ABB CIO-01 User manual

—
ABB INDUSTRIAL DRIVES
CIO-01 I/O module and distributed I/O bus
User's manual

CIO-01 I/O module 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

Table of contents
1 Safety instructions
7Contents of this chapter ........................................................................
7Use of warnings and notes .....................................................................
8General ..............................................................................................
8Safety during operation .........................................................................
2 Introduction to the manual
9Contents of this chapter ........................................................................
9Applicability ........................................................................................
9Compatibility ......................................................................................
9Target audience ...................................................................................
10Terms and abbreviations .......................................................................
10Cyber security disclaimer .......................................................................
10Related documents ..............................................................................
3 Hardware description and operation principle
11Contents of this chapter ........................................................................
12Product overview .................................................................................
12Layout drawing of CIO module .............................................................
13Distributed I/O bus topology ..................................................................
14Bus topology example - single drives .....................................................
15Bus topology example - multidrives ......................................................
16Fan control .........................................................................................
4 Mechanical installation
17Contents of this chapter ........................................................................
17Unpacking and examining the delivery ......................................................
18Installing the CIO module .......................................................................
5 Electrical installation
19Contents of this chapter ........................................................................
20Default I/O diagram .............................................................................
21Cabling instructions .............................................................................
22Wiring example ....................................................................................
6 Start-up
23Contents of this chapter ........................................................................
23Start-up procedure ...............................................................................
7 Program features
25Contents of this chapter ........................................................................
25Overview ............................................................................................
25Basic configuration of the distributed I/O bus ... .... . . . . . . . . ................ . . . . . . . . .....
25Settings .........................................................................................
Table of contents 5

26Service request parameters ....................................................................
26Settings .........................................................................................
26Diagnostic counters .............................................................................
26Settings .........................................................................................
26Identification run of the fans ..................................................................
26Settings .........................................................................................
8 Parameters
27Contents of this chapter ........................................................................
27Terms and abbreviations .......................................................................
28Summary of parameter groups ................................................................
28Parameter listing .................................................................................
28206 I/O bus configuration ..................................................................
33207 I/O bus service ...........................................................................
34208 I/O bus diagnostics .....................................................................
35209 I/O bus fan identification ..............................................................
9 Fault tracing
39Contents of this chapter ........................................................................
39Warning and fault indications .................................................................
39Auxiliary code ..................................................................................
40Warning and fault messages ...................................................................
41LEDs of the CIO module .........................................................................
10 Ordering information
43CIO-01 I/O module ...............................................................................
11 Maintenance
45Contents of this chapter ........................................................................
45Maintenance intervals ...........................................................................
45Replacing the CIO module ......................................................................
46Removing the CIO module ..................................................................
46Reinstalling the CIO module ................................................................
46Resetting the fan data after replacing a fan ................................................
12 Technical data
47Contents of this chapter ........................................................................
47Dimension drawing ..............................................................................
48Isolation areas .....................................................................................
49Specifications .....................................................................................
49Ambient conditions ..............................................................................
49Protection class ...................................................................................
49Materials ............................................................................................
50Applicable standards ............................................................................
Further information
6 Table of contents

Safety instructions
Contents of this chapter
The chapter contains the warning symbols used in this manual and the safety
instructions which you must obey when you install or connect an optional module to
a drive, converter or inverter. If you ignore the safety instructions, injury, death or
damage can occur. Read this chapter before you start the installation.
Use of warnings and notes
Warnings tell you about conditions which can cause injury 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 caused by electricity,
which can cause injury or death, or damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
1
Safety instructions 7

General
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or
death, or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do installation, commissioning or
maintenance work.
Obey all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, use or
service the drive. The complete safety instructions are given in ACS880
liquid-cooled multidrive cabinets and modules safety instructions
(3AXD50000048633 [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 the beginning of the
hardware manual.
Safety during operation
WARNING!
If the drive trips due to fan speed under limit (206.7 Fan speed fault limit), the
PWM signal for controlling the fan will remain at nominal reference speed,
which may lead to a restart of the fan even though the drive remains tripped.
8 Safety instructions
3

Introduction to the manual
Contents of this chapter
This chapter contains information on the applicability and intended audience.
Applicability
This document is applicable to the CIO-01 I/O module, later CIO module, and distributed
I/O bus. It contains hardware and firmware information specific to them. CIO module
is applicable to ACS880 liquid cooled cabinets and modules with the following 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 audience
This manual is intended for people who:
• design, install or commission a distributed I/O bus
• do maintenance or fault tracing work on the distributed I/O bus.
2
Introduction to the manual 9

Terms and abbreviations
DescriptionTerm
Type of control unitBCU
I/O module for controlling cooling fansCIO
Distributed drives communication system protocolDDCS
Digital inputDI
In the drive control program, user-adjustable operation instruction to the
drive, or signal measured or calculated by the drive.
In some (for example fieldbus) contexts, a value that can be accessed as an
object. For example, variable, constant, or signal.
Parameter
Type of control unitUCU
Cyber security disclaimer
This product can be connected to and communicate information and data via a network
interface. The HTTP protocol, which is used between the commissioning tool (Drive
Composer) and the product, is an unsecured protocol. For independent and continuous
operation of product such connection via network to commissioning tool is not
necessary. However it is Customer's sole responsibility to provide and continuously
ensure a secure 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
interface against any kind of security breaches, unauthorized access, interference,
intrusion, leakage and/or theft of data or information.
Notwithstanding any other provision to the contrary and regardless of whether the
contract is terminated or not, ABB and its affiliates are under no circumstances liable
for damages and/or losses related to such security breaches, any unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
Related documents
You can find manuals on the Internet. See below for the relevant code/link. For more
documentation, go to www.abb.com/drives/documents.
Manuals for ACS880 multidrives cabinets
Manuals for ACS880 multidrives modules
10 Introduction to the manual

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

Product overview
￭Layout drawing of CIO module
The following figure shows the layout of the CIO module.
8
8
9
4
5
6
7
3
2
1
Power supply XPOW1.
I/O bus termination resistor switch2.
RS-485 communication link (I/O bus)3.
Analog inputs XAI1, XAI24.
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 module7.
Digital inputs XDI1, XDI28.
Digital inputs/outputs XDIO1…XDIO49.
12 Hardware description and operation principle

Distributed I/O bus topology
The control unit of the drive or unit is connected to CIO modules through distributed
I/O bus. CIO modules monitor and control individual fans (maximum of 4 per module).
Typically, each cubicle that contains a fan, also contains a CIO module.
Single drives and multidrives differ in the amount of control units used 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 unit (ACS880-607LC)DBU
1-phase brake unit (ACS880-607LC)BRC
DC/DC converter unit (1607LC)DDC
Hardware description and operation principle 13

￭Bus topology example - single drives
There is only one I/O bus that controls all the fans in single drives.
Hardware description and operation principle 15
7-segment displays
Two 7-segment displays on the CIO-01 module show the 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 acknowledged by the CIO-01 module.
CIO-01 module controlling distributed I/O bus
Distributed I/O bus is controlled by CIO-01 I/O module. Typically, each cubicle that
contains cabinet fan, also contains one CIO-01 I/O module:
One CIO-01 I/O module contains connectors for four fans (speed reference output and
feedback of the fans), two analog inputs, and four digital inputs. You can physically
connect 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-01CIO-01
A
1
B BB
CIO-01*
Supply control unit (I/O bus master)1
Supply module cubicleA
Inverter module cubicleB
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.
*
One CIO module contains connectors for four fans (speed reference output and
feedback of the fans), two analog inputs, and four digital inputs. You can connect 16
CIO modules to the distributed I/O bus. Running numbers from 1 to 16 are used as
node numbers for the CIO modules.
14 Hardware description and operation principle

￭Bus topology example - multidrives
In multidrives, the control unit of each unit (supply, inverter, etc.) controls an I/O bus
of its own.
1
CIO-01 CIO-01 CIO-01
2
3
CIO-01CIO-01CIO-01CIO-01
2
CIO-01*
Supply control unit (I/O 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 operation principle 15

Fan control
CIO modules monitor fan speed signals separately for all fans. The diagram below
illustrates the fan control principle in an inverter unit.
Fan control is based on the status of the inverter unit IGBTs (modulating or not) and
the voltage level in the drive DC link. The I/O bus master sends both the modulation
status information and the DC voltage level value to all CIO modules. There are four
different operating modes:
• DC voltage is low and modulation is off, the 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 module.
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
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 
 
 
 
 
 


Modulation
status
DC voltage
Reference
fan speed
100 %
50 %
0 %
DC high
DC low
5 min
On
Off
Reference fan speedDC voltageModulation status
50 %HighOff
100 %HighOn
100 %High/LowTurned off less than 5 minutes ago
0 %LowOff
16 Hardware description and operation principle

Mechanical installation
Contents of this chapter
This chapter contains instructions on installing the module. The instructions are
intended for panel builders and system integrators who 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

Installing the CIO module
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or
death, or damage to the equipment can occur.
See chapter Safety instructions.
1. Do the Electrical safety precautions steps before you start the work. Refer to the
drive safety instructions.
2. Install the CIO module in a drive cabinet environment.
3. Make sure that the ambient conditions meet the requirements given in Ambient
conditions (Page 49) and the ambient conditions in the hardware manual of the
drive or unit.
4. 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.
20 Mechanical installation
Installing 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.
Install the CIO-01 module in a heated indoor environment. Ensure that the ambient
conditions meet the requirements given in Ambient conditions on page 56.
Fasten the module with screws on its corner holes.
Grounding the module
Fasten the module with screws on a conducting surface. If needed, use an additional
grounding wire under the screw.
18 Mechanical installation
4

Electrical installation
Contents of this chapter
This chapter describes the electrical installation of the CIO module. The instructions
are intended for panel builders and system integrators who 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

Default I/O diagram
Connectors of the CIO module and their default use is shown below.
DescriptionTerminal
Digital inputs/outputsXDIO1…XDIO4
Monitoring (DI1) and control (DO1) (PWM output) of fan 1
DI111
11
12
13
21
22
23
31
32
33
41
42
43
DCOM12
DO113
Monitoring (DI2) and control (DO2) (PWM output) of fan 2
DI221
DCOM22
DO223
Monitoring (DI3) and control (DO3) (PWM output) of fan 3
DI331
DCOM32
DO333
Monitoring (DI4) and control (DO4) (PWM output) of fan 4
DI441
DCOM42
DO443
Digital inputsXDI1, XDI2
CIO module miniature circuit breaker monitoring (0 = related warning or
fault is given, jumpered to 1 as default) (Parameter 206.50)
DI51
5
6
7
1
2
3
4
8
DCOM2
CIO module fuse monitoring. 0 = related warning/fault is given. Parameter
206.51
DI63
DCOM4
DI7: Not in use in the control program.
DI75
DCOM6
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)
DI87
DCOM8
Analog inputsXAI1, XAI2
Reserved for fan temperature monitoring with an NTC thermal switch. No
software support currently.
AI1+1
1
2
3
1
2
3
AI1-2
SHIELD3
Reserved for fan temperature monitoring with an NTC thermal switch. No
software support currently.
AI2+1
AI2-2
SHIELD3
RS-485 communication linkX485
RS-485 communication link (I/O bus).
B1
1
2
3
4
A2
GND3
SHIELD4
I/O bus terminationTERM
Termination resistor
ON OFF
Power supplyXPOW
20 Electrical installation