ABB RTAC-01 User manual

ABB Drives
Pulse Encoder Interface Module
RTAC-01
User’s Manual

Pulse Encoder Interface Module
RTAC-01
User’s Manual
3AFE 64486853 REV A EN
EFFECTIVE: 1.5.2002
© 2002 ABB Oy. All Rights Reserved.

RTAC-01 User’s manual iii
Safety instructions
Overview This chapter states the general safety instructions that
must be followed when installing and operating the
RAIO-01 Analogue 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 RTAC-01 User’s manual

RTAC-01 User’s manual v
Table of contents
Safety instructions
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 RTAC-01 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Warranty and liability information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Chapter 3 – Installation
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Terminal designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Encoder wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Phasing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Encoder output types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Node address selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Table of contents
vi RTAC-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

RTAC-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 RTAC-01
Pulse Encoder Interface 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 RTAC-01 User’s manual
What this manual
contains
This manual contains information on the wiring,
configuration and use of the RTAC-01 module.
Safety instructions are featured in the first few pages
of this manual.
Chapter 2 – Overview contains a short description of
the RTAC-01 Pulse Encoder Interface 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 RTAC-01 module.
Appendix A contains technical data.

RTAC-01 User’s manual 2-1
Chapter 2 –Overview
Overview This chapter contains a short description of the Pulse
Encoder Interface module, a delivery checklist, and
warranty information.
The RTAC-01
module
The RTAC-01 Pulse Encoder Interface module offers an
interface for a digital pulse encoder connection. A pulse
encoder should be used if accurate speed or position
(angle) feedback from the motor shaft is required.
Module layout
65432165432187
Fixing screw (GND)
Node ID selector (S1)
Diagnostic LEDs
Fixing screw
(CHASSIS)
0
8
4
C
2
6
A
E
1
3
5
7
9
B
D
F
Terminal block for
encoder signals (X2)
Terminal block for encoder
power connections (X1)
CHASSIS
GND
NODE ID
SHLD
RTAC-01
PULSE ENCODER INTERFACE
X2 X1
WD/
INIT
CHB CHA
SHLD CHA+ CHA- CHB+ CHB- CHZ+ CHZ- 0 V 0 V V OUT +15V V IN +24V

Chapter 2 –Overview
2-2 RTAC-01 User’s manual
Delivery check The option package contains:
• RTAC-01 module
• Encoder supply voltage selection jumper
• Two screws (M3×8 mm)
• This manual.
Compatibility The RTAC-01 is compatible with ACS 800 Standard
Application Program version ASXR7000 or later.
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.

RTAC-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 RTAC-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.
The module can alternatively be mounted on a DIN rail-
mountable AIMA-01 I/O Module Adapter (not available
at the time of publication).
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.
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 RTAC-01 User’s manual
Terminal
designations
X1 Marking Description
10V Encoder power supply, either 15 or 24 V DC (according
to jumper selection on terminals 4, 5 and 6).
(0 V is also used with single-ended encoder connection
for balancing the A+, B+ and/or Z+ conductors. See
Figures 3-3to 3-6.)
20V
3VOUT
4 +15V Encoder supply voltage selection:
Terminals 4 and 5 connected: 15 V (default)
Terminals 5 and 6 connected: 24 V
(Jumper is supplied with the RTAC module)
Max. 5 watts (see Power consumption below)
5VIN
6 +24V
Connected internally on the circuit board.
X2 Marking Description
1SHLD
Shield For earthing of the encoder cable shields. Internally
connected to the frame.
2SHLD
3A+ A
• Max. signal frequency: 200 kHz
• Signal levels:
“1” > 7.6 V, “0” < 5 V (for 15 V supply)
“1” > 12.2 V, “0” < 8 V (for 24 V supply)
• Input channels isolated from the logic, power supply,
and earth
• When the drive runs in the Forward direction,
channel A should lead channel B by 90° (electrical)
• Channel Z: One pulse per revolution (used in
positioning applications only)
4A- A
5B+ B
6B- B
7Z+ Z
8Z- Z

Chapter 3 –Installation
RTAC-01 User’s manual 3-3
Power
consumption
Without an external power supply, the RTAC-01 can
supply 5 W (at either 15 V or 24 V DC) to the encoder.
For higher power, an external power supply is required.
As the power consumption of the module depends on
many factors (e.g. max. speed of the motor, encoder
pulse number per revolution, encoder cable length and
leakage capacitance), it should be checked on each
occasion if an external power supply is needed. See the
encoder documentation for details. Figure 3-2shows
the approximate power consumption of an encoder with
differential outputs, based on actual measurements.
The external power supply should be connected as
shown below.
Note: With an external power supply, the voltage
selection jumper should be removed from X1.
Figure 3-1 External power supply connection diagram
X1
0 V
0 V
V OUT
+15V
V IN
+24V
SHLD
X2
RTAC
Vcc Vcc
0V
0V
1
2
3
4
5
6
2

Chapter 3 –Installation
3-4 RTAC-01 User’s manual
Figure 3-2 Approximate power consumption of an encoder for four different
cable lengths. The chart is based on a measurement with a 24 V DC, 1024 ppr
pulse encoder with differential outputs coupled to a motor shaft rotating at 1500
rpm.
0 150 300 450 600 750 900 1050 1200 15001350
0 600 1200 1800 2400 3000 3600 4200 4800 60005400
EPN = 2048 ppr:
EPN = 512 ppr:
EPN = 1024 ppr:
EPN = Encoder pulse number
Pidle = Encoder power consumption when idle. See encoder documentation.
Motor
speed
(rpm)
0 300 600 900 1200 1500 1800 2100 2400 30002700
Pidle
Pidle + 0.25 W
Pidle + 0.5 W
Pidle + 0.75 W
Pidle + 1.0 W
Pidle + 1.25 W
Pidle + 1.5 W
Pidle + 1.75 W
Pidle + 2.0 W
Encoder power
consumption
Cable length
300 m
150 m
100 m
20 m

Chapter 3 –Installation
RTAC-01 User’s manual 3-5
Encoder wiring The pulse encoder should be connected to the RTAC
module with a cable specified below.
Either a single-ended or differential connection can be
used, but the manufacturer’s recommendations should
be taken into account. Starting on page 3-8, there are
wiring diagrams for different encoder output types.
Compare encoder documentation and the diagrams
below to determine the output type.
Note: The cable shields should be earthed at the RTAC
module only if the encoder is not isolated from the
motor and earth. However, if the encoder is isolated
from the motor and earth, the cable shields are to be
connected to the encoder housing also.
Note: Do not route the encoder cables parallel to power
(eg. motor) cables.
Cable
construction
4 ×(2+1) Twisted pair cable with individual
and overall shields.
Conductor cross-
sectional area 0.5 to 1.0 mm2
Maximum cable length
Dependent on encoder output type as follows:
300 m (differential push-pull)
200 m (single-ended push-pull)
100 m (open collector or emitter)

Chapter 3 –Installation
3-6 RTAC-01 User’s manual
Phasing When the encoder is connected correctly, running the
drive in the Forward (positive speed reference) direction
should produce a positive encoder speed feedback.
On incremental encoders, the two output channels,
usually marked 1 and 2 or A and B, are 90°(electrical)
apart from each other. When rotated clockwise, most
encoders –but not all –have channel 1 leading channel
2 as illustrated below. Determine the leading channel by
referring to the encoder documentation or by measuring
with an oscilloscope.
The encoder output channel that leads when the drive
runs Forward should be connected to RTAC input A, the
output channel that trails to RTAC input B.
The zero reference output channel (usually marked 0, N
or Z) needs to be connected in positioning applications
only.
A or 1
Aor 1
B or 2
Bor 2
Z or 0
Z or 0

Chapter 3 –Installation
RTAC-01 User’s manual 3-7
Encoder output
types
The diagram presents some typical encoder output
types. The following pages include wiring diagrams for
each output type.
Push-pull Open collector
(Sinking)
Open emitter
(Sourcing)
VCC = Encoder input power supply voltage
RL= Load resistor at encoder output channel
RL2
VCC
RL1
VCC
OUT
RL
VCC
OUT
VCC
RL
VCC
OUT

Chapter 3 –Installation
3-8 RTAC-01 User’s manual
Wiring diagrams
Encoder output type: Push-pull
Output pulse order in Forward rotation: 1, 2
(With encoders with 2as the leading output,
1 and 2 should be wired to RTAC terminals B+ and A+ respectively.
1and 2 should be wired to RTAC terminals B- and A- respectively.)
Differential connection
Figure 3-3 Differential wiring of pulse encoders with push-pull outputs
1
2
1
1
0
0VVCC
2
X1
RTAC
A+
A-
B+
B-
Z+
Z-
2
0
15V
24V
Encoder supply
voltage selection
(15 or 24 V)
1
2
3
4
5
6
SHLD
SHLD
7
8
V OUT
+15V
V IN
+24V
1
2
3
4
5
6
0 V
0 V
X2