2VAA003057 A en S IO SD Series Analog Input Modules AI01 AI03 AI04 User Manual

Symphony Plus
S+ I/O: SD Series I/O

Analog Input Modules (AI01, AI03, AI04)
User Manual
D1
Symphony Plus
Symphony Plus
S+ I/O: SD Series I/O

Analog Input Modules (AI01, AI03, AI04)
User Manual
NOTICE
This document contains information about one or more ABB products and may include a description of
or a reference to one or more standards that may be generally relevant to the ABB products. The
presence of any such description of a standard or reference to a standard is not a representation that all
of the ABB products referenced in this document support all of the features of the described or referenced
standard. In order to determine the specific features supported by a particular ABB product, the reader
should consult the product specifications for the particular ABB product.
ABB may have one or more patents or pending patent applications protecting the intellectual property in
the ABB products described in this document.
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.
Products described or referenced in this document are designed to be connected and to communicate
information and data through network interfaces, which should be connected to a secure network. It is the
sole responsibility of the system/product owner to provide and continuously ensure a secure
connection between the product and the system network and/or any other networks that may be
connected.
The system/product owners must establish and maintain appropriate measures, including, but not limited
to, the installation of firewalls, application of authentication measures, encryption of data, installation of
antivirus programs, and so on, to protect these products, the network, its system, and interfaces against
security breaches, unauthorized access, interference, intrusion, leakage, and/or theft of data or
information.
ABB performs functionality testing on the products and updates that we release. However system/product
owners are ultimately responsible for ensuring that any product updates or other major system updates
(to include but not limited to code changes, configuration file changes, third-party software updates or
patches, hardware change out, and so on) are compatible with the security measures implemented. The
system/product owners must verify that the system and associated products function as expected in the
environment in which they are deployed.
In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any
nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential
damages arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without written permission from ABB,
and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose.
The software or hardware described in this document is furnished under a license and may be used,
copied, or disclosed only in accordance with the terms of such license. This product meets the
requirements specified in EMC Directive 2004/108/EC and in Low Voltage Directive 2006/95/EC.
TRADEMARKS
Symphony is a registered or pending trademark of ABB S.p.A.
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2015 ABB.
Release: December 2015

Document number: 2VAA003057 A
Preface
The AI01, AI03, and AI04 Analog Input Modules are part of the S+ SD Series I/O product family of the Symphony Plus
Control System. The AI01 module supports up to 16 channels of analog input. The AI03 module supports up to 8 RTD
analog input channels. The AI04 module supports up to 16 thermocouple analog input channels. These products and all
other Symphony Plus products are optionally available in conformal coated versions for use in harsh environments
(classified as G3 per ISA S71.04).
This user manual explains the AI01, AI03 and AI04 modules specifications and operation. It details the procedures
necessary to complete setup, installation, maintenance, troubleshooting, and replacement of the modules.
Support Services
ABB will provide assistance in the operation and repair of its products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.
When ordering parts, use nomenclature or part numbers and part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service office. Recommended spare parts lists, including prices are
available through the nearest sales or service office.
ABB has modern training facilities available for training your personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and scheduling.
Additional copies of this instruction, or other instructions, can be obtained from the nearest ABB sales office at a reasonable
charge.
Trademarks and Registrations
Registrations and trademarks used in this document include:
Symphony™ Plus Trademark of ABB S.p.A.

TABLE OF CONTENTS
TABLE OF CONTENTS
Safety Summary.......................................................................................................1
About This Book ......................................................................................................5

Document Conventions .......................................................................................5
Document Icons....................................................................................................5
1. Introduction.................................................................................................... 1-1
1.1 Overview ..............................................................................................................1-1
1.1.1 Mixed Symphony and Symphony Plus Systems..............................................1-2
1.2 Application...........................................................................................................1-2
1.3 Features ...............................................................................................................1-3
1.4 Intended User ......................................................................................................1-3
1.5 User Manual Content ..........................................................................................1-3
1.6 Using this Manual................................................................................................1-4
1.7 Document Conventions ......................................................................................1-4
1.8 Glossary of Terms and Abbreviations...............................................................1-4
1.9 Reference Documents.........................................................................................1-5
1.9.1 Downloading Reference Documents from SolutionsBank ...............................1-6
1.10 Related Nomenclature ........................................................................................1-6
1.11 Specifications ......................................................................................................1-7
1.11.1 Supported Input Types................................................................................... 1-11
1.12 Design Standards ..............................................................................................1-12
2. Description and Operation............................................................................ 2-1

2.1 Introduction .........................................................................................................2-1
2.2 Module Description .............................................................................................2-1
2.3 General Operation ...............................................................................................2-1
2.4 Controller Operation ...........................................................................................2-1
2.5 Functional Operation ..........................................................................................2-2
2.5.1 Isolated Measurement section .........................................................................2-2
2.5.2 Communication and Processing ......................................................................2-4
2.6 HN800 - Symphony Plus I/O Communication Bus ...........................................2-4
2.7 Power System Status ..........................................................................................2-4
3. Installation ...................................................................................................... 3-1

3.1 Introduction .........................................................................................................3-1
3.2 Unpacking and Inspection..................................................................................3-1
3.3 Setup and Physical Installation..........................................................................3-1
3.3.1 Equipment Usage in Hazardous Locations......................................................3-1
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TABLE OF CONTENTS
3.3.2 Labeling the Analog Input Modules..................................................................3-2

3.4 Device Label ........................................................................................................3-2
3.4.1 Electronic ID.....................................................................................................3-2
3.4.2 Establishing a Device Label.............................................................................3-2
3.5 Power Supply.......................................................................................................3-3
3.6 SD I/O Mounting Base Configuration ................................................................3-3
3.7 Mounting Bases...................................................................................................3-4
3.7.1 Attaching Horizontal Mounting Base to DIN-rail...............................................3-5
3.7.2 Attaching Vertical Mounting Base to DIN-rail ...................................................3-9
3.7.3 Inserting Module into Mounting Base.............................................................3-13
3.7.4 Removing Module from Mounting Base.........................................................3-14
4. Configuration ................................................................................................. 4-1

4.1 Introduction .........................................................................................................4-1
4.2 Configuration Tools.............................................................................................4-1
4.3 Symphony Plus Controller .................................................................................4-1
4.3.1 Download .........................................................................................................4-1
4.3.2 Verification .......................................................................................................4-1
4.3.3 Changes...........................................................................................................4-1
4.3.4 Firmware Download .........................................................................................4-2
4.4 Labels ...................................................................................................................4-2
4.4.1 Device Label ....................................................................................................4-2
4.4.2 Channel Label..................................................................................................4-3
4.4.3 Duplicate Labels ..............................................................................................4-3
4.5 Function Codes ...................................................................................................4-4
4.5.1 I/O Device Definition (FC 221) .........................................................................4-4
4.5.2 I/O Channel (FC 222, 223, 224, 225, and 229)................................................4-5
4.5.3 Test Status (FC 226) ........................................................................................4-9
5. Operating Procedures ................................................................................... 5-1

5.1 Introduction .........................................................................................................5-1
5.2 Startup ..................................................................................................................5-1
5.3 Operation .............................................................................................................5-1
5.4 Status Indicators .................................................................................................5-2
5.5 Status LEDs .........................................................................................................5-2
5.6 Startup Procedures .............................................................................................5-4
6. Troubleshooting............................................................................................. 6-1
6.1 Introduction .........................................................................................................6-1
6.2 I/O Module Status Code LEDs ............................................................................6-1
6.3 Error Messages and Corrective Action .............................................................6-2
ii 2VAA003057 A
TABLE OF CONTENTS
6.4 I/O Module Status ................................................................................................6-4

6.5 Diagnostics ..........................................................................................................6-4
6.5.1 Online...............................................................................................................6-4
6.5.2 Offline...............................................................................................................6-4
6.6 Controller Errors .................................................................................................6-4
6.7 Diagnostic Menu Operations..............................................................................6-5
7. Maintenance ................................................................................................... 7-1

7.1 General .................................................................................................................7-1
7.2 Special Handling .................................................................................................7-1
7.3 Printed Circuit Board Cleaning .........................................................................7-1
7.3.1 General Cleaning and Washing .......................................................................7-2
7.3.2 Module PCB Card Edge and Mounting Base Edge Connector Cleaning ........7-2
7.4 Checking Connections .......................................................................................7-2
8. Repair and Replacement ............................................................................... 8-1

8.1 Introduction .........................................................................................................8-1
8.2 Module Repair and Replacement .......................................................................8-1
8.3 Horizontal Mounting Base Fuse Replacement Procedure...............................8-1
8.4 Vertical Mounting Base Fuse Replacement Procedure ...................................8-2
9. Spare Parts ..................................................................................................... 9-1

9.1 Parts......................................................................................................................9-1
A. Symphony Plus Mounting Bases ................................................................. A-1

A.1 Introduction ........................................................................................................ A-1
A.2 Power Supply...................................................................................................... A-1
A.3 Mounting Base Labeling and Keying ............................................................... A-2
A.3.1 Installing SD Series I/O edge connector keys................................................. A-4
A.4 Mounting Base Wiring Examples.................................................................... A-11
2VAA003057 A iii
TABLE OF CONTENTS
iv 2VAA003057 A
LIST OF TABLES
LIST OF TABLES
Table 1-1: Glossary of Terms and Abbreviations .......................................................1-4

Table 1-2: Reference Documents ...............................................................................1-5
Table 1-3: Related Nomenclature ...............................................................................1-6
Table 1-4: Specifications ...........................................................................................1-7
Table 1-5: Supported Input Types ............................................................................1-11
Table 1-6: Design Standards ....................................................................................1-12
Table 4-1: I/O Channel Function Code Summary .......................................................4-5
Table 4-2: I/O Channel Specifications Summary ........................................................4-5
Table 5-1: AI01 module LED States ...........................................................................5-3
Table 6-1: Status Codes .............................................................................................6-1
Table 6-2: I/O Module Problem Reports .....................................................................6-2
Table 9-1: Miscellaneous Parts ..................................................................................9-1
Table A-1: Mounting Base types ................................................................................ A-1
Table A-2: Unique Key Sequence for SD Series I/O module type ............................. A-2
2VAA003057 A v
LIST OF TABLES
vi 2VAA003057 A
LIST OF FIGURES
LIST OF FIGURES
Figure 1-1: Symphony Plus I/O Architecture .............................................................. 1-1

Figure 1-2: Existing rack based Symphony system connected to Symphony Plus
I/O............................................................................................................. 1-2
Figure 2-1: Block Diagram for AI01 module................................................................ 2-2
Figure 2-4: SD I/O Power Wiring ................................................................................ 2-5
Figure 3-1: Recommended Power Supply Concept ................................................... 3-3
Figure 3-2: S+ I/O base Locking Lever Up ................................................................. 3-5
Figure 3-3: S+ I/O base DIN rail Capture Protrusions ................................................ 3-6
Figure 3-4: S+ I/O base attached to panel using Optional Panel Mounting Screw..... 3-7
Figure 3-5: Mounting HBX01L and HBX01R Bus Extenders...................................... 3-8
Figure 3-6: S+ I/O base Locking Lever Up ................................................................. 3-9
Figure 3-7: S+ I/O base DIN rail Capture Protrusions .............................................. 3-10
Figure 3-8: S+ I/O base attached to panel using Optional Panel Mounting Screw... 3-11
Figure 3-9: Mounting VBX01T and VBX01B Bus Extenders .................................... 3-12
Figure 3-10: Typical mounting of vertical bases and bus extenders to DIN rail ........ 3-13
Figure 3-11: Finger holds on the module .................................................................. 3-15
Figure 5-1: Front Panel View ...................................................................................... 5-2
Figure 6-1: S+ Diagnostic menu ................................................................................. 6-6
Figure A-1: Recommended Power Supply Concept .................................................. A-2
Figure A-2: Key slots and mounting labels location on horizontal mounting base ..... A-4
Figure A-3: Key slots and mounting labels location on vertical mounting base ......... A-5
Figure A-4: Location of connectors on horizontal mounting base .............................. A-6
Figure A-5: Location of connectors on vertical mounting base .................................. A-7
Figure A-6: Terminal numbering for field input signals on terminal blocks 1 and 2.... A-7
Figure A-7: Terminal numbering for internal field power wiring on terminal block 3
for horizontal mounting base ................................................................... A-8
Figure A-8: Terminal numbering for internal field power wiring on terminal block 3
for vertical mounting base ....................................................................... A-8
Figure A-9: Terminal assignment for HBS01-FPH mounting base .......................... A-10
Figure A-10: Terminal assignment for HBS01-EPD mounting base ........................ A-10
Figure A-11: Terminal assignment for HBS01-CJC mounting base......................... A-11
Figure A-12: HBS01-CJC Terminals ........................................................................ A-12
Figure A-13: Using AI03 module and HBS01-CJC with 2, 3, and 4 Wire RTDs....... A-13
Figure A-14: Using AI04 module and HBS01-CJC with thermocouples................... A-13
Figure A-15: Using AI01 module and HBS01-FPH with 2-wire Transmitters. .......... A-14
Figure A-16: Using AI01 module and HBS01-EPD with 2 and 4-wire Transmitters . A-15
2VAA003057 A vii
LIST OF FIGURES
viii 2VAA003057 A
Safety Summary
The following table categorizes the various safety precautions to be followed when using the AI01, AI03, and AI04 (AI)
modules:
Safety Precaution Description

Electrostatic Sensitive Device
Devices labeled with this symbol require special handling precautions as
described in sub-section 7.2- Special Handling of this user manual.
GENERAL WARNINGS Equipment Environment

All components, whether in transportation, operation or storage, must be in a
non-corrosive environment.
Electrical Shock Hazard During Maintenance

Disconnect power or take precautions to insure that contact with energized parts
is avoided when servicing.
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, OR NON-HAZARDOUS LOCATIONS
ONLY
2VAA003057 A 1
EXPLOSION HAZARD - Substitution of components can impair suitability for
Class I, Division 2. Refer to sub-section 9.1- Parts of this user manual, where
this General Warning statement is applicable.
AVERTISSEMENT: RISQUE D'EXPLOSION - SUBSTITUTION DE

COMPOSANTS PEUT NUIRE A LA CONFORMITE CLASSE 1, DIVISION 2
EXPLOSION HAZARD - Do not disconnect equipment unless power has been

switched off or the area is known to be non-hazardous. Refer to Appendix A:
Symphony Plus Mounting Bases of this user manual for power connection
instructions. Refer to appendix A.3.1- Installing SD Series I/O edge connector
keys of this user manual, where this General Warning statement is applicable.
AVERTISSEMENT: RISQUE D'EXPLOSION - NE PAS DECONNECTER

L’EQUIPEMENT QUE L'ALIMENTATION EST COUPEE OU QUE LA ZONE
EST CONNUE POUR ETRE NON DANGEREUX
Do not connect or disconnect the USB connector unless the area is known to be
non-hazardous. Refer to sub-section 6.7- Diagnostic Menu Operations of this
user manual, where this General Warning statement is applicable.
NE PAS UTILISER CONNECTEUR USB SAUF SI LA ZONE EST CONNUE

POUR ETRE NON DANGEREUX.
EXPLOSION HAZARD - Do not disconnect while circuit is ‘LIVE’ unless area is

known to be non-hazardous.
AVERTISSEMENT: RISQUE D'EXPLOSION - NE DECONNECTEZ PAS

LORSQUE LE CIRCUIT EST MOINS QUE L'ENVIRONNEMENT EST CONNU
POUR ETRE NON DANGEREUX
POTENTIAL ELECTROSTATIC CHARGING HAZARD - Wipe dust with a damp

cloth to avoid a potential electrostatic hazard. Refer to sub-section 7.3- Printed
Circuit Board Cleaning of this user manual, where this General Warning
statement is applicable.
POTENTIEL CHARGE ELECTROSTATIQUE DANGER - ESSUYEZ LA

POUSSIERE AVEC UN CHIFFON HUMIDE POUR EVITER UN DANGER
POTENTIEL ELECTROSTATIQUE
2 2VAA003057 A
SPECIFIC WARNINGS Permanent damage will occur to AI03 and AI04 modules, if the modules are
inserted into a powered HBS01-FPH/VBS01-FPH or HBS01-EPD/VBS01-EPD
mounting base. Use only the HBS01-CJC/VBS01-CJC mounting base for AI03
and AI04 modules. Also, use only supported module / base combinations. The
use of mounting base keys prevents modules from accidentally being inserted
into the wrong type of mounting base. Refer to Appendix A: Symphony Plus
Mounting Bases of this user manual for supported module / base combinations
and procedure details for inserting mounting base keys. Refer to sub-section
3.6- SD I/O Mounting Base Configuration of this user manual, where this Specific
Warning statement is applicable.
Do not mount the Symphony Plus mounting bases to the DIN rail while they are
powered. Do not connect an un-powered mounting base to a mounting base that
is powered. Refer to sub-section 3.7- Mounting Bases of this user manual,
where this Specific Warning statement is applicable.
Never clean electrical parts or components with live power present. Doing so
exposes you to an electrical shock hazard. Refer to sub-section 7.3- Printed
Circuit Board Cleaning of this user manual, where this Specific Warning
Wear eye protection whenever working with cleaning solvents.When removing

solvents from printed circuit boards using compressed air, injury to the eyes
could result from splashing solvent as it is removed from the printed circuit
board. Refer to sub-section 7.3- Printed Circuit Board Cleaning of this user
manual, where this Specific Warning statement is applicable.
There are exposed AC and DC connections inside the enclosure. These

exposed electrical connections present a shock hazard that can cause injury or
death. Refer to sub-section 7.4- Checking Connections of this user manual,
where this Specific Warning statement is applicable.
If input or output circuits are a shock hazard after disconnecting system power at
the power entry panel, then the door of the enclosure containing these externally
powered circuits must be marked with a warning stating that multiple power
sources exist. Refer to sub-section 7.4- Checking Connections of this user
manual, where this Specific Warning statement is applicable.
Permanent damage will occur to AI03 and AI04 modules, if the modules are
inserted into a powered HBS01-FPH/VBS01-FPH or HBS01-EPD/VBS01-EPD
mounting base. Use only the HBS01-CJC/VBS01-CJC mounting base with these
modules. Refer to appendix A.1- Introduction of this user manual, where this
Specific Warning statement is applicable.
Internal Field Power (TB3) and Field wiring (TB1 and TB2) to the mounting base
must be removed before installing connector keys. The connector keys are small
and can be easily lost. It is recommended to install these keys immediately after
unpacking the mounting base and before the mounting base is installed into an
enclosure. Do not install the keys to a mounting base that has the field power
active on it. Refer to appendix A.3.1- Installing SD Series I/O edge connector
keys of this user manual, where this Specific Warning statement is applicable.
2VAA003057 A 3
SPECIFIC CAUTION Do not touch the edge connectors on the printed circuit board when the module
is being powered from a USB cable connection. Refer to sub-section 6.7-
Diagnostic Menu Operations of this user manual, where this Specific Caution
Do not insert a module, which has a USB cable attached into a powered or un-
powered mounting base. Make sure to ALWAYS remove the USB cable before
installing a module to its base, and also make sure to ALWAYS remove the USB
cable before applying power to the base in which the module is installed. Refer
to sub-section 6.7- Diagnostic Menu Operations of this user manual, where this
Specific Caution statement is applicable.
Do not insert a module with an attached USB cable into a mounting base. Refer
to sub-section 6.7- Diagnostic Menu Operations of this user manual, where this
Use only approved fuses with proper current ratings. Refer to section 9- Spare
Parts of this user manual for fuse part number. Refer to sub-sections: 8.3-
Horizontal Mounting Base Fuse Replacement Procedure and 8.4- Vertical
Mounting Base Fuse Replacement Procedure of this user manual, where this
4 2VAA003057 A
About This Book
About This Book
Document Conventions
Microsoft Windows conventions are normally used for the standard presentation of material when entering text, key
sequences, prompts, messages, menu items, screen elements, etc.
Document Icons
This user manual uses the following document icons with a corresponding statement, wherever applicable, to point out
important information or useful hints to the user:
Electrical Warning icon: It indicates the presence of a hazard that could result in
electrical shock.
Warning icon: It indicates the presence of a hazard that could result in a plant shutdown
or personal injury.
Caution icon: It indicates the presence of a hazard that could result in corruption of
software or damage to equipment/property.
Information icon: It alerts the user to pertinent facts and conditions
Tip icon: It indicates advice on, for example, how to design your project or how to use a
certain function.
NOTE The Note statement highlights important information pertaining to a particular descriptive text (for
example: 'Module description', 'Installation', 'Configuration', or 'Operational procedure', etc.) in the
document.
Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property
damage, it must be understood that operation of damaged equipment could, under certain operational conditions, result in
degraded process performance leading to personal injury or death. Therefore, fully comply with all Warning and Caution
notices.
2VAA003057 A 5
About This Book
6 2VAA003057 A
Introduction Overview
1. Introduction
1.1 Overview
The AI01, AI03, and AI04 Analog Input Modules are part of the S+ SD Series I/O product family of the Symphony Plus
Control System. The AI01 module inputs 16 channels of analog signals, the AI03 module supports 8 channels of RTD input,
and the AI04 module supports 16 channels of thermocouple input (TC).The analog inputs are used by the controller to
monitor and control a process. The controller performs the control functions and the I/O modules provide the input and
output functions.
The following figure (Figure 1-1) shows the Symphony Plus I/O architecture using a Symphony Plus HPC800 controller:
NOTE: Since Figure 1-1 shows digital and analog modules on separate HN800 I/O segments, this does not indicate that
it is a requirement. Digital, analog, as well as HART and PROFIBUS Symphony Plus DIN rail modules can be mounted in
any combination on the same HN800 I/O segment.
Figure 1-1: Symphony Plus I/O Architecture
The HPC800 controller provides control signals to the I/O modules through the HN800 bus. The I/O modules condition and
forward the control signals to the field devices. The HBX01L and HBX01R bus extenders provide HN800 connection points
between the controller and the SD Series I/O modules. The HBX01L bus extender also provides a 24 VDC logic input
terminal to power all I/O modules on the same I/O segment.
NOTE: The above example (refer to Figure 1-1) shows horizontal mounting bases for the SD Series I/O modules. These
same modules can also be mounted vertically using VBS01-xxx mounting bases and VBX01x bus extenders. Refer to
Appendix A: Symphony Plus Mounting Bases of this user manual for more information on available mounting bases.
2VAA003057 A 1-1
Mixed Symphony and Symphony Plus Systems Introduction
1.1.1 Mixed Symphony and Symphony Plus Systems

The Symphony Plus and SD Series I/O modules are fully compatible with existing Symphony and INFI90 installations.
The following figure (Figure 1-2) shows an existing rack based Symphony system connected to the Symphony Plus I/O
modules:
Figure 1-2: Existing rack based Symphony system connected to Symphony Plus I/O
The PBA800 converts Hnet signals used by Symphony systems to HN800 signals that are used by the Symphony Plus I/O
modules.
1.2 Application
The S+ SD Series Analog Input Modules interface analog signals from field devices to the controller. The AI01 module is
used with conventional transmitters (BC, EQ, and PT) and standard analog inputs. The AI03 module interfaces analog
signals from two, three and four wire RTD inputs. The AI04 module interfaces analog signals from thermocouples.
1-2 2VAA003057 A
Introduction Features
1.3 Features
The design of the S+ SD Series I/O modules allow for flexibility in creating a process management system. All modules are
designed to operate in extreme temperatures from -20 to 70 degrees centigrade. All modules have optional G3 conformal
coated version to withstand harsh industrial environments. Mounting bases to mount SD Series I/O modules and controllers
either horizontally or vertically are available.
The modules store process data, control commands, and transmitter configuration data in memory. The analog input
module works to restore communication with a transmitter if a communication failure occurs. Upon restoring communication
with a failed transmitter, the analog input module checks the transmitter configuration before the controller resumes
updating the process control.
The AI01 module supports 16 bit signal resolution. It accepts inputs from conventional transmitters (BC, EQ, and PT) and
standard analog inputs of 4 to 20 milliamperes, 1 to 5 VDC, 0 to 5 VDC, 0 to 10 VDC, and -10 to +10 VDC.
The AI03 module is an 8 channel 2, 3, and 4-wire RTD input module. It supports 100  platinum - U.S. Laboratory Standard,
100  platinum - U.S. Industry Standard, 100  platinum - European Standard, 120  nickel, and 53  copper - Chinese
Standard and Japanese 100  platinum RTDs per JIS C 1604-1987 (1981 or 1997).
The AI04 module interfaces analog signals from thermocouples. Types B, E, J, K, L, N (14 AWG), N (28 AWG), R, S, T, U,
and Chinese E, S are supported. Signal ranges from -100 to +100 mV, or 0 to +100 mV are supported.
1.4 Intended User

Personnel who installs, operates, or maintains the S+ SD Series Analog Input modules must read this user manual before
performing any installation, operation, or maintenance procedures.
Installation of these modules requires an engineer or technician with experience in handling electronic circuitry.
Personnel working with the analog input modules must have:
• Experience working on these modules
• Knowledge of various precautions to take around AC/DC power.
• Knowledge of the Symphony Plus system and electronic principles (mandatory).
1.5 User Manual Content

This user manual consists of the following nine sections and one appendix:
• Introduction:
This section provides an overview of the S+ SD Series Analog Input modules. It contains features, a description,
reference documents, and specifications.
• Description and Operation

This section explains the theory of module operation.
• Installation:
This section details the handling precautions, installing and checking the S+ SD Series Analog Input modules.
• Configuration:
This section details I/O module configuration performed through a Symphony Plus Controller.
• Operating Procedures:
This section explains how to start up and operate the S+ SD Series Analog Input modules.
• Troubleshooting:
This section describes how to monitor transmitter errors from the status reports. It explains how to check for the S+
SD Series Analog Input module errors and the corrective actions to take.
2VAA003057 A 1-3
Using this Manual Introduction
• Maintenance:
This section describes the maintenance schedule for the S+ SD Series Analog Input modules.
• Repair and Replacement:

This section explains the steps to replace the S+ SD Series Analog Input modules.
• Spare Parts:
This section details the list of spare parts applicable to the S+ SD Series Analog Input modules.
• Appendix A: Symphony Plus Mounting Bases:

This appendix explains the installation and use of the S+ SD Series mounting bases.
1.6 Using this Manual

Make sure to read this user manual in sequence. It is important to become familiar with the entire contents of this user
manual before using the module.
The user manual is organized to enable quick information retrieval:
1. Read the Operating Procedures section before installing the module.
2. Perform the steps in the Installation section.
3. Refer to the Troubleshooting section to resolve problems if they occur.
4. Refer to the Maintenance section for scheduled maintenance requirements.
5. Refer to the Repair and Replacement section to replace a module.
1.7 Document Conventions

A term ‘x’ in a nomenclature or in a part number indicates a variable for that position (for e.g., ‘HBS01-xxx’, where ‘xxx’
could be 'FPH', 'FPN', or 'EPD).
1.8 Glossary of Terms and Abbreviations

The following table (Table 1-1) contains those terms and abbreviations that are unique to ABB or have a definition that is
different from standard industry usage.
Table 1-1: Glossary of Terms and Abbreviations
Term Definition
Controller or I/O Segment A controller or I/O segment is a collection of modules, mounting bases, and
bus extenders mounted on one or more DIN rails. A TER810, HN800 or
CW800 signal bus terminator is located at each end of the HN800 or
CW800 bus. The TER810 terminator installs into HBX01L, HBX01R, or
CTB81x bus extenders.
CW800 High speed, redundant, peer-to-peer communication link. Used to transfer

information between Symphony Plus HPC800 controllers.
EIA Electronic Industries Alliance.
External Field Power Power supplied directly to field devices without going through the
HBS01-xxx or VBS01-xxx mounting base.
Field Power (or I/O) Power needed for field signals.
FPGA Field Programmable Gate Array. It is an integrated circuit designed to be

configured by a customer or a designer after manufacturing.
FSR Full Scale Range.
1-4 2VAA003057 A
Introduction Reference Documents
Table 1-1: Glossary of Terms and Abbreviations (Continued)
Term Definition
Function code (FC) An algorithm which manipulates specific functions. These functions are
linked together to form the control strategy.
HN800 Redundant communication bus between the Symphony Plus Controller and
the Symphony Plus I/O modules.
Internal Field Power Power supplied to field devices through the HBS01-xxx or VBS01-xxx
mounting base TB3 connector.
Logic Power Power needed to run the module’s logic circuits.
SD I/O Symphony Plus DIN Rail I/O.
SD I/O Mounting Bases Provides input/output connection between plant equipment and the
(HBS01-FPH, HBS01-EPD, Symphony Plus modules.
HBS01-CJC, VBS01-FPH,
Nomenclatures which begin with the letter - ‘H’ mount on to horizontal DIN
VBS01-EPD, and VBS01-CJC)
rail.
Nomenclatures which begin with the letter - ‘V’ mount on to vertical DIN rail.
VDC Volts direct current.
1.9 Reference Documents

The following table (Table 1-2) lists ABB instructions for equipment that is referenced in this user manual:
Table 1-2: Reference Documents
Document ID Document Title
2VAA001586 S+ Control: HPC800, Harmony Process Controller User Manual.
2VAA003572 S+ Control & I/O: SPC700 Symphony Plus Controller User Manual.
2VAA000720R0001 S+ Control: Harmony Bridge Controller with Ethernet (BRC-410) User

Manual.
2VAA000844 S+ Engineering for Harmony Function Code Application Manual.
2VAA000812 S+ Engineering for Harmony Primary Interface Manual.
2VAA000813 S+ Engineering for Harmony Automation Architect Manual.
2VAA003056 S+ I/O: SD Series I/O - Digital Output Modules (DO01, DO02)

User Manual.
2VAA003014 S+ I/O: SD Series I/O - Digital Input Modules (DI01, DI02, DI03, DI04)
User Manual.
2VAA003058 S+ I/O: SD Series I/O - Analog Output Module (AO01) User Manual.
2VAA003059 S+ I/O: SD Series I/O - Pulse Input Module (PI01) User Manual.
2VAA004707 S+ I/O: SD Series HART Analog Input/Output Modules (AI02, AO02,

AI05,AO05) User Manual.
2VAA006342 S+ I/O: SD Series HART Analog Input/Output and Digital Input/Output

Modules (AD01, AD02) User Manual.
2VAA003057 A 1-5
Downloading Reference Documents from SolutionsBank Introduction
1.9.1 Downloading Reference Documents from SolutionsBank

Follow the given steps to download appropriate document referenced in the user manual:
1. Click on the following hyperlink- ‘SolutionsBank' to open the SolutionsBank Search web page.
NOTE: If you are unable to open the SolutionsBank hyperlink, then call ABB Sales Service representative for
SolutionsBank subscription access rights.
2. Click on the Advanced Search button in the SolutionsBank Search web page.
3. Enter appropriate document ID number followed by an asterisk mark (*) in the Doc ID: field.
For Example: Enter 2VAA000844* in the Doc ID: field to view/download appropriate versions of the
S+ Engineering for Harmony Function Code Application Manual.
4. Click on the Search button to view appropriate versions of the user manual.
5. Click on appropriate user manual title (for e.g: ‘S+ Engineering for Harmony Function Code Application Manual’)
to download it to the system.
1.10 Related Nomenclature

The following table (Table 1-3) lists the nomenclature related to the S+ SD Series Analog Input modules:
Table 1-3: Related Nomenclature
Nomenclature Description
HC800 Control processor module of the HPC800 controller.
CP800 Communication processor module of the HPC800 controller.
MB810 S+ Control mounting base. Mounts 1 HC800 and 1CP800 module. It

is a component of the HPC800 controller. The MB810 mounting base
is 125mm wide.
CTB810 and CTB811 S+ Control communication bus extenders. The CTB81x bus
extenders are 45mm wide.
TER810 S+ Control communication bus terminator. A terminator is required at

each end of the CW800 and HN800 communication bus.
NOTE: The TER810 terminator is a functional replacement for the

TER800 terminator.
TER800 Functionally equivalent to the TER810 terminator. The TER800

terminator must be used when terminating the bus on a PBA800;
otherwise, the TER810 terminator can be used with all SD Series
mounting bases and bus extenders.
PNI800 S+ Control Plant Network Interface module.
HBS01-FPH Mounting base for horizontal DIN rail, field power high.
HBS01-EPD Mounting base for horizontal DIN rail, external field power switched
on common.
HBS01-CJC Mounting base for horizontal DIN rail, cold junction compensation.
VBS01-FPH Mounting base for vertical DIN rail, field power high.
VBS01-EPD Mounting base for vertical DIN rail, external field power switched on
common.
VBS01-CJC Mounting base for vertical DIN rail, cold junction compensation.
1-6 2VAA003057 A
Introduction Specifications
Table 1-3: Related Nomenclature (Continued)
Nomenclature Description
HBX01L and HBX01R HN800 bus extenders for horizontal installation.

The HBX01L bus extender provides a 24 VDC power input connector
and an HN800 connection point. You can power up to 24 SD I/O mod-
ules from a single HBX01L bus extender. The HBX01x bus extenders
are 30 mm wide.
The HBX01R bus extender provides a connector that is used to
extend the HN800 bus to adjacent horizontal rows of SD I/O
modules. You can connect up to 64 SD I/O modules in this way to a
redundant Symphony Plus Controller.
VBX01T and VBX01B HN800 bus extenders for vertical installation.

The VBX01T bus extender provides a 24 VDC power input connector
and an HN800 connection point. You can power up to a maximum of
8 SD I/O modules from a single VBX01T bus extender.
The VBX01B bus extender provides a connector that is used to
extend the HN800 bus to adjacent vertical columns. You can connect
up to 64 SD I/O modules in this way to a redundant Symphony Plus
Controller.
The VBX01x bus extenders are 76 mm tall.
SPK800-xx Where: ‘xx’ = specifies cable length:

• 0A = .5 meters
• 01 = 1 meter
• 02 = 2 meters
• 03 = 3 meters
• 04 = 4 meters
HN800/CW800 communication bus cable - The cable is used to
extend the communication bus between bus extenders. This cable
carries HN800/CW800 logic signals only, i.e. 24VDC power is not
carried through this cable.
1.11 Specifications
The following table (Table 1-4) details the specifications for the S+ SD Series Analog Input modules:
Table 1-4: Specifications
Characteristic/Value
Property
AI01 AI03 AI04
Analog Input Channels 16 channels configurable 8 channels configurable 16 channels configurable

as current or voltage input. as 2, 3, or 4 wire RTD as Thermocouple or
input. millivolt input.
Analog Input Signal Types Refer to Table 1-5 for details of supported input signal types.
2VAA003057 A 1-7
Specifications Introduction
Table 1-4: Specifications (Continued)
Property
AI01 AI03 AI04
Dimensions:
Module with HBS01-xxx base 51 mm width, 190 mm height, 138 mm depth.
(2 in. width, 7.48 in. height, 5.43 in. depth).
Module with VBS01-xxx base 66 mm wide, 218 mm height, 138 mm depth
HBX01L 33 mm width, 190 mm height, 46 mm depth.

(1.3 in. width, 7.48 in. height, 1.82 in. depth).
HBX01R 33 mm width, 190 mm height, 31 mm depth.

(1.3 in. width, 7.48 in. height, 1.2 in. depth).
VBX01T 66 mm wide, 76 mm height, 48 mm tall
VBX01B 66 mm wide, 76 mm height, 33 mm tall
Weight:
Module 0.228 kg (0.502 lbs). 0.226 kg (0.498 lbs). 0.228 kg (0.502 lbs).
HBS01-xxx bases 0.288 kg (0.636 lbs).
HBX01L 0.136 kg (0.300 lbs).
HBX01R 0.113 kg (0.250 lbs)
VBS01-xxx bases 0.33 kg (0.72 lbs).

VBX01T 0.10 kg (0.23 lbs).
VBX01B 0.09 kg (0.20 lbs)
Maximum Field Cable Length 600 meters (656 yards).
Power Requirements (Logic

Power)3
Operating voltage ± 24 VDC (+12%, -10%) ± 24 VDC (+12%, -10%) ± 24 VDC (+12%, -10%)
Current .075A typical , 0.084A max 0.068A typical, 0.076A .065A typical, 0.073A
max max
Power Requirements (I/O

Power)3
Operating voltage 24 VDC +/- 10% N/A N/A
Current 20 mA/channel N/A N/A
Over voltage category 1 for power and inputs.

(EN 61010)
Isolation voltage 300 VDC/VRMS at 60 Hz (group isolated)

1,400 VRMS at 60 Hz for 2 sec (group isolated)
Input impedance Current mode (external N/A > 1 M

powered): 225  Voltage
mode: > 250k 
Resistive Load Current mode (system N/A N/A

powered): up to 750 
1-8 2VAA003057 A
Introduction Specifications
Property
AI01 AI03 AI04
A-to-D resolution 16 bits with polarity

Analog conversion 200 msec
Accuracy (% of full scale range Current Mode: +/-0.1% of +/-0.1% of FSR, FSR= +/-0.05% of FSR, FSR =
at 25°C) FSR, FSR = 25mA. 500  -100mV to +100mV
Voltage Mode: +/-0.1% of
FSR, FSR = 20VDC.
Temperature effect ±0.003%/degree C maximum
on measurement accuracy
Open Circuit Detection Time 15 seconds 5 seconds 5 seconds
Current limiting 26 mA nominal current N/A N/A

limit (current mode only).
Common mode voltage –12 VDC minimum, +15 VDC maximum

±12 VDC (±1 VDC) input span
±10 VDC (±5 VDC) input span
± 5 VDC (±10 VDC) input span
Rejection (50-60 Hz)

Normal mode –35 dB minimum
Common mode –90 dB minimum
DC Common mode rejection –90 dB minimum
EMI, RFI and Electrical Surge:
Electromagnetic compatibility
Conducted transients
Common Normal
Test
Mode Mode
Voltage/current surge (1.2/50 µS to 8/20 µS) ±2 kVP ±1 kVP
(IEC 1000-4-5, EN 61000-4-5)
Fast transient bursts ±2 kVP N/A
(IEC 1000-4-4, EN 61000-4-4)
Damped oscillatory wave, 0.1 MHz and 1 MHz ±1 kVP ±0.5 kVP
(IEC 1000-4-12, EN 61000-4-12)
Ring wave (IEC 1000-4-12, EN 61000-4-12) ±2 kVP ±1 kVP
Electrostatic discharge Contact: ±6 kV

(IEC 1000-4-2, EN 61000-4-2) Air: ±8 kV
Emission test RF radiated Class A

fields, 30 MHz to 1000 MHz
(ENV 55011)
2VAA003057 A 1-9
Specifications Introduction
Property
AI01 AI03 AI04
Magnetic and electromagnetic

fields
Power frequency magnetic Continuous: 30 ARMS/m
field (IEC 1000-4-8, Short duration: 300 ARMS/m
EN 61000-4-8)
Pulse magnetic field (IEC Peak value: 300 A/m
1000-4-9, EN 61000-4-9)
Damped oscillatory magnetic Peak value: 30 A/m
field, 0.1 MHz and
1 MHz (IEC 1000-4-10,
EN 61000-4-10)
Radiated radio-frequency Unmodulated RMS: 10 V/m
electromagnetic field, Amplitude modulated: 80% AM (1 kHz)
80 MHz to 1GHz
(ENV 50140)
Radiated radio-frequency Unmodulated RMS: 10 V/m
field, 900 ±5 MHz Pulse modulated: Duty cycle 50%, Rep. cycle 200 Hz
(ENV 50204)
Radio-frequency common Unmodulated RMS: 10 V/m
mode, amplitude modulated, Amplitude modulated: 80% AM (1 kHz)
0.15 MHz to 80 MHz Source impedance: 150 
(ENV 50141)
Harmonics and Flicker Test Electromagnetic compatibility (EMC), Part 2.
(IEC 61000-3-2) 2009
Environmental:
Ambient temperature
(operational)1 -20° to 70°C (-4° to 158°F)
Temperature (storage)1 -40° to 85°C (-40° to 185°F)
Relative humidity1 95% @ 40°C (104°F) (non-condensing)
Vibration 5 to 60 Hz 0.137 mm (0.0054 in.)

(operational sinusoidal) 60 to 150 Hz 1.0 G.
Vibration (transportation) 10 to 500 Hz
Shock (storage) 15 G, 11 msec
Drop 100 mm
Altitude (operational)1 Sea level to 3,048 meters (10,000 ft.).
Altitude (storage)1 Sea level to 12,192 meters (40,000 ft.)
Air quality4 ISA S71.04 G1

ISA S71.04 G3 compliance version is also available.
Mounting Mounts to standard 35 mm wide DIN rail.
Certifications5:
1-10 2VAA003057 A
Introduction Supported Input Types
Property
AI01 AI03 AI04
CE Mark declaration This product, when installed in a Symphony enclosure, complies with the
following Directives/Standards for CE marking.
EMC96 Directive EN50082-2 Generic Immunity Standard - Part 2: Industrial Environment
2004/108/EC EN50081-2 Generic Emission Standard - Part 2: Industrial Environment
EN61010-1 Safety Requirements for Electrical Equipment for
Low Voltage Directive
Measurement, Control and Laboratory Use - Part 1: General Requirements
2006/95/EC
Canadian Standards Certified for use as process control equipment in an ordinary (nonhazardous)
Association (CSA)2 location.
CSA Standard Association, Approval for the following category:

hazardous location6 Non-incendive for Class I Division 2, Groups A,B,C,D, T4
NOTES:
1. These product specifications exceed the testing limits specified in standard IEC 61010-1-12 (altitude up to 2000m,
maximum relative humidity of 80%, and operating temperature range of 5C to 40C). ABB has tested and certified this
product to the values given here.
2. This product is certified to CSA standard CSA 61010-1-12 3rd edition.
3. Logic power is supplied to the module through the HBX01L/VBX01T bus extender. IO Power is supplied through the
TB3 power connector on the HBS01-EPD/VBS01-EPD or HBS01-FPH/VBS01-FPH module mounting base.
4. Conformal coated product versions (ending in ‘A’, for e.g. ‘AI01A’) meet G3 air quality levels. Non-conformal coated
products (for e.g. ‘AI01’) meet G1 air quality levels.
5. The CTB810, CTB811, HBX01L, and HBX01R bus extenders and the HBS01-CJC, HBS01-EPD, HBS01-FPN,
HBS01-FPH mounting bases are certified to CSA standard - CSA 61010-1-12 3rd edition and contain the CSA
certification mark. These bus extenders and mounting bases also comply with CE requirements when used in
Symphony enclosure and contain the CE mark. Certifications for vertical mounting bases and bus extenders are
pending.
6. This equipment is suitable for use in Class I, Division 2 or non-hazardous locations only. HBX01L, HBX01R,
HBS01-CJC, HBS01-EPD, HBS01-FPH and HBS01-FPN are suitable for use in hazardous locations Class I, Division
2, Groups A,B,C,D T4 or non-hazardous locations only.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.
1.11.1 Supported Input Types

The following table (Table 1-5) lists the supported input types for the AI01, AI03 and AI04 modules:
NOTE: Refer to Function Code (FC) 222 section in the S+ Engineering for Harmony Function Code Application
Manual for required specifications to configure these input types.
Table 1-5: Supported Input Types

AI01
AI03
AI04
Description
4 to 20 mA •
1 to 5 V •
- 10 to 10 V •
0 to 10 V •
0 to 5 V •
Type S thermocouple •
Type R thermocouple •
Type E thermocouple •
2VAA003057 A 1-11
Design Standards Introduction
Table 1-5: Supported Input Types (Continued)
AI01
AI03
AI04
Description
Type J thermocouple •
Type K thermocouple •
Type T thermocouple •
Chinese type E thermocouple •
Chinese type S thermocouple •
Type L thermocouple •
Type U thermocouple •
Type N (14 AWG) thermocouple •
Type N (28 AWG) thermocouple •
Type B thermocouple •
- 100 to 100 mV •
- 0 to 100 mV •
US Lab Std. 100  platinum RTD •
US Ind Std. 100  platinum RTD •
Euro Std. 100  platinum (80°C) RTD •
120  nickel RTD •
Chinese 53  copper RTD •
Japanese 100  platinum RTD •
1.12 Design Standards

The following table (Table 1-6) lists the design standards for the S+ SD Series Analog Input modules:
Table 1-6: Design Standards
Category Standard Description
Safety CSA C22.2 No. 142 Safety standards for process control
equipment.
ANSI/ISA S82.01-1994
EN 61010-1 Safety standards for process control

equipment.
CSA C22.2 No. 1010.1
Environmental IEC 60068-2-1 Operating temperature
IEC 60068-2-2
IEC 60068-2-8, IEC 61298-3, Operating relative humidity

note 2
ISA S71.04 (ISA S71.04, IEC Air quality

60068-2-60; Level G3)
MIL-STD-810G, 501.5, 502.5 Storage and Transport Temperature

Test
MIL-STD-810G, 500.5 Low Air Pressure (Operational)
MIL-STD-810G, 500.5 Storage and Transport Altitude Test
1-12 2VAA003057 A
Introduction Design Standards
Table 1-6: Design Standards (Continued)
Category Standard Description

Vibration MIL-STD-810G, 514.6 Storage/transportation vibration
Category 1, basic transportation
IEC 60068-2-27 Shock
EN 610068-2-31 Drop
EN 61298-3
EN 60068-2-6 Operating vibration (sinusoidal)
IEC 61298-3
EMI, RFI, and IEC 61000-3-2 Harmonics and Flicker Test 2009;
Electrical Surge Electromagnetic Compatibility (EMC),
Part 2.
IEC 61000-4-2 ESD
IEC 61000-4-3 EMI susceptibility
IEC 61000-4-4 Electrical fast transient
IEC 61000-4-5 Electrical surges
IEC 61000-4-6 Conducted immunity
EN 61000-4-8 (level Magnetic fields
CISPR-11 and CISPR 16-1-1 Radiated emissions
EN 61000-4-11 Voltage Fluctuation Immunity Test
EN 61000-4-11 Voltage Deviation Immunity Test
EN 61000-6-2
CSPR 11 Conducted Emissions Test
CISP16-1-1
Flammable CSA C22.2 No. 213 Nonincendive equipment

atmospheres
ISA S12.12 Nonincendive equipment
FM Class 3611 Division 2 equipment
Flammability of IEEE 383 Intercabinet cables

product components
UL rating VW-1 Intracabinet cables
UL 94 V-0, V-1, V-2, or V5 Flammability of plastic materials
CE Mark directives 2006/95/EC Low voltage directive
2004/108/EC EMC directive
Certifications1 CSA Canadian Standards Association

safety standard
NOTES:
1. This product is certified to CSA standard CSA 61010-1-12 3rd edition.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
2VAA003057 A 1-13
Design Standards Introduction
1-14 2VAA003057 A
Description and Operation Introduction
2. Description and Operation

2.1 Introduction
This section explains the operation of the S+ SD Series Analog Input modules. The modules perform the following two
major tasks:
• Provides an interface by which a Symphony Plus Controller can input analog process data from external devices.
• Serves as a communication link between the Symphony Plus system and field devices.
The controller communicates with its I/O modules over the HN800 bus (refer to Figure 1-1). Each I/O module on the HN800
bus has a unique user-assignable device label that eliminates the need to manually set hardware addresses.
These modules are entirely different in functionality from previous I/O modules, especially the Harmony Rack I/O modules.
These modules are differentiated by function (high level, RTD, Thermocouple), since they provide space savings in an
increasingly dense cabinet and allow for more customization of control circuits. The function specialization of these modules
allows all configuration of the modules to be done through software, instead of jumpers as used in previous I/O modules
(Harmony Rack I/O modules). For these modules, no jumpers or user handling of the hardware (printed circuit board) is
required.
2.2 Module Description

The analog input modules consist of a single printed circuit board that is enclosed in a plastic housing.
A single screw attaches the module to the HBS01-xxx or VBS01-xxx mounting base. The mounting bases are attached to a
35mm DIN rail using a quick cam mechanism. Ten front panel LED status indicators display the input status and provide aid
in system test and diagnosis.
Logic power is provided to the module from the HBS01-xxx or VBS01-xxx mounting base. The mounting base receives its
power from an HBX01L or VBX01T bus extender, which connects through the side edge connector on HBS01-xxx (top edge
connector for VBS01-xxx). Isolated power for these measurement circuits is generated internally. Isolated power is not
required unless it is used as a field power source (for powering transmitters on AI01).
A diagnostic port (mini-USB) on the front of the module is used to access module utilities and to download firmware.
A Stop/Reset push button is used to halt module operation and to reset the module. It is accessible through a small hole on
the front of the module. If you press the push button once, it causes the module to perform an orderly shutdown. If you
press the push button a second time, it resets the module.
NOTE: Before you remove the module from its mounting base, make sure to press the Stop/Reset button once to halt the
module. If you fail to halt the module before removing it from its base, it could result in unpredictable I/O communications.
Refer to sub-section 3.7.4- Removing Module from Mounting Base of this user manual for detailed procedure.
2.3 General Operation

Upon receiving initialization from the controller, the modules store that information in memory and check the configuration of
each input channel. If all input channels check good, operation begins. If the modules detect a configuration error, then that
error appears in the module status report.
Under normal operation, the controller sends transmitter commands and requests process input data and status information
from the input module. The input module continuously reads each input channel, performs the necessary conversions, and
stores the data in memory. When the controller makes a request for data, the input module sends the current information
stored in its memory.
If a communication failure with one of the connected field devices occurs, the input module works to restore communication
while continuing normal operation. It checks the transmitter configuration upon restoring transmitter communication and
normal process control continues.
2.4 Controller Operation

The controller directs the operation of the transmitters or reads values from RTD or thermocouples, and holds their
operating strategy. FC 221, IO Device Definition, defines the settings for each IO module within the controller. A FC 222 is
then defined for each analog input channel for that module identified with FC 221. FC 222 (analog input/channel) reads the
analog inputs of the input modules. Operation begins when the controller is placed in the execute mode with FC 222 in its
configuration. When the controller enters the execute mode, it downloads the operating strategy to the analog input module.
The 'Channel Label' field must watch with FC 221 and FC 222 specifications for the configuration to properly download to
the selected module. The module must also have the same label for the controller to properly identify and configure the
module.
2VAA003057 A 2-1
Functional Operation Description and Operation
2.5 Functional Operation

This sub-section details the block diagrams for the AI01/03/04 series SD I/O cards. There are two functional sections:
• Isolated Measurement section
• Communication and Processing section
2.5.1 Isolated Measurement section

The AI01/03/04 modules are group isolated, where all measurement channels must be referenced to a common ground.
This common ground has 300V (DC) of working voltage isolation from the logic power bus that powers the communication
and processing section (refer to sub-section 2.5.2- Communication and Processing of this user manual for more details).
This prevents damage to the communication section and the other modules on the same logic power bus when the
measurement ground floats away from the logic power's ground.
2.5.1.1 AI01 Measurement Circuit
The AI01 module can measure a wide range of high-level analog inputs, which includes 4-20 mA, 1-5V, 0-10V, -10 to +10V
and 0 to 1V. The input to the AI01 input section uses the same two input pins, irrespective of the mode and the
measurement selected through S+ Engineering for Harmony tool. All control of the mode selection is done through the
software, no jumper settings are required.
The following figure (Figure 2-1) shows the block diagram for the AI01 module:
NOTE: The AI01 module has built-in current limiting as shown in Figure 2-1.
Figure 2-1: Block Diagram for AI01 module
2.5.1.2 AI03 Block Diagram
The AI03 module requires sending current out of the RTD that is being measured, which can be a 2, 3 or 4 wire RTD,
depending on how it is hooked up at the terminal block (refer to appendix A.4- Mounting Base Wiring Examples of this user
manual for more details). The current source is sent out to the field, as shown in Figure 2-2 through the ‘Force +’ terminal.
This is sent through the RTD and then is returned to the AI03 unit, where it is precisely measured and used in the
calculation of the RTD resistance (and by extension, temperature).
2-2 2VAA003057 A
Description and Operation Isolated Measurement section
2.5.1.3 AI04 Block diagram
The AI04 module is a low level thermocouple and mV measurement card with a standard voltage input. The input terminals
are extremely high impedance to leave the measured signals undisturbed. The bias is added to the input to allow for bipolar
measurement for the -100 mV to +100 mV measurement range. All linearization of thermocouple inputs is done in the
microcontroller, as explained in sub-section 2.5.2- Communication and Processing of this user manual.
2VAA003057 A 2-3
Communication and Processing Description and Operation
2.5.2 Communication and Processing

The communication and processing section of the AI boards includes a microcontroller and an FPGA to simultaneously
process incoming data from the isolated measurement section (as explained in sub-section 2.5.1- Isolated Measurement
section of this user manual), and to communicate with HN800 (as explained in sub-section 2.6- HN800 - Symphony Plus I/O
Communication Bus of this user manual) to push the data back to the main controller. Additional interaction includes the
front panel LEDs, which show the status of the SD I/O module and the USB port, which can be used to label and re-program
the firmware of the module.
Calibration and linearization data is stored on the processor and in the embedded memory. Units that are sent back to the
controller are already adjusted.
2.6 HN800 - Symphony Plus I/O Communication Bus

The HN800 communication bus is a high speed link used within an enclosure to connect a Symphony Plus Controller
(HPC800 or SPC700) to its associated I/O devices such as an AO01 module and AI02 or HAI805 modules (HART Analog
Input modules). The HN800 bus connects Net90, INFI90, Symphony and other Symphony Plus, or S800 I/O systems to the
Symphony Plus controllers.
HN800 communications between the controller and all modules within an I/O segment is done using the CTB811 and
HBX01x/VBX01T bus extenders. A cable connects the HN800 bus on the CTB811 mounting base to the bus extender on
the I/O segment.
A controller and its I/O modules form an individual subsystem within a process control unit (PCU).
NOTE: All Symphony Plus DIN rail (SD I/O and MB705/710/VB705/710) mounting bases do not require a module to be
installed in the base to extend the HN800 bus. This feature can be used to install empty bases in line with a populated
base, and also provides space for future expansion of the system.
NOTE: All SD I/O modules, SPC700 controllers and other SD IO devices can be located anywhere on the DIN rail
between SD I/O bus extenders - HBX01L or HBX01R for horizontal installations and VBX01T or VBX01B for vertical
instillations. The position along the DIN rail is not restricted. Similarly, the HN800 bus connection from an HPC800
controller can start from any SD I/O bus extender. You can connect up to 66 devices on a single HN800 bus (redundant
controller and 64 SD I/O modules). Redundant devices are equal to 2 devices on the HN800 bus.
2.7 Power System Status

The Symphony Plus system monitors the status of the power to each node. This status information can be displayed on a
human system interface. To use this feature, wire the 24 VDC power output to the terminal block on the HBX01L/VBX01T
bus extender labeled SA or SB. Field power status is also monitored (applicable to SD I/O mounting bases with a field
power connection).
Power status signals are fed through the bus extender to the SPC700 module. A high voltage level (24 VDC) is interpreted
as good status. A low voltage level (0 VDC) indicates bad status.
A connection must be made to both the SA and SB terminals on the power plug of the HBX01L/VBX01T bus extender. If
this connection is not made, then all modules on the segment generate a bad status indication and the Fault LED (F) begins
flashing on the modules. Refer to the second NOTE statement given under Figure 2-4 for method used to mask bad status
indication.
The following figure (Figure 2-4) is a wiring example, which shows how redundant power supplies can be connected to
Symphony Plus Controller and SD I/O segments:
2-4 2VAA003057 A
Description and Operation Power System Status
Figure 2-4: SD I/O Power Wiring
As shown in the example (refer to Figure 2-4), a connection is made from the power source to the SA and SB terminals on
the HBX01L bus extender. Other controller or I/O segments which share the same source can have the SA and SB outputs
jumpered together (refer to Figure 2-4). It is not required to run a dedicated wire to all SA and SB terminals on HBX01L bus
extenders from the same power source, if all segments use the same power source, and at least one segment has
dedicated SA and SB connections to each power source.
When using a non-redundant power source, run a jumper wire between the SA and SB terminals.
NOTE: Vertical mounting bases and bus extenders are wired in the same way as shown in this example (refer to
Figure 2-4).
NOTE: From Symphony Plus SD I/O Firmware Revision B_0 and later, FC 221 ‘I/O Device Definition’ Specification S34
can be used to independently mask: Power Status A, Power Status B, and Field Power Status for segments containing
only SD I/O modules (refer to below Note statement). When enabled, the masking operation applies to both the I/O
module status and the Fault LED. The default (zero) for specification 34 is ‘unmasked’ and all three power status checks
are enabled. Masking the I/O module status indicates that FC 221 does not generate a problem report or error summary
status when a power status fault is present, i.e. the selected power status fault is disabled.
When S34 = 0 Power Status Fault detection is enabled. Otherwise, when the ones digit = 1, the Field Power status is
masked. When the tens digit = 1, Power Status B is masked, 2 = Power Status A is masked, 3 = Power Status A and B are
masked.
For Example: S34 = 31 results in the masking of power status alarms for power status A and B, including field power.
2VAA003057 A 2-5
Power System Status Description and Operation
When power fault detection monitoring is disabled it is not required to wire the SA and SB terminals to the power source.
NOTE: Symphony Plus segments which contain controllers (SPC700, HPC800) and communication modules (PNI800,
PDP800, HAI805 and HAO805) must have a connection to power status SA and SB on the HBX01L/VBX01T bus
extender. The Fault LED (F) flashes when there is no power status connection to the segment.
SD I/O mounting bases with a field power connector, for e.g. HBS01-EPD, must be connected to a power source (or have
power fault detection disabled) to prevent automatic generation of problem reports and error summary status bits.
2-6 2VAA003057 A
Installation Introduction
3. Installation
3.1 Introduction
This section explains how to install the S+ SD Series Analog Input modules.
NOTE: Make sure you install the analog input modules properly per the instructions given in this section before you
perform the operating procedures (refer to section 5- Operating Procedures of this user manual) for the modules.
3.2 Unpacking and Inspection

Follow the given steps to unpack and inspect the module:
1. Examine the hardware immediately to verify it has not been damaged in transit.
2. Notify the nearest ABB sales office of any such damage.
3. File a claim for any damage with the transportation company that handled the shipment.
4. Use the original packing material and container to store the hardware.
5. Store the hardware in an environment of good air quality, free from temperature and moisture extremes.
3.3 Setup and Physical Installation

Prior to installation, ensure the correct mounting base is in place. There are no switches or jumpers that require
configuration on this module. Configuration is performed using the S+ Engineering for Harmony tool or the diagnostic port
located on the front of the module.
3.3.1 Equipment Usage in Hazardous Locations

The following important warnings must be followed when using this equipment in hazardous locations:
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, OR NON-HAZARDOUS LOCATIONS ONLY
EXPLOSION HAZARD
Substitution of components can impair suitability for Class I, Division 2.
AVERTISSEMENT: RISQUE D'EXPLOSION - SUBSTITUTION DE COMPOSANTS PEUT NUIRE A LA

CONFORMITE CLASSE 1, DIVISION 2
EXPLOSION HAZARD
Do not disconnect equipment unless power has been switched off or the area is known to be non-
hazardous. Refer to Appendix A: Symphony Plus Mounting Bases of this user manual for power
connection instructions.
AVERTISSEMENT: RISQUE D'EXPLOSION - AVANT DE DÉCONNECTER L'EQUIPEMENT, COUPER

LE COURANT OU S'ASSURER QUE L'EMPLACEMENT EST DÉSIGNÉ NON DANGEREUX.
Do not connect or disconnect the USB connector unless the area is known to be non-hazardous.
NE PAS BRANCHER OU DEBRANCHER LE CONNECTEUR USB SAUF SI LA ZONE EST CONNUE

POUR ETRE NON DANGEREUX.
EXPLOSION HAZARD -
Do not disconnect while circuit is ‘LIVE’ unless area is known to be non-hazardous.
AVERTISSEMENT: RISQUE D'EXPLOSION - NE DECONNECTEZ PAS LORSQUE LE CIRCUIT EST

MOINS QUE L'ENVIRONNEMENT EST CONNU POUR ETRE NON DANGEREUX
2VAA003057 A 3-1
Labeling the Analog Input Modules Installation
POTENTIAL ELECTROSTATIC CHARGING HAZARD.
Wipe dust with a damp cloth to avoid a potential electrostatic hazard.
AVERTISSEMENT - CHARGES DE DANGER POTENTIEL ELECTROSTATIQUE
ESSUYEZ LA POUSSIERE AVEC UN CHIFFON HUMIDE POUR EVITER UN DANGER

3.3.2 Labeling the Analog Input Modules

Each Analog Input modules is uniquely labeled on the HN800 bus. This label identifies the I/O module to the controller and
must be the same as the label set in the controller configuration.
3.4 Device Label

All Symphony Plus I/O modules must have a device label assigned to it to communicate on HN800. The Symphony Plus
Controller uses the device labels to direct messages to specific I/O modules and to identify the source of any received
messages. In the control configuration, device labels map function codes to specific I/O modules.
3.4.1 Electronic ID
Each I/O module has a unique electronic ID. This ID is fixed in memory and cannot be modified. This method of
identification:
• Eliminates the need for a physical address switch that must be uniquely set and subsequently recorded for
identification and configuration purposes.
• Removes any hardware address management requirements necessary to ensure each I/O module has a unique
identifier.
• Simplifies configuration.
The identification label on the I/O module gives the electronic ID of the I/O module. The electronic ID does not need to be
remembered or recorded for use in configuration because user-defined device labels are used instead. The Symphony Plus
Controller automatically associates device labels with electronic IDs during the device labeling process.
3.4.2 Establishing a Device Label

When an I/O module is first removed from its packaging or after it is initialized, it does not contain a device label. The device
labeling procedure explained in the S+ Engineering for Harmony Primary Interface Manual must be performed to establish
the label. Once the label is established, it is retained by the I/O module. The I/O module can be removed and reinstalled
without assigning a new label.
NOTES:
1. An I/O module needs to be relabeled after performing a firmware download. After copying firmware from one I/O
module to another, both the source I/O module and the destination I/O module must be relabeled.
2. Redundant I/O modules (future release) share the same device label. The primary I/O module defines or updates the
backup I/O module's device label automatically. This occurs even, if the backup I/O module does not currently have a
device label defined, or if it has a device label that is different from the primary I/O module's device label.
3. Labels may contain any ASCI character. The following labels are reserved for internal use by ABB:
• BRC_RIO_00 through BRC_RIO_63

• EMFP_00 through EMFP_31
• NPM_00, NPM_01, Label_undefined_xx, where ‘xx’ indicates any two characters
The device label for an I/O module must be a unique label. Labels can be assigned using any appropriate labeling scheme.
The labels should include appropriate details to easily identify and differentiate between devices.
The Symphony Plus Controller performs all device label management. This indicates that any changes, updates, and
additions are directed to the controller, which in turn communicates them to the appropriate individual IO modules.
NOTE: For compatibility reasons, the label for a Symphony Plus Controller is derived from its hardware address, which
cannot be modified.
3-2 2VAA003057 A
Installation Power Supply
3.5 Power Supply

It is strongly recommended to use different power supplies to power ABB Symphony Plus module system components
and field equipment.
Logic Power is used to provide power supply to the module system components and Field (I/O) Power is used to provide
power supply to the field equipment.
Examples of system components include the Symphony Plus Controller (HPC800 or SPC700), Communication Interface
(PNI800) and SD I/O modules.
Examples of field equipment include transmitters, meters, etc.
The power supplies can also be configured in a redundant configuration using independent voting units.
The following figure (Figure 3-1) shows a recommended power supply concept:
Figure 3-1: Recommended Power Supply Concept
3.6 SD I/O Mounting Base Configuration

A SD I/O mounting base connects the field device wiring to the system. Terminal headers (connection points) are located on
the mounting base.The terminal header can be used with pluggable terminal blocks, which allow field wiring to connect
directly to the base. The mounting bases also support the use of a pluggable cable assembly (part number = SPK0x-xxx).
One end of the cable assembly has a hood cable connector, which plugs into the mounting base. The other end of the cable
has 8 twisted pairs of wire. The SPK0x-xxx cable allows field wiring to connect to a marshalling enclosure, where fuses,
breakers, or customer specified terminal strips are located.
Selection of the appropriate mounting base is required to accept the analog field inputs sent to the AI0x module. Refer to
Appendix A: Symphony Plus Mounting Bases of this user manual for additional information.
Permanent damage will occur to AI03 and AI04 modules, if the modules are inserted into a powered
HBS01-FPH/VBS01-FPH or HBS01-EPD/VBS01-EPD mounting base. Use only the
HBS01-CJC/VBS01-CJC mounting base for AI03 and AI04 modules. Use only supported module / base
combinations. The use of mounting base keys prevents modules from accidentally being inserted into the
wrong type of mounting base. Refer to Appendix A: Symphony Plus Mounting Bases of this user manual for
supported module / base combinations and procedure details for inserting mounting base keys.
2VAA003057 A 3-3
Mounting Bases Installation
3.7 Mounting Bases

All Symphony Plus bus extenders, module and controller mounting bases attach to a standard 35mm wide DIN-rail. The
DIN rail must be mounted horizontally within the enclosure when using HBX01-xxx mounting bases and mounted vertically
when using VBS01-xxx mounting bases. ABB offers pre-formed panels that can be used to mount horizontal DIN rail into
enclosures with EIA standard 19 inch rails. Refer to section 9- Spare Parts of this user manual for information on applicable
part numbers.
All SD I/O mounting bases must be mounted in the direction for which the bases are intended, i.e. horizontal bases must be
used on horizontal DIN rail, and vertical bases must be mounted to vertical DIN rail.
A maximum of eight vertical bases can be connected between bus extenders.
NOTE: When mounting horizontal rows of modules in an enclosure, a minimum of 76mm [3 inches] must be kept
between the top of one Symphony Plus module and the bottom of another Symphony Plus module.
DIN rail must be mounted to rigid panels. The panels and DIN-rail must be electrically grounded. The DIN rail must be
attached to the panel with screws every 100 mm (4 in) to ensure good mechanical stability and a good chassis ground
connection. You can power up to 24 modules from a single HBX0xL/VBX01T bus extender.
Do not mount the Symphony Plus mounting bases to the DIN rail while they are powered.
Do not connect an un-powered mounting base to a mounting base that is powered.
NOTE: DIN rail end stops (ABB part number - 1948900A2) are required at each end of the I/O segment unless panel
mounting screws are used (refer to Figure 3-4 or Figure 3-8). One or both of these methods are required to prevent
movement of the mounting bases.
EXPLOSION HAZARD
Do not disconnect equipment unless power has been switched off or the area is known to
be non-hazardous. Refer to Appendix A: Symphony Plus Mounting Bases of this user
manual for power connection instructions.
AVERTISSEMENT: RISQUE D'EXPLOSION
NE DECONNECTEZ PAS LORSQUE LE CIRCUIT EST MOINS QUE

L'ENVIRONNEMENT EST CONNU POUR ETRE NON DANGEREUX
3-4 2VAA003057 A
Installation Attaching Horizontal Mounting Base to DIN-rail
3.7.1 Attaching Horizontal Mounting Base to DIN-rail

Follow the given steps to attach a horizontal mounting base to DIN-rail:
1. Lift up on the locking lever (refer to Figure 3-2).
Figure 3-2: S+ I/O base Locking Lever Up
2VAA003057 A 3-5
Attaching Horizontal Mounting Base to DIN-rail Installation
2. Hold the base at an angle to the DIN rail and hook the DIN rail under the DIN rail capture protrusions (refer to
Figure 3-3).
Figure 3-3: S+ I/O base DIN rail Capture Protrusions
3. Snap the mounting base down on to the DIN rail.

4. Slide the mounting base along the DIN rail to engage the side edge connectors into the adjacent mounting base.
NOTE: Ensure mounting base’s edge connectors are fully seated into the adjacent mounting base.
5. Push the locking lever into the locked position (down).

6. Attach the mounting base to the panel using the optional mounting screw (refer to Figure 3-4).
NOTE: The same procedure is used to mount HBX0xx bus extenders (refer to Figure 3-5).
7. Refer to procedure steps - 1 to 6 of sub-section 3.7.1- Attaching Horizontal Mounting Base to DIN-rail for the
next mounting base in the I/O segment.
8. Install a bus extender at each end of the I/O segment.
9. Install DIN rail end stops (ABB part number - 1948900A2) next to each bus extender at the ends of the I/O
segment unless panel mounting screws are used (refer to Figure 3-4).
NOTE: One or both of these methods are required to prevent movement of the mounting bases.
10. Use SPK800-xx cables to connect individual HN800 I/O segments together.
NOTE: You can connect up to 64 SD I/O modules in this way to a redundant Symphony Plus Controller.
3-6 2VAA003057 A
Installation Attaching Horizontal Mounting Base to DIN-rail
Figure 3-4: S+ I/O base attached to panel using Optional Panel Mounting Screw
2VAA003057 A 3-7
Attaching Horizontal Mounting Base to DIN-rail Installation
Figure 3-5: Mounting HBX01L and HBX01R Bus Extenders
NOTE: It is required to install one DIN rail end stop to the left of the HBX01L bus extender and one DIN rail end stop to
the right of the HBX01R bus extender.
3-8 2VAA003057 A
Installation Attaching Vertical Mounting Base to DIN-rail
3.7.2 Attaching Vertical Mounting Base to DIN-rail

Follow the given steps to attach a vertical mounting base to DIN-rail:
1. Install the air deflector (press the air deflector straight down into the base) prior to mounting the mounting base
to the DIN rail.
NOTE: Vertical mounting bases are supplied with a snap in air deflector to improve air flow around SD Series
I/O modules installed in this vertical orientation.
Do not twist the air deflector during installation.
2. Lift up on the locking levers (refer to Figure 3-6).
Figure 3-6: S+ I/O base Locking Lever Up
2VAA003057 A 3-9
Attaching Vertical Mounting Base to DIN-rail Installation
3. Hold the base at an angle to the DIN rail and hook the DIN rail under the DIN rail capture protrusions (refer to
Figure 3-7).
Figure 3-7: S+ I/O base DIN rail Capture Protrusions
4. Snap the mounting base down on to the DIN rail.

5. Slide the mounting base along the DIN rail to engage the side edge connectors into the adjacent mounting base.
NOTE: Ensure mounting base’s edge connectors are fully seated into the adjacent mounting base.
6. Push the locking levers into the locked position (down).

7. Attach the mounting base to the panel using the optional mounting screw (refer to Figure 3-8).
NOTE: The same procedure is used to mount HBX0xx bus extenders (refer to Figure 3-9).
8. Refer to procedure steps - 1 to 7 of sub-section 3.7.2- Attaching Vertical Mounting Base to DIN-rail for the next
mounting base in the I/O segment.
9. Install DIN rail end stops (ABB part number - 1948900A2) next to each bus extender at the ends of the I/O
segment unless panel mounting screws are used (refer to Figure 3-10).
NOTE: One or both of these methods are required to prevent movement of the mounting bases.
3-10 2VAA003057 A
Installation Attaching Vertical Mounting Base to DIN-rail
Figure 3-8: S+ I/O base attached to panel using Optional Panel Mounting Screw
2VAA003057 A 3-11
Attaching Vertical Mounting Base to DIN-rail Installation
Figure 3-9: Mounting VBX01T and VBX01B Bus Extenders
The following figure (Figure 3-10) shows how vertical Bus Extenders are mounted on each end of an SD IO segment.
NOTE: Up to 8 vertical mounting bases are allowed between the top and bottom bus extenders. DIN rail end stops are
required when panel mounting screws are not used as shown in Figure 3-10.
3-12 2VAA003057 A
Installation Inserting Module into Mounting Base
Figure 3-10: Typical mounting of vertical bases and bus extenders to DIN rail
3.7.3 Inserting Module into Mounting Base

Do not insert a module into a mounting base unless area is known to be non-hazardous.
NE PAS INSERER UN MODULE DANS UNE BASE DE MONTGE SAUF SI LA ZONE

EST CONNUE POUR ETRE NON DANGEREUX.
Follow the given steps to insert the module into the mounting base:
1. Ensure the mounting base is in its final location on the DIN rail and the mounting base's edge connectors are
fully seated into the adjacent mounting base.
2. Insert the module straight into the mounting base.
NOTE: Do not tilt the module at an angle during insertion.
3. Press the module down until it is fully inserted into the mounting base.
2VAA003057 A 3-13
Removing Module from Mounting Base Installation
4. Tighten the module locking screw into the mounting base.
NOTE: Torque the module mounting screw to 6in-lbs to 7in-lbs maximum or .68 N-m to .79 N-m
(Newton-meters). Do not overtighten the module mounting screw. Do not use drill drivers that do not have a
torque control mechanism.
3.7.4 Removing Module from Mounting Base

Do not remove a module from a mounting base unless area is known to be non-hazardous.
NE RETIREZ PAS UN MODULE A PARTIR D’UNE BASE DE MONTAGE SAUF SI LA ZONE

Follow the given steps to remove the module from the mounting base:
1. Press the Stop/Reset button once and wait for the module to halt.
2. Unscrew the module locking screw counter clockwise until the ejection spring ejects the screw free of the
mounting base.
3. Grasp the module at the top and bottom finger holds, and pull the module straight out of the mounting base, as
shown in the following figure (Figure 3-11):
3-14 2VAA003057 A
Installation Removing Module from Mounting Base
Figure 3-11: Finger holds on the module
NOTE: Do not shake or twist the module when trying to remove it out from the mounting base. Just pull the
module straight out of the mounting base.
NOTE: You can use the same removal procedure given in sub-section 3.7.4- Removing Module from Mounting Base of
this user manual for removing a module from vertical mounting bases (VBS01-FPH and VBS01-EPD).
2VAA003057 A 3-15
Removing Module from Mounting Base Installation
3-16 2VAA003057 A
Configuration Introduction
4. Configuration
4.1 Introduction
This section details I/O module configuration performed through a Symphony Plus Controller.
NOTE: The S+ Engineering for Harmony Function Code Application Manual contains I/O module configuration exam-
ples.
4.2 Configuration Tools

SD Series I/O modules can be configured and tuned using the following configuration tools:
• S+ Engineering for Harmony 1.0 and higher version.
• S+ Operations (1.1 and later)
NOTE: Only the S+ Engineering for Harmony tool has the required utilities to define device labels.
4.3 Symphony Plus Controller

Symphony Plus controllers - HPC800 and SPC700 support SD Series I/O modules. The controllers are used for
downloading and verifying process configuration executed by a SD Series I/O module. An I/O module performs its input and
output processing based on this process configuration.
4.3.1 Download
When an I/O module is first installed, it contains only a base configuration. This base configuration allows the module to
participate in the device labeling process. During the actual labeling process, an I/O device definition function code
(FC 221) with a device label is added to the base configuration. Once the label is established, the Symphony Plus Controller
can communicate and download appropriate configuration to the module. Refer to sub-section 4.4- Labels of this user
manual for more information.
The complete control configuration resides and is retained in the Symphony Plus Controller. The controller only off loads a
portion of the configuration to be executed by the I/O modules.
The controller automatically downloads the configuration during startup or after any configuration changes through a device
label that is already established in each I/O module. This device label in the module must match a device label in the control
configuration of the Symphony Plus Controller (i.e., I/O device definition function code).
4.3.2 Verification
The controller is responsible for verifying I/O module configuration. After losing and then regaining communication with an
I/O module, the controller issues commands to read, compare, and then download the configuration (if required). A
download occurs when the controller detects any of the following conditions:
• Excluded function code.
• Extra function code.
• Difference in Symphony Plus controller and I/O module specifications.
4.3.3 Changes
All control configuration changes made by the process engineer, technician, or operator affect the control configuration that
resides in the controller. These changes can include:
• Adding new function codes.
• Deleting existing function codes.
• Modifying and tuning specifications of existing function codes.
When a change is made to the control configuration that affects I/O modules, the controller automatically downloads the
changes to the appropriate modules.
2VAA003057 A 4-1
Firmware Download Configuration
For a non-redundant controller, all changes except tuning require the controller to be placed in Configure mode. The
controller and I/O modules do not execute the control configuration while in configure mode. For redundant controllers,
online configuration enables configuration changes without affecting the primary controller or interrupting the control
process. Refer to the S+ Engineering for Harmony Primary Interface Manual for an explanation of online configuration.
Tuning is the process of making changes to function code specifications while the controller and I/O modules are executing.
All specifications cannot be tuned. Only those specifically designated as tunable can be tuned. Refer to the S+ Engineering
for Harmony Function Code Application Manual to identify tunable function code specifications.
4.3.4 Firmware Download

The I/O module firmware includes a real-time operating system, HN800 support, and the function code environment. The
I/O system supports firmware downloads, which allows I/O module firmware to be updated without having to replace
physical components. All firmware downloads are performed using Composer tools and are managed by the Symphony
Plus Controller. Refer to the S+ Engineering for Harmony Primary Interface Manual for firmware download procedures.
The controller takes an I/O module offline to download new firmware. The module’s status LEDs indicate a 1, 4, 5, (0x19)
code when a firmware download is in process.
4.4 Labels
A label is a user-defined name assigned to a device (in FC 221) or an I/O point (in FC 222). In this case, device refers to an
I/O module. The S+ SD Series I/O system uses two types of labels: device and channel. The device and channel labels are
character strings saved in memory. Labels can be up to 32 characters.
NOTE: A device label is required, while channel labels are optional.
4.4.1 Device Label

All I/O modules must have a device label assigned to communicate on HN800. The controller uses the device labels to
direct messages to specific I/O modules and to identify the source of any received messages. In the control configuration,
device labels map function codes to specific I/O modules.
4.4.1.1 Electronic ID
Each I/O module has a unique electronic ID. This ID is fixed in memory and cannot be modified. This method of
identification:
• Eliminates the need for a physical address switch that must be uniquely set and subsequently recorded for
identification and configuration purposes.
• Removes any hardware address management requirements necessary to insure each I/O module has a unique
identifier.
• Simplifies configuration.
The identification label, which is physically attached to the side of the I/O module, gives the electronic ID of the I/O module;
refer to I/O Module description in section for further description. The electronic ID does not need to be remembered or
recorded for use in configuration because user-defined device labels are used instead. The Symphony Plus Controller
automatically associates device labels with electronic IDs during the device labeling process.
4.4.1.2 Establishing a Device Label
When an I/O module is first removed from its packaging or after it is initialized, it does not contain a device label. The device
labeling procedure explained in the S+ Engineering for Harmony Primary Interface Manual must be performed to establish
the label. Once the label is established, it is retained by the module. The module can be removed and reinstalled without
requiring a new label to be assigned.
NOTE: An I/O module needs to be relabeled after performing a firmware download. After copying firmware from one
module to another, both the source module and the destination module must be relabeled.
The device label for an I/O module can be any unique label. Labels can be assigned using any appropriate labeling
scheme. The labels must include proper details to easily identify and differentiate between devices and must be defined
consistently from module to module.
4-2 2VAA003057 A
Configuration Channel Label
The Symphony Plus Controller performs all device label management, indicating any changes, updates, and additions are
directed to the controller, which in turn communicates the changes, updates, and additions to the appropriate, individual I/O
module.
NOTE: For compatibility reasons, the label for a Symphony Plus Controller is derived from its hardware address, which
cannot be modified.
4.4.1.3 Predefining a Device Label
Generally, the device label that is defined for an I/O module is the last step of module installation or I/O module replacement
as described in Section 5 and Section 10 respectively. However, this is not a requirement. In some cases, it can be easier
and less time consuming to have the label assigned before beginning installation or replacement.
4.4.1.4 Online Configuration
Specification one of FC 221 contains the device label. This specification is not tunable, which indicates that it normally
cannot be changed while the controller is operating in Execute mode. However, the specification can be changed using
online configuration. If the device label is changed using online configuration, then the controller automatically changes the
module's label to match this new label. Refer to the S+ Engineering for Harmony Primary Interface Manual for an
explanation on online configuration.
4.4.2 Channel Label

A channel label identifies an I/O channel of an I/O module. A channel label can be any unique label. The label assignment
is optional and is not required for proper operation. It is strictly for ease of recognition during configuration and
maintenance. Channel labels are defined using FC 222.
A human system interface such as S+ Operations work station and other system nodes use a tag to acquire information
from an exception report and to perform process control. The channel label can be defined as a tag name in the system tag
database, if required. This allows easy identification of the relationship between an I/O module point and a tag in the system
tag database.
NOTE: Currently, S+ Operations supports tag names up to 50 characters in length; channel labels may be up to 32
characters long. The character length limit supported by other applications may be less than 32 characters. Ensure limits
on the length of tag names (in whatever application they are used) are not exceeded when configuring the channel
labels.
4.4.3 Duplicate Labels

Duplicate device labels on the same HN800 are not permitted. The Symphony Plus Controller checks for any duplicate
device labels and identifies any occurrences as a configuration error. The following paragraphs provide more details on
what occurs when a duplicate label is detected during configuration, startup, and normal operation.
Configuration:
If the controller configuration contains two or more device definition function codes (FC 221) with identical device labels
assigned, then the controller enters error mode and displays a duplicate label error on its LEDs.
Initial I/O System Startup:
The following occurs when duplicate device labels are detected on initial I/O system startup:
1. The offending I/O modules display a duplicate label error code (status LEDs 2, 4, and 5 on).
2. A status report indicating bad status is issued for each I/O module that has a duplicate label. This status
indication can be seen in the controller status bytes.
3. A device problem report indicating duplicate device labels is issued for the I/O modules that have the duplicate
labels. This report can be seen on a human system interface.
This does not affect control configuration execution and the controller continues to operate and communicate normally with
other I/O modules.
Normal Operation:
If an I/O module that has a duplicate label is inserted into a system that is already established communication with another
I/O module, then:
• The controller automatically relabels the offending module with the device label known as ‘Duplicate Label
Detected’. The text string appears in the device label specification (S1) in FC 221.
2VAA003057 A 4-3
Function Codes Configuration
• The offending I/O module displays a duplicate label error code (status LEDs 2, 4, and 5 on).
This does not affect control configuration execution and the controller continues to operate and communicate normally with
other I/O modules.
4.5 Function Codes

The Symphony Plus Controller and I/O module execute a control configuration made up of function codes linked together
and loaded in non-volatile memory to perform actual process control and process management. Function codes are
predefined, fixed function algorithms. The controller supports numerous function codes for building the control
configuration. The functions performed range from computing (function generator, square root, etc.) to control (PID, pulse
positioner, etc.) to I/O interface (analog input, digital output, etc.). Refer to the S+ Engineering for Harmony Automation
Architect Manual for information on how to build a control configuration.
I/O modules are configured using the following series of I/O module specific function codes:
• I/O device definition (FC 221)
• Analog in/channel (FC 222)
• Analog out/channel (FC 223).
• Digital in/channel (FC 224)
• Digital out/channel (FC 225)
• Test status (FC 226)
• Pulse In/Channel (FC 229)
The Symphony Plus Controller uses both SD Series I/O module and Harmony Rack I/O function codes simultaneously to
communicate with both SD Series I/O modules and Harmony rack I/O devices simultaneously.
4.5.1 I/O Device Definition (FC 221)

The I/O device definition function code (FC 221) is mainly used to group various I/O channel function codes of an I/O
module.
The function code supports up to 24 input or output channels (i.e., I/O channel function codes). Besides grouping the I/O
channels, the function code is also responsible for:
• I/O module and channel summary status reporting.
• Duplicate device label checking.
• Configuration verification.
• Redundancy checking and failover.
• Generating problem reports.
• Override, simulation, and status error inhibit permit.
4.5.1.1 Specifications
Following are the specifications of FC 221:

• Contains an I/O module device label. This associates the function code with a specific I/O module.
• Links I/O channel function codes. These function codes interface the I/O module inputs and outputs.
• Permits override, simulation, and status error inhibit modes for all linked I/O channels (i.e., master switch).
• Controls I/O module status reporting. A status error inhibit condition prevents I/O channel errors from being
included in the I/O module device status report made to the controller.
• Enables redundant I/O module checking.
• Identifies an external cold junction reference for thermocouple inputs.
These are just some of the function code capabilities. Refer to the S+ Engineering for Harmony Function Code Application
Manual for detailed function code descriptions, specifications, outputs, and capabilities.
4-4 2VAA003057 A
Configuration I/O Channel (FC 222, 223, 224, 225, and 229)
4.5.2 I/O Channel (FC 222, 223, 224, 225, and 229)
The I/O channel function codes allow for single channel modularity, where one I/O channel function code reads the input
value or drives the output of one channel. Specifications are set on a per channel basis rather than on an I/O group basis.
The function codes provide addressing, startup, execute (i.e., run time), override, simulation, and failure mode operation
specifications. The I/O channel function codes are exception reporting function codes.
Tables (Table 4-1 and Table 4-2) summarize some of the I/O channel function code capabilities. Refer to the S+ Engineering
for Harmony Function Code Application Manual for detailed function code descriptions, specifications, outputs, and
capabilities.
Table 4-1: I/O Channel Function Code Summary
FC I/O Purpose Normal Mode Output
222 Analog input Reads analog input channel data. Analog input value in engineering
units and the channel status.
223 Analog output Sets analog output demand value Readback analog output value in
and acquires output channel read- engineering units and the channel
back data. status.
224 Digital input Reads digital input channel data. Digital input state (0 or 1) and the
channel status.
225 Digital output Sets digital output state and acquires Readback digital output state (0 or 1)
output channel readback data (if and the channel status.
applicable).1
229 Pulse input Provides addressing, startup, run- Pulse input value (in specified EUs)
time, and failure mode specifications with quality and alarm.
for an individual or redundant pair of
pulse input channels on a SD I/O
block.
NOTE:
1. All digital output channels do not support readback based on the I/O module type.
Table 4-2: I/O Channel Specifications Summary
Function Code
Specification Description 222 223 224 225 229
(AI) (AO) (DI) (DO) (PI)
Alarming Alarm state   
High alarm (EU)   
Low alarm (EU)   
Identification Channel label    
2VAA003057 A 4-5
I/O Channel (FC 222, 223, 224, 225, and 229) Configuration
Table 4-2: I/O Channel Specifications Summary (Continued)
Function Code
Specification Description 222 223 224 225 229
(AI) (AO) (DI) (DO) (PI)
I/O Custom range high limit 

characteristics
Custom range low limit 
Deviation limit1  
EU Identifier   
High value (EU)   
Input type 
Low value (EU)  
Significant change (EU)  
Value to output  
I/O conditioning A/D conversion accuracy  2
Debounce period 
EU conversion or shaping algorithm 

precedence
Lead wire resistance 
Shaping algorithm 
I/O source Normal input or undefined     
Override enable     
Override value     
Simulation enable     
Simulation value    
Operation Default state on stall  
Readback enable 
Status error inhibit     
NOTES:
1. In normal mode, this is redundant I/O deviation limit. In override mode, this is
override deviation limit. In simulation mode this is simulation deviation limit.
2. Readback A/D conversion accuracy for analog outputs.
An I/O module prevents the use of any I/O channel function codes it does not support.
For Example: A DO01 block supports 16 digital output channels, where it allows using only digital out/channel function
codes (FC 225) and additionally channels one through 16 only.
4-6 2VAA003057 A
Configuration I/O Channel (FC 222, 223, 224, 225, and 229)
4.5.2.1 I/O Channel Data
An I/O channel function code reports channel data in automatically generated exception reports. Channel data includes
quality, alarm status, channel status, analog value or digital state, and a time-stamp. The data can be read by an external
device such as a human system interface. The information is also available at the I/O channel function code outputs, which
can be accessed by other local function codes.
Quality:
The quality reported by an I/O channel function code is either good or bad as determined by the function code.
Alarm Status:
For an analog channel, the alarm status indicates that the value reported is within normal limits or has reached or passed
either a high alarm or low alarm limit. The alarm limits are defined in I/O channel function code specifications.
For a digital channel, one of its two digital states can be selected as an alarm state. The alarm state is selected with an I/O
channel function code specification. When the channel toggles to the selected alarm state, an alarm is reported.
Channel Status:
Channel status is reported in the form of problem reports, which appear on a human system interface. Refer to Section 8 for
channel problem report details.
Value or State:
The analog value is reported in IEEE real-4 format. The analog state is reported as either a boolean logic one or zero.
Time-Stamp:
The time-stamp is the system time at which a value is read. The time is in milliseconds.
4.5.2.2 Suspect Condition
The function code tests redundant inputs and outputs to determine suspect condition. It also tests actual value against an
override or simulated value. Actual value refers to an input value for analog or digital inputs and a demanded output value
for analog or digital outputs. For analog inputs and outputs, the suspect indication is controlled by the deviation limit
specification set in the I/O channel function codes (refer to Table 4-2).
NOTE: Only readback capable digital outputs can indicate suspect while in normal mode.
For redundant inputs and outputs, the function code reports a suspect condition when:
• Redundant analog input states are of good quality but do not match.
• Redundant analog output states (readback) are of good quality but do not match.
• Redundant analog input values are of good quality but there is a difference between the redundant analog inputs.
The difference is greater than the deviation limit specified in the function code.
• Redundant analog output values (readback) are of good quality but there is a difference between the readback
values for the redundant analog outputs. The difference is greater than the deviation limit specified in the function
code.
In this case, suspect warns that if a failover from primary to backup should occur, the difference in redundant values can be
significant enough to cause a process failure.
NOTE: Currently, SD Series I/O modules do not support redundancy.
For override and simulation inputs and outputs, the function code reports a suspect condition when:
• In override or simulation mode, the override or simulation analog input state does not match the actual analog input
state.
• In override mode, the override analog output state does not match the readback output demand state.
• In override mode, there is a difference between the override analog input value and the actual input value. The
difference is greater than the deviation limit specified in the function code.
• In simulation mode, there is a difference between the simulation analog input value and the actual input value. The
difference is greater than the deviation limit specified in the function code.
• In override mode, there is a difference between the override analog output value and the readback output demand
value. The difference is greater than the deviation limit specified in the function code.
• In simulation mode, there is a difference between the simulation analog output value and the readback output
demand value. The difference is greater than the deviation limit specified in the function code.
2VAA003057 A 4-7
I/O Channel (FC 222, 223, 224, 225, and 229) Configuration
In this case, the suspect warns that if the mode is changed from either override to normal, or simulation to normal, the
difference between actual value and override value or between actual value and simulation value can be significant enough
to cause a process upset.
NOTE: When an IISAC01 Analog Control Station is in manual/override/auto-bypass mode and is bypassing the analog
output of the CIO block, the suspect status is not set while in override or simulation mode. The station itself is responsible
for preventing the process upset. This is accomplished by maintaining bypass control over the analog output until the
control output of its station function block (FC 80) matches the demand output of the station.
4.5.2.3 Exception Reporting
Each I/O channel function code is an exception reporting function code. Exception reported data can appear as dynamic
values, alarms, and state changes on displays and in reports generated by operator interfaces and other system nodes.
Exception reporting is automatic. An I/O channel function code generates an exception report periodically to update data,
after a process point reaches a defined alarm limit or changes state, or after a significant change in value occurs.
The segment control (FC 82) and analog I/O channel function codes (FC 222 and 224) have specifications that control
exception reporting. Specifically, the segment control function code contains minimum and maximum exception reporting
times and the I/O channel function codes contain a significant change specification used to trigger exception reporting.
4.5.2.4 Engineering Units (EU)
Analog I/O channel function codes automatically perform engineering unit conversions on analog input, output demand, and
output readback values. Analog inputs and readback values are converted based on the engineering unit low value, high
value, and EU identifier specifications. Also, input type and range selection for analog inputs factors into the engineering
units conversion.
For Example:
A high level analog input signal has a range of 0 to 10 VDC. The actual input signal is at 5 VDC. The engineering unit
associated with the input is percent (%); therefore, the high limit is 100 and the low limit is zero. For this signal, the I/O
module reports the input value as 50 percent.
Alarm limits and significant change are expressed in engineering units.
4.5.2.5 I/O Source
There are three input or output source selections for each I/O channel:
• normal
• override
• simulated.
The source is selected by setting certain I/O channel function code specifications (refer to Table 4-2). A value or state is
identified as either normal, simulated, or overridden when reported. Additionally, an I/O channel can be undefined. An
undefined channel is ignored during control configuration execution.
NOTE: The override, simulation, and status error inhibit permit specification (S26) in the I/O device definition function
code acts as the master switch for enabling or disabling the override and simulation I/O source options for individual
channels.
Normal:
The I/O source is normal as long as the override, simulation, or undefined options are not selected. Normal is the default
input or output source selection.
Override:
The override option allows the I/O channel value or state to be manually overridden (locally substituted) to support system
checkout or field testing. An override enable specification controls the override function and an override value specification
sets the substitute value. The value specification is tunable and can be changed from a human system interface or by
another function code.
4-8 2VAA003057 A
Configuration Test Status (FC 226)
Simulation:
The simulation option allows the I/O channel value or state to be simulated by some other function code. A simulation
enable specification controls the simulation function and a simulation value specification selects the simulation value
source.
NOTES:
1. An override value takes precedence over a simulated value. Both override and simulated values take precedence
over a normal input value.
2. Override and simulation modes do not function when the I/O channel is set to undefined input.
4.5.2.6 HN800 Stall Mode (Default State)
A default state on stall specification in output channel function codes selects a failure mode output. An output channel goes
to the configured default state when HN800 communication or communication with the Symphony Plus Controller is lost.
For an analog output, the options are zero percent output, 100 percent output, and hold current output.
For a digital output, the options are zero state output, one state output, and hold current output. An output automatically
returns to normal (i.e., controlled output) after communication is re-established.
4.5.2.7 Status Reporting
A status error inhibit specification in I/O channel function codes controls error status reporting. If status reporting is disabled,
then any channel errors are not reflected in I/O module device status reports. Module device status reports are integrated
into Symphony Plus Controller status reports. This permits disabling status reporting during testing and for an out of service
point. However, it does not disable input or output value and alarm status reporting.
NOTE: The override, simulation, and status error inhibit permit specification (S26) in the I/O device definition function
code acts as the master switch for enabling or disabling status error inhibiting for individual channels.
4.5.2.8 Alarming
Alarm status reports are used to trigger alarming features such as display changes (e.g., colors and dynamic symbols),
alarm tones, external annunciators, and automatic logging features. System alarming starts at the controller and I/O module
level. When an I/O channel function code reports an analog value or digital state, it also includes alarm status information.
Low and high alarm limit specifications in analog I/O channel function codes are used to set up alarming. A low alarm
condition is reported when an input value or output readback value is at or below the low alarm limit. Similarly, a high alarm
condition is reported when the value is at or above the high alarm limit.
An alarm state specification in analog I/O channel function codes is used to set up alarming. One of the two analog channel
states can be selected as an alarm state. When the input or output readback toggles to the designated alarm state, an
alarm condition is reported.
4.5.2.9 Shaping Algorithms
The following shaping algorithms (i.e., computing functions) can be used with the analog input channel function code:
• Function generator (FC 1).
• Square root (FC 7).
• Polynomial (FC 167).
An engineering unit conversion/shaping algorithm precedence specification in the analog input channel function code
determines when the shaping is applied, either before or after engineering unit conversion.
4.5.3 Test Status (FC 226)

The test status function code (FC 226) provides access to SD Series I/O status information. Any I/O block specific function
code can be tested for status (i.e., I/O device definition and I/O channel function codes). Refer to the S+ Engineering for
Harmony Function Code Application Manual for the statuses that can be accessed with this function code.
The test status function code checks the status up to four status conditions from the same function code. It is a four input
logical OR function that sets the output to a logic zero if all tested status conditions are false, and to a logic one, if one or
more tested status conditions are true.
2VAA003057 A 4-9
Test Status (FC 226) Configuration
4-10 2VAA003057 A
Operating Procedures Introduction
5. Operating Procedures
5.1 Introduction
This section explains the startup and operating procedures for the S+ SD Series Analog Input modules.
5.2 Startup
Do not insert a module into a mounting base unless area is known to be non-hazardous.
NE PAS INSERER UN MODULE DANS UNE BASE DE MONTAGE SAUF SI LA ZONE

Follow the given steps to start up the module:

1. Apply power to the module by inserting it into a powered mounting base.
2. Place the controller in execute mode.
Communication between the module and the controller begins automatically, if there are no configuration errors and the
controller is in the execute mode.
Upon startup, all channels are marked bad quality. The controller sends the module configuration and the module begins
checking each channel. If the module detects a channel that is set up for an analog input and there are no other errors, the
module marks that channel good quality and begins checking the next channel.
5.3 Operation
Normal operation begins after the module completes the communication checks of all input channels. During operation, the
function code specifications can be tuned through a human system interface. Refer to the S+ Engineering for Harmony
Function Code Application Manual for more information on FC 222 (analog input).
NOTE: Online configuration changes which affect the mode of operation are not supported for FCs 222 and 133. A mode
change (reset) of the controller or module may be required for changes to take effect.
2VAA003057 A 5-1
Status Indicators Operating Procedures
5.4 Status Indicators

The AI modules have status LED indicators on the front panel to aid in system test and diagnosis. There are 10 LEDs - a
Run LED, a Fault LED and eight Operation and Diagnostic LEDs. The location of the LEDs are shown in Figure 5-1. During
normal operation, LEDs 1 through 6 are off and LEDs 7 and 8 are on.
Figure 5-1: Front Panel View
5-2 2VAA003057 A
Operating Procedures Status LEDs
5.5 Status LEDs

All S+ SD Series Analog Input modules have two LEDs (red/green) on their front panels that indicate module status.
The following table (Table 5-1) details the status LED states for the AI01 analog input module:
Table 5-1: AI01 module LED States
LED LED State Description
‘R’ - Run LED RED Module has halted or never established communication with a controller.
Refer to section 6- Troubleshooting of this user manual for details on
LED codes displayed on LEDS 1-8.
OFF Module has not been labeled.
BLINKING GREEN Module has lost communication with the controller.
SOLID GREEN Module is labeled and is communicating with the controller (normal
operation).
‘F’ - Fault LED OFF No fault condition present (normal operation).
BLINKING RED Power status fault (SA or SB).

or
Fault has been detected in the Field Power circuit (AI01 only).
SOLID RED Module fault has been detected.
‘1 - 6’ Diagnostic LEDS OFF Normal operation.
ON An error is detected. Refer to section 6- Troubleshooting of this user

manual for details on error code definitions (‘R’ LED also changes to
solid red).
‘7 - 8’ Diagnostic LEDS OFF Abnormal operation.
ON Normal operation (unless ‘R’ LED is solid red, then LED indicates an
error code).
operation).

solid red).
2VAA003057 A 5-3
Startup Procedures Operating Procedures
Table 5-2: AI03 module LED States (Continued)

error code).
operation).


solid red).
error code).
5.6 Startup Procedures

The controller controls the startup of the AI modules and is fully automatic. FC 221 in the controller configuration enables the
AI modules. Specification S1 of FC 221 is the I/O module address device label.
5-4 2VAA003057 A
Troubleshooting Introduction
6. Troubleshooting
6.1 Introduction
This section explains the error indications and corrective actions for the S+ SD Series Analog Input modules.
6.2 I/O Module Status Code LEDs

The eight status indicators on the front of the I/O module show both normal and error status codes. The status codes
appear in binary format.
NOTE: LED eight is the most significant bit.
The following table (Table 6-1) lists the various status codes and possible corrective actions:
Table 6-1: Status Codes
Code LED On Condition Corrective Action

0 0x00 – – – – – – – – Initializing Normal operation. No action required.
1 0x01 1 – – – – – – – Nonvolatile memory checksum error Initialize the module using the diagnostic port.
5 0x05 1 – 3 – – – – – Configuration error: undefined block Check the controller status. Verify the following in the
controller configuration:
• Function block inputs reference valid function block
outputs.
• Function block inputs restricted to specific function
code types are connected properly to function block
outputs.
6 0x06 – 2 3 – – – – – Configuration error: data type conflict Check the controller status. Verify the following in the
controller configuration:
• No data type mismatches for function block inputs.
• Constant specifications are within valid range limits.
10 0x0A – 2 – 4 – – – – Software error Contact ABB Tech Support.
17 0x11 1 – – – 5 – – – Nonvolatile memory write error Same corrective actions as error code 1.
19 0x13 1 2 – – 5 – – – Read-only memory checksum error Program image in read-only memory is corrupt.
Contact ABB Tech Support.
23 0x17 1 2 3 – 5 – – – Duplicate HN800 address Each I/O module is manufactured with its own unique
device ID. If this error occurs, then replace the
I/O module.
24 0x18 – – – 4 5 – – – Invalid block type Internal error. Replace the I/O module.
25 0x19 1 – – 4 5 – – – Firmware download in progress No action required(1).
26 0x1A – 2 – 4 5 – – – Duplicate device label detected Device label assigned to the module is already in use
by another I/O module. Define a unique device label.
35 0x23 1 2 – – – 6 – – Write violation Reset the I/O module. If error persists, then replace
49 0x31 1 – – – 5 6 – – Memory or CPU fault the I/O module.
50 0x32 – 2 – – 5 6 – – Bus error

51 0x33 1 2 – – 5 6 – – Illegal instruction
52 0x34 – – 3 – 5 6 – – Internal error - trace or privilege error
53 0x35 1 – 3 – 5 6 – – Internal error - spurious or unassigned
exception
54 0x36 – 2 3 – 5 6 – – Internal error - divide by 0 or CHK
instruction
55 0x37 1 2 3 – 5 6 – – Internal error - undefined TRAP
instruction
56 0x38 – – – 4 5 6 – – Board level hardware error Replace the I/O module.
62 0x3E – 2 3 4 5 6 – – MFT Timed out Reset I/O module. If error persists, then replace the
module.
2VAA003057 A 6-1
Error Messages and Corrective Action Troubleshooting
Table 6-1: Status Codes (Continued)
Code LED On Condition Corrective Action

63 0x3F 1 2 3 4 5 6 – – Normal stop Reset the I/O module.
64 0x40 – – – – – – 7 – Configuration downloaded Normal operation. No action required.
128 0x80 – – – – – – – 8 Normal operation (backup I/O module)
192 0xC0 – – – – – – 7 8 Normal operation (primary I/O module)
NOTE: – = off.
(1) If the firmware download is interrupted, for e.g. a power failure, then the module displays this code until the download completes. The
firmware download must be restarted using the same method (either through the S+ Engineering for Harmony tool or through the
diagnostic menu) that was used when the failure occurred.
6.3 Error Messages and Corrective Action

The status of the AI modules are available by checking the controller for good quality on its input blocks. Use any human
system interface such as a workstation running the S+ Operations software to observe the status. Refer to the appropriate
human system interface manual for the steps to call up the module status report (refer to Table 6-2).
The I/O device definition function code is responsible for problem reporting. The Symphony Plus Controller performs the
actual reporting.
The device problem report includes the following details to trace I/O module related problems:
• I/O device definition function block number (FC 221).
• Device label.
• Error type (refer to Table 6-2).
• The I/O channel problem report includes:
• Channel function block number (FC 222, 223, 224, or 225).
• Channel label.
• I/O device definition function block number (FC 221).
• Device label.
• Error type (refer to Table 6-2).
The following table (Table 6-2) details the I/O Module Problem Report:
Table 6-2: I/O Module Problem Reports
Error Type Description Corrective Action

Bad field power Device Field power problem. Check the condition of the power connector on
status the HBX0xL/VBX01T bus extender.
Check the condition of the power connector on
the HBS01-xxx/VBS01-xxx mounting base
(TB3).
If problem persists, then replace the I/O
module.
Bad HN800 Device No communication on the indicated Steps:
channel A or B HN800 channel.
1. Reset the I/O module.
2. Check the condition of the communications
connector on the bus extenders. If condition is
bad, then replace the I/O module.
3. Check the condition of connecting cables. If
condition is bad, then replace the cable.
4. Replace the I/O module, if problem persists.
6-2 2VAA003057 A
Troubleshooting Error Messages and Corrective Action
Table 6-2: I/O Module Problem Reports (Continued)
Error Type Description Corrective Action

Bad power Device Logic power problem for the Check the condition of the power connector on
input A or B indicated power input. the HBX01L/VBX01T bus extender.
Check the condition of the power connector on
the HBS01-xxx/VBS01-xxx mounting base
(TB3).
If problem persists, then replace the I/O
module.
Bad readback Channel Expected output and actual output Steps:
status are different.
1. Replace the I/O module, if failure in the
readback circuitry.
2. Replace the I/O module, if failure in the I/O
channel circuitry.
Bad reference Device Input from onboard reference Replace the I/O module.
status circuitry used for drift correction is
invalid.
Module Device Nonvolatile memory checksum or Initialize I/O module using the S+ Engineering
nonvolatile write error. for Harmony tool. If error persists, then replace
memory failure the I/O module.
Calibration Channel I/O module is out of calibration. I/O Replace the I/O module.
modules are factory calibrated.
Channel Channel Overvoltage or undervoltage Steps:
failure/out of condition exits for the indicated
1. Check configuration to verify proper range
range channel.
selection.
2. Check field wiring connections.
Cold junction Device Input from internal or external cold Steps:
reference junction reference used for
1. Replace the I/O base, if Cold junction
temperature compensation is
reference input from RTD onboard I/O base
invalid.
failed.
2. Check external CJC, field wiring, and
connections, if external cold junction reference
input failed.
Configuration Device Some type of error exists in the I/O Check the controller status. Correct any invalid
mismatch module configuration in the input references, data type conflicts, range
controller. errors, etc.
Duplicate label Device Controller detected a device label Redefine the device label for one of the
defined the same on more than one modules.
I/O module; duplicate device labels
are not permitted.
No response Device I/O module missing, not inserted Steps:
(offline) properly, or no power.
1. Verify I/O module is present and inserted
properly.
2. Verify the I/O module is powered up.
3. Reset the I/O module.
2VAA003057 A 6-3
I/O Module Status Troubleshooting
6.4 I/O Module Status

I/O module status information is reported to the Symphony Plus Controller where it is integrated into the controller’s status
report. Refer to the S+ Control: HPC800, Harmony Process Controller User Manual, S+ Control: SPC700 Symphony Plus
Controller User Manual, or S+ Control: Harmony Bridge Controller with Ethernet (BRC-410) User Manual for module status
report details. The I/O module includes the following types of status information in its report to the controller:
• HN800 communications (channel A and B).
• Configuration.
• Power.
• Local I/O.
Status information can be acquired directly from the I/O device definition function code and the I/O channel function codes
using FC 226 (test status). Refer to Test Status (FC 226) details in the S+ Engineering for Harmony Function Code
Application Manual for further description.
6.5 Diagnostics
The I/O module firmware contains various diagnostic routines to verify proper operation of components and circuitry. Some
diagnostic routines are run automatically during startup (online), while other diagnostic routines can be invoked manually
(offline).
6.5.1 Online
An I/O module runs the following online diagnostic checks during startup:
• HN800
• Data converters (D-to-A and A-to-D)
• I/O channel bus
• Memory
• Power status
• Voltage references
If any of these checks detect a hardware problem, then the I/O module provides error status code indications (if possible)
and the module halts. Refer to Table 6-1 to comprehend the status codes.
6.5.2 Offline
The offline tests can be run to verify operation of a suspect I/O module or to check module integrity after installation. The
offline diagnostics must only be run during installation or when the system is down.
6.6 Controller Errors

Verify that the label set in the module is the same as the label defined in FC 221, specification S1. If not, then:
1. Remove the module and change the setting of S1 to correspond with the module configuration (Refer to sub-
section 3.3- Setup and Physical Installation of this user manual for procedure details on how to set a label and to
install a digital input module).
- OR -
2. Modify the label in the module configuration FC 221, (specification S1) to correspond with the label set on S1.
Then, use a human system interface to modify the configuration (Refer to the appropriate human system
interface instruction for detailed procedures on how to modify a function code specification).
The controller generates a MISSING SLAVE MODULE error, if the HN800 bus is not connected between the I/O module
and the controller. Verify whether the bus connection is unbroken between the controller and the module, and if the TER810
terminator is properly installed in the bus extender.
6-4 2VAA003057 A
Troubleshooting Diagnostic Menu Operations
6.7 Diagnostic Menu Operations

You can perform the following actions on the I/O module using the Diagnostic menu:
• Label Module
• Firmware download
• Format NVM
Do not connect, disconnect, or use the USB diagnostic port unless area is known to be
non-hazardous.
NE PAS CONNECTER, DECONNECTER, OU D'UTILISER LE PORT DIAGNOSTIC USB

SAUF SI LA ZONE EST CONNUE POUR ETRE NON DANGEREUX.
Following are the required prerequisites to access the Diagnostic menu using the USB port:
• USB to mini-USB cable.
• PC with terminal emulator software installed that is capable of running Xmodem protocol (e.g. TeraTerm).
• USB to RS232 converter driver from Future Technology Devices International Ltd. (FTDI) FT232R.
Follow the given steps to access the S+ Diagnostic menu:
NOTE: The preferred method of formatting NVM or firmware download is through the S+ Engineering for Harmony tool.
1. Press the STOP/RESET button and wait for the module to display red light (i.e. STOP Code LEDs 1,2,3,4,5,6).
NOTE: The SD I/O module requires a Windows Combined Driver Model (CDM) interface driver, which can be
installed on most Windows platforms.
In some situations, Windows Update can be used to automatically locate and download the device driver for
this interface. If Windows Update is unable to locate the correct driver, then you can download the FT232R
interface driver from the manufacturer's web web site - http://www.ftdichip.com
Currently, the driver file is named as CDM v2.12.00 WHQL Certified.exe. The following application note (from
the manufacturer's web site) describes the driver installation procedure:
"Document Reference No.: FT_000160 FTDI Drivers Installation guide for Windows 7 Application Note AN_119
Version 1.0"
2. Configure the COM port to 115, N, 8, and 1 (115K baud, no parity, 8 data bits, and 1 stop bit) using terminal
emulation software.
3. Select no flow control.
4. Connect computer to the USB port on the module.
NOTE: The USB cable can be connected to the module when it is installed into a powered or un-powered
mounting base. Additionally, the USB cable can also be connected to a module that is not installed within a
mounting base, i.e. out-of-the-box. In this case, logic power for Diagnostic menu operations is provided from
the host PC through the USB cable. This feature allows Diagnostic menu operations to be performed away
from the enclosure where it can be more convenient to perform labelling, firmware downloads, etc.
Do not touch the edge connectors on the printed circuit board when the module is being powered
from a USB cable connection.
Do not insert a module, which has a USB cable attached into a powered or un-powered mounting
base. Make sure to ALWAYS remove the USB cable before installing a module to its base, and also
make sure to ALWAYS remove the USB cable before applying power to the base in which the module
is installed.
5. Press the STOP/RESET button and wait for the module start up to complete (LEDs 7, 8 are lit).
6. Enter any character until an asterisk (*) appears on the screen. This indicates that the port is ready to receive
instructions.
7. Enter the following text, 'S+' (uppercase letter 'S' followed by 'plus' sign) using hyperterminal emulation software
to startup the S+ General Operations menu.
8. Select an operation to perform.
2VAA003057 A 6-5
Diagnostic Menu Operations Troubleshooting
The following figure (Figure 6-1) shows a sample Diagnostic menu. The menu displays the label assigned to the
module and a list of available operations.
Figure 6-1: S+ Diagnostic menu
9. Remove the USB cable once you finish configuring the module.
Do not insert a module with an attached USB cable into a mounting base.
6-6 2VAA003057 A
Maintenance General
7. Maintenance
7.1 General
Following are some basic procedures for keeping all components of the S+ SD Series Analog Input modules in good
working condition:
• The operating environment must be clean and free of corrosive and conductive contaminants.
• The ventilation slots in the module housings should be kept clean and unclogged by dust to ensure proper cooling.
NOTE: Use a soft bristle brush to clean the slots when needed.
• For general cleaning, use a lint-free cloth and a mild, all-purpose, non-flammable, commercial spray cleaner to
remove dirt, fingerprints, and grease from the equipment.
NOTE: Spray the cleaner on the cloth and not directly on the equipment.
• Proper grounding procedures should be followed for electrostatic discharge (ESD) protection. Refer to sub-section
7.2- Special Handling of this user manual for more details.
7.2 Special Handling

Observe the following steps when performing maintenance activities:
1. Avoid touching the printed circuit boards edge connector.
2. Handle the module by holding the plastic housing.
NOTE: Do not hold the module using its mounting screw.
3. Use a grounded wrist strap whenever the module's top cover has been removed.
4. Use ABB's field static kit (part number 1948385x1) when working with the modules. The kit grounds the
technician and the static dissipative work surface to the same ground point to prevent damage to the circuitry by
electrostatic discharge.
5. Use an antistatic vacuum to remove dust from the assembly, if required.
6. Avoid touching the circuitry when the module cover has been removed.
7. Verify that all devices coming in contact with the printed circuit board are properly grounded.
8. Ground all test equipment.
7.3 Printed Circuit Board Cleaning

POTENTIAL ELECTROSTATIC CHARGING HAZARD.
Wipe dust with a damp cloth to avoid a potential electrostatic hazard.
AVERTISSEMENT - CHARGES DE DANGER POTENTIEL ELECTROSTATIQUE
ESSUYEZ LA POUSSIERE AVEC UN CHIFFON HUMIDE POUR EVITER UN DANGER

There are several circuit board cleaning procedures in this section. These procedures cover circuit board cleaning and
washing, cleaning edge connectors and circuit board laminate between edge connectors. Use the procedures that meet the
needs of each circuit board. Remove all dust, dirt, oil, corrosion or any other contaminant from the circuit board.
Perform all cleaning and handling of the printed circuit boards at static safe work stations. Always observe the steps in
section 3- Installation of this user manual when handling printed circuit boards.
Never clean electrical parts or components with live power present. Doing so exposes you to an electrical
shock hazard.
Wear eye protection whenever working with cleaning solvents. When removing solvents from printed circuit
boards using compressed air, injury to the eyes could result from splashing solvent as it is removed from the
printed circuit board.
2VAA003057 A 7-1
General Cleaning and Washing Maintenance
7.3.1 General Cleaning and Washing

If the printed circuit board needs minor cleaning, then remove dust and residue from the printed circuit board surface using
clean, dry, filtered compressed air or an antistatic field service vacuum cleaner.
NOTE: It is not required to remove the module cover to perform this operation. The module cover should only be
removed by an ABB Service personnel.
7.3.2 Module PCB Card Edge and Mounting Base Edge Connector Cleaning
Follow the given steps to clean the card edge and edge connector:
1. Use a solvent mixture of 80% isopropyl alcohol (99.5% electronic grade) and 20% distilled water.
2. Soak a lint-free cloth with the solvent mixture.
3. Work the cloth back and forth over the gold fingers on the module's PCB card edge and the contacts on the
mounting base's edge connector.
4. Repeat with a clean cloth that is soaked with the solvent mixture.
5. Dry the contact area by wiping with a clean lint-free cloth.
6. Do not energize the module or the mounting base until all liquid has evaporated.
Follow the given steps to clean tarnished or deeply stained contacts:

1. Use a nonabrasive eraser to remove tarnish or stains.
NOTE: Fiberglass or nylon burnishing brushes can also be used.
2. Use the 80/20 isopropyl alcohol/water solution during burnishing to minimize electrostatic discharge.
NOTE: Do not use excessive force while burnishing. Use only enough force to shine the contact surface.
3. Inspect the contacts after cleaning to assure no loss of contact surface.

4. Wipe clean with a lint-free cloth.
7.4 Checking Connections

NOTE: Power to the enclosure should be off while performing this preventive maintenance task.
There are exposed AC and DC connections inside the enclosure. These exposed electrical connections
present a shock hazard that can cause injury or death.
If input or output circuits are a shock hazard after disconnecting system power at the power entry panel, then
the door of the enclosure containing these externally powered circuits must be marked with a warning stating
that multiple power sources exist.
Check all signal wiring, power and ground connections within the enclosure to verify their integrity. When checking
connections, always turn a screw, nut or other fastening device in the direction to tighten only. If the connection is loose,
then it needs to be tightened. If the connection is tight, then the tightening action verifies that it is secure. There must not be
any motion done to loosen the connection.
NOTES:
1. Verify whether all power connections within the enclosure are secure.
2. Verify whether all field wiring connections to the bus extenders are secure.
7-2 2VAA003057 A
Repair and Replacement Introduction
8. Repair and Replacement

8.1 Introduction
This section explains the replacement procedures for the S+ SD Series Analog Input modules.
NOTE: There are no special tools required to replace an AI module.
8.2 Module Repair and Replacement

If the AI module is faulty, then replace it with a new module. Do not try to repair the module because the replaced
components can affect the module performance. System power may remain applied during module removal and
replacement.
Follow the given steps to replace a module:
1. Unscrew the module locking screw.
NOTE: The screw is spring loaded and it pop ups to indicate the module can be removed.
2. Pull the module out of the mounting base. (Refer to the removal procedure, if required.)
3. Configure the replacement module.
NOTE: Ensure that the label of the replacement module is the same as the original module.
4. Align the replacement module with the mounting base.

5. Insert the module into the mounting base.
6. Secure the module using the module locking screw.
7. Return to normal operation.
8.3 Horizontal Mounting Base Fuse Replacement Procedure

Follow the given steps to remove and replace the fuse in the HBS01-EPD and HBS01-FPH mounting bases: (Refer to
Figure A-4 for fuse location.)
NOTE: This procedure can be performed while the mounting base is installed on the DIN rail.
1. Remove the I/O power connector from the HBS01-xxx mounting base.
Once you remove the I/O power connector from the HBS01-xxx mounting base, the ‘F’ fault LED on the module
front cover blinks red.
2. Grasp the fuse in the HBS01-xxx mounting base using an appropriate hand tool (e.g., use the small, bent nose,
needle nose pliers), and pull the fuse out of the socket.
NOTE: Make sure not to apply more force than required when pulling the fuse out of the socket to avoid
breaking the plastic fuse housing.
3. Examine the socket from which the fuse was removed to note the pin orientation.
4. Use the same tool that was used to remove the fuse, to grasp the fuse, properly orient the pins, and then install
the fuse into the HBS01-xxx mounting base.
Use only approved fuses with proper current ratings. Refer to section 9- Spare Parts of this
user manual for fuse part number.
5. Reinstall the I/O power connector into the HBS01-xxx mounting base.
Once you reinstall the I/O power connector into the HBS01-xxx mounting base, the ‘F’ Fault LED on the module
front cover turns off.
2VAA003057 A 8-1
Vertical Mounting Base Fuse Replacement Procedure Repair and Replacement
8.4 Vertical Mounting Base Fuse Replacement Procedure

Follow the given steps to remove and replace the fuse in the VBS01-EPD and VBS01-FPH mounting bases: (Refer to
Figure A-5 for fuse location.)
NOTE: This procedure can be performed while the mounting base is installed on the DIN rail.
1. Remove the I/O power connector from the VBS01-xxx mounting base.
Once you remove the I/O power connector from the VBS01-xxx mounting base, the ‘F’ Fault LED on the module
front cover blinks red.
2. Remove the module from the mounting base.
3. Remove the fuse cover from the top of the mounting base to expose the fuse.
4. Grasp the fuse in the VBS01-xxx mounting base using an appropriate hand tool (e.g., needle nose pliers), and
pull the fuse out of the socket to avoid breaking the plastic fuse housing.
NOTE: Make sure not to apply more force than required when pulling the fuse out of the socket to avoid
breaking the plastic fuse housing.
5. Examine the socket from which the fuse was removed to note the pin orientation.
6. Use the same tool that was used to remove the fuse, to grasp the fuse, properly orient the pins, and then install
the fuse into the VBS01-xxx mounting base.
Use only approved fuses with proper current ratings. Refer to section 9- Spare Parts of this
user manual for fuse part number.
7. Replace the fuse cover and re-install the module.

8. Reinstall the I/O power connector into the VBS01-xxx mounting base.
Once you reinstall the I/O power connector into the VBS01-xxx mounting base, the ‘F’ Fault LED on the module
front cover turns off.
8-2 2VAA003057 A
Spare Parts Parts
9. Spare Parts
9.1 Parts
Order parts without commercial descriptions from the nearest ABB sales office. Contact ABB Automation for assistance in
determining the quantity of spare parts to keep on hand for your particular system.
EXPLOSION HAZARD
Substitution of components can impair suitability for Class I, Division 2.
AVERTISSEMENT: RISQUE D'EXPLOSION - SUBSTITUTION DE COMPOSANTS PEUT NUIRE A LA

CONFORMITE CLASSE 1, DIVISION 2
The following table (Table 9-1) lists the S+ SD Series I/O modules spare parts:
Table 9-1: Miscellaneous Parts
Part Number Description Product Image
SPKEY01 Edge Connector Key - package of 100.
1945820A15001 Fuse, 5A for Mounting base.
1949926A2 2-Pin clamping screw type Power Plug for

TB3 on Mounting Base.
Wire range: AWG # 30-12
Wire strip length: 5.0 mm (0.2 in)
Tightening torque: 0.4 N·m (3.5 lb·in) to
0.5 N·m (4.4 lb·in) maximum
1949920A11 16-Pin Plug-able clamping screw type

terminal header for TB1 and TB2 on
Mounting Bases (2 required).
Wire range: AWG #22-12, stranded or
solid, AWG #12 stranded
Wire strip length: AWG #12-22: 7.87 mm
(0.31 in), AWG #12 12.45 mm (0.49 in)
Tightening torque: 0.4 N·m (3.5 lb·in)
2VAA003057 A 9-1
Parts Spare Parts
Table 9-1: Miscellaneous Parts (Continued)
SPK800-xx HN800/CW800 communication bus cable.

The cable is used to extend the
communication bus between bus
extenders.
Where: ‘xx’= specifies cable length
0A = .5 meters
01 = 1 meter
02 = 2 meters
03 = 3 meters
04 = 4 meters
1949078A1 35 mm DIN Rail; Steel, 2 meters long.
SPK01B-xx1 Marshalling cable assembly; hooded

connector on one end and eight twisted
wire pairs on the other end. Cable exists
from bottom of cable hood. Two cables are
required per mounting base. Cable plugs
into TB1 and TB2 terminals on HBS01-xxx
mounting bases.
Where ‘xx’ = specifies cable length
04 = 4 meters
05 = 5 meters
06 = 6 meters
10 = 10 meters
SPK01T-xx2 Marshalling cable assembly; hooded

connector on one end and eight twisted
wire pairs on the other end. Cable exits
from top of cable hood. Two cables are
mounting bases.
Where ‘xx’ = specifies cable length:
04 = 4 meters
05 = 5 meters
06 = 6 meters
10 = 10 meters
9-2 2VAA003057 A
Spare Parts Parts
SPK02B-xx1 Marshalling cable assembly; hooded

connector on both ends. Cable exists from
bottom of both cable hoods. Two cables
are required per mounting base. Cable
plugs into TB1 and TB2 terminals on
HBS01-xxx mounting bases.
04 = 4 meters
05 = 5 meters
06 = 6 meters
10 = 10 meters
SPK02T-xx2 Marshalling cable assembly; hooded

connector on both ends. Cable exits from
top of both cable hoods. Two cables are
mounting bases.
04 = 4 meters
05 = 5 meters
06 = 6 meters
10 = 10 meters
DRMP-19 Horizontal DIN rail mounting panel for EIA

standard 19-inch rack enclosures. It is
used with MB810 mounting bases (for
mounting HPC800 controllers), CTB81x
bus extenders, ITU805 and PTU810
mounting bases (for mounting HAI805,
HAO805, and PDP800 modules). It
includes 1 piece of DIN rail mounted to a
rigid zinc plated steel panel. It also
includes 10 M5 screws and cage nuts for
mounting the bases using the panel
mounting lugs (optional).
DRMP-19 SD Horizontal DIN rail mounting panel for EIA

standard 19-inch rack enclosures. It is
used with SD I/O HBS01-xx mounting
bases, HBX01x bus extenders, and
MB7xx mounting bases (for mounting
SPC700 controllers). It includes 1 piece of
DIN rail mounted to a rigid zinc plated
steel panel. It also includes 10 M3 screws
and cage nuts for panel mounting the
bases (optional).
2VAA003057 A 9-3
Parts Spare Parts
1948900A2 DIN rail end stop.

It is used to prevent SD I/O and controller
mounting bases from sliding along the DIN
rail. One DIN rail end stop is used at each
end of the SD I/O or controller stick.
TER810 HN800/CW800 bus terminator
NOTE:
1. Mounting bases are not supplied with terminal headers (1949920A1) or marshalling cable assemblies
(SPK01-xx).
9-4 2VAA003057 A
Symphony Plus Mounting Bases Introduction
A. Symphony Plus Mounting Bases

A.1 Introduction
The S+ SD Series Analog Input modules can be inserted into the following three mounting bases, as shown in the following
table (Table A-1):
Table A-1: Mounting Base types
Base Module
HBS01-FPH or VBS01-FPH AI01 analog input module
HBS01-EPD or VBS01-EPD
HBS01-CJC or VBS01-CJC AI03 analog input module

AI04 analog input module
NOTE: The selection of the mounting base depends on the preferred method of powering field devices and physical
orientation of the modules.
Permanent damage will occur to AI03 and AI04 modules, if the modules are inserted into a powered
HBS01-FPH/VBS01-FPH or HBS01-EPD/VBS01-EPD mounting base. Use only the
HBS01-CJC/VBS01-CJC mounting base with these modules.
The mounting bases employ a flexibly wiring scheme, which allows either 16-pin, pluggable terminal strips or SPK01-xxx
cables to be used. Refer to section 9- Spare Parts of this user manual for part numbers for the terminal strips and cabling
options.
NOTE: Terminal strips and cables (for TB1 and TB2) are not supplied with mounting bases.
The HBS01-FPH/VBS01-FPH and HBS01-EPD/VBS01-EPD mounting bases also have a removable power plug (TB3) that
is used to supply power to field devices.
A.2 Power Supply

It is strongly recommended to use different power supplies to power ABB Symphony Plus module system components
and field equipment.
Logic Power is used to provide power supply to the module system components and Field (I/O) Power is used to provide
power supply to the field equipment.
Examples of system components include the Symphony Plus Controller (HPC800 or SPC700), Communication Interface
(PNI800) and SD I/O modules.
Examples of field equipment include transmitters, meters, etc.
The power supplies can also be configured in a redundant configuration using independent voting units.
The following figure (Figure A-1) shows a recommended power supply concept:
2VAA003057 A A-1
Mounting Base Labeling and Keying Symphony Plus Mounting Bases
Figure A-1: Recommended Power Supply Concept
A.3 Mounting Base Labeling and Keying

A rating label located on the side of the mounting base provides information on the power requirements, agency
certifications, and nomenclature details of the assembly. A second label located on the side of the mounting base contains
a serial number used by ABB for quality assurance purposes. These labels cannot be viewed when the mounting base is
installed to a DIN rail inside an enclosure. If information from these two labels is required, then the mounting base needs to
be removed from the DIN rail to view the information. A third label - mounting base ID label has been added to the assembly
to provide easier identification of the mounting base when it is installed in an enclosure. This label is located on the face of
the mounting base and is clearly visible when the mounting base is installed, and a module is not present in the mounting
base. This label shows an abbreviated version of its full nomenclature, for e.g. ‘FPH’.
Mounting bases can be used with more than one type of SD Series I/O module. This multi-purpose feature of mounting
bases simplifies the management of spare parts. However, there is a potential risk of a wrong module being plugged into a
mounting base to which it is not intended to be installed. The SD Series I/O system provides the following two methods to
prevent a wrong module from being plugged into a mounting base:
• Mounting base labeling: The SD Series I/O module type labels that are available from ABB are attached to the
mounting base directly under the mounting base ID label. When using a mounting base, attach the mounting base
ID label on to the mounting base. This label provides clear identification details of which module type can be
inserted into the mounting base.
• Mounting base keying: The SD Series I/O edge connector (refer to Figure A-2) accepts keys (part number -
‘SPKEY01’) which, when installed, prevent the insertion of an incorrect module type into the mounting base. Each
SD Series I/O module has a unique set of slots on its printed circuit board edge. These slots align with installed
connector keys to prevent the physical installation of a module into the wrong mounting base. Keys are supplied
with the mounting base assembly.
The following table (Table A-2) details the unique key sequence for each SD Series I/O module type:
Table A-2: Unique Key Sequence for SD Series I/O module type
Product
Description Key Slot 1 Key Slot 2
Nomenclature
AI01 SD Series 16 Channel High Level Analog Input Module with group 5 18
channel isolation.
AI02 SD Series 16 Channel HART Analog Input Module, with group channel 5 19
isolation and shared HART modem.
A-2 2VAA003057 A
Symphony Plus Mounting Bases Mounting Base Labeling and Keying
Table A-2: Unique Key Sequence for SD Series I/O module type (Continued)
Product
Description Key Slot 1 Key Slot 2
Nomenclature
AI03 SD Series 8 Channel RTD Input Module with group channel isolation. 13 20
AI04 SD Series 16 Channel Thermocouple and mV Input Module with group 13 20

channel isolation.
AI05 SD Series 8 Channel HART Analog Input Module with individual channel 6 19
isolation, and dedicated HART modem on each channel.
AO01 SD Series 16 Channel Analog Output Module with group channel 7 19

isolation.
AO02 SD Series 16 Channel HART Analog Output Module with group channel 7 19
isolation, and shared HART modem.
AO05 SD Series 8 Channel HART Analog Output Module with individual 8 19

channel isolation, and dedicated HART modem on each channel.
AD01 SD Series Analog/Digital Input/Output Module. 11 19
AD02 SD Series Analog/Digital Input/Output Module. 11 19
DI01 SD Series 16 Channel Low Voltage (24VDC/48VDC) Digital Input 9 15

Module with individual channel isolation, and SOE function.
DI02 SD Series 16 Channel High Voltage (125VDC/120VAC) Digital Input 9 15

Module with individual channel isolation, and SOE function.
DI03 SD Series 16 Channel Low Voltage (24VDC only) Digital Input Module 9 16
with individual channel isolation.
DI04 SD Series 16 Channel Low Voltage (48VDC only) Digital Input Module 9 16
with individual channel isolation.
DO01 SD Series 16 Channel Low Voltage (24VDC/48VDC) Digital Output 10 16

Module with individual channel isolation.
DO02 SD Series 16 Channel Low Voltage (24VDC/48VDC) Digital Output 10 16

Module with individual channel isolation, and built-in over-current
protection/detection and read back monitoring.
PI01 SD Series 8 Channel Pulse Input Module with individual channel 12 17

isolation.
2VAA003057 A A-3
Installing SD Series I/O edge connector keys Symphony Plus Mounting Bases
A.3.1 Installing SD Series I/O edge connector keys

The following figure (Figure A-2) shows location of labels and keying slots on horizontal mounting bases:
NOTE: Use this figure (Figure A-2) to determine the position in which to insert the keys on the SD Series I/O edge
connector. The keys are installed between the connector's contacts. Triangular indentations in the mounting base
plastic mark key slot locations. Larger triangles indicate the key slot locations 0, 5, 10, 15, 20, and 25.
Figure A-2: Key slots and mounting labels location on horizontal mounting base
A-4 2VAA003057 A
Symphony Plus Mounting Bases Installing SD Series I/O edge connector keys
The following figure (Figure A-3) shows location of labels and keying slots on vertical mounting bases:
Figure A-3: Key slots and mounting labels location on vertical mounting base
Follow the given procedure steps to install the connector keys:

Internal Field Power (TB3) and Field wiring (TB1 and TB2) to the mounting base must be
removed before installing connector keys.
The connector keys are small and can be easily lost. It is recommended to install these
keys immediately after unpacking the mounting base and before the mounting base is
installed into an enclosure. Do not install the keys to a mounting base that has the field
power active on it.
1. Identify the module type to be used with the mounting base.
2. Refer to the information given in Table A-2 to identify the proper keying sequence for the module.
3. Use the arrows on the mounting base (refer to Figure A-2) to identify the proper position on the connector.
4. Press in the key into the connector until it sits flush within the connector.
Use needle nose or clamping pliers to hold the keys during insertion.
5. Verify whether the module inserts fully into the mounting base.
NOTE: If the module does not insert fully into the mounting base, then re-check key locations. This step must
be performed using un-powered modules and bases.
2VAA003057 A A-5
6. Apply appropriate SD Series I/O module type label to the mounting base (if being used).
The following figure (Figure A-4) shows location of connectors on horizontal mounting bases:
NOTE: TB3 and F1 are not present on the HBS01-CJC mounting base.
Figure A-4: Location of connectors on horizontal mounting base
A-6 2VAA003057 A
The following figure (Figure A-5) shows location of connectors on vertical mounting bases:
Figure A-5: Location of connectors on vertical mounting base
The following figure (Figure A-6) shows the terminal numbering for field input signals on terminal blocks 1 and 2 (TB1, TB2):
Figure A-6: Terminal numbering for field input signals on terminal blocks 1 and 2
2VAA003057 A A-7
The following figure (Figure A-7) shows the terminal numbering for the internal field power wiring on terminal block 3 (TB3)
on the HBS01-EPD and HBS01-FPH mounting bases:
Figure A-7: Terminal numbering for internal field power wiring on terminal block 3 for horizontal
mounting base
TB3 on the HBS01-FPH and HBS01-EPD mounting bases is used to supply internal field power to the mounting base. The
HSB01-FPH mounting base always requires this connection, irrespective of internal or external field power being used. The
HBS01-EPD mounting base does not require this connection, if field devices are being powered using external field power
only.
The following figure (Figure A-8) shows the terminal numbering for the internal field power wiring on terminal block 3 (TB3)
on the VBS01-EPD and VBS01-FPH mounting bases:
Figure A-8: Terminal numbering for internal field power wiring on terminal block 3 for vertical
mounting base
A-8 2VAA003057 A
TB3 on the VBS01-FPH and VBS01-EPD mounting bases is used to supply internal field power to the mounting base. The
VSB01-FPH mounting base always requires this connection, irrespective of internal or external field power being used. The
VBS01-EPD mounting base does not require this connection, if field devices are being powered using external field power
only.
The following specifications are applicable to the TB3 connector (ABB part number 1949926A2):
• Wire range: AWG # 30-12
• Wire strip length: 5.0mm [.197"]
• Tightening torque 0.4Nm [3.5 lb-in] to .5Nm [4.4 ib-in] max
EXPLOSION HAZARD
Do not disconnect equipment unless power has been switched off or the area is known to be non-
hazardous.
AVERTISSEMENT: RISQUE D'EXPLOSION - NE PAS DECONNECTER L’EQUIPEMENT QUE

L'ALIMENTATION EST COUPEE OU QUE LA ZONE EST CONNUE POUR ETRE NON DANGEREUX
The following figures (Figure A-9 to Figure A-11) show the terminal assignments for the HBS01-FPH, HBS01-EPD, and the
HBS01-CJC mounting bases:
NOTE: The mounting bases have no user configurable switches or jumpers.
NOTE: Terminal assignments are the same for the VBS01-FPH, VBS01-EPD and HBS01-CJC mounting bases as
described for the horizontal mounting bases (HBS01-FPH, HBS01-EPD and HBS01-CJC).
2VAA003057 A A-9
Figure A-9: Terminal assignment for HBS01-FPH mounting base
Figure A-10: Terminal assignment for HBS01-EPD mounting base

A-10 2VAA003057 A
Symphony Plus Mounting Bases Mounting Base Wiring Examples
Figure A-11: Terminal assignment for HBS01-CJC mounting base
A.4 Mounting Base Wiring Examples

The following figures (Figure A-12 to Figure A-16) show typical wiring arrangements for the HBS01-CJC-, HBS01-EPD, and
HBS01-FPH mounting bases.
NOTE: Wiring arrangements are the same for the VBS01-FPH and VBS01-EPD mounting bases as described here for
the horizontal bases (HBS01-FPH and HBS01-EPD).
2VAA003057 A A-11
Mounting Base Wiring Examples Symphony Plus Mounting Bases
The following figure (Figure A-12) shows the terminals on the HBS01-CJC that are used to wire signals for both AI03 and
AI04 modules:
Figure A-12: HBS01-CJC Terminals
A-12 2VAA003057 A
The following figure (Figure A-13) shows 2, 3, and 4 wire RTDs wired to an AI03 module / HBS01-CJC mounting base pair:
Figure A-13: Using AI03 module and HBS01-CJC with 2, 3, and 4 Wire RTDs
The following figure (Figure A-14) shows HBS01-CJC mounting base wiring examples for wiring thermocouples used with
the AI04 module:
Figure A-14: Using AI04 module and HBS01-CJC with thermocouples
2VAA003057 A A-13
The following figure (Figure A-15) shows a 2-wire, 4-20mA transmitter (internal field power) wired to an AI01 module /
HBS01-FPH mounting base pair:
Figure A-15: Using AI01 module and HBS01-FPH with 2-wire Transmitters.
A-14 2VAA003057 A
The following figure (Figure A-16) shows a 4-wire, 4-20mA transmitter (voltage mode), a 2-wire, 4-20mA transmitter
(external Field power), and a 4-20mA transmitter (external Field power with channel fusing) wired to an AI01 module /
HBS01-EPD mounting base pair:
Figure A-16: Using AI01 module and HBS01-EPD with 2 and 4-wire Transmitters
2VAA003057 A A-15
A-16 2VAA003057 A
INDEX
INDEX
A I
I/O block
Abbreviations 4
Device label 2
Address switch (S1) 4 Electronic ID 2
Alarming 9
I/O Channel (FC 222, 223, 224, 225) 5
I/O Device Definition (FC 221) 4
C Indicators 2
Certifications 9 Input/output
Channel Label 3 Channel data 7
Checking Connections 2 I/O source 8
Cleaning Installation 3
Edge connectors 2 Intended User 3
Printed circuit boards 1
Configuration 1
L
Configuration Tools 1
Labels 2
Controller Errors 4
Channel 3
Controller Operation 1
Device 2
Controller or I/O Segment 4 Duplicate 3
CW800 4
LED
Status 2
D Logic Power 2, 1
Description and Operation 3
design standards 11
M
Device label 2
Dipswitch 1
Magnetic and electromagnetic fields 8
Maintenance 4, 1
Duplicate Labels 3
Manual Content 3
Module Description 1
E Module Repair and Replacement 1
Edge Connector Cleaning 2 Module replacement 1
Electromagnetic compatibility 8 Mounting Bases 3
Engineering Units (EU) 8
Environmental 9
N
Errors
Controller 4
Nomenclature 1
Establishing a Device Label 2
Exception Reporting 8 O
Online Configuration 3
F Operating Procedures 3, 1
Overview 1
Failure modes, outputs
Hnet stall mode 9
Features 3 P
Field (I/O) Power 2, 1 Parts 1
Firmware Download 2 Power Supply 2
Firmware download 2 Power System Status 4
Function code (FC) 4 Printed Circuit Board Cleaning 1
Function Codes 4
I/O channel 5 R
I/O device definition 4 Red/green LED 2
Test status 9 Reference Documents 5
Functional Operation 2 Related Nomenclature 6
Repair and Replacement 4, 1
G Replacement, module 1
General Cleaning and Washing 1
Glossary 4 S
S1 address switch 1, 4
H SD Series I/O edge connector keys 4
HN800 4 Setup and Physical Installation 1
HN800 Stall Mode 9 Shaping Algorithms 9
Specifications 6
Startup 1
Status LEDs 2
2VAA003057 A 1
INDEX
Status Reporting 9
Suspect Condition 7
Symphony Plus Controller 1
Symphony Plus Mounting Bases 1
T
Terms and abbreviations 4
Test status, FC 226 9
Time Synchronization 2
Troubleshooting 3, 1
U
unique key sequence 2
2 2VAA003057 A
ABB Inc. NOTICE
Document Number: 2VAA003057 A

Power Generation This document contains information about one or more
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reference to one or more standards that may be
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features of the described or referenced standard. In
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Copyright © 2015 by ABB.

All rights reserved.
Release: December 2015

2VAA003057 A en S IO SD Series Analog Input Modules AI01 AI03 AI04 User Manual

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2VAA003057 A en S IO SD Series Analog Input Modules AI01 AI03 AI04 User Manual

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Symphony Plus

S+ I/O: SD Series I/O

S+ I/O: SD Series I/O

Copyright © 2015 ABB.

Release: December 2015

Symphony™ Plus Trademark of ABB S.p.A.

About This Book ......................................................................................................5

2. Description and Operation............................................................................ 2-1

3. Installation ...................................................................................................... 3-1

3.3.2 Labeling the Analog Input Modules..................................................................3-2

4. Configuration ................................................................................................. 4-1

5. Operating Procedures ................................................................................... 5-1

6.4 I/O Module Status ................................................................................................6-4

7. Maintenance ................................................................................................... 7-1

8. Repair and Replacement ............................................................................... 8-1

9. Spare Parts ..................................................................................................... 9-1

A. Symphony Plus Mounting Bases ................................................................. A-1

Table 1-1: Glossary of Terms and Abbreviations .......................................................1-4

Figure 1-1: Symphony Plus I/O Architecture .............................................................. 1-1

Safety Precaution Description

GENERAL WARNINGS Equipment Environment

Electrical Shock Hazard During Maintenance

AVERTISSEMENT: RISQUE D'EXPLOSION - SUBSTITUTION DE

EXPLOSION HAZARD - Do not disconnect equipment unless power has been

AVERTISSEMENT: RISQUE D'EXPLOSION - NE PAS DECONNECTER

NE PAS UTILISER CONNECTEUR USB SAUF SI LA ZONE EST CONNUE

EXPLOSION HAZARD - Do not disconnect while circuit is ‘LIVE’ unless area is

AVERTISSEMENT: RISQUE D'EXPLOSION - NE DECONNECTEZ PAS

POTENTIAL ELECTROSTATIC CHARGING HAZARD - Wipe dust with a damp

POTENTIEL CHARGE ELECTROSTATIQUE DANGER - ESSUYEZ LA

Wear eye protection whenever working with cleaning solvents.When removing

There are exposed AC and DC connections inside the enclosure. These

About This Book

Information icon: It alerts the user to pertinent facts and conditions

Figure 1-1: Symphony Plus I/O Architecture

1.1.1 Mixed Symphony and Symphony Plus Systems

1.4 Intended User

1.5 User Manual Content

• Description and Operation

• Repair and Replacement:

• Appendix A: Symphony Plus Mounting Bases:

1.6 Using this Manual

1.7 Document Conventions

1.8 Glossary of Terms and Abbreviations

Table 1-1: Glossary of Terms and Abbreviations

CW800 High speed, redundant, peer-to-peer communication link. Used to transfer

EIA Electronic Industries Alliance.

Field Power (or I/O) Power needed for field signals.

FPGA Field Programmable Gate Array. It is an integrated circuit designed to be

FSR Full Scale Range.

Table 1-1: Glossary of Terms and Abbreviations (Continued)

Logic Power Power needed to run the module’s logic circuits.

SD I/O Symphony Plus DIN Rail I/O.

VDC Volts direct current.

1.9 Reference Documents

Table 1-2: Reference Documents

Document ID Document Title

2VAA001586 S+ Control: HPC800, Harmony Process Controller User Manual.

2VAA000720R0001 S+ Control: Harmony Bridge Controller with Ethernet (BRC-410) User

2VAA000844 S+ Engineering for Harmony Function Code Application Manual.

2VAA000812 S+ Engineering for Harmony Primary Interface Manual.

2VAA000813 S+ Engineering for Harmony Automation Architect Manual.

2VAA003056 S+ I/O: SD Series I/O - Digital Output Modules (DO01, DO02)