SAPHIR ACX 32 Hardware Description

1 Foreword and Notes on Use

1.1 Foreword

Rising demands on building systems engineering and building management are reflected in increasing automation of building services. In the area of controls for the HVAC OEM business, the rising demands are being met with the new "SAPHIR" system, which will supersede the existing Siemens system "COMPAS" in the lower price/performance range.

The SAPHIR OEM primary controller is a powerful DDC compact controller that has been developed for use in HVAC applications.

It is optimized for the functional demands and geographical distribution of building services installations and has been designed for deployment in small systems, HVAC devices and local automation nodes within large buildings.

The SAPHIR ACX 32 model was specifically designed to accommodate requests for more RAM storage and more analog outputs arising from the existing practical applications of SAPHIR ACX 30.

1.2 Notes on Use

This manual primarily addresses users of the SAPHIR OEM primary controller. The main focus is on project engineering, installation and commissioning of the SAPHIR OEM primary controller.

For operation and planning of the SAPHIR OEM primary controller, please refer to the following manual:

• SAPHIR SACUS 32, User's Guide (Order No: CE2P3691en)

You can order this publication from SBT HVAC Products, Zug.

1.3 Abbreviations

HVAC: Heating, Ventilation, Air-Conditioning

ADC: Analog-to-Digital Converter

NMI: Non-Maskable Interrupt

PWM: Pulse Width Modulation

SPI: Serial Peripheral Interface

MSR: Mess-Steuer-Regeltechnik (instrumentation and control)

ID: Identification

HMI: Human-Machine Interface

DDC: Direct Digital Control

Warning Symbol Passages introduced by this symbol indicate a warning to help prevent incorrect operation.

Stop Symbol Passages introduced by this symbol indicate that the text must be read with special attention.

Tip Symbol Paragraphs with this symbol provide tips.

1.4 Chapters in this Document

• Chapter 2: This chapter contains a brief description of "SAPHIR".
• Chapter 3: This chapter provides configuration examples.
• Chapter 4: Describes the SAPHIR hardware.
• Chapter 5: Details of assembly, installation and setup guidelines.

2 System Description

The following contains an overall description of a SAPHIR system.

2.1 General

The SAPHIR system comprises a basic device, operating system software for the basic device, and engineering software, as well as additional tools, such as SACUS or WEBCC, which provide for implementation of HVAC applications.

Two module slots, to which communication modules can be attached, provide extension possibilities. An external RS422 port to which external I/O modules can be connected provides an additional extension possibility.

This document describes the SAPHIR ACX 32 hardware and operating system, as well as the system's setup and wiring.

Separate operation manuals describe the operating system software and the SAPRO 32 and SACUS 32 engineering software.

3 Planning Basis and System Design

3.1 SAPHIR ACX 32 System Design

The following provides a current list of the SAPHIR components:

• ACX3x.xxx: SAPHIR controller
• ACX8x.xxx: SAPHIR HMI
• ACX5x.xxx: SAPHIR communication cards
• ACX4x.xxx: SAPHIR I/O expansion modules
• ACX9x.xxx: SAPHIR plug-in terminal set

Figure 1: Block diagram with components

A diagram shows the SAPHIR controller (ACX32) connected to communication cards (ACX5x), I/O expansion modules (ACX4x), an operating unit (ACX8x.910), and PC tools (ACX93...).

3.2 SAPHIR Tools

The following tools are required for engineering SAPHIR:

• SAPRO 32: engineering tool with hardlock
• SACUS 32: optional for parameterization and evaluation
• WEBCC: for generating web pages
• SAPHIR Scope: optional for parameterization and evaluation; includes UNICODE support (multilanguage)
• SAPHIR Loader: for downloading operating system updates to the controller
• Rainbow Loader: an HTML page that enables all project-specific data (MSR task, HMI templates and object handler languages) to be downloaded to the controller using Internet Explorer

4 Hardware

4.1 SAPHIR Control Assembly

4.1.1 Design

The SAPHIR control assembly comprises a motherboard and two different optional plug-in modules. The motherboard is a 6-layer printed circuit board that contains all electronic components and connectors. Communication connection solutions can be implemented on the modules. The motherboard has two 55-pin socket connectors for connecting the modules. The motherboard is installed in a double sheet metal housing. The housing is designed for installation on a DIN top-hat rail or mounting plate. The power supply and process signals are connected via plug-in terminals.

Figure 2: SAPHIR ACX 32 motherboard

An illustration shows the layout of the SAPHIR ACX 32 motherboard with labeled modules and connectors.

4.1.2 Motherboard

Figure 3: SAPHIR block diagram

A block diagram illustrates the SAPHIR motherboard's architecture, showing connections between the C167SR microcontroller, RAM, Flash EPROM, various interfaces (SPI, UART, RS232), inputs (DIL switches, LED, I/O extension), and outputs (analog, digital).

4.2 Technical data

General data

• Overall device dimensions: 280 mm x 158 mm x 54 mm
• Motherboard dimensions: 280 mm x 150 mm, 6x multilayer
• Module dimensions: 105 mm x 76 mm
• Weight: Approx. 1.3 kg
• Color: RAL 7016 (dark green)
• Attachment: Mounting on 35 x 7.5 mm DIN top-hat rail

Interfaces:

• Peripheral interfaces (X1...X12): WAGO Cage Clamp terminal blocks
• Serial interface (X13): 8-pin RJ45 jack
• External interface (X14): 9-pin D-SUB jack
• Module interface (X15): 55-pin, 5-row male connector
• Module interface (X16): 55-pin, 5-row male connector

Memory:

• Internal data memory: 1 Mbyte RAM, 4 Mbyte flash, 128 kbit EEPROM

Microcontroller:

• CPU: C167SR-LM, 16 bit (20 MHz)

Real-time clock: Buffered 2 days min. Accuracy max. 10min/Year

Inputs and outputs:

• Relay outputs BO1...BO8: 12...250 VAC, max. 2 A. Recommended min. 0.5A, 12 VAC/VDC. Changeover contacts.
• Universal inputs UI1...UI14: Configurable for voltage (0...10 V), current (0...20 mA), temperature (Ni1000, Pt1000, Pt100, NTC, PTC), or digital input (24 V).
• Voltage input: 0...10 V, non-floating. Input impedance: Approx. 100 kΩ. Resolution: Up to 12 bit (default 10 bit). Offset error: 0.2%. Gain error: ±0.3%.
• Current input: 0...20 mA (via ext. 100 Ω shunt). Resolution: 12 bit (default 10 bit). Offset error: 0.5%. Gain error: ±1%.
• PT100 elements: Sensor current: 400 μA. Resolution: 0.1 K. Accuracy: ±2 K.
• PT100, NI1000 elements: Sensor current: 400 μA. Resolution: 0.1 K. Accuracy: ±0.5 K.

Environmental conditions:

• Air pressure: Operation: Min. 700 hPa (max. 3000 m AMSL). Transport: Min. 260 hPa (max. 10'000 m AMSL).
• Temperature: Operation: 0...+50 °C. Storage: -30...+70 °C.
• Humidity class: F as per DIN 40040.
• Degree of protection: IP20 as per EN 60 529.

Type test reports:

• Mechanical strength: DIN IEC 68-2-32
• EMC measurement: Immunity as per IEC 801-3 class 3, EN 50081-1 and EN 50082-2.
• Electric strength: EN 50082-2 test of inputs and outputs at overvoltage of 24V passed, fire safety at 240 Veff is given.
• Vibration and shock test: EN60068-2-27/31/32 as per test specifications DIN IEC 68-2-6, DIN IEC 68-2-27.
• Climatic test: EN 60 068-2-14
• Storage temperature: EN 60 068-2-1/2
• Humidity test: DIN IEC 60 068-2-30
• Temperature-rise test: EN 60 068-2-14

4.3 Interfaces

4.3.1 RS232 Interface

For general service and diagnostic purposes, the RS232 interface is brought out to connector X13. In addition to software loading functions, such as the bootstrap loader, operating system loading and MSR tasks, the RS232 interface is also used to connect an external monitoring and operator unit. In order to supply the external HMI, a 12 V supply voltage is brought out to the X13 connector. The voltage is short-circuit proof.

Connector: X13, 8-pin RJ45

4.3.2 External Communication Interface

In case the number of data points in the ACX32 controller is insufficient for a given application, an additional, external communication interface provides for connection of external slave I/O modules. The interface is physically configured as an RS422 bus interface on D-SUB jack X14. The signal lines are terminated internally with 120 Ω.

The overall system comprises an ACX32 master and up to 15 slave I/O modules (see section 5.3.10 for an example). The following can currently be connected as slave modules:

• ACX42.12: 4 relay outputs, 12 universal inputs
• ACX41.08: 8 relay outputs
• ACX32: As slave

Connector: X14, 9-pin D-SUB jack

Warning Symbol If 2 ACX32s are interconnected as master and slave, the signals must be crossed over, i.e. signal from pin no. 2 to 3, and from pin no. 7 to 8 (refer to section 5.3.10)!

4.3.3 Module Interface

In order to implement communication application solutions, SAPHIR has two equivalent module slots, which makes it very versatile with regard to connectivity, and enables it to operate with a number of different communication busses. The two module interfaces are connected directly to the microcontroller's data/address/control bus. The modules' hardware identifiers are read via an ID signal. This enables the operating system software to automatically identify the inserted modules and start the respective drivers. As an additional power supply, the rectified 24 VAC prime power is brought out to the module connector. The modules are connected using the X15 and X16 55-pin male connectors.

Module connector X15:

Module connector X16:

4.4 Inputs and Outputs

4.4.1 Relay Outputs

8 DC-decoupled relay outputs BO1...BO8 provide for potential-free control of process operations (motors, actuators, lamps etc). The digital outputs are designed as floating relay contacts. The contacts support a load of 230 VAC and a maximum of 2 A.

The relays are arranged in two groups:

• BO1...BO4: changeover
• BO5...BO8: changeover

Warning Symbol Use only 1 working voltage within each group: 230 VAC or safety extra-low voltage. Mixing within one group is not permitted!

Recommendation: minimum relay loading is recommended:

• 230 VAC ±20%: 5 mA
• 24 VAC ±20%: 20 mA
• 5 VDC: 100 mA

The relays are controlled directly via the controller's I/O ports.

Figure 4: Relay output connection

A wiring diagram shows a typical relay output connection for the SAPHIR unit.

Warning Symbol Any suppressor circuit, interference suppression etc. must be provided externally according to the application!

The cross-section of the connecting wires should not exceed 2,5 mm² because of the Cage Clamp terminals.

4.4.2 Fast Binary Inputs

The four fast binary inputs BI1...BI4 are used to interrogate switching states, and for counting switching pulses at a maximum switching frequency of 50 Hz. These inputs are connected directly to interrupt-generating ports of the microcontroller. This provides for a quick reaction to signal changes.

Only floating contacts must be connected to the binary inputs. The contacts are interrogated with approx. 24 V / 6 mA. The counter frequency is restricted to approx. 50 Hz via the software.

Figure 5: Binary input connection

A wiring diagram shows the connection for fast binary inputs.

The cross-section of the connecting wires should not exceed 1.5 mm² because of the Cage Clamp terminals.

4.4.3 Analog Outputs

PWM analog outputs: The 4 PWM analog outputs AO1...AO4 are implemented via the controller's internal PWM outputs. The PWM signal is converted to the analog range of 0...10 VAC via an RC element and an amplifier module. A feedback circuit connecting the analog outputs to the controller's internal analog inputs is used to calibrate the outputs.

The PWM analog outputs have the following features:

• AO1...AO4 produce voltages between 0...+10 VDC
• Maximum load current 5 mA
• 10 bit resolution
• Voltage outputs are short-circuit proof.
• The setting time is typically 60 ms.
• The AO... are non-floating.
• Protective circuit: up to +24 V without destruction
• Maximum load impedance: 2 kΩ

DAC analog outputs: The 4 DAC analog outputs AO5...AO8 are implemented via a quad DAC. The 2.5 V output signal is converted to the analog range of 0...10 VAC via an amplifier module.

The DAC analog outputs have the following features:

• AO5...AO8 produce voltages between 0...+10 VDC
• Maximum load current 5 mA
• 12 bit resolution
• Voltage outputs are short-circuit proof.
• The setting time is typically 3 ms (software reaction time).
• The AO... are non-floating.
• Protective circuit: up to +24 V without destruction
• Maximum load impedance: 2 kΩ

Figure 6: Analog output connection

A wiring diagram illustrates analog output connections.

The cross-section of the connecting wires should not exceed 1.5 mm² because of the Cage Clamp terminals.

EMC measures: Use shielded cables as signal cables. Each analog output should be connected to a twisted pair. The shield must be connected broadly to a shield bus in front of the SAPHIR unit.

4.4.4 Universal Inputs

The central element of the universal inputs is a sigma-delta ADC. One of the 14 universal inputs is connected to the ADC via a multiplexer and analog switch. A scan list defined via the software determines the processing sequence. The 14 universal inputs UI1... UI14 have a common reference point and are electrically connected to the SAPHIR unit.

Each input is configurable as follows via the software:

• 0...10 V voltage input
• 0...20 mA / 4...20 mA current input (only via external 100 Ω shunt)
• Temperature Ni1000, Pt1000, Pt100 (with approx. 400 μA sensor current)
• Temperature NTC, PTC (up to approx. 4.5 kΩ, from then on with external shunt resistor)
• Digital input (24 V, max. 4.5 mA)

An analog input signal is converted in approx. 30 ms. When configured as a digital input, the conversion time is reduced to approx. 12 ms. In the worst case, the conversion time for all 14 universal inputs is approx. 420 ms. The universal inputs are controlled via multiplexers.

Refer to the SAPHIR circuit diagrams for detailed information on the control of the multiplexers and analog switches according to input configuration.

Cables: The cross-section of the connecting wires should not exceed 1.5 mm² because of the Cage Clamp terminals.

EMC measures: With the exception of the digital input, only shielded, twisted pair signal cables should be used as connecting wires. Each universal input should be connected to a twisted pair. Observe the following in the case of three-wire connected, active transducers:

• The transducer should be connected via two twisted pairs. One conductor pair is used for the power supply, the other for the signal, but the ground is removed at the transducer.

The shield must be connected broadly to a shield bus in front of the SAPHIR unit.

Figure 7: Universal input connection

A diagram illustrates various universal input connection types, including voltage, current, and Pt1000 inputs.

4.5 Real-Time Clock

SAPHIR is equipped with a real-time clock. It supports the following functions:

• Time indication in hours/minutes/seconds
• Calendar with leap-year
• Manual winter/summer time changeover
• Day of week

The real-time clock is buffered against power failure for at least two days. The clock information is retained during this period. Afterwards, the clock must be set manually (via HMI or PC).

4.6 Indications and Switches

4.6.1 Light-Emitting Diodes (LEDs)

The SAPHIR unit is equipped with four LEDs for optical status indication. The LEDs are controlled via an external port that is addressed by the microcontroller's chip select signal (CS2).

Indication meanings:

Individual ACX32 Application with an ACX32 with no communication card (RCC) installed.

- ACX32 master Master-slave application with a communication card (RCC) installed.

- ACX32 slave

4.6.2 DIL Switches

A 4x DIL switch is installed on the SAPHIR unit. The ON position of a switch supplies the "0" state at the corresponding port pin. The DIL switches are read via port P5 of the controller.

4.6.3 Bridges

The bootstrap loader is activated via bridge X19. The bridge must be inserted before the SAPHIR unit is powered up (see Fig. 2). As long as bridge X19 is inserted, the operating system cannot boot, and all LED's are on!

4x bridge module X17 on the SAPHIR unit is used to set various software modes (see also Fig. 2). The bridges are read directly by the controller port. An inserted bridge supplies a "0" at the corresponding port pin.

• X17 1/2 is to Bridge, if the Saphir is used as a Slave.
• X17 3/4 not used
• X17 5/6 not used
• X17 7/8 at the left Site, is to Stop the Task.

5 Assembly, Installation and Setup Guidelines

5.1 General Setup Notes

With the use of electronic components in automation, increasing attention must be paid to electromagnetic immunity. Typical sources of interference noise such as relays, fluorescent lamps, converters, HF generators, commutator rotors and switching controllers generate high-frequency signals that are injected directly, inductively or capacitively into the module where they can disturb or even destroy it.

Observe the following points with regard to the installation of electronic components in field panels:

• Use a galvanized assembly plate to ground racks, mains filters, shield busses and other components.
• Keep grounding connections broad and short.
• Attach shielded cables broadly to the shield bus.
• Route circuits with a high interference potential separately.
• Connect relays with freewheeling diodes or RC elements.
• Keep the wiring of modules with strong interference emissions physically separate from the module.
• Use filters positioned as close as possible to the field panel inlet to reduce mains interference.
• Ground power supplies via ground terminal as close as possible to the module using the 0 V connection.
• Install input terminals and shield busses directly at the field panel's cable inlet.
• Where not directly welded together, establish a broad electrical contact between all field panel parts, or assemble with contact washers.
• Use two-end shield connection (to ground) always with a bonding conductor.

Additionally, the following general rules should be observed during installation and commissioning:

• The devices are equipped with components that are sensitive to electrostatic discharge. Therefore, the usual precautions for electrostatic sensitive devices (ESD) should be taken.
• Printed circuit boards must not be removed from the device.
• Devices must not come into contact with charged or chargeable objects. Use approved tools only.

The following is not permitted with voltage applied:

• Removal and insertion of plug-in cables
• Changing of bridges and components
• Removal and insertion of communication modules

Devices must only be transported in their original packaging (or in suitable ESD packaging)! Any manipulation of the device beyond the appropriate proper operation and installation voids all warranties.

5.2 SAPHIR ACX32

Figure 9: SAPHIR ACX32

An image shows the SAPHIR ACX32 unit.

Warning Symbol Accidental connection of voltages greater than AC 29 V (e.g. AC 240 V) to the low-voltage connections will destroy the device.

Stop Symbol The connection sequence of the SAPHIR device is as follows: First connect the peripheral signals, then the power supply.

Warning Symbol In order to protect against accidental contact with relay connections at voltages of Ueff > 42 V, the device must be installed in an enclosure (preferably a control panel). It must be impossible to open the enclosure without the aid of a key or tool.

5.2.1 Behavior in the Event of Malfunction

Check the following in case of malfunction:

• 24 V power supply
• Correct connection of plug-in cables
• Correct connection of peripheral devices
• Watchdog error occurred?
• Diagnostics via LEDs on device front (see section 4.6.1)

If the malfunction cannot be corrected in this way, exchange the device and return it to the manufacturer's facility.

5.2.2 Connectors

WAGO Cage Clamp female connectors are provided for connection of the power supply and peripheral signals to the SAPHIR unit.

Figure 11: Connector assignment

A detailed diagram shows the connector assignments for the SAPHIR unit, including universal inputs, analog outputs, binary inputs, binary outputs, and power supply connections.

5.3 Wiring Examples

5.3.1 Basic Wiring of SAPHIR

The following illustration shows a wiring example of the SAPHIR unit.

Stop Symbol The 24 VAC supply voltages for the SAPHIR unit and the active transmitters/sensors must be generated via a transformer with two separate windings (short circuit hazard). Alternatively, two 24 V transformers can be used.

Figure 13: Basic power supply wiring

A wiring diagram illustrates the basic power supply connection for the SAPHIR unit.

5.3.2 SAPHIR with Digital Outputs

Wiring example with relay outputs: AC24...250V, 2A relay outputs

Figure 14: Relay outputs

A wiring diagram shows the connection for relay outputs.

Warning Symbol Any suppressor circuit, interference suppression etc. must be provided externally according to the application!

5.3.3 SAPHIR with Fast Counter Inputs

Wiring example with the digital inputs configured as fast counter inputs (max. 50 Hz).

Figure 15: Fast counter inputs

A wiring diagram shows the connection for fast counter inputs.

5.3.4 SAPHIR with Analog Outputs

Figure 16: Analog outputs

A wiring diagram illustrates analog outputs, including connections for a rotary actuator and a voltage input.

5.3.5 SAPHIR with Passive Sensor

Wiring example with Ni1000, Pt1000 or Pt100 configured as a passive sensor.

Figure 17: Passive sensor

A wiring diagram shows the connection of a passive temperature sensor (Ni1000, Pt1000, Pt100) to the universal inputs.

5.3.6 SAPHIR with Temperature Sensor

Wiring example with NTC or PTC temperature sensor. An NTC/PTC sensor is connected to universal input Ul11 (X12.7, X12.8). Above a resistance value of approx. 4.5 kΩ, an external shunt resistor must be connected.

Inquire first whether an NTC/PTC sensor characteristic has been implemented in the software.

Figure 18: Temperature sensor

A wiring diagram shows the connection of an NTC/PTC temperature sensor, including the use of a shunt resistor.

5.3.7 SAPHIR with Active Sensor

Wiring example with an active sensor with 0...20 mA or 4...20 mA output signal. An active sensor with a 0...20 mA current output is connected to universal input U13 (X11.5, X11.6). For this purpose, a 100 Ω shunt resistor must be connected in parallel to the input. The accuracy of the current input is largely determined by the accuracy of the shunt resistor. A resistor with a tolerance of 0.1% is recommended.

Figure 19: Active sensor with max. 20 mA output signal

A wiring diagram shows the connection of an active sensor with a 0-20mA or 4-20mA output signal.

5.3.8 SAPHIR with Active Sensor

Wiring example with an active sensor with DC 0...10 V output signal.

Figure 20: Active sensor with DC 10 V output signal

A wiring diagram shows the connection of an active sensor with a 0-10V output signal.

5.3.9 SAPHIR with Digital Input

Wiring example with 2 digital inputs, e.g. status signal.

Figure 21: Digital inputs

A wiring diagram shows the connection of digital inputs.

5.3.10 SAPHIR with Slave Modules

Wiring example of ACX32 master and AXC42.12 or ACX41.08:

Figure 22: ACX32 master and I/O extension

A wiring diagram illustrates the connection between an ACX32 master and an I/O extension module.

DIL switches:

• S1: Defines address of the slave (0 = OFF / 1 = ON)
• S2: Termination of the last slave: For the last slave module of the connected slaves, both DIL switches of S2 have to be fixed to ON position!

Wiring example of ACX32 master and AXC32 slave:

Figure 23: ACX32 master and slave

A wiring diagram shows the connection between an ACX32 master and an ACX32 slave.

Dil Switch and Bridge Module:

• S1: Defines address of the slave (0 = OFF / 1 = ON)
• X17: If ACX32 controller is used as slave: to set the software mode of AXC32 for slave at bridge module X17/1-2 an inserted bridge all to the right has to be!