ABB RAIO-01 User manual

ABB Drives
Analogue I/O Extension Module
RAIO-01
User’s Manual

Analogue I/O Extension Module
RAIO-01
User’s Manual
3AFE64484567 REV B EN
EFFECTIVE: 2009-04-21
© 2009 ABB Oy. All Rights Reserved.

RAIO-01 User’s manual 5
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
6 RAIO-01 User’s manual

RAIO-01 User’s manual 7
Table of contents
Safety instructions
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table of contents
Chapter 1 – Introduction
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What this manual contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2 – Overview
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The RAIO-01 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Warranty and liability information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 3 – Installation
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mounting onto RMIO board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mounting onto AIMA adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removing and refitting the cover of the enclosure . . . . . . . . . . . . . . . . . . . . . 15
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input mode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Input signal type selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Terminal designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Node ID selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Table of contents
8 RAIO-01 User’s manual
Chapter 4 – Fault tracing
Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Option slot installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
AIMA-01 I/O Module Adapter installation . . . . . . . . . . . . . . . . . . . . . . . .21
Appendix A – Technical data

RAIO-01 User’s manual 9
Chapter 1 – Introduction
Intended
audience
The manual is intended for the people who are
responsible for commissioning and using an RAIO-01
Analogue I/O Extension module with the ACS800 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
10 RAIO-01 User’s manual
What this manual
contains
This manual contains information on the wiring,
configuration and use of the RAIO-01 module.
Safety instructions are featured in the first few pages
of this manual.
Chapter 2 – Overview contains a short description of
the RAIO-01 Analogue 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 RAIO-01 module.
Appendix A contains technical data.

RAIO-01 User’s manual 11
Chapter 2 – Overview
Overview This chapter contains a short description of the
Analogue I/O Extension module, a delivery checklist
and warranty information.
The RAIO-01
module
The RAIO-01 Analogue I/O Extension module offers
two bipolar current (±0[4]…20 mA) or voltage
(±0[2]…10 V or ±0…2 V) inputs and two unipolar
current (0[4]…20 mA) outputs with 12-bit resolution.
The analogue inputs and outputs are galvanically
isolated as a group from each other and the power
supply.
Module layout
123456 123456
Fixing screw (GND)
Node ID selector
Module status LED
Fixing screw
(CHASSIS)
Configuration switch
(behind cover)
0
8
4
C
2
6
A
E
1
3
5
7
9
B
D
F
CHASSIS
GND
Node ID
AO1+ SHLD SHLD AO1- AO2+ AO2- AI1- SHLD SHLD AI1+ AI2- AI2+
WD/
INIT
RAIO-01
ANALOGUE I/O EXTENSION
X2 X1
Terminal block for
analogue outputs (X2)
Terminal block for
analogue inputs (X1)

Chapter 2 – Overview
12 RAIO-01 User’s manual
Delivery check The option package contains:
• RAIO-01 module
•Twoscrews
• This manual.
Compatibility The RAIO-01 is compatible with the ACS800 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.

RAIO-01 User’s manual 13
Chapter 3 – Installation
WARNING! Follow the safety instructions given in this
guide and in the Hardware Manual of the drive.
Mounting The RAIO-01 is to be inserted into an optional module
slot on either the RMIO board of the drive, or on an
AIMA-01 I/O Module Adapter. 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/AIMA
adapter.
On installation of the module, the signal and power
connection to the drive is automatically made through a
38-pin connector.
Mounting onto
RMIO board
1. Insert the module carefully into SLOT 1 or SLOT 2
on the RMIO board of the drive 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.
3. Remove the cover of the module enclosure (see
page 15).
4. Set the configuration DIP switches of the module to
the required position (pages 16 and 17) and refit the
cover.

Chapter 3 – Installation
14 RAIO-01 User’s manual
Mounting onto
AIMA adapter
1. Insert the module carefully into SLOT 1, SLOT 2 or
SLOT 3 on the AIMA adapter 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.
3. Remove the cover of the module enclosure (see
page 15).
4. Set the configuration DIP switches of the module to
the required position (pages 16 and 17).
5. Set the node ID for the module (page 20) and refit
the cover.

Chapter 3 – Installation
RAIO-01 User’s manual 15
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 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 1 Removing and refitting the cover
Switches
Figure 2 Top view of the module, cover removed
Cover
Retaining clips
BaseCover
Retaining clips
Base
X2 X1
123456 123456
0
8
4
C
2
6
A
E
1
3
5
7
9
B
D
F
ON
12345 6
ON
123456
AI1 signal mode
AI1 signal level
AI2 signal mode
AI2 signal level
Node ID selector (S1)
Pos. 0,1,2,…,E,F ID 0,1,2,…,14,15
Configuration switch (S2)

Chapter 3 – Installation
16 RAIO-01 User’s manual
Input mode
selection
The operating mode of the analogue inputs can be
selected using the configuration DIP switch (S2) on the
circuit board of the module. The drive parameters must
be set accordingly.
In bipolar mode, the analogue inputs can handle
positive and negative signals. The resolution of the A/D
conversion is 11 data bits (+ 1 sign bit). The way the
drive interprets the negative range of the inputs
depends on the settings of the drive. See the Firmware
Manual of the drive.
In unipolar mode (default), the analogue inputs can
handle positive signals only. The resolution of the A/D
conversion is 12 data bits.
DIP switch setting
Input signal type
Analogue input AI1 Analogue input AI2
±0(4)…20 mA
±0(2)…10 V
±0…2 V
0(4)…20 mA
0(2)…10 V
0…2 V
(Default)
ON
123456
ON
123456
ON
123456
ON
123456

Chapter 3 – Installation
RAIO-01 User’s manual 17
Input signal type
selection
Each input can be used with a current or voltage signal.
The selection is made with the configuration DIP switch
(S2) on the circuit board of the module.
Input signal
type
DIP switch settings
Analogue input 1 Analogue input 2
Current signal
±0(4)…20 mA
(Default)
Voltage signal
±0(2)…10 V
Voltage signal
±0…2 V
ON
123456
ON
123456
ON
123456
ON
123456
ON
123456
ON
123456

Chapter 3 – Installation
18 RAIO-01 User’s manual
Terminal
designations
The RAIO-01 is equipped with two 6-pole non-
detachable screw-type connectors. Terminal block X1
provides the connection for the analogue input signals,
and X2 provides the connection for the analogue output
signals. Each terminal block includes two terminals for
the cable shield (see also Figure 3).
X1 Marking Description
1AI1-
Analogue
input 1
Current signal
±0(4)…20 mA
Input impedance 100 Ω
Galvanically isolated as a
group (see page 24) from
the analogue outputs,
power supply and earth.
Voltage signal
±0(2)…10 V or ±0…2 V
Input impedance 200 kΩ
Galvanically isolated as a
group (see page 24) from
the analogue outputs, power
supply and earth.
2AI1+
3AI2-
Analogue
input 2
4AI2+
5SHLD Cable shield AC earthing. Connected via an RC circuit to the
frame.
6SHLD
X2 Marking Description
1AO1+
Current
output 1
Current signal
0(4)...20 mA
Load resistance max. 700 Ω
Galvanically isolated as a group (see page 24) from the
analogue inputs, power supply and earth.
2AO1-
3AO2+
Current
output 2
4AO2-
5SHLD
Cable shield AC earthing (via an RC circuit to the frame).
6SHLD

Chapter 3 – Installation
RAIO-01 User’s manual 19
Wiring 0.5 to 1.5 mm2twisted pair cable with individual and/or
overall shields should be used for analogue signals.
The shields should be connected to the SHLD terminals
on the RAIO-01 module. See the example below.
Figure 3 Wiring example
Note: If the transducers or indicators are located far
away from each other, earth the shield at one unit
through a capacitor (e.g. 10 nF/400 V) to avoid
circulating earth current flow.
Note: X1 and X2 have separate RC circuits as shown
above, i.e. the SHLD terminals on one terminal block
are connected together and earthed through a common
RC circuit.
AI1+
AI1-
SHLD
Transducer 1
AI2+
AI2-
SHLD
Transducer 2
Indicator 1
Indicator 2
T
SHLD
AO2-
AO2+
SHLD
AO1-
AO1+
RAIO-01
P
X2X1

Chapter 3 – Installation
20 RAIO-01 User’s manual
Node ID selection If the RAIO-01 module is mounted onto an external
AIMA-01 I/O Module Adapter, 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 5.
Programming The communication between the module and the drive
is activated by a drive parameter. (Ensure that the
parameter settings correspond to the mode switch
setting of the module.) The RAIO-01 can replace and/or
extend certain standard inputs and outputs. See the
drive Firmware Manual, Parameter Group 98.
Note: The new settings take effect only when the
module is powered up.