ABB RDIO-01 User manual

ABB Drives
Digital I/O Extension Module
RDIO-01
User’s Manual

Digital I/O Extension Module
RDIO-01
User’s Manual
3AFE 64485733 REV B EN
EFFECTIVE: 10.2.2003
© 2003 ABB Oy. All Rights Reserved.

RDIO-01 User’s manual iii
Safety Instructions
Overview This chapter states the general safety instructions that
must be followed when installing and operating the
RDIO-01 Digital I/O Extension module.
The material in this chapter must be studied before
attempting any work on, or with, the unit.
In addition to the safety instructions given below, read
the complete safety instructions of the specific drive you
are working on.
General safety
instructions
WARNING! All electrical installation and maintenance
work on the drive should be carried out by qualified
electricians only.
The drive and adjoining equipment must be properly
earthed.
Do not attempt any work on a powered drive. After
switching off the mains, always allow the intermediate
circuit capacitors 5 minutes to discharge before working
on the frequency converter, the motor or the motor
cable. It is good practice to check (with a voltage
indicating instrument) that the drive is in fact discharged
before beginning work.
The motor cable terminals of the drive are at a
dangerously high voltage when mains power is applied,
regardless of motor operation.
There can be dangerous voltages inside the drive from
external control circuits even when the drive mains
power is shut off. Exercise appropriate care when
working on the unit. Neglecting these instructions can
cause physical injury or death.

Safety Instructions
iv RDIO-01 User’s manual

RDIO-01 User’s manual v
Table of contents
Safety Instructions
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-iii
General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-iii
Table of contents
Chapter 1 – Introduction
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
What this manual contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chapter 2 – Overview
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
The RDIO-01 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Warranty and liability information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Chapter 3 – Installation
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Removing and refitting the cover of the enclosure . . . . . . . . . . . . . . . . . . . . 3-2
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Digital input hardware filter suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Terminal designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Digital input wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Node ID selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Table of contents
vi RDIO-01 User’s manual
Chapter 4 – Fault tracing
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Option slot installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
I/O Module Adapter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Appendix A – Technical data

RDIO-01 User’s manual 1-1
Chapter 1 – Introduction
Intended
audience
The manual is intended for the people who are
responsible for commissioning and using an RDIO-01
Digital I/O Extension module with the ACS 800 drive.
The reader is expected to have a basic knowledge of
electrical fundamentals, electrical wiring practices and
how to operate the drive.
Before you start It is assumed that the drive is installed and ready to
operate before starting the installation of the extension
module.
In addition to conventional installation tools, have the
drive manuals available during the installation as they
contain important information not included in this
manual. The drive manuals are referred to at various
points of this document.

Chapter 1 – Introduction
1-2 RDIO-01 User’s manual
What this manual
contains
This manual contains information on the wiring,
configuration and use of the RDIO-01 module.
Safety instructions are featured in the first few pages
of this manual.
Chapter 2 – Overview contains a short description of
the RDIO-01 Digital I/O Extension module, a delivery
checklist and warranty information.
Chapter 3 – Installation contains instructions for
module hardware settings, mounting and cabling.
Chapter 4 – Fault tracing explains fault tracing and
the LED indications of the RDIO-01 module.
Appendix A contains technical data.

RDIO-01 User’s manual 2-1
Chapter 2 – Overview
Overview This chapter contains a short description of the Digital
I/O Extension module, a delivery checklist and warranty
information.
The RDIO-01
module
The Digital I/O Extension module (RDIO) offers three
digital inputs (24…250 V DC or 110…230 V AC) and
two relay outputs (1250 VA/250 V AC or 5 A/24 V DC).
The isolation voltage between the digital inputs, digital
outputs and power supply is 2.5 kV (1.5 kV between DI2
and DI3).
WARNING! According to international standards,
applying voltages below 50 V (DC or AC) and above
150 V (AC or DC) simultaneously to the digital inputs
and/or outputs of the RDIO-01 is not allowed.
Additionally, only voltages of the same nominal level
should be applied simultaneously to digital inputs DI2
and DI3 due to reduced isolation voltage.

Chapter 2 – Overview
2-2 RDIO-01 User’s manual
Module layout
Delivery check The option package contains:
• RDIO-01 module
• Two screws (M3×8 mm)
• This manual.
Compatibility The RDIO-01 is compatible with the ACS 800 Standard
Application Program version ASXR7000 or later.
123 1234
Fixing screw (GND)
Node ID selector
Module status LEDs
Fixing screw
(CHASSIS)
Configuration switch
(behind cover)
0
8
4
C
2
6
A
E
1
3
5
7
9
B
D
F
Terminal blocks for relay
outputs (X21 and X22)
Terminal blocks for digital
inputs (X11 and X12)
CHASSIS
GND
NODE ID
RDIO-01
DIGITAL I/O EXTENSION
R1NC R1CM R1NO R2NC R2CM R2NO DI1A DI1B DI2A DI2B DI3A DI3B
WD/
INIT
DI3 DI2 DI1
X
21
X
22
X
11
X
12
12123

Chapter 2 – Overview
RDIO-01 User’s manual 2-3
Warranty and
liability
information
The warranty for your ABB drive and options covers
manufacturing defects. The manufacturer carries no
responsibility for damage due to transport or unpacking.
In no event and under no circumstances shall the
manufacturer be liable for damages and failures due to
misuse, abuse, improper installation, or abnormal
conditions of temperature, dust, or corrosives, or
failures due to operation above rated capacities. Nor
shall the manufacturer ever be liable for consequential
and incidental damages.
The period of manufacturer's warranty is 12 months,
and not more than 18 months, from the date of delivery.
Extended warranty may be available with certified start-
up. Contact your local distributor for details.
Your local ABB Drives company or distributor may have
a different warranty period, which is specified in their
sales terms, conditions, and warranty terms.
If you have any questions concerning your ABB drive,
contact your local distributor or ABB Drives office.
The technical data and specifications are valid at the
time of printing. ABB reserves the right to subsequent
alterations.

Chapter 2 – Overview
2-4 RDIO-01 User’s manual

RDIO-01 User’s manual 3-1
Chapter 3 – Installation
WARNING! Follow the safety instructions given in this
guide and in the ACS 800 Hardware Manual.
Mounting The RDIO-01 is to be inserted into the position marked
SLOT 1 or SLOT 2 on the drive. The module is held in
place with plastic retaining clips and two screws.The
screws also provide the earthing of the I/O cable shield
connected to the module, and interconnect the GND
signals of the module and the RMIO board.
On installation of the module, the signal and power
connection to the drive is automatically made through a
38-pin connector.
Mounting procedure:
1. Insert the module carefully into SLOT 1 or SLOT 2
on the RMIO board until the retaining clips lock the
module into position.
2. Fasten the two screws (included) to the stand-offs.
3. Remove the cover of the module enclosure –
directions are given below.
4. Set the configuration DIP switches of the module to
the required position and refit the cover.
Note: Correct installation of the screws is essential for
fulfilling the EMC requirements and for proper operation
of the module.

Chapter 3 – Installation
3-2 RDIO-01 User’s manual
Removing and
refitting the cover
of the enclosure
To choose operating mode and input signal type, the
cover of the module enclosure must be removed. This
can be done by carefully bending the two cover
retaining clips with a small screwdriver (see Figure 3-1)
and lifting the cover off.
Refit the cover by pushing it back into its place until the
retaining clips lock it into position.
Figure 3-1 Removing and refitting the cover
Switches
Figure 3-2 Top view of the module, cover removed
Cover
Retaining clips
BaseCover
Retaining clips
Base
X21
Node ID selector (S1)
Pos. 0,1,2,…,E,F ID 0,1,2,…,14,15
Configuration switch (S2)
0
8
4
C
2
6
A
E
1
3
5
7
9
B
D
F
ON
1234
DI3 HW filtering
DI2 HW filtering
DI1 HW filtering
Unused
ON
1234
123 123412123
X22 X11 X12

Chapter 3 – Installation
RDIO-01 User’s manual 3-3
Digital input
hardware filter
suppression
For faster input signal detection with a DC signal, the
hardware filter of the digital input in question can be
disabled using the configuration DIP switch (S2) on the
circuit board of the module. Disabling the hardware
filtering will however reduce the noise immunity of the
input.
Note: Always have the hardware filtering enabled with
an AC input signal.
Note: Actuator no. 4 is unused.
Hardware
Filtering
DIP switch settings
Digital input
DI1
Digital input
DI2
Digital input
DI3
Enabled
(Default)
Disabled
ON
1234
ON
1234
ON
1234
ON
1234
ON
1234
ON
1234

Chapter 3 – Installation
3-4 RDIO-01 User’s manual
Terminal
designations
Marking Description
X11
DC signal:
24 to 250 V, 4…10 mA
Signal levels: “1” > 12 V; “0” < 8 V
AC signal:
110 to 230 V ±10%, max. 4 mA
Signal levels: “1” > 40 V; “0” < 20 V
DI1:
Galvanically isolated from other digital inputs, relay
outputs and power supply (2.5 kV AC, 1 min)
DI2 and DI3:
Galvanically isolated as a group from DI1, relay
outputs and power supply (2.5 kV AC, 1 min).
Galvanically isolated from each other
(1.5 kV AC, 1 min)
1DI1A
Digital
input DI1
2DI1B
X12
1DI2A
Digital
input DI2
2DI2B
3DI3A
Digital
input DI3
4DI3B
Marking Description
X21
Relay outputs RO1 and RO2:
Max. continuous current: 2 A rms
Switching capability:
8 A (24 V DC, resistive load)
0.4 A (120 V DC, resistive load)
2000 VA (250 V AC)
Galvanically isolated from each
other, digital inputs and power
supply (2.5 kV AC, 1 min)
1R1NC
Relay
output 1
2R1CM
3R1NO
X22
1R2NC
Relay
output 2
2R2CM
3R2NO

Chapter 3 – Installation
RDIO-01 User’s manual 3-5
Wiring 0.5 to 1.5 mm2twisted pair unshielded cable with an
appropriate voltage rating should be used for digital
signals.
WARNING! According to international standards,
applying voltages below 50 V (DC or AC) and above
150 V (AC or DC) simultaneously to the digital inputs
and/or outputs of the RDIO-01 is not allowed.
Additionally, only voltages of the same nominal level
should be applied simultaneously to digital inputs DI2
and DI3 due to reduced isolation voltage.
Note: Do not route signal cables parallel to power
cables.
Digital input wiring
examples
RDIO
DIxA
DIxB
110…230 V AC ±10%
RDIO
DIxA
DIxB
24…250 V DC
(polarity unimportant)

Chapter 3 – Installation
3-6 RDIO-01 User’s manual
Node ID selection If the RDIO-01 module is mounted onto external I/O
Module Adapter AIMA-01, choose the proper node ID
for the module using the node ID selector (S1, range
1…15). Setting the node ID is not required when the
module is mounted into SLOT 1 or SLOT 2 on the drive.
The default setting of selector S1 is 2.
Programming The communication between the module and the drive
is activated by a drive parameter. The RDIO-01 can
replace and/or extend certain standard inputs. See the
drive Firmware Manual, Parameter Group 98.
Note: The new settings take effect only when the
module is powered up.