Advance Optima Continuous Gas Analyzers

Syscon
System Controller, I/O Modules, Power Supply Unit

Service Manual 43/241000 EN Rev. 1

Contents

History......................................................................................................................................................................4
Explanations of Syscon ...........................................................................................................................................4
Material required ..............................................................................................................................................6
System bus (CAN)............................................................................................................................................6
Extension of the system bus cable...................................................................................................................6
Syscon1 Electronic Module .....................................................................................................................................7
Connection diagram of the electronic module with Syscon1 ...........................................................................7
Syscon1 component diagram ..............................................................................................................................9
Syscon2 Electronic Module ...................................................................................................................................12
Connection diagram of the electronic module with Syscon2 .........................................................................12
Syscon2 component diagram ............................................................................................................................13
Syscon3 Electronic Module ...................................................................................................................................16
Connection diagram of the electronic module with Syscon3 .........................................................................16
Syscon3 functional structure..............................................................................................................................16
Syscon3 system start .........................................................................................................................................17
Internal Interfaces...........................................................................................................................................18
External Interfaces .........................................................................................................................................19
Syscon 3 Block Diagram ................................................................................................................................20
Syscon3 component diagram ............................................................................................................................21
Modules of the Syscon Boards..............................................................................................................................24
Printed circuit boards / Modules.........................................................................................................................24
Analog I/O printed circuit board .........................................................................................................................26
Digital I/O printed circuit board...........................................................................................................................28
Printed circuit board 8-way mA output card .......................................................................................................30
Profibus Module .................................................................................................................................................31
Modbus module (RS232/RS485) .......................................................................................................................32
Digital I/O module...............................................................................................................................................33
Analog output module (2-way mA).....................................................................................................................34
Analog output module (4-way mA).....................................................................................................................35
Analog input module (4-way mA).......................................................................................................................36
Power supply unitr..............................................................................................................................................37
Technical data of the power supply unit .........................................................................................................37
Power supply unit...............................................................................................................................................38
Technical data of the power supply unit .........................................................................................................38
Fault messages and interpretation during the booting process:............................................................................39
Replacement of Syscon1 with Syscon3 ................................................................................................................42
Tools required .................................................................................................................................................42
Material required ............................................................................................................................................42
Procedure .......................................................................................................................................................43
Replacement of Syscon2 with Syscon3 ................................................................................................................49
Tools required .................................................................................................................................................49
Material required ............................................................................................................................................49
Procedure .......................................................................................................................................................50
Replacement of Syscon2 by Syscon3 in ACX.......................................................................................................55
Material required ............................................................................................................................................55
Procedure .......................................................................................................................................................55
Recommended documentation and software ........................................................................................................59
Summary information on: ...................................................................................................................................60
Optima SMT ...................................................................................................................................................60
Optima Remote HMI.......................................................................................................................................60
TCT.................................................................................................................................................................60

43/24-1000 EN Rev. 1 Syscon Service Manual 3

History
Advance Optima has been manufactured since 1996 and was also sold under this name until 2003. The new
version AO2000 has been supplied since June 2003. Externally this system distinguishes itself from the
previous systems by the light colour of the housing, the colours used in the design of the keyboard film in
accordance with the ABB directives, the initials on the door and the rating plate.
There is a new version of the Syscon board with altered features in the electronic module. The analog/digital
I/Os on the Syscon1 board and the modbus are now issued by the Syscon2 board via separate modules. These
modules are linked to the Syscon2 via a multipolar plug connection.
The following I/O modules are related
 Analog output module (mA outputs)
 Digital I/O module
 Modbus module (RS232 and RS485 interface)
 Profibus module (RS485 interface for Profibus DP, MBP and for Profibus PA).
CAN cards can be installed on Syscon3 only after conversion from Syscon1 or Syscon2. In systems delivered
with Syscon3 no slots for CAN cards are available in the rear panel.
Syscon1 CAN cards Slot X11 to X15
Syscon2 CAN cards Slot X11 to X13
The display and the HMI printed circuit board correspond unchanged to the previous production status.
Spare parts can be found in the spare parts catalog.
As only very few Syscon1 boards are now available, the Syscon2 board is not downwards-compatible, in the
event of service a special approach in keeping with the respective application is required.
Since 2009, a new generation of the Syscon is available for our analyzer series, it is called Syscon3. The board
guarantees full compatibility with previous versions. All CAN cards or I/O cards are portable after conversion
from Syscon1 or Syscon2 to Syscon3.
No complete replacement set is available for installation of the Syscon3 in systems which are equipped with
Syscon1 and Syscon2. For organisational reasons 3 material items are available which must be combined as
required. More information can be found in the chapter Replacement of Syscon (1 for 3) and (2 for 3).

Explanations of Syscon
The Syscon (system controller) is a functional modules of the Advance Optima analyzer system. The task of
Syscon is to coordinate signal processing of the individual components and to administer the function of the
system. Measured values and status messages from the individual modules are collected via CAN bus,
processed and evaluated in order to be made available to a higher-level system via Ethernet or bus connection.
Syscon can control the calibrations of connected analyzer modules.
Decentralized I/O units can be collected and controlled by the system via CAN bus. The evaluation and
processing of these signals is provided by a function block configuration.
The Syscon board used in the central processing unit is an innovation pointing to the future which offers great
flexibility regarding performance and customized options through a transparent modular structure.

4 Syscon Service Manual 43/24-1000 EN Rev. 1

Diagram of possible Syscon connections:

3 1 2

4 5

1 A

5 C

Legend for A: Decentralised CAN bus connections

1. Advance Optima analyzer module
2. SCC sample gas cooler with I/O card
3. SCC-F sample gas feed-in unit with I/O card
Legend for B: Possible signal connections
1. Modbus
2. Profibus
3. Ethernet
4. Analog input and output signals (printed circuit boards/modules)
5. Digital input and output signals (printed circuit boards/modules)
Legend for C: Central processing unit with Syscon board, internal connections
1. Advance Optima analyzer modules
2. Syscon
3. System monitoring, control of calibration and function block configuration, parameter setting, display and
operator panel
4. Internal pneumatics only in connection with analyzer module
5. Operator control unit with display

43/24-1000 EN Rev. 1 Syscon Service Manual 5

Material required
Select the required instruction material according to the length of the lines and the foreseeable current load.
 Length of the RS485 lines 1200m max. (transmission rate 19200 bit/s max.).
 Length of the RS232 lines 15m max.
Note:
Identify the cables or the sockets of the I/O cards so that they can be clearly assigned to the corresponding I/O
card.

System bus (CAN)

The system bus has a linear structure; its maximum length is 350 m.

Extension of the system bus cable

Note:
When the standard system bus cables and plugs are not used to extend the system bus, the specifications in
the following table must be observed:
System bus cable specification
Shielded cable twisted-pair wires
Number of wires, cross-
2 x 2 x 0.25 mm2
section
Inductance approx. 0.67 mH/km
Impedance approx. 80 
Coupling (1 kHz) approx. 300 pF/100 m
Operating capacity Wire–wire approx. 120 nF/km, wire–shield approx. 160 nF/km

The system bus cable must be fed through a metal junction box with metal cable connectors for reasons of
electromagnetic capability. The shielding must be placed on the cable connectors. The unused wire of the 4-wire
extension cable must be connected to a PE terminal in the junction box.

6 Syscon Service Manual 43/24-1000 EN Rev. 1

Syscon1 Electronic Module
Connection diagram of the electronic module with Syscon1

 X01 ower supply connection 115 / 230V AC

 X02 digital outputs
 X03 analog outputs and digital inputs
 X04 Ethernet-10BASE2 interface (optional)
 X05 RS-485 interface
 X06 RS-232C interface
 X07 system bus (CAN)
 X08 Ethernet-10BASE-T interface
 X11 to X15 analog and digital I/O cards (optional)

Connection of I/O contacts from Syscon1 board

X02 pin layout of the Syscon1 board

43/24-1000 EN Rev. 1 Syscon Service Manual 7

Terminal layout for standard function block application
X02 digital I/O on the Syscon1 board
Digital output DO1 Failure
DO2 Function control
Configuration for individual
DO3 Maintenance request
status signals
DO4 External solenoid valve

Digital output DO1 Collective status

DO2 Alarm value 1)
Configuration for collective
DO3 Alarm value 1)
status signals
DO4 External solenoid valve
1) Digital output: sequence of alarm values and sequence of components configured in the analyzer.
X03 pin layout of the Syscon1 board

Terminal layout for standard function block application

X03 analog outputs and digital inputs on the Syscon1 board

Analog outputs 3) AO1 Output measured value

AO2 Output measured value
DI1 Start autocalibration
Digital inputs DI2 Disable autocalibration
DI3 Zero point correction
DI4 End point correction
3) Analog output: Sequence of current outputs and sequence of components configured in the analyzer.

RS-485 interface X05 of the Syscon1 board

2 RTxD–
5 4 3 2 1
3 RTxD+
9 8 7 6 5 GND

RS-232C interface X06 of the Syscon1 board

2 RxD
1 2 3 4 5
3 TxD
6 7 8 9 5 GND

Ethernet 10BASE T interface X08 of the Syscon1 board

1 10TT+
1 8
2 10TT-
3 10TR+
6
10TR-

8 Syscon Service Manual 43/24-1000 EN Rev. 1

Syscon1 component diagram

1 2

8 7

Syscon1 legend
1. Cutout 1
2. RAM storage module
3. Memory module (8 MB or 16 MB)
4. Reset contact
5. Display / keyboard connection (HMI)
6. Buffer battery (5 years of buffer time, battery is replaceable)
7. Power supply connection int. power supply unit
8. Cutout 2

43/24-1000 EN Rev. 1 Syscon Service Manual 9

 1 2 3 4

6 5

Legend for Syscon1 cutout 1

1. Connection for
4 digital inputs
4 digital outputs
2 analog outputs
2. CAN bus connection
3. RS232 interface connection (hyperterminal interface)
4. RS232/RS485 interface connection
5. 10BASE-2 connection
6. 10BASE-T Ethernet connection

10 Syscon Service Manual 43/24-1000 EN Rev. 1

 1

8 7 6

Legend for Syscon1 cutout 2

1. X11 PCI Slot4 and CAN connection
2. X12 PCI Slot3 and CAN connection
3. X13 PCI Slot2 and CAN connection
4. X14 PCI Slot1 and CAN connection
5. X15 CAN connection Ethernet card
6. Internal CAN bus connection
7. AT bus
8. AT bus

43/24-1000 EN Rev. 1 Syscon Service Manual 11

Syscon2 Electronic Module
Connection diagram of the electronic module with Syscon2

 X01 power supply connection 115 / 230V AC

 X07 system bus (CAN)
 X08 Ethernet-10/100BASE-T interface
 X11 to X13 analog I/O cards, digital I/O cards, Ethernet card, 8-way analog output card (optional)
 X20 to X29 Profibus module, RS232/RS485 module, analog output module, digital I/O module (optional)
 X31 with no function
 X32 with no function
Note:
For approval reasons, the Syscon2 may not be used in an analyzer with DMT approval.

12 Syscon Service Manual 43/24-1000 EN Rev. 1

Syscon2 component diagram

1 2 3

8 7

Legend for Syscon2

1. Buffer battery (5 years of buffer time, battery is replaceable)
2. Power supply connection int. power supply unit
3. CAN bus connection
4. X13 PCI Slot1 and CAN connection
5. X12 PCI Slot2 and CAN connection
6. X11 PCI Slot3 and CAN connection
7. Cutout 1
8. Cutout 2

43/24-1000 EN Rev. 1 Syscon Service Manual 13

 1 2

Legend for Syscon2 cutout 1

1. Modbus connection and I/O modules (low speed)
2. Profibus module connection (high speed)
3. USB1 connection, at present without use
4. USB0 connection, at present without use
5. Connection 10/100BASE-T Ethernet (green LED displays Link active, yellow LED data transfer)
6. CAN bus connection

14 Syscon Service Manual 43/24-1000 EN Rev. 1

 6

Legend for Syscon2 cutout 2

1. DRAM storage module
2. Compact Flash Card (data storage, operating software, data record storage (backup))
3. LED (orange flashes briefly during data transfer to the Compact Flash Card)
4. LED (orange maintenance request)
5. LED (green power supply on)
6. Display / keyboard connection (HMI)

Note:
Pre-initialised Compact Flash Card with current SMT version should be carried as aid to performing a system
test. If the system starts error-free with the Compact Flash Card, it must be assumed that the available data
record contains errors.

43/24-1000 EN Rev. 1 Syscon Service Manual 15

Syscon3 Electronic Module
Connection diagram of the electronic module with Syscon3

 X01 power supply connection 115 / 230V AC

 X07 system bus (CAN)
 X08 Ethernet-10/100BASE-T interface
 X09 Ethernet-10/100/1000BASE-T interface (connection service PC)
 X20 to X29 Profibus module, RS232/RS485 module, analog output module, digital I/O module (optional)
 X31 with no function
 X32 with no function

NOTE.
For approval reasons, the Syscon3 must not be used in
 ACF-NT system
 Analyzers with DMT approval
 Systems with approval as per 13th and 17th Federal Emission Control Act (BImSchv), which contain
Uras14, Magnos16, Magnos106, Limas11 or MultiFID14.

Syscon3 functional structure

Main processor:
controls and monitors the individual interfaces. The signals received are evaluated by existing, specific software,
processed and displayed as signals (graphics, status or measured value).
Graphic controller:
Activation of the display, the status LEDs and signal acquisition of the operator keyboard.
Real-Time Clock RTS:
The task consists of storing logbook entries with a precise time-stamp and starting automatic calibration without
delay. The buffer battery with socket enables data retention during supply voltage interruptions. The battery life
is approximately 5 years.
Supply voltage:
Syscon3 is supplied by an internal, special power supply unit with unipolar 24V DC voltage. Operating voltages
required for the board are generated locally. 5V DC and 24V DC supply voltages are supplied for the I/O
modules.

16 Syscon Service Manual 43/24-1000 EN Rev. 1

Watchdog and voltage monitor:
The processor is monitored by means of this implemented function. In the event of a fault a reset is triggered; if
three resets are generated in a fixed time window, this generates a continuous reset. This continuous reset can
only be reset by a warm start (power off/on).

Syscon3 system start

After a cold restart of the system, the boot loader is started.
The following boot sources are available:
 System1 : The standard system for normal operation
 System2 : Rescue System for an emergency.
The system is loaded if the boot loader detects an error in System1 or if a jumper is plugged into the
Syscon3 board. This system starts to enable communication with the system via SMT.

Note:
If there is a jumper at position Bit 0 on the associated edge connector when the system is started, the rescue
system is started. In this way the operating system detects any additional jumpers plugged in (Bit1, Bit2, Bit3)
and evaluates this information.
 If a jumper is plugged in at position Bit 0, the rescue system is activated
 If a jumper is plugged in at position Bit 0 and a jumper at position Bit 1, on starting the IP addresses are
deleted and reset to the default values again.
 If a jumper is plugged in at position Bit 0 and a jumper at position Bit 2, on starting the databases with
instrument configuration data are deleted.
 If a jumper is plugged in at position Bit 0 and a jumper at position Bit 3, the complete data partition is
formatted, the IP addresses are deleted and reset to the default values again, and the backup configuration
and time zone deleted. The databases with instrument configuration data are not influenced by this jumper
combination.
 If a jumper is plugged in at positions Bit 0, Bit 2 and Bit 3, the complete data partition is formatted, the IP
addresses are deleted and reset to the default values again. The backup configuration, the time zone and
the instrument configuration data from the database are deleted.
This mechanism may be helpful if the rescue system does not start any more either. This could theoretically
happen if the data in the data partition are faulty as the rescue system tries to read the IP addresses from
this partition at the start.

Default values for the interface

 Default value for the X09 interface: 192.168.1.1/255.255.255.0
 Default value for the X08 interface: 192.168.2.1/255.255.255.0

43/24-1000 EN Rev. 1 Syscon Service Manual 17

 Jumper Bit0: Rescue-System activated
Jumper Bit1: IP address reseted with default values
Jumper Bit2: Cancellation of configuration and data base
Jumper Bit3: Cancellation of partition „ Media / Data“

Jumper Bit1 , Bit2 and Bit3 are only activ, if the Jumper Bit0 is pluged too

Bit0
Bit1
Bit2
Bit3

Internal Interfaces
I/O module:
Up to 5 modules can be assembled on this interface through stacking technology. The interface consists of two
separate plug connections. One plug connection provides a low-speed interface and the second plug
connection a high-speed interface. A digital I/O module only requires the low-speed interface, however, a
profibus module requires the high-speed interface in addition.
CAN Extender:
The CAN extender is installed only when converting from Syscon1 or Syscon2 to Syscon3 and allows for further
use of existing CAN I/O boards of the old system. The signals and supply voltages necessary for operation of
the cards are supplied via the transmission socket on Syscon3. A PCI or ISA function is no longer provided and
the option of using a separate network card therefore does not exist.
HMI (operator control and display unit):
Connection of the film keyboard, activation of the display and the 3 status LEDs via an adapter board with
display controller
Parallel I/O purge gas monitor:
Connection of an optional pressure sensor, to measure and monitor the housing pressure in systems with case
purging. In the event of a fault a potential-free contact opens. A bipolar connection for reading in is available on
the board.

18 Syscon Service Manual 43/24-1000 EN Rev. 1

External Interfaces
1 2

5 4 3

1. X08 Ethernet 10/100/1000BASE-T interface (Default IP address 192.168.2.1/255.255.255.0)

2. X09 Ethernet 10/100/1000BASE-T interface connection of service PC (default IP address
192.168.1.1/255.255.255.0)
are available via RJ-45 socket with visual feedback signal of link and speed status on the rear wall of the
electronic module. Parameters can be set separately for both interfaces for network connections.
3. Green LED (data connection / link)
4. Red LED (data transfer / speed status)
5. CAN interface
is available by means of a 3-pin socket on the rear wall of the electronic module. Interface for
communication with external Advance Optima analyzer modules, WIN block basic modules, interface card
of the SCC-F sample gas feed-in unit and the SCC-C sample gas cooler.
USB interfaces
are currently available without a function on the rear wall of the electronic module and are covered by sheet
metal.
USB1: High-speed interface
USB2: Full-speed interface

43/24-1000 EN Rev. 1 Syscon Service Manual 19

Syscon 3 Block Diagram

internal
Interface

Parallel IO
Power Supply SPI
internal USB 3
Mezzanin High Speed
Mezzanin Low Speed
Flash OnBoard
HMI

Circuit board
Syscon3
external
Interface

DC/DC Converter for Ethernet 1 10/100/1000

internal voltage Ethernet 2 10/100/1000
USB 1
Service USB 2
OnBoard
CAN
RTC Real Time Clock
Watchdog
Debug RS232
Graphics Controller
with SD RAM
Display Interface

Storage
OnBoard

SD RAM
NOR Flash
NOR Flash

20 Syscon Service Manual 43/24-1000 EN Rev. 1

Syscon3 component diagram

1 2

5 4 3

Legend for Syscon3

1. Cutout 1
2. Cutout 2
3. RAM working storage
4. Not for service activity
5. Buffer battery (5 years of buffer time, battery is replaceable)
Syscon2 installed in an analyzer system in category 3G may be used with buffer battery.
Syscon3 installed in an analyzer system in category 2G must not be used with buffer battery.

43/24-1000 EN Rev. 1 Syscon Service Manual 21

Legend for Syscon3 cutout 1
1. Display / keyboard connection (HMI)
2. Power supply connection int. power supply unit
3. Connection of external pressure sensor (use in American region)
4. Connection of internal system bus analyzer module (SNE or AMC)
5. Connection of external system bus analyzer module (rear wall electronic module)
6. Connection for internal CAN extender board
7. Not for service activity
8. Modbus connection and I/O modules (low speed)
9. Profibus module connection (high speed)
10. Status LEDs
 L1 currently without function
 L2 red fault Syscon (power supply / Watchdog active)
 L3 yellow maintenance request
 L4 green power supply)
11. Activation of the rescue system (set jumper)
12. Not for service activity

22 Syscon Service Manual 43/24-1000 EN Rev. 1

Legend for Syscon3 cutout 2
1. Not for service activity (plug-in jumper not set)
2. Not for service activity
3. Not for service activity
4. Not for service activity
5. X32 USB (currently without function)
6. X32 USB (currently without function)
7. X09 Ethernet 10/100/1000BASE-T connection (connection service PC)
8. X08 Ethernet10/100/1000BASE-T connection

43/24-1000 EN Rev. 1 Syscon Service Manual 23

Modules of the Syscon Boards

Printed circuit boards / Modules

Table

Syscon1 Syscon2 Syscon3

X X X

Analog I/O printed circuit

board

X X X

Digital I/O printed circuit

board

x X X

Printed circuit board

8-way mA output card

Network card

CAN Bus Extender

24 Syscon Service Manual 43/24-1000 EN Rev. 1

 X X

Profibus module

X X

Modbus module

X X

Digital I/O module

X X

Analog output module

2-way mA

Analog output module

4-way mA

Analog input module

4-way mA

43/24-1000 EN Rev. 1 Syscon Service Manual 25

Analog I/O printed circuit board

Connection of analog I/O printed circuit board

Pin layout of analog I/O printed circuit board

1
2
3 DO1 NC max. 30 V / 1 A
4 C
5 NO
6 DO2 NC max. 30 V / 1 A
7 C
8 NO
+ - 9 DI1 + - 12 ...24 V DC
10
+ - 11 DI2 + - 12 ...24 V DC
12
50  13 AI1 U -10 ...+ 10 V, Rein = 1 M oder
14 I -20...+20 mA, Bürde 50 ,
15 C bis 10 V gegeneinander getrennt
16 AI2 U -10 ...+ 10 V, Rein = 1 M oder
50 
17 I -20...+20 mA, Bürde 50 ,
18 C bis 10 V gegeneinander getrennt
19 AO1 + 0/4...20 mA, max. 750 
20 -
21 AO2 + 0/4...20 mA, max. 750 
22 -

DO1…DO2 digital outputs:

Potential-free alternating contacts, contact rating 30 V/1 A max.
Note:
The relays must be operated at any time within the specified data. Inductive or capacitive loads must be
connected with corresponding protective measures (freewheeling diodes for inductive and serial resistances for
capacitive loads).
DI1…DI2 Digital inputs:
Opto-electronic coupler with internal power supply 12…24 VDC, switchable with potential-free contacts,
alternatively: switchable with external power 12…24 VDC, common negative pole

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AI1…AI2 analog inputs:
–20…+20 mA, load 50  or –10…+10 V, Rein = 1 M, to 10 V separated from each other
AO1…AO2 analog outputs:
0/4…20 mA (configurable, factory set to to 4…20 mA ), common negative pole, electrically isolated towards the
ground, can be grounded as necessary, extension compared with local protective depotential 50 V max., load
750  max. The output signal may not be smaller than 0 mA.
Design:
22-pin plug-in terminal strip for stranded wire or solid wire with 1,5 mm2 max. (16AWG)
Note:
The terminal layout with input and output signals is contained in the Analyzer data sheet supplied with the gas
analyzer. The relays are displayed in a de-energized state. The de-energized state corresponds to the state in
the event of a fault ("fail safe").

Terminal layout for Syscon1 standard function block application

Analog I/O card Slot 1 (X11)

Digital output 1) DO1 Alarm value

DO2 Alarm value
Digital input DI1 Calibration cell on / off
DI2 Retain current output
Analog input 2) AI1 External measured value
AI2 External measured value
Analog output 3) AO1 Output measured value
AO2 Output measured value
1) Digital output:
Sequence of alarm values and sequence of components configured in the analyzer.
2) Analog input:
Current input 4…20 mA corresponds to display 0…100 % span
3) Analog output:
Sequence of current outputs and sequence of components configured in the analyzer.

Terminal layout for Syscon1 standard function block application

Analog I/O card Slot 2 (X12)

Digital output 1) DO1 Alarm value

DO2 Alarm value
Digital input DI1 Pump on / off
DI2 External failure
Analog input 2) AI1 External measured value
AI2 External measured value
Analog output 3) AO1 Output measured value
AO2 Output measured value
1) Digital output:
Sequence of alarm values and sequence of components configured in the analyzer.
2) Analog input:
Current input 4…20 mA corresponds to display 0…100 % span
3) Analog output:
Sequence of current outputs and sequence of components configured in the analyzer.
Note:
This CAN I/O card can be used in Syscon3 if a system was upgraded from Syscon1 or Syscon2 by means of a
Syscon3 conversion set.
No standard functions for this printed circuit board are available for Syscon2 and Syscon3. The desired
functions must be manually configured in the system.

43/24-1000 EN Rev. 1 Syscon Service Manual 27

Digital I/O printed circuit board

Digital I/O printed circuit board connection

Pin layout of digital I/O printed circuit board

1
2
3 DO1 NC max. 30 V / 1 A
4 C
5 NO
6 DO2 NC max. 30 V / 1 A
7 C
8 NO
9 DO3 NC max. 30 V / 1 A
10 C
11 NO
12 DO4 NC max. 30 V / 1 A
13 C
14 NO
+ - 15 DI1 + - 12 ...24 V DC
16
+ - 17 DI2 + - 12 ...24 V DC
18
+ - 19 DI3 + - 12 ...24 V DC
20
+ - 21 DI4 + - 12 ...24 V DC
22

DO1…DO4 digital outputs:

Potential-free alternating contacts, contact rating 30 V/1 A max.
Note:
The relays must be operated at any time within the specified data. Inductive or capacitive loads must be
connected with corresponding protective measures (freewheeling diodes for inductive and serial resistances for
capacitive loads).
DI1…DI4 digital inputs:
Opto-electronic coupler with internal power supply 12…24 VDC, switchable with potential-free contacts,
alternatively: switchable with external power 12…24 VDC, common negative pole

28 Syscon Service Manual 43/24-1000 EN Rev. 1

Design:
22-pin plug-in terminal strip for stranded wire or solid wire with 1.5 mm2 max. (16AWG)
Note:
The terminal layout with input and output signals is contained in the Analyzer data sheet supplied with the gas
analyzer. The relays are displayed in a de-energized state. The de-energized state corresponds to the state in
the event of a fault ("fail safe").
Terminal layout for Syscon1 standard function block application
Digital I/O card Slot 3 (X13)
DO1 Measuring range 1
Digital outputs DO2 Measuring range 2 if configured
Measuring range feedback signal Component 1
DO3 Measuring range 3 if configured
DO4 Measuring range 4 if configured
DI1 Measuring range 1
Digital inputs DI2 Measuring range 2 if configured
Measuring range switch-over Component 1
DI3 Measuring range 3 if configured
DI4 Measuring range 4 if configured
Digital output:
Sequence of alarm values and sequence of components configured in the analyzer.

Terminal layout for Syscon1 standard function block application

Digital I/O card Slot 4 (X14)
DO1 Alarm values
Digital outputs DO2 Alarm values
DO3 Alarm values
DO4 Alarm values
DI1 Calibration cell in / out
Digital inputs DI2 Retain current output
DI3 Pump on / off
DI4 External failure

Terminal layout for Syscon1 standard function block application

Digital I/O card Slot 5 (X15)
DO1 External solenoied valve for sample gas
Digital outputs DO2 External solenoied valve for zero reference gas
DO3 External solenoied valve for span reference gas
DO4 External pump on / off
DI1 Pump on / off
Digital inputs DI2 External failure
DI3 External failure
DI4 External failure

Note:
This CAN I/O card can be used in Syscon3 if a system was upgraded from Syscon1 or Syscon2 by means of a
Syscon3 conversion set.
No standard functions for this printed circuit board are available for Syscon2 and Syscon3. The desired
functions must be manually configured in the system.

43/24-1000 EN Rev. 1 Syscon Service Manual 29

Printed circuit board 8-way mA output card

Connection of printed circuit board 8-way mA output card

Pin layout of printed circuit board 8-way mA output card

1
2
3
4 AO1 + 0/4...20 mA, max. 750 
5 -
6 AO2 + 0/4...20 mA, max. 750 
7 -
8 AO3 + 0/4...20 mA, max. 750 
9 -
10 AO4 + 0/4...20 mA, max. 750 
11 -
12
13
14 AO5 + 0/4...20 mA, max. 750 
15 -
16 AO6 + 0/4...20 mA, max. 750 
17 -
18 AO7 + 0/4...20 mA, max. 750 
19 -
20 AO8 + 0/4...20 mA, max. 750 
21 -
22

AO1…AO8 analog outputs:

0/4…20 mA (par configurable, factory set to to 4…20 mA ), 2 groups each with 4 analog outputs with respective
common negative pole, electrically isolated towards the ground, can be grounded as necessary, extension
compared with local protective depotential 50 V max., load 750  max. The output signal may not be smaller
than 0 mA.
Design:
22-pin plug-in terminal strip for stranded wire or solid wire with 1.5 mm2 max. (16AWG)
Note:
The terminal layout with output signals is contained in the Analyzer data sheet supplied with the gas analyzer.

30 Syscon Service Manual 43/24-1000 EN Rev. 1

Note:
This CAN I/O card can be used in Syscon3 if a system was upgraded from Syscon1 or Syscon2 to Syscon3 by
means of a conversion set.
No standard functions for this printed circuit board are available for Syscon2 and Syscon3. The desired
functions must be manually integrated into the system.

Profibus Module

Profibus module connection

RS485 MBP

6 1 2 3 4

Pin layout of the Profibus module (RS485 interface)

01 – Not in use
02 M24 24 V output voltage ground
03 RxD/TxD-P Receive/transmit data-Plus, B line
04 – Not in use
05 DGND Data transmission potential (reference potential re supply voltage)
06 VP Supply voltage Plus (5 V)
07 P24 24 V output voltage Plus, max. 0.2 A
08 RxD/TxD-N Receive/transmit data-N, A line
09 – Not in use
Design: 9-pin sub-D socket connector

Pin layout of the MBP interface (not intrinsically safe)

01 +
02 Not in use
03 –
04 GND
Design:
4-pin plug-in terminal strip for stranded wire or solid wire with 1 mm2 max. (17AWG). Observe information
regarding material required.
Note:
The module must always be clipped onto the Syscon2 and Syscon3 as a first printed circuit board (X20 / X21).

43/24-1000 EN Rev. 1 Syscon Service Manual 31

Modbus module (RS232/RS485)

Connection Modbus module (RS232/RS485)

RS232 RS485

1 1

6 6

Pin layout RS232 interface

02 RxD
03 TxD
05 GND
Design: 9-pin Sub-D pin plug

Pin layout f RS485 interface

02 RTxD–
03 RTxD+
05 GND
Design: 9-pin Sub-D socket connector

Note:
The module can be clipped onto Syscon2 and Syscon3 at any position.

32 Syscon Service Manual 43/24-1000 EN Rev. 1

Digital I/O module

Digital I/O module connection

DI4 DI3 DI2 DI1 DO4 DO3 DO2 DO1

1 3 5 7 9 11 13 15 17 19 21 23

2 4 6 8 10 12 14 16 18 20 22 24

Pin layout of the digital I/O printed circuit board

1 DI4 -
2 +
12-24 V
24V 3 GND
5 DI3 -
6 +
12-24 V
24V 4 GND
7 DI2 -
8 +
12-24 V
24V 9 GND
11 DI1 -
12 +
12-24 V
24V 10 GND
13 DO4 NO max. 30 V / 1 A
15 Common
17 NC
14 DO3 NO max. 30 V / 1 A
16 Common
18 NC
19 DO2 NO max. 30 V / 1 A
21 Common
23 NC
20 DO1 NO max. 30 V / 1 A
22 Common
24 NC

DI1…DI4 Digital inputs:

Opto-electronic coupler with internal 24 VDC power supply. Activation alternatively with potential-free contacts,
with external 12…24 VDC voltage or with PNP or NPN Open Collector drivers.
DO1…DO4 Digital outputs:
Potential-free alternating contacts, contact rating 30 V/1 A max.

43/24-1000 EN Rev. 1 Syscon Service Manual 33

Note:
The relays must be operated at any time within the specified data. Inductive or capacitive loads must be
connected with corresponding protective measures (freewheeling diodes for inductive and serial resistances for
capacitive loads).
Design:
2x12-pin plug-in terminal strip for stranded wire or solid wire with 1 mm2 max. (17AWG).
Observe information regarding material required.
Note:
The module can be clipped onto Syscon2 and Syscon3 at any position. The terminal layout with input and
output signals is contained in the Analyzer data sheet supplied with the gas analyzer. The relays are displayed
in a de-energized state. The de-energized state corresponds to the state in the event of a fault ("fail safe").

Analog output module (2-way mA)

Analog output module (2-way mA) connection

Analog output module (2-way mA) pin layout

1 AO1 + 0/4...20 mA, max. 750 

2 -
3 AO2 + 0/4...20 mA, max. 750 
4 -

AO1…AO2 analog outputs:

0/4…20 mA (parameters can be set, factory-set to 4…20 mA ), common negative pole, electrically isolated
towards the ground, can be grounded as necessary, extension compared with local protective depotential 50 V
max., load 750  max. The output signal may not be smaller than 0 mA.
Design:
4-pin plug-in terminal strip for stranded wire or solid wire with 1 mm2 max. (17AWG).
Note:
The module can be clipped onto Syscon2 and Syscon3 at any position. Comply with required materials. The
terminal layout is contained in the Analyzer data sheet supplied with the analyzer.

34 Syscon Service Manual 43/24-1000 EN Rev. 1

Analog output module (4-way mA)

Analog output module (4-way mA) connection

Pin layout of analog output module (4-way mA)

AO1…AO8 analog outputs:

0/4…20 mA (configurable, factory-set to 4…20 mA), common negative pole, electrically isolated towards the
ground, can be grounded as necessary, extension compared with local protective depotential 50 V max., load
750  max. The output signal may not be smaller than 0 mA.
Design:
8-pin plug-in terminal strip for stranded wire or solid wire with 1 mm2 max. (17AWG).
Note:
The module can be clipped onto Syscon3 at any position. Comply with required materials. The terminal layout is
contained in the Analyzer data sheet supplied with the gas analyzer.

43/24-1000 EN Rev. 1 Syscon Service Manual 35

Analog input module (4-way mA)

Analog input module (4-way mA) connection

1 3 5 7 9

2 4 6 8 10

Analog input module (4-way mA) pin layout

50 
1 AI1 I 0...20 mA, Bürde 50 
50  2 C
3 AI2 I 0...20 mA, Bürde 50 
50  4 C
5 AI3 I 0...20 mA, Bürde 50 
50  6 C
7 AI4 I 0...20 mA, Bürde 50 
8 C
9 +24 V Energieversorgung für
10 GND externen Sensor

AI1…AI2 analog inputs:

0…20 am, load 50 
+24 V Power output:
+24 V DC to supply an external sensor, protected by 100 mA fuse (self-resetting fuse)
Design:
2x5-pin plug-in terminal strip for stranded wire or solid wire with 1 mm2 max. (17AWG).
Note:
The module can be clipped onto Syscon3 at any position. Comply with required materials. The terminal layout is
contained in the Analyzer data sheet suppled with the gas analyzer.

36 Syscon Service Manual 43/24-1000 EN Rev. 1

Power supply unit

Mains connection power supply unit (746751)

SL

+ 24V

PF

+ 24V
+ 24V

Power supply unit terminal layout (746751)

Note:
Input voltage of the power supply unit can be switched

Technical data of the power supply unit

Input voltage, 85 V…115 V…140 V AC, max. 2.5 A
current drain 185 V…230 V…264 V AC, max. 1.25 A
Mains frequency range 50…60 Hz
Power consumption max. 175 W
Output 24 V DC  5 %, 6A at 40°C, 4 A at 70°C
Rated power 144 W
G-fuse link as per EN 60127-2,
Miniature fuse
rated power 4 A, time-lag fuse (for 115 V AC and for 230 V AC)
Mains connection 3-pin grounded-instrument connector as per EN 60320/C14

43/24-1000 EN Rev. 1 Syscon Service Manual 37

Power supply unit

Mains connection power supply unit (758047 / 758118)

SL ( grün / gelb )

+ 24V ( grau oder rot )

( schwarz oder blau )

PF ( weiß oder braun )

(schwarz oder blau )
( schwarz oder blau )
+ 24V ( grau oder rot )
+ 24V ( grau oder rot )

Mains connection power supply unit (758118)

grün = green, gelb = yellow, grau = gray, rot = red, schwarz = black, blau = blue, weiß = white, braun = brown

Technical data of the power supply unit

Input voltage, 100…240 V AC, –15 %, +10 %,
current drain max. 2.2 A
Mains frequency range 50…60 Hz ± 3 Hz
Power consumption max. 187 W
24 V DC  5 %
Output to supply the electronic module and one installed in the central processing unit or
(as an option) or of an external analyzer module
Rated power 144 W
Mains connection 3-pin grounded-instrument connector as per EN 60320/C14,

38 Syscon Service Manual 43/24-1000 EN Rev. 1

Fault messages and interpretation during the booting process:

Process Alarm Syscon1 Syscon2 Syscon3 Actions for fault recovery

Working storage
None, display black, red LED ”ERROR” illuminated X
Power-On Replace working storage

None, display black X X Display remains black (but display unit OK):
Syscon board (hardware) or BIOS defective.
PC-BIOS initialization None, display black Replace Syscon board

Operating system start Loading Operating System… System stops at one of these
alarms:
ABB AO2000 Series starting… System software on the Compact Flash
AO system software start X
Please wait. defective.
Replace Compact Flash
Starting Applications…
Successful system check:
Then monitoring is taken over by the Normal system start.
Start of AO application
HMI application

ABB AO2000 Series starting… System software on the Compact Flash

defective.
Serious System Damage!
Replace Compact Flash.
One or more System Files are damaged.
The “Rescue Mode” is an aid to rescuing the
Error in system check Please restart the system in Rescue Mode, connect X
data on the Compact Flash.
with SMT and load new software. However, this action can only be performed
The system will reboot in 10 seconds. during development.
The released versions of the SMT software
Countdown, then reboot. do NOT support this feature.

43/24-1000 EN Rev. 1 Syscon Service Manual 39

 Syscon1 Syscon2
Software system
controller
(1.1.x / 1.1.x) (1.2.0 / 1.2.0) (1.2.1 / 1.2.0) (1.3.0 / 1.3.0) (1.3.1 / 1.3.0) (1.3.3 / 1.3.3) (1.3.4 / 1.3.3) (1.4.0 / 1.4.0) (2.0.0 / 2.0.0) 3.0.1**
consisting of (firmware /
system software)
not available 2.1.2 2.1.5 2.2.1 2.2.6 2.2.8 2.2.13 2.3.0/ use only version 3.0.5**
Optima SMT required for
download of system
2.3.1 * 2.5.0
controller software

1.1.x 1.2.x 1.2.x 1.2.x 1.2.x 1.2.x 1.2.x 1.2.x 1.2.x 1.2.x
1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0
1.3.2 1.3.2 1.3.2 1.3.2 1.3.2 1.3.2 1.3.2 1.3.2 1.3.2
Software analyzer module 1.3.3 1.3.3 1.3.3 1.3.3 1.3.3 1.3.3 1.3.3 1.3.3 1.3.3
1.4.0 1.4.0 1.4.0 1.4.0 1.4.0 1.4.0 1.4.0 1.4.0 1.4.0
2.0.0 2.0.0
2.0.4 2.0.4
Software I/O boards 1.1.0 1.2.0 1.2.0 1.2.0 1.2.0 1.2.0 1.2.0 1.2.0 1.2.0 1.2.0

Calibration & Test

Software
replaced by Optima TCT

Use software Use software Use software Use software Use software Use software Use software Use software Use software Use software
Optima TCT V2.2.7 V2.2.7 V2.2.7 V2.2.7 V2.2.7 V2.2.7 V2.2.7 V2.2.7 V2.2.7 V2.2.7

not compatible 2.00.026 2.00.026 2.00.026 2.00.026 2.00.026 2.00.026 2.00.026 2.00.026 (with new 2.00.026 (with new
Modbus definition Modbus definition
Optima M-DDE file) file)

Optima Remote HMI not available 1.2.0 1.2.0 1.3.0 1.3.0 1.3.3 1.3.3 1.4.0 2.0.0 3.0.1
not compatible 1.0.3 1.0.3 1.0.3 1.0.3 1.0.3 1.0.3 (1.0.3) (1.0.3) 1.4.3
Optima ActiveX
1.2.1 1.2.1 1.2.1 1.2.1 1.2.1 1.2.1 1.2.1 1.2.1
not compatible 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 not
Optima Plant Pilot
1.3.1 1.3.1 1.3.1 1.3.1 1.3.1 1.3.1 1.3.1 1.3.1 recommended***
Vers. Oct 03 Vers. Oct 03 Vers. Oct 03 Vers. Oct 03 Vers. Oct 03 Vers. Oct 03 Vers. Oct 03 Vers. Oct 03 Vers. Oct 03 Vers. Oct 03
AnalyzeIT Explorer 1.2.1 1.2.1 1.2.1 1.2.1 1.2.1 1.2.1 1.2.1 1.2.1 1.2.1 1.2.1
1.2.2 1.2.2 1.2.2 1.2.2 1.2.2 1.2.2 1.2.2 1.2.2 1.2.2 1.2.2
Update to current - - Update to Update to - required for PFG - Upgrade to new For software
version system controller system controller approved gas TCT version is version 3.x.x,
recommended. software 1.3.4 / software 1.3.4 / warning devices mandatory when
Remarks 1.3.3 1.3.3 using analyzer Syscon 2
software 2.0. hardware is
mandatory.

* V 2.3.0 & 2.3.1 are good for software download. Only if a BIOS update is really necessary use new V 2.3.1
** Update from 2.0 to 3.0.1 is possible: New Syscon 2 hardware is required!
*** Use AnalyzeIT Explorer

Note: Information contained in the table is current at the time of printing, subsequent versions will be set in ASN.

40 Syscon Service Manual 43/24-1000 EN Rev. 1

 Syscon2 Syscon3
Software system
4.0.2**
controller 4.0.3 ** 5.0.2 ****
3.0.1** 3.0.2** 3.0.5* 3.0.6** 4.0.1** special version for ACX, 5.0.0**** 5.0.1 ****
consisting of (firmware / special version for LS25 special version for LS25
no general release
system software)

Optima SMT required for 4.0.3** 5.0.1**** 5.0.2****

download of system 3.0.5** 3.0.7** 3.0.10** 3.0.11** 4.0.1** 4.0.2** 5.0.0****
controller software 3112001 3112037 3112031

1.2.x 1.2.x 1.2.x 1.2.x 1.2.x 1.2.x 1.2.x

1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0 1.3.0
1.3.2 1.3.2 1.3.2 1.3.2 1.3.2 1.3.2 1.3.2
Software analyzer module 1.3.3 1.3.3 1.3.3 1.3.3 1.3.3 1.3.3 1.3.3
SNE
1.4.0 1.4.0 1.4.0 1.4.0 1.4.0 1.4.0 > version 1.4.x 1.4.0
3100462
2.0.0 2.0.0 2.0.0 2.0.0 2.0.0 2.0.0 > version 2.0.x 2.0.0 > version 2.0.x > version 2.0.x
2.0.4 2.0.4 2.0.4 2.0.4 2.0.4 2.0.4 2.0.4
2.0.6 2.0.6 2.0.6 2.0.6 2.0.6 2.0.6 2.0.6
2.0.7 2.0.7 2.0.7 2.0.7 2.0.7 2.0.7 2.0.7
Software I/O boards 1.2.0 1.2.0 1.2.0 1.2.0 1.2.0 1.2.0 1.2.0
Software AMC module 3.2.6 3.2.6 3.2.6 3.2.6
3112028 3.2.14 3.2.14 3.2.14 > version 3.2.4 3.2.14 > version 3.2.4 > version 3.2.4
3112029 (OEM / EGA) 3.2.16 3.2.16 3.2.16 3.2.16
Use software Use software Use software Use software Use current software Use current software version Use current software version Use current software Use current software version Use current software version
V2.2.7 V2.2.7 V2.2.7 V2.2.7 version (October 2010: V3.0.6) (October 2010: V3.2.14) version (October 2010: V3.2.14) (October 2010: V3.2.14)
Optima TCT (October 2010: V3.0.6) (October 2010: V3.0.6)

2.00.026 (with new 3.0.2 3.0.2 3.0.2 3.0.2 3.0.2 3.0.2 3.0.2 3.0.2 3.0.2
Modbus definition
Optima M-DDE file)

Optima Remote HMI 3.0.1 3.0.2 3.0.5 3.0.6 4.0.1 4.0.2 4.0.3 5.0.0 5.0.2 5.0.2
1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 1.1.1 1.2.5 1.2.5
1.2.2 1.2.2 1.2.2 1.2.2 1.2.1 1.2.1 1.2.1 1.2.1 1.2.6 1.2.6
1.2.2*** 1.2.2*** 1.2.2*** 1.2.2***
AnalyzeIT Explorer 1.2.3 1.2.3 1.2.3 1.2.3
1.2.4 1.2.4 1.2.4 1.2.4
1.2.5 1.2.5 1.2.5 1.2.5
1.2.6 1.2.6 1.2.6 1.2.6
OPC Server 2.0.0 2.0.0
FB Designer as from beta version 1.01.1025 as from beta version 1.01.1025

Upgrade from version 4.0.1 to version IO modules supported:

Uninstall version 5.0.0 prior to installation of Upgrade from version 5.0.0 to version 5.0.2
4.0.3 with AO-SMT. Installation parallel to 4-way analog input
version 5.0.1. with AO-SMT or USB stick.
existing software version. 4-way analog output

Timeout of AO2000 increased from 10 to Timeout of AO2000 increased from 10 to 25

Software Migration Tool allows only upgrade
25 seconds (violation of time limit fixed seconds (violation of time limit fixed
of version 5.0.0.
(communication error)) (communication error))
Remarks
Reading of data sets version 2.x, 3.x, 4.0.x
Persistent system booting or restarting and 5.0.0. Persistent system booting or restarting after
after adding a LS25 fixed. System requirements Windows XP or adding a LS25 fixed.
Windows Vista
Reading of data sets version 2.x, 3.x, 4.0.x
Rescue mode allows system start in case of and 5.0.0.
need. System requirements Windows XP or
Windows Vista
AO2000 Series Software version 5.0 (42/24-10 EN Rev. 9)
Operator's manual 42/24-25 EN Rev.3 42/24-25 EN Rev. 4 AO2000 Instructions in brief (41/24-100 EN Rev. 6)
LS25 (41/24-109 EN Rev. 2)

* Released only for analyzer modules ZO23 and LS25

** New Syscon2 hardware required!
*** AMC modules require version 1.2.2
**** New Syscon3 hardware required!

Note: Information contained in the table is current at the time of printing, subsequent versions will be set in ASN.

43/24-1000 EN Rev. 1 Syscon Service Manual 41

Replacement of Syscon1 with Syscon3
Tools required
 Service PC
 Ethernet cable (twisted)
 Software
 SMT Version 2.0
 HMI Version 2.0
 SMT Version 5.0
 HMI Version 5.0
 5.5mm spanner
 8mm spanner
 Allen key 4mm
 Crosshead screwdriver

Material required
To convert Syscon1 to Syscon3, the following materials must be supplied:
 758108 Syscon3
 990055 Digital I/O-module (with mounting material)
 990056 Analog output module (2-way mA) (with mounting material)
 769229 Syscon3 modification set
 Content
3 units blank panel (I/O-module in X24…X29 not available)
3 units cover plate / slot filler (CAN-I/O printed circuit boards in X11…13 not available)
1 unit bracket
1 unit CAN Extender Board
1 unit connection CAN bus
30 units screws M3x8mm1
1 unit Product CD
1 unit Operating instructions EN / DE
Note:
Existing CAN-I/O printed circuit boards and I/O modules must be recycled.
The necessary I/O modules must be ordered separately for any extensions.

42 Syscon Service Manual 43/24-1000 EN Rev. 1

 3

4
5

1
4

5 5

Procedure
1. Data protection after connection of service PC and Syscon1 with SMT
2. Only SMT configurations found in SMT Version 2.0 are to be imported into Syscon3. For an update of SMT
versions < 2.0, an operative Syscon1 with a memory module of 16 MB is necessary.
Note:
If an SMT file is not available as a result of a faulty Syscon1, necessary configuration must be newly assembled.
3. Switch off power supply.
4. Detach electrical connections (5) from Syscon1.
Power supply unit, display, analyzer module (CAN bus connector (rear wall), RS232/RS485 interface (rear
wall)
5. Undo mounting studs of the power supply unit, remove power supply unit (3)
6. Undo mounting studs of the electronic cassette (1) and (4), remove electronic cassette
7. Dismounting of existing printed circuit boards (2). These printed circuit boards are plugged into the CAN
Extender of the Syscon3, if existing function block configurations with I/O modules supplied cannot be
implemented.

43/24-1000 EN Rev. 1 Syscon Service Manual 43

 8

8. CAN Extender (6) is connected to the Syscon3 (8) via the plug connection (7).

44 Syscon Service Manual 43/24-1000 EN Rev. 1

 9

10

11

12

13

16 14

12

16 16 12 15

9. Plug Syscon3 and CAN Extender together (15) and mount on the metal bracket (16) using the screws (12).
10. Plug I/O modules (11 und 13) onto the Syscon3 and printed circuit board (9) in slot of the CAN Extender. Fix
I/O modules with screws (10) on the rear wall.
Note:
If the insert of a Profibus I/O module is provided, this is always mounted as the first module on the Syscon3
(X20 / X21).
11. Assembly of the CAN bus connection (14) between electronic cassette rear wall and Syscon3.

43/24-1000 EN Rev. 1 Syscon Service Manual 45

 17

18
18 18

12. Insert electronic cassette with mounted Syscon3 into the Advance Optima system and fix with screws (17)
and (18).

46 Syscon Service Manual 43/24-1000 EN Rev. 1

 19

20

21

13. Install power supply unit (20)

14. Establish electrical connections to the Syscon3 (21):
power supply unit, display, CAN bus connection between electronic cassette rear wall and Syscon3.
15. Close slots (19) of unavailable I/O modules with blank panels.
16. Switch on power supply.
17. After booting has finished, connect service PC using an Ethernet interface of the Syscon3.
Standard setting for X08: IP address 192.168.1.2 / IP address mask 255.255.255.0
Standard setting for X09: IP address 192.168.1.1 / IP address mask 255.255.255.0
Saved SMT file of Version 2.0 must be installed using SMT software Version 5.x.x.
Warning
For service purposes only the X09 interface is to be used with the address 192.168.1.1 / IP address mask
255.255.255.0.
Note:
Analog or digital inputs and outputs configured in the SMT file are first assigned to existing I/O modules and
then to the printed circuit boards plugged in the CAN Extender.

43/24-1000 EN Rev. 1 Syscon Service Manual 47

Note:
After installing the SMT file, the system reboots. Assignments of the signals must be monitored and external
connections created.
18. Saving the SMT file
Note:
It is useful to clarify in the run-up whether only I/O modules should be used for external connections. These I/O
modules must be ordered separately.

48 Syscon Service Manual 43/24-1000 EN Rev. 1

Replacement of Syscon2 with Syscon3
Tools required
 Service PC
 Ethernet cable
 Software
 SMT Version 5.0
 HMI Version 5.0
 5.5 mm spanner
 8 mm spanner
 Allen key 4 mm
 Crosshead screwdriver

Material required
To convert Syscon2 to Syscon3, the following materials must be supplied:
 758108 Syscon3
 769229 Syscon3 modification set
 Content
3 units blank panel (I/O-module in X24…X29 not available)
3 units cover plate / slot filler (CAN-I/O printed circuit boards in X11…13 not available)
1 unit mounting bracket
1 unit CAN Extender Board
1 unit connection CAN bus
30 units screws M3x8mm1
1 unit Product CD
1 unit Operating instructions EN / DE
Note:
Existing CAN-I/O printed circuit boards and I/O modules must be recycled.
The necessary I/O modules must be ordered separately for any extensions.

43/24-1000 EN Rev. 1 Syscon Service Manual 49

 3

4
5

5 5
9 10 8 7 6

Procedure
1. Data protection with SMT after connection of service PC and Syscon2.
Note:
If an SMT file is not available as a result of a faulty Syscon2, necessary configuration must be newly assembled.
2. Switch off power supply
3. Detach electrical connections (5) from Syscon2.
Power supply unit, display, analyzer module (CAN bus plug)
4. Undo mounting studs (3) of the power supply unit, remove power supply unit.
5. Undo mounting studs (1) and (4) of the electronic cassette, remove electronic cassette
6. Undo mounting studs (2) and (6) of the I/O modules and remove spacing pins (7).
7. Dismount existing printed circuit boards (10) in slots. These printed circuit boards are plugged into the CAN
Extender of the Syscon3, if existing function block configurations with I/O modules supplied cannot be
implemented.

50 Syscon Service Manual 43/24-1000 EN Rev. 1

 11

12

13

14

15

18 16

14

18 18 14 17

8. Plug Syscon3 and CAN Extender together (17) and mount on the metal bracket using the screws (14) and
(18).
9. Plug I/O modules (13) and (15) onto the Syscon3 and printed circuit board (11) in slot of the CAN Extender.
The I/O modules are to be arranged before fixing so that simple fixing on the rear wall is possible by means
of the screws (12).
Note:
If the insert of a Profibus module is provided, this is always mounted as the first module on the Syscon3 (X20 /
X21).
10. Assembly of the CAN bus connection (16) between electronic cassette rear wall and Syscon3.

43/24-1000 EN Rev. 1 Syscon Service Manual 51

 19

20
20 20

11. Insert electronic cassette with mounted Syscon3 into the Advance Optima system and fix with screws (19)
and (20).

52 Syscon Service Manual 43/24-1000 EN Rev. 1

 21

22

23

12. Insert power supply unit (22)

13. Establish electrical connections to the Syscon3 (23)
power supply unit, display, CAN bus analyzer module, CAN bus connection between electronic cassette
rear wall and Syscon3
14. Close slots (21) of unavailable I/O modules with blank panels.
15. Switch on power supply.
16. After booting has finished, connect service PC using an Ethernet interface of the Syscon3.
Standard setting for X08 IP address 192.168.1.2 / IP address mask 255.255.255.0
Standard setting for X09 IP address 192.168.1.1 / IP address mask 255.255.255.0
Saved SMT file of Version > 3.x.x must be installed using SMT software Version 5.x.x.
Warning:
For service purposes only the X09 interface is to be used with the address 192.168.1.1 / IP address mask
255.255.255.0.
Note:
Analog or digital inputs and outputs configured in the SMT file are first assigned to existing I/O modules and
then to the printed circuit boards plugged in the CAN Extender.

43/24-1000 EN Rev. 1 Syscon Service Manual 53

Note:
After installing the SMT file, the system reboots. Assignments of the signals must be monitored and external
connections created.
17. Saving the SMT file
Note:
It is useful to clarify in the run-up whether only I/O modules should be used for external connections. These
modules must be ordered separately.

54 Syscon Service Manual 43/24-1000 EN Rev. 1

Replacement of Syscon2 by Syscon3 in ACX
Material required
To convert Syscon2 to Syscon3, the following materials must be supplied:
 758108 Syscon3
 8329306 Conversion set ACX to Syscon3, consisting of
1 pc. Electronic cassette ACX
2 pcs. Blank panels
15 pcs. Screw M3x8
1 pc. Product CD
1 pc. Operator’s manual DE
1 pc. Operator’s manual EN

1 1

Procedure
1. Data protection with SMT after connection of service PC and Syscon2.
Note:
If an SMT file is not available as a result of a faulty Syscon2, necessary configuration must be newly assembled.
2. Undoing of the screw (1) and removal of the cover. The components mounted in the electronic cassette (2)
can be seen.

6 5 4 3

43/24-1000 EN Rev. 1 Syscon Service Manual 55

3. Pull power plug (6)
4. Detach external connections to I/O modules (3), Profibus module (4) and CAN bus (5).

9
8

5. Detaching of the grounding cable (8).

6. Disconnection of the internal power supply cable (9) to Syscon2.
7. Undo the mounting studs (7) of the power supply unit and remove.

10 10

11

8. Disconnection of the power supply cable (11) to Syscon2. Remove mounting nuts (10) and withdraw display.

56 Syscon Service Manual 43/24-1000 EN Rev. 1

 13 14

12 15

15

9. For each I/O module or Profibus module first undo the screws (15), then the screws (14) or the spacing pins
(13). Detaching of the CAN bus connection (12), plug on the Syscon2 and dismounting of the jack from the
electronic cassette.

16 16

16 16

10. The Syscon2 must not be dismounted; the complete electronic cassette can be removed by removing the
nuts (16) from the front door of the ACX system.

43/24-1000 EN Rev. 1 Syscon Service Manual 57

 18

17
19

24 23 22 21

20

Legend for Syscon2 electronic cassette in ACX

17. Cutout for electronic cassette electrical connections
20. Electronic cassette without built-in components
21. USB ports
22. Ethernet connections

11. Mount the Syscon3 on the threaded inserts (19) of the electronic cassette for Syscon3. The electronic
cassette is not installed in the front door at this time.
12. Establish CAN bus connection, insert plug in the Syscon3 and socket into the case wall (23) of the
electronic cassette.
13. Profibus module (always as the first plugged-in module) and I/O modules must be mounted on the Syscon3
with screws and spacing pins and fixed in the case wall of the electronic cassette by means of screws (18).
14. Installing of the display. Fastening by means of nuts. Insert connecting cable between display and Syscon3.
15. Mounting of the electronic cassette on the rear wall of the front door. Tighten the four fastening nuts finger-
tight.
16. Installing of the power supply unit. Insert grounding cable in the electronic cassette. Insert plug to internal
power supply on the Syscon3.
17. Establish external connections to I/O modules, Profibus module and CAN bus on the Syscon3.
18. Insert power plug
19. Install the saved SMT configuration after booting the system with the requisite SMT version.
20. Unused cutouts for I/O modules are provided with blank plate.

Note:
This instruction for Syscon replacement in an ACX system is a previous version. When the documentation
appeared not all the information was available yet.

58 Syscon Service Manual 43/24-1000 EN Rev. 1

Recommended documentation and software
Care should be taken that the current status of the documentation is included. Publications in this regard are
stored in ASN.
Listed documentation was available at the time the documentation was produced.
Operating
instructions
Operating instructions
42/23-50 DE
Advance SCC
Operating instructions
42/23-51 DE
SCC-F Sample gas feed-in unit
Operating instructions
42/24-10 DE Rev. 5
Advance Optima SW Version 2.0
Operating instructions
42/24-10 DE Rev. 8
Advance Optima SW Version 4.0
Operating instructions
42/24-10 DE Rev. 9
Advance Optima SW Version 5.0
Operating instructions
42/24-25 DE Rev.4
SMT Version 5.0
Operating instructions
42/24-15 DE Rev. 0
Advance Optima Profibus-DP interface
Function blocks – Descriptions and Configuration 30/24-200-2 DE
Advance Optima – Terminal layout of 2001

Technical
Information
AO 2000 Profibus-DP/PA Interface 30/24-315 DE Rev.1
AO 2000 Modbus and MDDE 30/24-315 DE Rev.1

Service Videos
Syscon3 Service Video

Recommended
software
Software compatibility table
HMI Version 5.x
SMT Version 2.0
SMT Version 4.x
SMT Version 5.x Light Version
SMT Version 5.x
GSD File für AO2000 Version 5.x

Service Notes
Advance Optima – AO2000
A-059 DE
Replacement of Syscon 1 by Syscon 2

Spare Parts Catalog

Spare parts catalog Analytical Technology 2/2009

Note:
For any tests of the Profibus interface of the system it is recommended that the following are supplied:
 Profibus Mastercard for service computers
 Software pertaining to Profibus Mastercard
 Connecting cable
No information on the aforementioned supports is available in ASN.

43/24-1000 EN Rev. 1 Syscon Service Manual 59

Summary information on:
Optima SMT
Optima SMT is a software tool for
- simple updating of Advance Optima system software.
- storage and installation of data records (configurations).
- national language adaptions
- generation of a system overview and a Profibus image
 SMT Version 2.x
 SMT Version 2.0 is only intended for Syscon1 use
SMT Version 2.0 can install data records with SMT Version 1.x
and perform an upgrade of the data record installed, which can be imported into Syscon1.
 SMT Version 2.0 must not be installed in addition to an older program version, if during installation the
displayed directories are transferred.
 SMT Version 4.x (for combination of SNE and AMC modules)
 SMT Version 4 is only intended for Syscon2 use, not downwards-compatible
SMT Version 4 can install data records with SMT Version 2.x
and perform an upgrade of the installed data record, which can be imported into Syscon2.
 SMT Version 4 must not be installed in addition to an older program version, if during installation the
displayed directories are transferred.
 SMT Version 5.x
 SMT Version 5.x is only intended for Syscon3 use, not downwards-compatible.
SMT Version 5.x can install data records of SMT Versions 2.x, 3.x or 4.x
and perform an upgrade of the installed data record, which can be imported into Syscon3.
 In addition to an older program version, SMT Version 5.x can be installed. For user files the directory
“Own files / Analyse IT / SMT” is created.
 The languages available are German-English, German-Dutch, English-Dutch, English-Spanish, English-
Italian, English-French, and English-Brazilian Portuguese.

Optima Remote HMI

Optima Remote HMI (Human Machine Interface) is a program for the complete remote control of Advance
Optima via a PC (see section “Remote control/Remote maintenance”). The identical display of the display and
control unit on the screen permits access to measured values, clear text messages, calibration and
configuration data.
The connection is made via the Ethernet interface with TCP/IP protocol. There are the known versions of point-
to-point connection and Ethernet network connection.
Note:
The HMI version must have the same version index as the installed SMT version.

TCT
The TCT software is test and calibration software for configuration, calibration and testing of analyzer modules,
pneumatic modules and I/O cards. Data records can be read out, processed with the TCT, saved for the
purpose of archiving and written into the EEPROM of the module again.

60 Syscon Service Manual 43/24-1000 EN Rev. 1

ABB has Sales & Customer Support expertise The Company’s policy is one of continuous product
in over 100 countries worldwide. improvement and the right is reserved to modify
the information contained herein without notice.
www.abb.com
43/241000 EN Rev. 1

Printed in the Fed. Rep. of Germany (10.10)

 ABB 2010

ABB Automation GmbH

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