This document provides information about connecting and installing the RDCU-02(C) control unit hardware. It includes:
1. A diagram showing the layout of connectors on the RDCU-02(C) unit.
2. Safety instructions for working with the unit and guidelines for identifying unit types.
3. Instructions for mechanically installing the unit, including fastening it to a mounting rail and removing/replacing the cover.
4. Details on wiring connections for I/O, optional modules, and power.
5. A connection diagram showing how to connect a control panel to the unit.
This document provides information about connecting and installing the RDCU-02(C) control unit hardware. It includes:
1. A diagram showing the layout of connectors on the RDCU-02(C) unit.
2. Safety instructions for working with the unit and guidelines for identifying unit types.
3. Instructions for mechanically installing the unit, including fastening it to a mounting rail and removing/replacing the cover.
4. Details on wiring connections for I/O, optional modules, and power.
5. A connection diagram showing how to connect a control panel to the unit.
This document provides information about connecting and installing the RDCU-02(C) control unit hardware. It includes:
1. A diagram showing the layout of connectors on the RDCU-02(C) unit.
2. Safety instructions for working with the unit and guidelines for identifying unit types.
3. Instructions for mechanically installing the unit, including fastening it to a mounting rail and removing/replacing the cover.
4. Details on wiring connections for I/O, optional modules, and power.
5. A connection diagram showing how to connect a control panel to the unit.
This document provides information about connecting and installing the RDCU-02(C) control unit hardware. It includes:
1. A diagram showing the layout of connectors on the RDCU-02(C) unit.
2. Safety instructions for working with the unit and guidelines for identifying unit types.
3. Instructions for mechanically installing the unit, including fastening it to a mounting rail and removing/replacing the cover.
4. Details on wiring connections for I/O, optional modules, and power.
5. A connection diagram showing how to connect a control panel to the unit.
RDCU-02(C) layout Designations A…C and J1 refer to the section Mechanical installation below. The connectors (X…) are explained under Technical data further below.
A B A
X39
C X20 X34
X21 X31
J1
X32 X22
X23 X33 C X25
X26 X68 X27 X57
A B A
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Safety instructions 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. Avoid touching the circuit board (RMIO) inside the RDCU-02(C) unit in order to minimise the risk of damage caused by static electricity. Do not use excessive force when detaching connectors or removing the cover of the unit.
Identifying different types of unit
Before installation, check that the RDCU-02(C) unit has the correct application program for the converter hardware in question. There is a label attached to the cover of the RDCU-02(C) unit that lists “SW TYPE”, “SW CODE” and “DEVICE TYPE”. “SW TYPE” identifies the application program that is loaded into the RDCU-02(C) unit. Some of the most common “SW TYPE” codes are AMXRxxxx (ACS600/800 System Application Program), ASxRxxxx (ACS600/800 Standard Application Program), AHxRxxxx (ACS800 Pump Control Application Program), and IxxRxxxx ISU (IGBT Supply Unit Application Program). Check that the application program corresponds to the original order. Check also that the “DEVICE TYPE” indicated matches that of the converter hardware.
Mechanical installation
General The RDCU-02(C) can be mounted on a vertical or horizontal 35 × 7.5 mm DIN rail. The unit should be mounted so that air can freely pass through the ventilation holes in the housing. Mounting directly above heat-generating equipment should be avoided.
WARNING! Avoid installing the RDCU in the immediate vicinity of sources of
electromagnetic disturbance, such as relays, contactors, brake choppers and motor cabling. The minimum recommended distance from such components is 500 mm. Installing metallic screening between the unit and the source of disturbance is highly recommended, and may reduce the required distance.
The RDCU is grounded to the mounting rail by two screws.
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Fastening the unit to the mounting rail
Note: Set jumper J1 (if necessary; see the Isolation and grounding diagram) before fastening the unit. Setting J1 can be further facilitated by removing the cover (see Removal and replacement of cover below for further instructions). The jumper can also be set using long-nosed pliers or tweezers without removing the cover. • Align the four retaining clips (A) at the top and bottom edges of the cover with the mounting rail, and carefully press the module onto the rail until the clips catch on the edges of the rail. • Using two screws, fasten the base plate of the RDCU by the two mounting holes (B) to the mounting rail. Make sure the contact surfaces are free from dirt or grease. This is essential for the operation of the control unit since the screws provide the grounding for the unit.
Removal of unit from mounting rail
• Remove the two screws (B) holding the base plate of the unit to the mounting rail. Carefully bend the retaining clips (A) at the upper and lower edges of the cover outwards to release the unit completely from the mounting rail.
Removal and replacement of cover
• Remove all detachable (screw-type) terminal plugs from the RDCU, and disconnect any cables connected to the unit. Remove any optional modules. If desired, the unit can be removed from the mounting rail as described above to facilitate the following steps. • With a screwdriver or similar tool, carefully release the four cover retaining clips (C) on the right-hand side while simultaneously pulling the right-hand edge of the cover gently away from the base plate. • Shift the cover to the left to free its left-hand edge, then pull it to detach it completely from the base and circuit board. • Replace the cover in reverse order to the above (left-hand edge first). If the unit is already mounted onto its mounting rail, align the retaining clips (A) so that they catch on the mounting rail.
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Wiring
General The shields of the I/O cables should be grounded to the chassis of the cubicle as close to the RDCU as possible. Use grommets at all cable entries. Handle fibre optic cables with care. When unplugging fibre optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibres with bare hands as the fibre is extremely sensitive to dirt. The maximum long-term tensile load for the fibre optic cables included is 1 N; the minimum short-term bend radius is 25 mm (1”).
Digital/Analogue input/output connections
See the Firmware Manual of the application program in question.
Installation of optional modules
Follow the instructions given in the user manual of the module.
Other connections See also the wiring diagram below. Powering the RDCU The RDCU is powered through connector X34. The unit can be powered from the power supply board of the inverter (or IGBT supply) module, provided that the maximum current of 1 A is not exceeded. The RDCU can also be powered from an external 24 V DC supply. Note also that the current consumption of the RDCU is dependent on the optional modules attached. (For current consumption of optional modules, see their respective user manuals.) Fibre optic connection to inverter/IGBT supply module Connect the PPCS link of the AINT (ACS 800 series modules) or NINT (ACS 600 series modules) board of the inverter (or IGBT supply) module to fibre optic connectors V57 and V68 of the RDCU. Note: The recommended maximum distances for the fibre optic link is 10 m (for plastic [POF] cable). In case longer distances are required, contact an ABB representative.
Voltage: +10 VDC, 0, -10 VDC ±0.5% (Full scale range) at 25 °C (77 °F). Temperature coefficient: ±100 ppm/°C (±56 ppm/°F) max. Maximum load: 10 mA Applicable potentiometer: 1 to 10 kohm
Analogue inputs (X21)
General: Two programmable differential current inputs (0 mA / 4 mA … 20 mA, Rin = 100 ohm) and one programmable differential voltage input (-10 V / 0 V / 2 V … +10 V, Rin = 200 kohm). The analogue inputs are galvanically isolated as a group (see Isolation and grounding below) Isolation test voltage: 500 VAC, 1 min Max. common mode voltage between the channels: ±15 VDC Common mode rejection ratio: > 60 dB at 50 Hz Resolution: 0.025% (12 bit) for the -10 V … +10 V input, 0.5% (11 bit) for the 0 … +10 V and 0…20 mA inputs Inaccuracy: ±0.5% (Full scale range) at 25 °C. Temperature coefficient: ±100 ppm/ °C max.
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Analogue outputs (X21)
General: Two programmable current outputs: 0 (4) … 20 mA, RL < 700 ohm Resolution: 0.1% (10 bit) Inaccuracy: ±1% (Full scale range) at 25 °C (77 °F). Temperature coefficient: ±200 ppm/°C (±111 ppm/°F) max.
Digital inputs (X22)
General: Six programmable digital inputs (common ground: 24 VDC, -15% … +20%) and a start interlock input (DIIL). Group isolated, can be divided into two isolated groups (see Isolation and grounding below). Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0” (high temperature), open circuit “0” (high temperature). Internal supply for digital inputs (+24 VDC) is short-circuit proof. An external 24 VDC supply can be used instead of the internal supply. Isolation test voltage: 500 VAC, 1 min Logical thresholds: < 8 VDC “0”, > 12 VDC “1” Input current: DI1 to DI5: 10 mA; DI6: 5 mA Filtering time constant: 1 ms
24 VDC power output (X23)
Voltage: 24 VDC ±10%, short-circuit proof Maximum output current: 250 mA (without any optional modules inserted)
Relay outputs (X25, X26, X27)
General: Three programmable relay outputs Switching capacity: 8 A at 24 VDC or 250 VAC; 0.4 A at 120 VDC Minimum continuous current: 5 mA rms at 24 VDC Maximum continuous current: 2 A rms Isolation test voltage: 4 kVAC, 1 min
Slot 1 (X31) General: For connection of I/O extension modules (such as RAIO and RDIO), pulse encoder interface (RTAC), or fieldbus adapters (such as RPBA and RMBA)
Slot 2 (X32) General: For connection of I/O extension modules (such as RAIO and RDIO) or pulse encoder interface (RTAC)
DDCS (X33) General: For connection of RDCO-0x(C) DDCS Communication module
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24 VDC power input (X34)
Voltage: 24 VDC ±10% Typical current consumption (without option modules): 250 mA Maximum current consumption: 1200 mA (with option modules inserted) Pin designations: 1 = not used; 2 = +24 V; 3 = 0 V
Jumper J1 General: See Isolation and grounding below Pitch: 2.54 mm
LEDs “Power”: Green; denotes +5 V power OK “Fault”: Red
Ambient conditions Operating temperature: +0 … +60 °C (32…140 °F) Storage temperature: -40 … +70 °C (-40 … +158 °F)
Applicable standards Immunity: IEC 61800-3 (Limits: Industrial, Second environment); EN 50081-2 (Limits: Industrial) Emission: EN 50081-2 (Limits: Industrial) PELV requirements: The terminals of the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also fulfil the requirements.
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Isolation and grounding
(Test voltage: 500 V AC)
X20 1 VREF 2 GND X21 1 VREF 2 GND 3 AI1+ 4 AI1- Common mode voltage between 5 AI2+ channels ±15 V 6 AI2- 7 AI3+ 8 AI3-
