ABB CIO-01, User Manual

Page 1: ... ABB INDUSTRIAL DRIVES CIO 01 I O module and distributed I O bus User s manual ...

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Page 3: ...odule and distributed I O bus User s manual Table of contents 1 Safety instructions 4 Mechanical installation 5 Electrical installation 6 Start up 3AXD50000126880 Rev C EN Original instructions EFFECTIVE 2023 08 02 ...

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Page 5: ...erview 12 Layout drawing of CIO module 13 Distributed I O bus topology 14 Bus topology example single drives 15 Bus topology example multidrives 16 Fan control 4 Mechanical installation 17 Contents of this chapter 17 Unpacking and examining the delivery 18 Installing the CIO module 5 Electrical installation 19 Contents of this chapter 20 Default I O diagram 21 Cabling instructions 22 Wiring exampl...

Page 6: ...this chapter 39 Warning and fault indications 39 Auxiliary code 40 Warning and fault messages 41 LEDs of the CIO module 10 Ordering information 43 CIO 01 I O module 11 Maintenance 45 Contents of this chapter 45 Maintenance intervals 45 Replacing the CIO module 46 Removing the CIO module 46 Reinstalling the CIO module 46 Resetting the fan data after replacing a fan 12 Technical data 47 Contents of ...

Page 7: ...y or death or damage to the equipment They also tell you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those cau...

Page 8: ... English Read the software function specific warnings and notes before changing the default settings of a function For each function the warnings and notes are given in the section describing the related user adjustable parameters Read the task specific safety instructions before starting the task See the section describing the task For single drives the complete safety instructions are given at t...

Page 9: ...g control programs ACS880 primary control program v2 9x or later ACS880 diode supply control program ADILX v2 5x or later ACS880 IGBT supply control program AISLX v2 7x or later ACS880 DC DC converter control program ADCLX v2 7x or later ACS880 brake control program ABCLX v2 7x or later Compatibility CIO module is compatible with the cooling fans used in the ACS880 liquid cooled drives Target audi...

Page 10: ...e connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls prevention of physical access application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the inte...

Page 11: ...Hardware description and operation principle Contents of this chapter This chapter describes the CIO module and the distributed I O bus 3 Hardware description and operation principle 11 ...

Page 12: ... 4 7 segment displays for node number 1 99 Blinking node value indicates that the configuration change is pending Solid node value indicates that the node ID configuration value has been ac knowledged by the CIO module 5 Push buttons for node number selection S1 decreases and S2 increases node number 6 LEDs of the CIO module 7 Digital inputs XDI1 XDI2 8 Digital inputs outputs XDIO1 XDIO4 9 12 Hard...

Page 13: ...sed to control the CIO modules Single drives have one control unit for all CIO modules and multidrives have multiple ISU DSU DBU BRC INU BCU CIO CIO CIO CIO CIO ISU DSU BRC INU DDC DBU BCU CIO CIO BCU CIO CIO CIO Single drive Multidrive Control unit control board inside a casing BCU IGBT supply unit ACS880 207LC ISU Diode supply unit ACS880 307LC DSU Inverter unit ACS880 107LC INU 3 phase brake un...

Page 14: ... 32 CIO 01 I O modules to the distributed I O bus in maximum and only activate 16 of them at maximum from the I O bus master Description A Supply module cubicle B Inverter module cubicle A B CIO 01 CIO 01 CIO 01 A 1 B B B CIO 01 Supply control unit I O bus master 1 Supply module cubicle A Inverter module cubicle B CIO module only monitors the fan status energized or not The module does not supply ...

Page 15: ... bus master 1 Inverter control unit I O bus master 2 Converter control unit I O bus master 3 CIO module only monitors the fan status energized or not The module does not supply power to the fan or control the fan speed The auxiliary power supply of the drive supplies the fan directly The fan operates at full speed when the auxiliary power switch is closed and energized Hardware description and ope...

Page 16: ...e fan speed reference is 0 DC voltage is high and modulation is off the fan speed reference is 50 DC voltage is high and modulation is on the fan speed reference is 100 there is a 5 minute delay for the fan speed reference reset after the modulation is stopped 16 Hardware description and operation principle Fan control The following diagrams describe how the cabinet fan is controlled by the CIO 01...

Page 17: ...ho install drive modules and related components such as CIO module into user defined cabinet For ABB cabinet installed drives the CIO modules are installed wired and commissioned at the ABB factory Unpacking and examining the delivery 1 Open the package 2 Make sure that the package contains the CIO module 3 Make sure that there are no signs of damage 4 Mechanical installation 17 10 ...

Page 18: ... Fasten the module with screws on its corner holes and a conducting surface that is grounded to the cabinet main PE terminal If needed use an additional grounding wire under the screw Mechanical installation stalling the module WARNING Obey the safety instructions See chapter Safety instructions on page 9 If you ignore the safety instructions injury or death can occur all the CIO 01 module in a he...

Page 19: ... install drive modules and related components such as CIO module into user defined cabinets For cabinet installed drives the CIO modules are installed wired and commissioned at the ABB factory The wiring diagrams in this chapter are simplified presentations For details see the example circuit diagrams included in the hardware manuals for the multidrive modules 5 Electrical installation 19 11 ...

Page 20: ...r 206 50 DI5 1 5 6 7 1 2 3 4 8 DCOM 2 CIO module fuse monitoring 0 related warning fault is given Parameter 206 51 DI6 3 DCOM 4 DI7 Not in use in the control program DI7 5 DCOM 6 DI8 Can be used for any purpose by using IEC program or general supervi sion function of the firmware 0 related warning or fault is given Para meter 206 53 DI8 7 DCOM 8 Analog inputs XAI1 XAI2 Reserved for fan temperature...

Page 21: ...les to CIO modules 3 Connect the serial communication cable to CIO modules and to the control unit 4 On the last CIO module at the rear end of the bus change the TERM plug to position ON On the control unit end make sure the TERM plug is in position OFF 5 Connect the fan input and output signals to CIO modules 6 Connect the additional monitoring signals to CIO module if in use Electrical installat...

Page 22: ... 1 I O bus 2 Reserved for analog inputs for NTC temperature measurement Currently no software support 3 Monitoring and control of fans 4 Digital inputs 5 I O bus termination I O bus must be terminated at its physical ends 6 22 Electrical installation ...

Page 23: ...ets and modules safety instructions 3AXD50000048633 English If you ignore the safety instructions injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work Hardware settings Check the mechanical and electrical installation of the drive See the hardware manuals Terminate the I O bus at its physical ends set the...

Page 24: ...rst start of the supply unit in order to power up the drive main and auxiliary circuits On the first start the control program performs identification run for the fans to detect the 100 rotation speed level Identification run is performed whenever the control program detects fans without existing identification run results and fans are commanded to start When the identification run is finished the...

Page 25: ...er Each CIO module on the I O bus controls the speed of its fans with PWM reference signals and monitors the speed of its fans with tachometer actual signals The settings of the distributed I O bus can be accessed via control panel or Drive composer PC tool Basic configuration of the distributed I O bus Distributed I O bus is taken into use with 206 1 I O bus enable User can define warning and fau...

Page 26: ...outs for each node and parameter 208 6 shows the sum of timeouts in all nodes User can reset error and timeout counters 208 80 Settings Parameters parameter group 208 I O bus diagnostics Identification run of the fans An identification run is performed whenever there are no existing identification run results for a fan and fans are commanded to start Identification run is performed to detect the 1...

Page 27: ... signals can be reset Actual signal In the following table shown on the same row as the parameter name Def The default value of a parameter In the following table shown on the same row as the parameter range or for each selection FbEq16 16 bit fieldbus equivalent The scaling between the integer used in communication and the value shown on the panel when a 16 bit value is selected for transmission ...

Page 28: ...an speed is below the value given with this parameter in relation to requested Fan speed fault limit 206 7 reference the control program generates fault 8E12 Fan speed Parameter value 0 means that no fault will be generated 1 10 Fault limit for fan speed 0 0 100 0 90000 h uint32 Defines the warning limit for fan lifetime When the fan has been running longer in hours than the value given with this ...

Page 29: ...ive Node 5 fan 1 b0 1 Fan 2 of node 5 is active Node 5 fan 2 b1 1 Fan 3 of node 5 is active Node 5 fan 3 b2 1 Fan 4 of node 5 is active Node 5 fan 4 b3 1 Fan 1 of node 6 is active Node 6 fan 1 b4 1 Fan 2 of node 6 is active Node 6 fan 2 b5 1 Fan 3 of node 6 is active Node 6 fan 3 b6 1 Fan 4 of node 6 is active Node 6 fan 4 b7 1 Fan 1 of node 7 is active Node 7 fan 1 b8 1 Fan 2 of node 7 is active ...

Page 30: ...30 1 Failure in fan 1 of node 1 Node 1 fan 1 failure b0 1 Failure in fan 2 of node 1 Node 1 fan 2 failure b1 1 Failure in fan 3 of node 1 Node 1 fan 3 failure b2 1 Failure in fan 4 of node 1 Node 1 fan 4 failure b3 1 Failure in fan 1 of node 2 Node 2 fan 1 failure b4 1 Failure in fan 2 of node 2 Node 2 fan 2 failure b5 1 Failure in fan 3 of node 2 Node 2 fan 3 failure b6 1 Failure in fan 4 of node...

Page 31: ...12 fan 3 failure b14 1 Failure in fan 4 of node 12 Node 12 fan 4 failure b15 1 1 0000h FFFFh uint16 Shows statuses of fans in nodes 13 16 Fan supervision status 13 16 206 33 1 Failure in fan 1 of node 13 Node 13 fan 1 failure b0 1 Failure in fan 2 of node 13 Node 13 fan 2 failure b1 1 Failure in fan 3 of node 13 Node 13 fan 3 failure b2 1 Failure in fan 4 of node 13 Node 13 fan 4 failure b3 1 Fail...

Page 32: ... O Node 12 b11 Status of digital input DI6 of node 13 I O Node 13 b12 Status of digital input DI6 of node 15 I O Node 14 b13 Status of digital input DI6 of node 15 I O Node 15 b14 Status of digital input DI6 of node 16 I O Node 16 b15 1 1 0000h FFFFh uint16 Indicates the logical state of digital input DI8 of each I O node CIO DI8 status 206 43 Status of digital input DI8 of node 1 I O Node 1 b0 St...

Page 33: ...This group is used to show the output of selected fans This group is only visible with a BCU or UCU control unit 1 uint16 Selects the node for the operation selected with uint16 in parameter 207 03 Note All the parameters in this parameter group concern the selected node only Node ID number 207 1 1 1 Node ID number 1 99 uint16 Selects the fan s of the selected node 207 01 for the operation selecte...

Page 34: ...bus errors 208 5 1 1 Number of Modbus errors 0 2147483647 uint32 Displays a sum of time outs in all of the nodes see parameters 208 11 208 26 A time out is a request response Timeouts 208 6 cycle in the I O bus where the bus master sends a request but does not get a correctly formed response message in return within the time window reserved for the cycle 1 1 Number of timeouts 0 2147483647 uint32 ...

Page 35: ...0 Hz real32 Displays the result of the identification run for fan 4 of node 1 Node 1 fan 4 pulse freq 209 4 1 Hz 10 Hz Result of the identification run for fan 4 of node 1 0 0 5000 0 Hz 0 0 Hz real32 Displays the result of the identification run for fan 1 of node 2 Node 2 fan 1 pulse freq 209 5 1 Hz 10 Hz Result of the identification run for fan 1 of node 2 0 0 5000 0 Hz 0 0 Hz real32 Displays the...

Page 36: ... Result of the identification run for fan 2 of node 6 0 0 5000 0 Hz 0 0 Hz real32 Displays the result of the identification run for fan 3 of node 6 Node 6 fan 3 pulse freq 209 23 1 Hz 10 Hz Result of the identification run for fan 3 of node 6 0 0 5000 0 Hz 0 0 Hz real32 Displays the result of the identification run for fan 4 of node 6 Node 6 fan 4 pulse freq 209 24 1 Hz 10 Hz Result of the identif...

Page 37: ...f the identification run for fan 2 of node 11 Node 11 fan 2 pulse freq 209 42 1 Hz 10 Hz Result of the identification run for fan 2 of node 11 0 0 5000 0 Hz 0 0 Hz real32 Displays the result of the identification run for fan 3 of node 11 Node 11 fan 3 pulse freq 209 43 1 Hz 10 Hz Result of the identification run for fan 3 of node 11 0 0 5000 0 Hz 0 0 Hz real32 Displays the result of the identifica...

Page 38: ...sult of the identification run for fan 2 of node 15 Node 15 fan 2 pulse freq 209 58 1 Hz 10 Hz Result of the identification run for fan 2 of node 15 0 0 5000 0 Hz 0 0 Hz real32 Displays the result of the identification run for fan 3 of node 15 Node 15 fan 3 pulse freq 209 59 1 Hz 10 Hz Result of the identification run for fan 3 of node 15 0 0 5000 0 Hz 0 0 Hz real32 Displays the result of the iden...

Page 39: ... fault causes can be identified and corrected using the information in this chapter If not contact ABB representative Auxiliary code Some faults and warnings have an auxiliary code for identifying the CIO module in question The auxiliary code is a hex word that indicates the node ID Node ID Auxiliary code Hex Node ID Auxiliary code Hex 9 0000 0008 1 0000 0000 10 0000 0009 2 0000 0001 11 0000 000A ...

Page 40: ...ital input DI5 of the ap propriate CIO module Some of the bits of the MCB status word are 0 206 40 CIO MCB monitoring AE94 Check node ID1 Check fuses and digital input DI6 of the appropriate CIO module Some of the bits of the fuse status word are 0 206 41 CIO fuse monitoring AE95 Check node ID1 By default DI8 is not in use Some of the bits of the DI8 status word are 0 206 43 CIO DI8 monitoring AE9...

Page 41: ...e change Orange ie green and red Data transmission is ongoing on the RS 485 communication link CIO 01 module received a message and generated a reply Blinking green NETWORK No communication on the RS 485 communication link com munication timeout has been exceeded Red The module is powered 24 V supply Green PWR DO status for each channel Lit when output is high Green DO1 DO4 DI status for each chan...

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Page 43: ...ordered separately The distributed I O bus controls and supervises each cabinet fan separately It indicates malfunctioning fans by warning or fault messages One CIO 01 can monitor and control up to 4 cabinet fans Ordering code Qty Data Type 3AXD50000041983 1 CIO 01 I O module for distributed I O bus control CIO 01 10 Ordering information 43 ...

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Page 45: ... them injury or death or damage to the equipment can occur See chapter Safety instructions Before replacing the CIO module check the node number of the old CIO module Node numbers are defined at start up See Start up If a CIO module is replaced all the fans connected to the replaced CIO module need to be replaced as well For instructions on how to replace the fan see the appropriate hardware manua...

Page 46: ...drive cabinet Reinstalling the CIO module For instructions on installing the CIO module see chapters Mechanical installation and Electrical installation Resetting the fan data after replacing a fan If fans are replaced with new ones identification run result and internal run time counters on the CIO module need to be reset To reset fan data do the following 1 Set parameter 207 1 to the node the fa...

Page 47: ...Technical data Contents of this chapter This chapter contains the technical data of the CIO module Dimension drawing 12 Technical data 47 ...

Page 48: ...mm isolation CPU and analog inputs functional 1 0 mm isolation Communication interface functional 1 0 mm isolation 1 2 3 4 5 6 7 8 8 8 8 Communication interface 5 230 V AC reinforced isolation 1 Digital I O 6 24 V DC functional isolation 2 Analog inputs 7 Power supply 3 PE 8 CPU 4 48 Technical data ...

Page 49: ...ply input frequency DI1 DI4 input frequency DI5 DI8 input impedance Analog inputs AI 1 kohm Input impedance 0 5 0 V Analog voltage measurement range NTC measurement Not in use 5 V 5 10 kohm 1 3975 supply voltage nominal NTC value 25 C accuracy B value Ambient conditions 40 C 85 C 40 185 F Storage temperature 0 to 70 C 32 158 F Operating temperature 90 non condensing Maximum relative humidity 5000 ...

Page 50: ...Applicable standards See Electrical planning instructions for ACS880 liquid cooled multidrive cabinets and modules 3AXD50000048634 English 50 Technical data ...

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