ABB AC 31 Installation and operating instructions
ASSEMBLY AND OPERATION MANUAL
AC31 Adapter
Supplement to the Existing Documentation
—
Table of contents
1 AC31 Adapters................................................................................................................................................. 3
1.1 Introduction................................................................................................................................................ 3
1.2 Overview of AC31 adapters (replacement devices).................................................................................. 3
1.3 System data and CS31 bus system data.................................................................................................. 4
1.3.1 System data of the AC31 adapters............................................................................................ 4
1.3.2 CS31 bus system data............................................................................................................. 10
1.4 Replacement devices: CPU.................................................................................................................... 18
1.4.1 Replacement device 07KT9x-AD............................................................................................. 19
1.5 Replacement devices: I/O modules......................................................................................................... 56
1.5.1 Replacement device 07DC91-AD............................................................................................ 57
1.5.2 Replacement device 07DC92-AD............................................................................................ 72
1.5.3 Replacement device 07AI91-AD.............................................................................................. 88
1.5.4 Replacement device 07AC91-AD.......................................................................................... 107
1.5.5 Replacement device 07AC91-AD2........................................................................................ 121
1.5.6 Replacement unit DC501-CS31-AD....................................................................................... 137
2 Index............................................................................................................................................................. 161
Table of contents
2018/09/243ADR010122, 8, en_US2
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1 AC31 Adapters
1.1 Introduction
The modular product line of the AC31 adapter series includes modular exchange components
for control systems of the Advant Controller 31 (90 series). The simple exchange of individual
components allows existing customers to maintain their PLCs in a quick and cost-effective
manner. Extensive software modifications are not required.
Each replacement device is based on trend setting technologies of the AC500 series. There-
fore, by exchanging components it is not only possible to replace the existing device, but also to
profit from new functions and improved product quality.
During the development of the AC31 adapter series, care was taken to keep the device configu-
ration identical to the configuration of the AC31 devices. Consequently, the technical documents
for the AC31 devices are still valid and serve as reference:
●Software description (only available in English)
●System description Advant Controller 31
Only unavoidable deviations, for example due to technical limitations, are described in this
document.
CAUTION!
Installation and maintenance work on the device must be performed by a quali-
fied electrician in line with the recognized technical rules, regulations and rele-
vant standards such as EN 60204-1.
For safety instructions, please refer to
Regulations for the erection of installations.
1.2 Overview of AC31 adapters (replacement devices)
An AC31 adapter (replacement device) is available for the following AC31 devices of the 90
series (existing devices):
Existing devices: AC31
(90 series)
Replacement devices: AC31
adapters
Replacement device is based
on the following AC500
device
CPU devices:
07KT94-ARC
07KT98-ARC
07KT98-ARC-DP
07KT98-ARC-ETH
07KT98-ETH-DP
--
07KT94-ARC-AD *)
07KT98-ARC-AD
07KT98-ARC-DP-AD
07KT98-ARC-ETH-AD
07KT98-ETH-DP-AD
07KT98-ARC-ETH-DP-AD
PM590, DA501 and DA502
*) Customer specific product not available for current sales
Replacement
devices for
AC31
Note regarding
product docu-
mentation
AC31 Adapters
Overview of AC31 adapters (replacement devices)
2018/09/24 3ADR010122, 8, en_US 3
Existing devices: AC31
(90 series)
Replacement devices: AC31
adapters
Replacement device is based
on the following AC500
device
I/O modules:
07DC91 07DC91-AD DC532
07DC92 07DC92-AD DO524
07AC91 07AC91-AD (8-Bit) AO523
07AC91 07AC91-AD2 (12-Bit) AX522
07AI91 07AI91-AD AI523
DC501-CS31 DC501-CS31-AD DC532
1.3 System data and CS31 bus system data
The system data described in this chapter are valid for the following replacement devices:
● 07KT94-ARC-AD
● 07KT98-ARC-AD
● 07KT98-ARC-DP-AD
● 07KT98-ARC-ETH-AD
● 07KT98-ETH-DP-AD
● 07KT98-ARC-ETH-DP-AD
● 07AC91-AD
● 07AC91-AD2
● 07AI91-AD
● 07DC91-AD
● 07DC92-AD
● DC501-CS31-AD
Please also observe the CS31 bus system data
Ä
Chapter 1.3.2 “CS31 bus system data”
on page 10.
The devices of the AC31 adapter series do not have marine approval.
NOTICE!
AC31 Adapter IO modules must only be used with an ABB CPU with Master
CS31 bus (e.g. AC31 07KT9x, AC31-Adpater 07KT9x-x-x-AD or AC500 CPU).
1.3.1 System data of the AC31 adapters
1.3.1.1 Operating and environmental conditions
Table 1: Supply voltages
Voltages according to IEC 61131-2:
24 V DC Process and supply voltage 24 V DC (-15 %, +20 %
without residual ripple)
Absolute limits 19.2 V ... 30 V incl. residual
ripple
AC31 Adapters
System data and CS31 bus system data > System data of the AC31 adapters
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Residual ripple £ 5 %
Polarity reversal protection 10 s (test duration), perma-
nently present on AC31
adapters
Bridging time for power interruptions according to IEC 61131-2:
DC supply Interruption < 10 ms
Time between 2 interruptions
> 1 s
CAUTION!
System damage caused by voltage!
Exceeding the maximum supply or process voltage (>30 V DC) results in per-
manent system damage (destruction).
Table 2: Operating and environmental conditions
Temperature:
-> Operation 0 °C ... +55 °C (vertical mounting position, ter-
minals upward and downward)
-> Storage -40 °C ... +75 °C
-> Transport -40 °C ... +75 °C
Humidity max. 95 %, without condensation
Air pressure:
-> Operation > 800 hPa / < 2000 m
-> Storage > 660 hPa / < 3500 m
1.3.1.2 Creepage distances and clearances
The creepage distances and clearances correspond to overvoltage category II, pollution degree
2.
1.3.1.3 Test voltages for type test
Test voltages for type test according to IEC 61131-2:
Table 3: Impulse testing
Data Voltage Duration
24 V circuits (supply, 24 V inputs/outputs), when electri-
cally isolated from other circuitry
500 V 1.2 / 50 µs
CS31 interface from other circuitry 500 V 1.2 / 50 µs
Ethernet 500 V 1.2 / 50 µs
ARCNET 500 V 1.2 / 50 µs
COM interfaces, electrically isolated 500 V 1.2 / 50 µs
Enabling input, electrically isolated 500 V 1.2 / 50 µs
AC31 Adapters
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Table 4: AC voltage tests
Data Voltage Duration
24 V circuits (supply, 24 V inputs/outputs), when electri-
cally isolated from other circuitry
350 VAC 60 s
CS31 interface from other circuitry 350 VAC 60 s
Ethernet 350 VAC 60 s
ARCNET 350 VAC 60 s
COM interfaces, electrically isolated 350 VAC 60 s
Enabling input, electrically isolated 350 VAC 60 s
1.3.1.4 Power Supply Units
For the supply of devices, use power supply units according to PELV specification.
1.3.1.5 Electromagnetic compatibility
Table 5: Immunity
Data Value
Immunity against electrostatic discharge
(ESD)
According to EN 61000-4-2, zone B, criterion
B
-> Interference voltage with air discharge 8 kV
-> Interference voltage with contact discharge 4 kV
ESD with communication connectors Ensure that any electrostatic charge is dis-
charged prior to contact with the communica-
tion connectors (e.g. by touching an earthed
metal object). Otherwise malfunctions may
occur.
ESD module carrier connectors Do not touch the plug connecting the module
carrier on the bottom side of the device.
ESD external coupler interface Do not touch the plug to the flat ribbon cable.
Immunity against the influence of radiated
interference (CW radiated)
According to EN 61000-4-3, zone B, criterion
A
-> Test field strength 10 V/m (except ITU transmission bands 87…
108 MHz, 174…230 MHz and 470…790 MHz
-> 3 V/m)
-> Maximum temporary deviation during irradi-
ation
Analog current output signals max. 1.5 %.
Devices affected:
07AC91-AD, 07AC91-AD2,
07KT94-ARC-AD, 07KT98-ARC-AD,
07KT98-ARC-DP-AD, 07KT98-ARC-ETH-AD,
07KT98-ETH-DP-AD, 07KT98-ARC-ETH-DP-
AD
Immunity against transient interference vol-
tages (burst)
According to EN 61000-4-4, zone B, criterion
B
-> Voltage supply 2 kV
-> Enabling input 2 kV
AC31 Adapters
System data and CS31 bus system data > System data of the AC31 adapters
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Data Value
-> Digital inputs/outputs 1 kV
-> Analog inputs/outputs 1 kV
-> CS31 system bus 1 kV
-> Serial RS-232 interfaces (COM) 1 kV
-> ARCNET 1 kV
-> Ethernet 1 kV
-> I/O supply, DC out 1 kV
Immunity against the influence of power
related interference (CW radiated):
According to EN 61000-4-6, zone B, criterion
A
-> Test voltage Zone B, also according to 10 V
Immunity against transient interference vol-
tages with high energy (surge)
According to EN 61000-4-5, zone B, criterion
B
-> Voltage supply DC, enabling input 0.5 kV CM / 0.5 kV DM *)
-> I/O supply, DC out 0.5 kV CM / 0.5 kV DM *)
-> Shielded buses 1 kV CM *)
-> I/O analog, I/O DC unshielded 1 kV CM / 0.5 kV DM *)
Emitted interference (radiation): -
-> From radiated interferences According to EN 55011, group 1, class A
*) CM = Common Mode, DM = Differential Mode
The devices of the AC31 adapter series do not have marine approval.
1.3.1.6 Mechanical data
Data Value
Degree of protection IP20
Housing According to UL 94
Vibration resistance according to EN 61131-2 All three axes
2 Hz ... 15 Hz, continuous 3.5 mm
15 Hz ... 150 Hz, continuous 1 g
Vibration resistance with SD card plugged 15 Hz ... 150 Hz, continuous 1 g
Shock resistance All three axes
15 g, 11 ms, semi-sinusoidal
1.3.1.7 Earthing
The AC31 adapter devices can be earthed as follows:
AC31 Adapters
System data and CS31 bus system data > System data of the AC31 adapters
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Fig. 1: Earthing of devices 07AC91-AD, 07AC91-AD2, 07AI91-AD, 07DC91-AD and 07DC92-AD
AC31 Adapters
System data and CS31 bus system data > System data of the AC31 adapters
2018/09/243ADR010122, 8, en_US8
Fig. 2: Earthing of device DC501-CS31-AD
Fig. 3: CPU earthing
When earthing the replacement devices, observe the following:
● Install the AC31 adapter devices onto an earthed mounting plate to ensure a uniform refer-
ence potential of all equipment.
● Implement the connections between switchgear cabinet, mounting plate, PE rail and shield
rail with low impedance.
AC31 Adapters
System data and CS31 bus system data > System data of the AC31 adapters
2018/09/24 3ADR010122, 8, en_US 9
● Install the lines in groups (power lines, power supply lines, signal lines, data lines).
● Use lines with braided cable shield for analog signals. Earth the shield on both sides and
make sure that no compensation currents flow through the cable shield. For this purpose,
use a potential equalization line with current carrying capacity, for instance on systems con-
sisting of several switchgear cabinets.
Further information concerning CS31 bus earthing:
1.3.2 CS31 bus system data
1.3.2.1 Wiring
Table 6: Bus line
Data Value
Configuration 2 cores, twisted, with common shield
Cross section > 0.22 mm² (24 AWG)
Recommendation: 0.5 mm² corresponds to Ø
0.8 mm
Twisting rate > 10/m (symmetrically twisted)
Core insulation Polyethylene (PE)
Resistance per core < 100 Ω/km
Characteristic impedance approx. 120 Ω (100 ... 150 Ω)
Capacitance between the cores < 55 nF/km (in case of higher capacitance
values, the maximum possible bus length is
reduced)
Terminating resistors 120 Ω ¼ W at both ends
Notes Cables with PVC core insulation and core
diameter of 0.8 mm can be used up to a
length of approx. 250 m. In this case, the ter-
minating resistor is 100 Ω. Cables with PE
core insulation can be used up to a length of
approx. 500 m.
The baud rate used on the CS31 bus is 187.5 kBaud.
1.3.2.2 Bus topology
A CS31 system bus always contains only one CS31 bus master to control the bus. Up to 31
CS31 slaves can be controlled by one bus. The CS31 bus master has no address, whereas the
CS31 slaves can accept addresses in the range from 0 - 61, depending on CS31 slave type.
Possible CS31 bus masters:
● 07KT94-ARC-AD, 07KT94
● 07KT98-ARC-AD, 07KT98
● 07KT98-ARC-DP-AD
● 07KT98-ARC-ETH-AD
● 07KT98-ETH-DP-AD
● 07KT98-ARC-ETH-DP-AD
AC31 Adapters
System data and CS31 bus system data > CS31 bus system data
2018/09/243ADR010122, 8, en_US10
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