Cio 01
Cio 01
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CIO-01 I/O module for distributed
I/O bus control
User’s manual
Table of contents
1. Safety instructions
4. Mechanical installation
5. Electrical installation
6. Start-up
Table of contents
1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety in installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Unpacking and examining the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Grounding the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Terminal designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General cabling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Wiring example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6. Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hardware settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. Program features
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Basic configuration of the distributed I/O bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Service request parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Diagnostic counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Identification run of the fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8. Parameters
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Summary of parameter groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Parameter listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
206 I/O bus configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
207 I/O bus service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
208 I/O bus diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
209 I/O bus fan identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8
Safety instructions 9
1
Safety instructions
Use of warnings
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. The manual uses these warning
symbols:
Electricity warning tells you about hazards from electricity which can cause
injury or death, or damage to the equipment.
General warning tells you about conditions, other than those caused by
electricity, which can cause injury or death, or damage to the equipment.
10 Safety instructions
General
Follow all safety instructions delivered with the drive before you install, commission, or use
the drive. For single drives, the complete safety instructions are given at the beginning of
the hardware manual. For multidrive safety instructions, see Safety instructions for
ACS880 multidrive cabinets and modules (3AUA0000102301 [English]) for air-cooled
modules, and Safety instructions for ACS880 liquid-cooled multidrive cabinets and
modules (3AXD50000048633 [English]) for liquid-cooled modules.
Read the software function specific warnings and notes before changing the default
settings of the function. For each function, the warnings and notes are given in the
subsection the function or the related user-adjustable parameters.
Safety in installation
These instructions are for all who install or connect an optional module to a drive,
converter or inverter and need to open its front cover or door to do the work.
WARNING! If the drive trips due to fan speed under limit (parameter 206.07), 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.
Introduction to the manual 11
2
Introduction to the manual
Applicability
This document is applicable to the CIO-01 I/O module and ACS880 distributed I/O bus. It
contains hardware and firmware information specific to them. For other information on the
drive, see the drive hardware or firmware manual.
Target audience
This manual is intended for people who design, commission, or operate the drive system.
Related documents
A list of related manuals is printed on the inside of the front cover.
12 Introduction to the manual
Cybersecurity disclaimer
This product is designed to be connected to and to communicate information and data via
a network interface. 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, 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. ABB and its
affiliates are not liable for damages and/or losses related to such security breaches, any
unauthorized access, interference, intrusion, leakage and/or theft of data or information.
See also ACS880 diode supply control program firmware manual (3AUA0000103295
[English]), and ACS880 IGBT supply control program firmware manual (3AUA0000131562
[English]).
Hardware description and operation principle 13
3
Hardware description and
operation principle
Product overview
Layout drawing of CIO-01 I/O module
The following figure shows the layout of the CIO-01 I/O module.
5
4
8
9
2
No. Description
1. Power supply XPOW
2. Termination resistor switch
3. RS-485 communication link
4. Analog inputs XAI1, XAI2
5. 7-segment displays
6. Push buttons
7. LEDs of the CIO-01 module
8. Digital inputs XDI1, XDI2
9. Digital inputs/outputs XDIO1…XDIO4
Push buttons
Push button Description
S1 Node number decreases
S2 Node number increases
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.
Example
A B
Description
A Supply module cubicle
B Inverter module cubicle
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.
16 Hardware description and operation principle
Fan control
The following diagrams describe how the cabinet fan is controlled by the CIO-01 module.
Modulating
Modulation or diode
status mode 5min
Stopped
DC status DC high
(100 V on)
DC low
(50 V off)
Fan speed
reference
Hardware description and operation principle 17
Modulating
Fan reference
Timer
ran out
DC low
Modulation
Modulating
status
Stopped
Post fan-on timer
DC high
DC status
DC low
18 Hardware description and operation principle
Mechanical installation 19
4
Mechanical installation
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.
5
Electrical installation
Warnings
Terminal designations
Connectors of the CIO-01 module and their default use is shown below. For further details
on wiring, see the delivery-specific circuit diagrams.
Wiring
Connect the external control cables to the applicable module terminals.
Wiring example
XPOW
Power supply +24V
24 V DC
GND
XAIx
Analog inputs
for NTC AIx+
NTC
temperature AIx-
measurement SHIELD
Monitoring and
FAN XDIOx
control of fans Tacho DIx
Common DCOM
PWM DOx
XDIx
DIx
Digital inputs
DCOM
6
Start-up
Start-up procedure
Tasks
Safety
WARNING! Obey the safety instructions during the start-up procedure. See Safety
instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]) for
air-cooled modules, and Safety instructions for ACS880 liquid-cooled multidrive cabinets
and modules (3AXD50000048633 [English]) for liquid-cooled modules. If you ignore the safety
instructions, injury or death, or damage to the equipment can occur.
Hardware settings
Check the mechanical and electrical installation of the drive. See the hardware manual.
Terminate the I/O bus at its physical ends: set the termination resistor switch of the CIO-01 module
on the other end of the I/O bus to ON position, and terminate the other end of the I/O bus on the ZCU
or BCU control unit. Set intermediate termination resistors to OFF position.
Note: When using a ZCU control unit as an I/O bus master, make sure that ZCU control unit is of
type ZCU-14 rev. B or later.
Set the correct node number to each CIO-01 module (or make sure that the correct node number is
set): use the up and down buttons of the CIO-01 module.
Parameter settings
Set parameter 206.01 I/O bus enable to Yes.
ACS880-07CLC: Set bit 15 of parameter 195.20 HW options word 1.
Activate the CIO-01 modules by selecting the node numbers with parameter 206.18 Node activation.
Verify that all nodes communicate without errors. You can use parameters of parameter group 208
I/O bus diagnostics to help in verification and debugging.
Close the cabinet doors before performing identification run to guarantee normal operation
conditions concerning air flow.
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 control program shows the detected results (100% level feedback pulse
frequencies) in the parameters of parameter group 209 I/O bus fan identification for each fan. The
fans are ready for use. Note:
• Verify that the detected feedback pulse frequencies are reasonable for the fan types. For allowed
reference speed ranges, see the sticker inside each cabinet door.
• Every start of fans performs the identification run for fans that do not have an existing result
available.
• If fans are later replaced with new ones, identification run result and internal run-time counters on
the CIO-01 module need to be reset. To reset, set parameter 207.03 Command selection to Reset
fan data and trigger the operation with parameter 207.10 Service request trigger for the selected
node.
• If CIO-01 module is replaced, all the fans connected to the replaced CIO-01 module need to be
replaced as well. Otherwise the run-time supervision does not work properly.
Review the parameters of parameter group 206 I/O bus configuration to guarantee that supervision
limits etc. are suitable for the application.
Program features 27
7
Program features
Overview
Distributed I/O bus controls and supervises each cabinet fan separately. It detects
malfunctioning fans and indicates them with warning or fault messages. The control
program performs identification run for cabinet fans to detect nominal speed values of the
fans.
Typically, the control unit of the supply unit acts as an I/O bus master. Cabinet fans in drive
cubicles are controlled with separate PWM (pulse-width modulation) outputs. When the
control program detects a malfunctioning fan, DDCS communication delivers the warning
code from the supply unit to the inverter unit. You can access the settings of the distributed
I/O bus via panel bus or Drive composer PC tool.
28 Program features
Settings
Parameters: parameter group 206 I/O bus configuration
Settings
Parameters: parameter group 207 I/O bus service
Diagnostic counters
The control program displays amounts of messages (packets) sent by master (208.01,
208.02), and certain errors (208.03…208.05) on the distributed I/O bus. Parameters
208.11…208.26 show the amount of timeouts for each node, and parameter 208.06 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
Settings
Parameters: parameter group 209 I/O bus fan identification
Parameters 29
8
Parameters
Parameter listing
No. Name/Value Description Def/FbEq16
206
206 I/O bus configuration Basic configuration of the distributed I/O bus.
206.01 I/O bus enable Enables/disables the use of distributed I/O bus. No
No Distributed I/O bus is disabled. 0
Yes Distributed I/O bus is enabled. 1
206.06 Fan speed warning Defines the warning limit for fan speed. When fan speed is 75.0%
limit below the value given with this parameter (in relation to
requested reference), the control program generates warning
AE92 Fan speed. Parameter value 0 means that no warning
will be generated.
0.0…100.0% Warning limit for fan speed. 1 = 1%
206.07 Fan speed fault limit Defines the fault limit for fan speed. When fan speed is below 50.0%
the value given with this parameter (in relation to requested
reference), the control program generates fault 8E12 Fan
speed. Parameter value 0 means that no fault will be
generated.
0.0…100.0% Fault limit for fan speed. 1 = 1%
206.08 Fan on-time Defines the warning limit for fan lifetime. When the fan has 90000 h
warning limit been running longer (in hours) than the value given with this
parameter, the control program generates warning AE91 Fan
lifetime exceeded.
0…596523 h Warning limit for fan lifetime. 1=1h
206.09 Communication loss Defines a timeout for monitoring a node. The control program 2 s
time monitors whether an active node can not be found on the I/O
bus. If a communication break lasts longer than the timeout,
the control program generates warning AE90 I/O bus
communication.
0…600 s Communication loss time. 1=1s
206.18 Node activation Activates communication for nodes 1…16. 0000h
0000h…FFFFh Statuses of miniature circuit breaker input (digital input DI5). 1=1
206.41 Fuse monitoring Indicates the status of fuse monitoring input (digital input DI6) 0000h
status of each I/O node.
9
Additional parameter data
Actual signal Signal measured or calculated by the supply unit. Usually can only be monitored but
not adjusted; some counter-type signals can however be reset.
Analog src The parameter can be set to the value of another parameter by choosing “Other”,
and selecting the source parameter from a list.
In addition to the “Other” selection, the parameter may offer other pre-selected
settings.
Binary src The value of the parameter can be taken from a specific bit in another parameter
value (“Other”). Sometimes the value can be fixed to 0 (false) or 1 (true). In addition,
the parameter may offer other pre-selected settings.
FbEq32 32-bit fieldbus equivalent: The scaling between the integer used in communication
and the value shown on the panel when a 32-bit value is selected for transmission to
an external system.
The corresponding 16-bit scalings are listed in chapter Parameters (page 29).
Term Definition
Type Parameter type. See Analog src, Binary src, List, PB, Real.
Fieldbus addresses
Refer to the User’s manual of the fieldbus adapter.
Additional parameter data 45
10
Fault tracing
Safety
WARNING! Only qualified electricians are allowed to service the supply unit. See
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]) for air-cooled modules, and Safety instructions for
ACS880 liquid-cooled multidrive cabinets and modules (3AXD50000048633 [English]) for
liquid-cooled modules.
Warning messages
Code Warning Cause What to do
(hex)
AE90 I/O bus communication Communication break noticed Check I/O bus wiring, powering of the
on I/O bus. nodes and node number settings on the
CIO-01 module. Parameters of
parameter group 208 I/O bus diagnostics
can be used to identify the nodes that are
timing out.
AE91 Fan lifetime exceeded Warning limit for fan lifetime See the auxiliary code for indication of
(parameter 206.08) has been module IDs that contain fans that have
exceeded. exceeded their lifespan. Auxiliary code is
a bit word where bit 0 indicates CIO-01
module assigned to node ID 1.
Replace the failing fan and reset the fan
data via parameter group 207 I/O bus
service.
AE92 Fan speed Fan speed is under limit Check fan feedback. See parameters
(parameter 206.06). 206.30…206.33 for individual failing fans.
AE93 Fan speed feedback Error in fan speed feedback. See the auxiliary code for node(s) giving
error faulty feedback indication for fan(s).
Auxiliary code is a bit word where bit 0
indicates CIO-01 module assigned to
node ID 1.
Check fan feedback. Verify the
identification run results against the
tachometer pulse count of the fan
feedback.
AE94 CIO MCB monitoring Warning related to miniature Check miniature circuit breaker and
circuit breaker. Some of the digital input DI5.
bits of the MCB status word are
0.
AE95 CIO fuse monitoring Warning related to fuses. Check fuses and digital input DI6.
Some of the bits of the fuse
status word are 0.
AE97 CIO DI8 monitoring Warning related to digital input Check digital input DI8.
DI8.
Fault tracing 51
Fault messages
Code Fault Cause What to do
(hex)
8E12 Fan speed Fan speed is under limit Check fan feedback. See parameters
(parameter 206.07). 206.30…206.33 for individual failing fans.
8E13 I/O module version Communication services of the See the auxiliary code for incompatible
mismatch CIO-01 module are CIO-01 module. Auxiliary code is a bit
incompatible with the firmware word where bit 0 indicates CIO-01
version on the control unit. module assigned to node ID 1.
Replace the incompatible CIO-01
module.
8E14 CIO MCB monitoring Fault related to miniature circuit Check miniature circuit breaker and
breaker. Some of the bits of the digital input DI5.
MCB status word are 0.
8E15 CIO fuse monitoring Fault related to fuses. Some of Check fuses and digital input DI6.
the bits of the fuse status word
are 0.
8E17 CIO DI8 monitoring Fault related to digital input Check digital input DI8.
DI8.
11
Technical data
Dimension drawing
Technical data 55
Isolation areas
• Power supply (functional 1.0 mm isolation)
• Digital I/Os (230 V AC TN reinforced 4.5 mm isolation)
• CPU and analog inputs (functional 1.0 mm isolation)
• Communication interface (functional 1.0 mm isolation)
CIOB-01
1
PE
2 24 V DC functional
PE PE
isolation
PE
56 Technical data
Specifications
Input voltage 24 V (-15%/+20%)
Maximum input current 1A
Current consumption 100 mA (typical)
RS-485
• power supply 5 V (±5%), 100 mA
• communication data rate < 200 kbps
Digital outputs (DO)
• power supply 15 V (±5%), 20 mA
• modulation frequency < 2 kHz
• maximum sinking current 100 mA
Digital inputs (DI)
• power supply 15 V (±5%), 100 mA
• input frequency 4× < 2 kHz, 4× < 100 Hz
• input impedance 1250 ohm
Analog inputs (AI)
Input impedance > 1 kohm
Analog voltage measurement range 0…5.0 V
NTC measurement (Not in use.)
• supply voltage 5 V (±5%)
• nominal NTC value (25 °C) 10 kohm
• accuracy 1%
• B value 3975
Ambient conditions
Storage temperature -40 °C…+85 °C (-40…185 °F))
Operating temperature +0 to +70 °C (32…158 °F)
Maximum relative humidity 90% (non condensing)
Maximum operating altitude 5000 m (16404 ft)
Protection class
IP20
Materials
Housing Hot-dip zinc coated steel, cover painted
Package Cardboard
Applicable standards
See Electrical planning instructions for ACS880 liquid-cooled multidrive cabinets and
modules (3AXD50000048634 [English]).
—
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and
service contacts can be found by navigating to abb.com/searchchannels.
Product training
For information on ABB product training, navigate to new.abb.com/service/training.