parameters;

14 Reset button;

15 Status/diagnostic LEDs: COM1 (green, COM1 traffic), USB (white, USB activity), MSG (red, message), RUN (green, program status run/stop),

PWR (blue, power supply ON);

16 X13 : 3 poles plug to connect OP3 (SPDT 16 A) output relay;

17 X14 : 3 poles plug to connect OP2 (SPDT 16 A or SPST-NO 30 A) output relay;

18 X15 : 3 poles plug to connect OP1 (SPDT 16 A or SPST-NO 30 A) output relay;

19 X16 : 4 poles plug to connect OP14... OP16 SPST-NO 5 A output relays;

20 X17 : 4 poles plug to connect OP12... OP13 (SPST-NO 5 A output relays or

12 V outputs for SSR drives or 4 A/250 Vdc SSR outputs);

21 X18 : 4 poles plug to connect OP7... OP8 (SPST-NO 5 A output relays or

12 V outputs for SSR drives or 4 A/250 Vdc SSR outputs).

Mounting position

- Mount the module vertically;

- In order to help the ventilation flow of air, respect the distances between modules and walls or other modules.

Mounting position (mm) min. 80 min. 60

55 min. 100

Mounting/removing the modules on/from the DIN rail

1 C lip the upper part of the module to the rail ;

2 Rotate the module downwards until the lower hook engages the DIN rail ;

3 Switch OFF the Power Supply

With two fingers, press in the area indicated by the arrow until the hook is freed from the DIN guide ;

4 Turn and lift the module upwards to remove the CPU from the DIN rail.

Mounting the module

1

2

Removing the module

Disposal

The appliance (or the product) must be disposed of separately in compliance with the local standards in force on waste disposal.

Accessories

24 Vdc Power supply

APS2ALEDR12024 (120 W, 5.0 A),

APS2ALNDR75-24 (75 W, 3.2 A),

APS2ALMDR20-24 (20 W, 1.0 A)

Screw Terminal Blocks

APS2/??

3

4

X18 X17 X16

X10

X11

X6 X7

Electrical connections

X5

Terminals connections and plugs

X12

X8

X4

Conn. Label

X1

1

2

X2

24 Vac/dc

Signals

Power Supply

1 Neutral (high voltage input)

2 DI5 Line (high voltage input)


X3



1 OP9 SPST-NO relay

2 OP10 SPST-NO relay

3 OP11 SPST-NO relay

4 Common pole of the relays

X2 X1

Conn. Label Signals

1 RS485 D+ connection

X12

X13

2 RS485 D connection

3 RS485 Ground connection

1 NC pole of OP3 relay

2 Common pole of OP3

3 NO pole of OP3 relay

X14

1

NC pole of OP2 SPDT relay.

Not connected for SPST-NO

30 A relay


3

NO pole of OP2 relay (SPDT

16 A or SPST-NO 30 A)

X15 X14 X13 X3

X15

X18

X15

X18

X14

X17

X14

X17

X13

X16

X13

X6

X16

X10

X6

X7

X3

X10

X11

X3

X7

Description

Flexible cable section:

L

Stripped wire

Plugs of all terminals

0.2... 2.5 mm ² (AWG24... AWG12)

Screw: 7mm Spring: 10mm

Flat blade screwdriver 0.6 x 3.5 mm 0.4 x 2.5 mm

Tightening torque 0.5... 0.6 Nm -

X5 X4

- The green terminals are male connectors (pitch 3.5 or 5 mm), the corresponding female plugs are snap-on connectors with screw or spring terminals for connecting the wires. The connectors terminals are labelled;

- Made with self extinguishing material as required by UL94 V0 standard;

- Overvoltage cathegory/pollution degree II/2;

- Max. load current/section 8 A/2.5mm

- Test pulse voltage: 4 kVp.

² at 65°C;

A

A

Make sure that the overall current absorption (modules and field devices) matches the power supply;

In order to avoid excessive voltage drops, install the most power consuming modules closer to the power supply.

Conn. Label

X4

1 Ground

2 DI1

3 DI2

4 DI3

5 DI4

X5

X6

Signals

6 24 V for Digital Inputs


2 NC pole of OP6 relay


4 NO pole of OP5 relayv


1 AO4 Positive pole

2 AO3 Positive pole

3 AO2 Positive pole

4 AO1 Positive pole

5 Common pole of the AOs

Conn. Label

X15

X16

X17

1

Signals

NC pole of OP2 SPDT relay.

Not connected for SPST-NO

30 A relay


3

NO pole of OP2 relay (SPDT

16 A or SPST-NO 30 A)





1

2

OP12 5 A relay common

Negative pole of OP12 SSR

Pole of OP12 SSR Drive

OP12 5 A relay NO pole

Positive pole of OP12 SSR


X11

X2

X5

X8

Power supply (X1 connector)

X4

- Connector : 24 Vac/dc

(–10...+10%), 15W max.;

- The power supply terminals

( X1-1 and X1-2 ) are not polarized as the CPU acceps both the 24 Vac

X18 and 24 Vdc.

X17

X12

Vac/Vdc

X1 Power Supply connector

Conn. Label Signals

1 CN4 Positive pole

2 CN3 Positive pole

X7

X16

3 CN2 Positive pole

4 CN1 Positive pole

5 Ground

1 Ground

2 Transmitters PWS (12 V)

X8

3 AI1 Negative pole

4 AI1 Positive pole (TC)

5 AI2 Negative pole

6

7

X10

Positive pole (TC)

Negative pole

8 AI3 X11

9 AI4 Negative pole

10 AI4 Positive pole (TC)

X10 USB USB Type A port

X11 ETH RJ45 Ethernet port

X5

Conn. Label

X17

(cnt.)

3

4

1

2

3

4

Signals







X4

5 A relay common












High Voltage (mains) Digital Inputs (X2 connector)

X2 1

X8

X1

X15

- Connector X2 : DI5... DI8 High

Voltage Digital Inputs;

- Terminal 1 (CV) is the common (neutral) terminal of the 100... 240 Vac digital inputs DI5... DI8;

- Respect the connection shown, the common terminal is shared by the

4 digital inputs.

k

X14 X13

High voltage inputs, remove the mains and pay extreme attention while performing these input connections.

Line Neutral

X2 High voltage

Digital Inputs

X6

Digital outputs: SPST-NO Relays (X3 connector)

- Connector X3 : OP9... OP11

SPST-NO relays outputs;

X7

- Insulation: 2500 V beween channel and Power Supply and between channel and main electronics.

1

X3 - SPST-NO 5A relay terminals

X2 X1

X18 X17 X16 X5 X4

X10

X11

X12

X15

X18

X15

X18

X14

X17

X14

X17

X13

X18

X15

X16

X15

X5

X18

DI1... DI4 Digital Inputs (X4 connector)

X4 - DI1... DI4 terminals

- Connector X4 : DI1... DI4 digital inputs;

- Insulation: 800 V between channel ad Power Supply.

X6 X7

X17

X17

X14

1 X4

X13

X10

X3

X11

X5

X16

X2

X12

AI1... AI4 Analogue Input (X8 connector)

TC

X8

X8

X4

X10

X1

X11

- Connector X8 : AI1... AI4 digital inputs;

- Respect the polarity shown;

- Pay attention to correctly connect the power source (12 Vdc);

- Type: 0/4... 20 mA, TC (J, K, L, N, R,

X5

- Resolution: 16 bit;

X4

- Accuracy: 0.5% of span (linear inputs),

0.5% (temp.) ±1°C (cold junction);

- Input impedance: 120 k Ω (V),

<200 Ω (mA).

X12 m Verify the option ordered for

AI1... AI4 Inputs.

X18

X15

X13

X10 X12

TC TC TC TC

X8 Analogue input terminals

X6

X16

X17

X14

X3

X6

X11

X7

X17

X5 - OP4... OP6 relay output terminals

X16

X18

X15

OP4... OP6 Digital Outputs (X5 connector)

X8

X14

X17

- Connectors X5 :

2 SPST NO relays (OP4, OP5) +

1 SPDT relay (OP6);

X5 loads);

X6

X4

X7

X17 and Power Supply and between

X13

X15 X12 X14

X3

1

X10

X2 X1

X11

X13

X5

1

X16

Pt100/Pt1000

2 wires input

X6

X8

X4

X2

X7

X10 X12

X11

X16

X3

X7

X13

+

X15

+

1

AO1... AO4 Analogue Output (X6 connector)

+

X6

X2

X14

X11

G

X6 - AO1... AO4 terminals

X3

X8

X5

X1

- Connector X6 : AO1... AO4 analoue outputs;

X8

- For the analogue output, respect the polarity shown;

X4 X6 X7 and Hz;

X2 Ω ;

- Resolution: 16 bit; m

X1

- Accuracy: 0.5%;

- Insulation:

X14

X3

800 V Channel-Power supply,

50 V channel-main electronics;

These outputs are ordered in pairs (AO1/AO2 and AO3/AO4).

Verify the option ordered for

AO1/AO2 and AO3/AO4 Inputs.

X13

X12 X10

A A A A

X11

B b

B b

B b

B b


1

X2

0/4... 20 mA active transmitter

X6 X7

X8

+

-

+

-

+

-

+

-


X14 X13

X6

Special (High Speed) Digital Inputs (X7 connector)

1

X3

X7

24 Vdc

+

X7 - DI1... DI4 terminals

X2

In the drawing are connected only 2 counter inputs as an example (CN2 and CN4).

Frequency meter input:

- The channels can manage up to 10 kHz signals having a duty-cycle that guarantees minimum of ON signal

X18 X17

Impulse counter input:

- The minimum time of an impluse must be 20 ms;

Digital input:

- The input circuit is internally closed to System Ground.

m Verify the option ordered for

CN1... CN4 Inputs.

X16

X10

X11

X5

1

X2

NPT inputs

X8

X8

X4


X5

0/4... 20 mA 2 wires passive Transmitter

X8

1 X8

X2

X12

X12

X4

X1

X1


USB port connector

X10 - USB type A connector

- USB type A receptacle ( X10 ) to connect a flash drive (system files upload or data logging download).

USB type A

X15 X14 X13

X6 X7

X3

X8

X2 X1

X18 X17 X16 X5 X4

X10

X11

X12

X15

X18

X14

X14

X17

X17

X15

X18

X13

X16

X13

X14

X16

X17 X16

Ethernet connector (X11 connector)

X11 - Ethernet RJ45 connector

Status/traffic LEDs

X5

- Connector X11 : The Ethernet connection is made through a standard

J45 connector;

- The 2 green LEDs near the Ethernet connector show the port status and the communication traffic.

X4

OP1 Digital Output: SPST-NO 30 A or SPDT 16 A Relay (X14 connector)

X18

First option:

SPST-NO 30A X17

- Connector X14 : OP2 first option

SPST-NO relay output.

- Rate: 30 A (for resistive loads).

- Insulation: 2500 V beween channel

X6 m

X16

OP2 output.

X10 X12

X15 X13

X10

X3

X11

OP2 X11

X14 - Configurable relay terminals

X10

X13

X11

X12 - RS485 connector

X6

X5

D+ D- GND

1 X12

X3

Serial Communications Port (X12 connector)

X7

X12

X4

POL+ POL- NONE TERM

X2

- Connector X12 : RS485 port to connect a fieldbus network using the

Modbus protocol (master/slave) or serial ASCII;

- The line settings can be configured using the specific DIP switches:

SW Description

1 Line polarization Pull-Up

Default

OFF

OFF 2 X1

3 Not used

4 110 Ω line termination OFF

DIP switch settings

X15

X18

OP2

Second option:

SPDT 16A

- Connector X14 : OP2 second option

SPDT relay output.



X6

X17


OP2 output.

X16

X3

X10

DIP switches

- Insulation from other electronics:

1.6 kV.

SPDT 16A


X11

X5

X2

X12

X2

X5

X8

X4

X8

X12

X1

X1

X4

X6

X10

X6

X18

X3

X11

X7

X7

X15

X3

X14

X17

X5

Sytem Pushbutton and Status LEDs

Status LEDs

X2

X8

X16

X4

System pushbutton

X1

- The 5 Status LEDs are:

COM (green), USB (white),

MSG (RED), RUN (green) and

PWR (blue).

- The meaning of the various LEDs behaviours are fully described in the “ SAT1 User Manual ”.

X4 m The system pushbutton performs different operations accorndingly to the system status but does not restart the CPU or

X10

X12

X11

OP2 Digital output: SPST-NO 30 A or SPDT 16 A Relay (X15 connector)

First option:

X17

- Connector X15 : OP1 first option

SPST-NO relay output.


- Insulation: 2500 V beween channel and Power Supply and between


OP1 output.

X7

OP1

X14 X13

X10

X3

X11


X2

Digital Output: SPDT 16 A Relay (X13 connector)

X8

X6

X3

- Connector X13 : OP3 SPDT relay output;

- Rate: 16 A (for resistive loads);

X7 channel and main electronics.

Digital output: SPDT 16 A Relay

(X13 connector)

X2

X1

OP3

X1

Second option:

SPDT 16A

OP1

X14

- Connector X15 : OP1 second option

SPDT relay output.




OP1 output.

X13 X3

X13 - SPDT 16A relay terminals

SPDT 16A


X5

X2

X12

X2

X8

X4

X8

X1

X1

X15

X18

X14

X18

X17

Digital outputs: SPST Relays (X16 connector)

X16 - SPST-NO 5A relay terminals

- Connector X16 : OP14... OP16

SPST-NO relays outputs;



1

X5 X4

X10

X11

X12

Digital outputs: Configurable Outputs (X18 connector)

X18 - Configurable output terminals

1

X17

- Connector X18 : OP7, OP8 first option 2 relays outputs;

Relays:

- 2 SPST-NO relays;



m

First option:

2 SPST-NO 5A

X10

X11

Digital outputs: Configurable Outputs (X17 connector)


- Connector X17 : OP12, OP13 first option 2 relays outputs;

Relays:

- 2 SPST-NO relays;


X6 X7

1

X16 and Power Supply and between channel and main electronics.


OP12 and OP13 outputs.

X13

First option:

2 SPST-NO 5A

X3 X2 X1

X10 X12

X11

OP7


LOAD

SSR

LOAD

SSR

OP8

+ +

X4

1

X15

12VDC for SSR

X14

X17

- Connector X18 : OP7, OP8 second option: 2 x 12 Vdc for SSR ;

SSR drives:

- Voltage output 0/12 Vdc;


- Outputs not isolated.


X7

X16

X13

X10

X3

X11

X18

X15


LOAD

SSR

LOAD

SSR

OP12 OP13

+ +

X14

1

Second option:

12VDC for SSR

X13

X16

- Connector X17 : OP12, OP13 second option: 2 x 12 Vdc for SSR .

SSR drives:

- Voltage output 0/12 Vdc;


- Outputs not isolated.


X10

X3

X5

X2

X12

OP7


LOAD LOAD

Fuse Fuse

NO NO

OP8

X8

X4

1

X15

X1

SSR 4A/250V

X14

X11

X17

- Connector X18 : OP12, OP13 third option: SSR relays .

SSR:

- Rate: 4 A, 250 Vac;

- Zero Crossing Function;

- Insulation: 2500 V between channe-

X7 m

X6



X16

X13 X3

X10

X11

X18

X15


LOAD LOAD

Fuse Fuse

OP12

NO NO

OP13

1

X14

Third option:

SSR 4A/250V

X13

X16

- Connector X17 : OP12, OP13 third option: SSR relays .

SSR:

- Rate: 4 A, 250 Vac;

- Zero Crossing Function;

- Insulation: 2500 V between channe-

X6 m

X7



X5

X3 X2

X10 X12

X11

X8

X4

X14 X13

X6

X3

X7

X5

X5

X2

X12

X8

X4

X1

X2

X12

X8

X4

X5

X2

X12

X8

X4

X1

X1

X15 X14 X13

X6 X7

X3

X8

X2 X1

SUGGESTED WIRES ROUTING

AI and DO cables

100

X18 X17 X16

X10

X11

X5 X4

X12

100

Power cables

X15 X14 X13

X6 X7

X3

X8

X1

100

Output cables

100

AI and DI cables

A Despite the fact that the instrument has been designed to work in an harsh and noisy environment, it is strongly recommended to follow the following suggestions.

All the wiring must comply with the local regulations.

The supply wiring should be routed away from the power cables. Avoid to use electromagnetic contactors, power relays and high power motors nearby.

Avoid power units nearby, especially if controlled in phase angle. Keep the low level sensor input wires away from the power lines and the output cables.

Power lines and output cables must also be at 100 mm (min.) away from the CPU.

If this is not achievable, use shielded cables on the sensor input, with the shield connected to earth.

A

Warning!

Whenever a failure or a malfunction of the device may cause dangerous situations for persons, things or animals, please remember that the plant must be equipped with additional devices which will guarantee safety.

How to Order

SAT1 = CPU of the Programmable Logic Controller with 24 Vac/Vdc Power Supply

AI1: Analogue Input 1 Pre-Configured

A = mA

C = Pt100

M = PT1000

N = NTC

T = TC


A = mA

C = Pt100

M = PT1000

N = NTC

T = TC


A = mA

C = Pt100

M = PT1000

N = NTC

T = TC


A = mA

C = Pt100

M = PT1000

N = NTC

T = TC

AO1O2: Analogue Outputs 1 and 2

= Not provided

A = mA Outputs

D = Digital Outputs

F = PWM/Frequency Outputs

V = Voltage Outputs

AO3O4: Analogue Outputs 3 and 4

= Not provided

A = mA Outputs

D = Digital Outputs

F = PWM/Frequency Outputs

V = Voltage Outputs

DIGFI: High Speed Digital Inputs CN1... CN4

= Not provided

T = 4 High Speed Digital Inputs

ID: Free of Voltage Digital Inputs DI1... DI4

= Not provided

L = 4 Free of Voltage Digital Inputs

DIGVI: Main Voltage Digital Inputs DI5... DI8

= Not provided

V = 4 Main Voltage Digital Inputs

OO1: Digital Output OP1

F = Relay SPST-NO 40 A (faston)

H = Relay SPST-NO 30 A

S = Relay SPDT 16 A


F = Relay SPST-NO 40 A (faston)

H = Relay SPST-NO 30 A

S = Relay SPDT 16 A


S = Relay SPDT 16 A

OO456: Digital Outputs OP4... OP6

R = 2 relays SPST-NO 16 A + 1 relay SPDT 8 A

OO78: Digital Outputs OP7... OP8

O = 2 digital outputs 12 VDC for SSR drive

Q = 2 SSR digital outputs

R = 2 relays SPST-NO 5 A

OO9AB: Digital Outputs OP8... OP11

= Not provided


OOCD: Digital Outputs OP12 and OP13

O = 2 digital outputs 12 VDC for SSR drive

Q = 2 SSR digital outputs


OOEFG: Digital Outputs OP14... OP16


SCM: Serial Communications Port

= Not provided

I = Insulated RS485

S = Not Insulated RS485

SAT1

Connector map m SAT1 is a compex instrument with a very limited space for the connection labels.

Refer to the image that follows to identify each connector and find the position of terminal 1.

All the connections previously described are based on these 2 details

Ascon Tecnologic SAT1 Open case customizable Multifunction Controller Installation Manual

Installation

Manual

Integrated system,

CPU module with on-board I/O

model

Contents

- General description

- Accessories

- Installation

- Electrical connections

- Electric safety

General description

Installation

%Rh

%Rh

Disposal

Accessories

24 Vdc Power supply

Screw Terminal Blocks

Electrical connections

Warning!

How to Order

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