Month: April 2025

Introduction
EasyLine is both a powerful and affordable line of instruments for the monitoring of gas concentrations in numerous applications. EasyLine is based on the proven and reliable analyzer technology of ABB for extractive continuous gas analysis. EasyLine is available in two versions, which are optimized for the various installation requirements of the respective location.

Field of application and purpose: The Magnos28 oxygen analyser is used to monitor the oxygen concentration in safety-relevant systems and meets the safety requirements of IEC/EN 61508. This manual provides system planners, constructors and maintenance personnel with information and safety instructions for the integration of the analyser into safety instrumented systems.
Definition of standards and terms: The IEC 61508 standard is followed, defining terms such as hazardous failure, safety-related systems, and safety functions. Safety Integrity Levels (SIL) are classified as levels 1 – 4 and are determined by parameters such as Probability of Mean Failure (PFDAVG), Probability of Hazardous Failure per Hour (PFH), etc.

Models and scope of application: The EL3000 series (EL3020, EL3040) and the EL3060 series are available for general and hazardous areas (Zone 1, Zone 2), with single channel (1oo1) or redundant (1oo2) operation. The different models have corresponding catalogue numbers.

Safety functions and settings: The safety function of the analyser is to convert the oxygen measurement into a 4 – 20mA analogue current signal. Pressure variations can affect the measurement, either by setting the atmospheric pressure at the installation site in the device or by using the pressure signal to calibrate the measurement via an external PLC. Changes to the original configuration will alter the safety features, which must be changed and access codes activated after configuration to prevent misuse.
Maintenance and testing: At least once a year a verification test of the overall safety function is carried out, including calibration, relay testing, parameter setting and calibration data checking. Periodic check of analyser functionality, including calibration of measured values, simulation of failure modes, testing of digital outputs, etc., with variations for different communication configurations.

SIL compliance statement: ABB declares that the analyser (without flow and pressure sensors) complies with EN61508 (2010) part2. The SIL capability is level 2 for single-channel use and level 3 for redundancy, giving safety parameters and probability of failure in different operating modes, subject to the conditions of use.

Management summary
Result of the Determination of Safety Parameters for EL3020/3040/3060with Magnos28 The safety parameters of the oxygen analyzerEL3020/3040/3060 with Magnos28″including the elements SSI, AMC, AO2 or AO4, IO and sensor have been determined.(The safety parameters of AO2 and AO4 are similar. AO4 is used,because its (PFDavg) und PFH are higher.) The analysis of embeX comprises the changed parts of SSi; the parameters of the unchanged parts have been taken from the existing reports.

.For the analyzer Magnos28 for oxygen measurement the follwoing measurement ranges have been considered: smallest range O to 0.5 vol.%,standard range O to 25 vol.%, largest range O to 100 vol. %.The safety function of the device is the measured oxygen concentration as linear 4 …20 mA analogue current signal. A signal deviation of more than t5%full scale is considered as a dangerous failure. Current signals s 2.5 mA and >21.5 mA shall be interpreted by the control unit (e.g. PLC), which shall be connected in series, as analyzer failure.The fault relay, working in normally energized mode, is part of the safety function, because several internal faults are signaled by de-energizing the relay and not via the current output.”

ABB Advance OptimaAO2000 Series

ABB Analytical possesses decades of experience in the area of explo sion protection. 

This competence is unified with a unique portfolio based on the Advance Optima and EasyLine series.

Simplicity is key for safe operation in hazardous areas and ABB Ana lytical offers the right analyzer portfolio from extractive to in situ analyzers.

Independent if ATEX, IECEx, CSA, or further local approvals are needed 

for installation in plants with potentially explosive gas atmospheres in Zone 1 and Zone 2,

ABB is your one stop shop.

Advance Optima and EasyLine Two analyzer series fits all

With Advance Optima (AO2000 Series) and EasyLine (EL3000 and EL3060 Series) ABB offers a broad range of continuous gas analyzers for 

the measurement in hazardous areas. 

From simple measuring task up to complex and flexible system solution, these are all possible with the EL3000, AO2000 and EL3060.

Furthermore, a wide variety of different measuring technologies are available with all needed local certificates ex-works.

Zone 2 non-flammable gases / Class I, Div. 2 AO2000

Whole functionality and flexibility of the Advance Optima series is also available for Zone 2 installation, for measurement of non-flammable gases, 

or for Class I, Division 2 installation. 

There is no need for additional case purging, all the assemblies have been tested to ensure that they are non-incendive.

Protection concept

An AO2000 Safety Concept device is based on non-incentive

Ex nA electronic components and a simplified pressurized

encapsulation Ex pyb around the analyzer module Uras26,

Caldos25/27 and Magnos28

Smart purge concept

To separate the flammable gases from the Zone 2 environment, only the gas path will be purged and not the whole housing. 

This lowers the purge gas consumption to a minimum.

The Uras26 uses a special safety cell where only the windows of the measuring cuvette are purged by inert gas (e.g. N 2 ).

The purge gas pressure is kept slightly above the sample gas pressure, this prevents the sample gas from escaping into the purge gas path.

The analyzers Caldos/Magnos are purged by using the same procedure. 

Only the measuring chambers in the thermostat housings are purged. 

The sample gas is fed directly from the external connections into the measuring chamber, so that encapsulation from the electronics is also provided here.

Smart monitoring concept

With the Safety Concept, the monitoring system for the Ex p protection is part of the system software.

There is no need to use external purge controller and alarms will be generated. Furthermore, the system can be continuously monitored via networks,

 offers digital alarm contacts and error messages, also as e-mail,

 SMS or can be connected to the asset management software “AnalyzeIT Explorer”

Models and features for different zones

Zone 2 (non-flammable gases)/Class I, Div. 2 (AO2000): based on non-excited Ex nC electronics, encapsulated in IP54 enclosure, 

without additional purge system. Available with modules such as Uras26, 

Magnos28 and Caldos25/27 in 19’ drawer and wall mounted housings for integrated control and monitoring and ease of operation.

Zone 2 (flammable gases) AO2000 ‘Safety Concept’: Reduced purge gas consumption with non-excited Ex nA electronics and simplified pressurised encapsulated Ex pyb, purge gas only circuit. The monitoring system is integrated in the software, 

eliminating the need for an external purge controller and allowing remote monitoring.

Zone 1 / Class I, Div. 2 (AO2000 – LS25): In-situ measurement for harsh conditions and fast process control. Installation in Zone 1 etc.

 is possible based on the explosion-proof design with limitation of light radiation Ex op is. Flexible components for high temperatures, 

high pressures, dusty and corrosive gases.

Zone 1 (AO2040 – Fidas24 Ex): Designed around the standard AO2040 housing for the measurement of total hydrocarbons. Based on a pressurised encapsulated Ex pxb and intrinsically safe Exib display and control unit, it does not require complex installation and separate certification,

 and can be purged with instrument air.

Zone 1 (EL3060): Combines the measurement performance of the Advance Optima series with the simplicity of the EasyLine series. 

It features an Ex db control unit and an additional Ex eb junction box, allowing a wide range of analyser modules to be combined for ease of operation.

Zone 2 (EL3040): For the measurement of non-flammable gases in hazardous area Zone 2. Based on non-sparking Ex ec electronics, 

encapsulated in an IP65 enclosure, eliminating the need for an additional purge system. Simple configuration, integration and operation, 

control of external solenoid valves, support for a variety of communication protocols.

Analyser module technical parameters: Uras26 for a wide range of infrared reactive gases; Magnos28 for oxygen measurement with high accuracy; electrochemical O2 Sensor for low-cost measurement of oxygen; Fidas24 for the detection of hydrocarbons with good stability; 

Caldos25 for highly corrosive environments; Caldos27 for a wide range of measurements and a fast response; LS25 in-situ laser 

The LS25 in-situ laser analyser is designed to operate in harsh conditions.

ABB EL3020 EL3040 Continuous Gas Analyzers

Specification

Measurement techniques and ranges: 

The analysers include a variety of measurement techniques, 

Uras26 infrared photometer is based on the principle of non-dispersive infrared absorption, and can measure CO, 

NO and other gases, with measurement ranges such as CO from 0 – 100 ppm to 0 – 100 vol.%, etc.; 

Limas23 ultraviolet photometer adopts different methods to measure NO, NO 2, and SO 2, and the measurement ranges are also different.

Stability index: each analyser has different performance in stability, 

Uras26 linearity deviation ≤1% of span, repeatability ≤0.5% of span, zero drift ≤1% of span per week, etc.; 

Limas23 linearity deviation ≤1% of span, repeatability ≤0.5% of span, zero drift ≤2% of span per week for NO week, etc.

Response time and calibration: Warm-up time and 90% response time are different, 

Uras26 warm-up time without thermostat is about 30 minutes, 90% response time T90 ≤ 2.5 seconds;

 calibration methods are automatic, manual and external control, 

automatic calibration is commonly used in built-in calibration cell or single-point calibration.

Electrical interfaces and gas connection: Equipped with Ethernet, Modbus, 

Profibus and other electrical interfaces, as well as a variety of I/O modules; gas connection methods, different models of analysers with different gas inlet, 

outlet and connection interface.

Other specifications: 19-inch rack-mountable (EL3020) and wall-mountable (EL3040) housings, with protection ratings of IP20 and IP65;

 power supply requirements of AC 100 – 240V and DC 24V, etc., with different power consumption for different analysers.

Technical features

Multi-measurement technology integration: Adopting a variety of advanced measurement technologies to accurately detect different gas characteristics 

and meet the needs of complex gas composition monitoring.

Powerful Measurement Functions: One instrument can measure up to five sample compositions, with a wide range of flexible adjustments, 

and can also be combined with different analysers to meet special measurement requirements.

Convenient operation and maintenance: automatic calibration function, which can be initiated based on time, external signals or Modbus, 

simplifies the calibration process; self-monitoring function prompts maintenance needs in time.

Flexible configuration and communication: A variety of electrical interfaces are provided to facilitate communication 

and data transmission with external systems; parameters can be set through 

the configuration software to achieve analogue output and digital input/output functions.

Reliable safety performance: high protection level of the shell, adapt to different installation environments;

 through a variety of safety certifications, in line with European and other regional standards, some models have explosion-proof design.

Additional models

EL3020-HC (Highly Corrosive Gas Specific): On the basis of the original, for highly corrosive gas environment, 

using more corrosion-resistant materials, optimising the gas circuit design, 

enhancing the resistance to corrosive gases, suitable for chemical, metallurgical and other industries containing highly corrosive gas monitoring scenarios.

EL3040-EX (Enhanced Explosion-proof): 

Enhanced explosion-proof performance to meet the requirements of higher explosion-proof level in hazardous areas, 

adopting special explosion-proof design and materials to ensure safe and stable operation in flammable and explosive environments, 

which can be used for gas monitoring in hazardous areas such as petroleum and natural gas extraction.

Application Scenarios

Monitoring in the energy sector: Gas analysis is crucial in the production and use of energy. In the petrochemical industry, the Fidas24 flame ionisation detector measures hydrocarbon content and is used to monitor the gas composition in crude oil processing and natural gas transmission to ensure safe and efficient energy production and transmission. In thermal power generation, by monitoring the oxygen content in the combustion process, the combustion efficiency can be optimised, energy consumption can be reduced, and power generation efficiency can be improved.

Gas quality detection: In the process of gas production and storage, the quality of gas needs to be strictly controlled.ZO23 trace oxygen analyzer is used to measure the trace oxygen in pure gas, to ensure that the quality of high purity gases used in the electronic industry meets the requirements, and to avoid the performance and quality of electronic products being affected by impurity gas. During the storage and transport of gases, by monitoring the composition of gases, problems such as leakage can be detected in time to ensure the safety of gas storage and transport.

ABB EasyLine EL3000 Series Continuous gas analyzers

Overview of the gas analyzers

Measuring technology (analyzers)

The following analyzers are available for selection:

• Uras26 infrared photometer

for the measurement of infrared-active gas components,

e.g. CO, NO, SO 2

• Limas23 ultraviolet photometer

for the measurement of NO, NO 2 and SO2

• Magnos206 oxygen analyzer

for the measurement of O2 in process gas or in N 2

• Magnos28 oxygen analyzer

for the measurement of O2 in process gas or in N 2

• Magnos27 oxygen analyzer

for the measurement of O2 in flue gas or in N 2

• ZO23 trace oxygen analyzer

for the measurement of O2 in pure gases (N 2, CO 2, Ar)

• Caldos27 thermal conductivity analyzer

for the measurement of binary gas mixtures with different

thermal conductivity, e.g. Ar in O2, H 2 in Ar, CH4 in N 2

• Fidas24 flame-ionization detector

for the measurement of hydrocarbons

• Electrochemical oxygen sensor

for the measurement of O2

Magnos206 and Magnos28 can also be used in combination with

Uras26 or Limas23.

Magnos27 and Caldos27 can also be used in combination with

Uras26.

Fidas24 and ZO23 cannot be used in combination with one of the

other analyzers.

The electrochemical oxygen sensor can only be used in combination with Uras26 or Limas23. 

Two electrochemical oxygen sensors can be used in combination with Uras26 with separate gas paths (only in model EL3020).

Each analyzer has one physical measurement range per sample component. 

A section of the physical measurement range can be mapped to the current output (analog output) by on-site configuration.

Calibration is always executed in the physical measurement range. 

The permissible measurement range limits are given by the specification of the smallest and largest measurement ranges for the individual analyzers.

A total of up to five measurement components can be measured with one gas analyzer.

Calibration

Calibration can be performed automatically or manually or exter-

nally controlled via the Modbus.

Automatic calibration for all sample components together is normally started on a cyclically time-controlled basis; 

it can also be started by an external control signal or via the 

Modbus as well as manually on the display and operator control unit of the gas

analyzer.

Normally, simplified calibration methods with the built-in calibration cells or the socalled single-point calibration are used for automatic calibration. 

If calibration with test gases is required the control of solenoid valves for switching on five test gases, 

zero gas and sample gas via digital outputs can be configured

Measurement techniques and ranges

Uras26 Infrared Photometer: Based on the principle of non-dispersive infrared absorption, with 1 or 2 beam paths,

it is possible to measure a wide range of gases such as CO

CO2 and other gases. Minimum measuring ranges e.g. 0 – 100 ppm for CO, 

number of measuring ranges 2, freely adjustable within the specified range, special versions for air separation units.

Limas23 UV-photometer: UV-RAS and NDUV method for NO, NO 2 and SO2, up to 3 components, 

with adjustable measuring ranges, e.g. 0 – 50ppm to 0 – 5000ppm for NO.

Oxygen analyser series: Oxygen analysers Magnos206, Magnos28, Magnos27 and ZO23 measure oxygen content based on different principles. 

The measuring ranges can be adjusted, e.g. 

Magnos206 and Magnos28 have a minimum measuring range of 0 – 2 vol.% O2Magnos27 has a measuring range of 0 – 10 vol.% O2, 

and ZO23 can be adjusted from 0 – 1 ppm to 0 – 250,000 ppm O2.

Other analysers: the Caldos27 thermal conductivity analyser for binary gas mixtures, 

the Fidas24 flame ionisation detector for hydrocarbon measurements 

and the electrochemical oxygen sensor for oxygen measurements each have their own specific measurement ranges and application scenarios.

Stability and influencing factors

Stability indexes: Each analyser has different performance in terms of stability, 

such as Uras26 with linearity deviation ≤1% of span and repeatability ≤0.5% of span; 

Limas23 with linearity deviation ≤1% of span and repeatability ≤0.5% of span, etc. 

These indexes reflect the measurement results of the analysers, such as the Uras26 with linearity deviation ≤1% of span and repeatability ≤0.5% of span. 

These indicators reflect the reliability of the analyser’s measurement results.

Influencing factors: Flow rate, temperature, air pressure and other factors will affect the measurement. 

For example, Uras26 is within the detection limit of flow rate in the range of 20 – 100l/h; Limas23 is within the permissible range of ambient temperature, 

with zero point ≤1% of span per 10 °C, and sensitivity ≤1.5% of measured value per 10 °C.

ABB Drive contactors Type DA & EHDB

Description

Type DA

• 60 amps size

• 500 volt DC ratings

• 160 and 300 volt DC normal closed

ratings for dynamic braking

• Low energy auxiliary contacts available

(17V, 5mA)

• Mechanically interlocked version available

for reversing applications

Product Overview
DA Series: 60A rated, 500V DC rated, 160V and 300V DC normally closed dynamic braking ratings,
2-pole (2-pole normally open) and 3-pole (2-pole normally open, 1-pole normally closed) options, auxiliary contacts available, double-break design,
DIN-rail mounting, 85%-110% of rated control voltage range, UL and CSA listed.
EHDB Series: Rated 220 – 960A, available in 2 pole (2 normally open) and 3 pole (2 normally open, 1 normally closed),
600V DC turning capacity and 300V DC breaking capacity, 1 normally open, 1 normally closed auxiliary contact as standard,
extractable coil on some models for reversible applications, double break and interrupting chamber design, 85%-110% rated control voltage range,
UL and CSA listed. UL and CSA listed.

Technical Data
DA Series: Normally open mains 60A (500VDC), Normally closed poles with different current values at different voltages,
Connection wire sizes 8 – 1 AWG, Mechanical life of 5 million cycles, Electrical life of 1.5 million cycles,
Operational frequency of 600 cycles/hour, Coils with different power consumption and action times, Weight approximately 2.4 lbs,
Operating temperature -25°C to 50°C.
EHDB Series: Varying models with normally open main poles 220 – 960A (600VDC),
normally closed poles with varying parameters, connecting wire sizes from 8 – 30 to (3) 2 – 600 kcmils, 5 million cycles mechanical life,
1.5 million cycles electrical life, 300 cycles per hour operating frequency, coil power consumption and action times vary by AC and DC,
weight 9.2 – 38 lbs. Operating temperature -40°C to 70°C.

ABB automatic transfer switch technical characteristics
Safe and reliable changeover mechanism:
The changeover mechanism is equipped with three stabilising positions,
which effectively isolate the two asynchronous power sources,
fundamentally eliminating the risk of short-circuiting between
the power sources and ensuring safety even in complex situations where transient voltages exist.
The switch is set up for both manual and automatic operation modes and can be locked in a variety of ways to prevent misuse.
In case of emergency, manual operation is not limited by the power supply, guaranteeing operational reliability.

Advanced Control Unit Functions:
The OMD series control unit is feature-rich and can clearly display various system statuses, including line status,
switch positions, alarm messages and operation modes. Users can conveniently configure them,
and the OMD800 is equipped with an LCD display that supports eight languages, which greatly facilitates the use of users in different regions.
The control unit can accurately measure various parameters of the power supply,
such as three-phase and single-phase voltage, frequency, etc., and can flexibly set voltage thresholds, frequency thresholds,
and a variety of time delay parameters to meet the needs of different application scenarios.

Wide application adaptability:
The products cover a wide range of current sizes from 160 to 1600 amps, which can be adapted to equipment and systems
with different power requirements. The rated insulation voltage, operating voltage and other electrical parameters comply with a variety of standards,
and can be used in industrial plants, terminals, airports, data centres and other places that require high reliability of power supply,
providing a stable power switching solution for all kinds of complex environments.

Automatic Transfer Switches

Growing importance of a secure power supply
ABB’s range of automatic transfer switches goes from 160 to 1600 Amperes.
There are three types of ATSs with three different OMD control units: OMD200, OMD300 and OM800.
ABB’s ATSs have the features and functionality that makes them suitable for diverse applications:industrial plants, docks, airports and data centers.
Safe and reliable operation
The change-over mechanism has three stable positions,which ensure isolation of the two asynchronous power supplies.
No risk of short circuit between the sources, even in the presence of transient voltages
The switch has a selector to choose between manual and automatic operation.
Automatic operation is disabled by padlocking the latch or by fitting the handle.
Both manual and automatic operation can be prevented by padlocking the handle in O position.
Unwanted operation prevented Manual operation is always possible in emergency situations, even without electricity.
All-time safe and reliable operation

Easy installation
The design of ABB automatic transfer switch is advanced and compact.
The OMD control unit can be adjusted according to the depth of the panel and the voltage sensing kit is installed at the factory.
Reduce installation cost and time
The motor operator of the ATS is protected by a fuse. If the operation frequency is exceeded, the fuse protects the motor.
No more expensive repair work
It is also possible to purchase the control units and motorized change-over switches as separate components, so the users can build the automatic transfer switch by themselves if desired.
User friendly interface
The panels of the OMD control units show the status of the system clearly: line status, switch position, alarms and operation mode (manual or automatic).
The OMD can be configured in an easy way.
OMD800 shows the information on a LCD display, with menus available in eight languages.
Simplicity of usag

How to choose the right ABB automatic transfer switch model according to the actual demand
Determine the electrical parameters:
According to the actual power and current of the equipment, confirm the required rated current, rated voltage, rated insulation voltage,rated thermal current
and other parameters.
For example, if the rated current of the equipment is 160A, you can consider OTM160 series; if the working voltage of the equipment is 208-415V AC,
you need to choose the model with the corresponding voltage range.
Considering the functional requirements:
If you want to monitor the line voltage, frequency and other parameters in real time,
you need to choose a model with corresponding measurement functions,
such as OTM_C2D_, OTM_C3D_, OTM_C8D_ series have voltage and frequency measurement functions.
When the requirements for power failure detection are high,
it is necessary to pay attention to whether the detection functions of under-voltage, over-voltage,
phase loss and voltage unbalance meet the needs, and these functions are available in all three series.
If you need to configure the parameters flexibly,
you can choose the model that meets the requirements of the configuration method, such as the OTM_C8D_ series,
which can be set with various parameters through the keyboard and LCD.
Combined with the application scenario:
In industrial plants, data centres and other places with high requirements for continuity of power supply, the reliability and switching speed of the switches should be emphasised,and models with stable performance and short switching times can be selected.

When connecting transformers and generators, it is necessary to consider whether the switch supports such application scenarios.
The relevant series of products in this document are all suitable for switching between transformers and generators.
Pay attention to the installation conditions: Select the right size switch for the installation space,
refer to the dimensioned drawings in the documentation.
If the installation space is limited, choose a compact model. Consider compatibility with other equipment,
including electrical interfaces, communication protocols, etc., to ensure seamless connection to existing systems.
Weigh the cost of the budget: the price of different models varies,
under the premise of meeting the needs, compare the price of different models and choose a cost-effective product.
Consider the later maintenance costs, such as accessory replacement costs, repair difficulty, etc.

ABB DCS 600 MultiDrive ABB DCS 600 MultiDrive Thyristor Power Converters Series

Electrical Specifications

Power supply parameters: The power supply of the electronic equipment has various specifications such as 115V/230V, 

which need to be matched with the corresponding transformer; 

the rated voltage of the armature circuit converter power supply and the excitation power supply unit need to satisfy the specific conditions, 

or else measures need to be taken. 

There is no special phase sequence requirement for the main power supply connection,

but an isolation transformer should be installed when using oscilloscopes to achieve potential isolation and avoid ground loops.

Motor-related parameters: 

The motor voltage and the excitation voltage are calculated differently for different models of DCS 600. 

For example, for the DCS 601, the maximum motor voltage U Amax = line voltage * 1.16 (2 – quadrant unit);

 the excitation voltage is calculated according to different standards for different excitation power supply units. 

In addition, parameters such as rated motor current and rated motor field current are involved for the relevant control and monitoring.

Control specifications

Control functions: Various control functions are available, e.g. the emergency stop function is set via binary input DI5 

and different stop modes and ramp times can be selected. 

The software is divided into two parts, SDCS – CON – 2 and SDCS – AMC – DC. 

The internal signal connections for data transfer via automatic and programmable channels cover the transfer of a wide range of parameters and the realisation

of functions.

Parameter setting: Numerous parameters are used to set and adjust the operating status  of the device, such as setting the rated value parameters (rated line voltage, rated power converter current, etc.), 

control mode parameters (selection of modes such as speed control, torque control, etc.), 

and controller parameters (parameter adjustment of current controllers, speed controllers, EMF controllers, etc.).

Communication specifications

Communication interface and protocol: 

When communicating with a variety of devices, there are requirements for hardware connection and software settings. 

For example, to communicate with APC, YPQ112B board is used, cable length is 0.2-20m,

 plastic optical fibre, and specific parameters are set by software; to communicate with Profibus, NPBA02 board is used, 

and corresponding parameters need to be set by software, and attention should be paid to the data updating and consistency checking before communication.

Communication Parameters: The parameter settings are different in different communication modes, 

such as module type, mode, driver number, bit rate and other parameters for Profibus communication; 

Modbus PLUS communication requires setting module type, mode, driver number and various data-related parameters.

Other specifications

Safety related: There is an emergency stop button, and the operation should follow the relevant safety regulations. 

Electrostatic discharge may damage the equipment, should take appropriate protective measures.

Environmental conditions: equipment storage and transport to meet certain environmental conditions,

 operation of the environment temperature, humidity, altitude and other requirements to ensure the normal operation of the equipment .

Technical characteristics

Diversified control functions: support a variety of control modes, such as speed control, 

torque control and excitation mode, which can meet the needs of different industrial applications. 

With automatic adjustment function, such as current controller and excitation current controller can be automatically tuned, 

which can adapt to different motor and load characteristics and optimise the control performance. 

The control mode and characteristics can be flexibly adjusted by setting different parameters, such as setting the speed feedback mode (analogue tacho, encoder or EMF signal), adjusting the controller parameters (KPS, TIS, etc.) to optimize the control response.

Strong communication capability: it can communicate with various devices, such as APC, AC 70, AC 80, FCI, Profibus, Modbus PLUS, CS 31, etc., adapting to different industrial automation system architectures. Adopting plastic optical fibre and other communication media, the transmission speed is fast, for example, the transmission speed can reach 4Mb when communicating with AC 70, AC 80 and so on. Flexible communication settings, different devices need to set the corresponding parameters for communication, such as node type, driver number, communication protocol-related parameters, etc., to ensure stable communication.

Perfect protection mechanism: It is equipped with various fault detection and protection functions, 

which can detect over-current, over-voltage, under-voltage, over-speed, ground fault, motor overload, 

overheating and other faults, and send out signals in time to take corresponding protection measures, 

such as cutting off circuits, alarms, etc., to protect the safety of equipments and personnel. 

Fault signals and alarm signals are abundant, through the control board seven-segment display and control panel LCD display,

 it is easy for operators to find and deal with the problem in time, and some of the faults can be restored through the reset operation.

Flexible parameter adjustment: A large number of parameters are provided for equipment setting and optimisation, 

covering motor parameters, power supply parameters, control parameters, etc.,

 which can be precisely adjusted according to the actual application requirements to adapt to different motors and working scenarios.

 Parameters can be set in various ways, through the control panel CDP 312 or PC programme DRIVES WINDOW, easy to operate, and in the case of replacement of control boards, 

etc., there is a corresponding parameter saving and setting process.

Reasonable software structure: the software is divided into two parts, 

SDCS-CON-2 and SDCS-AMC-DC, which are processed by different processors, 

and the internal signal uploading and data transmission through the automatic and programmable channels ensures 

the co-ordinated work of all parts of the equipment. The software is equipped with a version identification function,

 which allows the software version to be viewed through the parameters, facilitating management and maintenance,

 and checking the compatibility of the software version when parameters are uploaded and downloaded.

Application Scenario

Industrial motor drive: In all kinds of industrial production, it is commonly used to drive DC motors, such as those in machine tools,

 textile machinery, printing machinery and other equipment. It has various control modes, such as speed control, torque control and excitation mode, 

which can accurately adjust the speed and torque of the motor according to the operating requirements of different equipment, ensuring stable operation of the equipment. 

In the process of machine tool machining, according to the requirements of machining process, the speed control mode can precisely adjust the motor speed to ensure the machining accuracy; in the textile machinery, the torque control mode can ensure the stable conveying of yarn under different tensions.

Automation production line: It is suitable for driving various equipments in automation production line, 

and connecting with automation control system (e.g. APC, AC 70, AC 80, etc.) through various communication modes 

(e.g. Advant, Profibus, Modbus PLUS, etc.) to realise remote control 

and monitoring of equipments. In the automobile production line, DCS 600 can control the motors of robotic arms, 

conveying devices and other equipment, and accurately control the motor movements according to the instructions of the production process,

 so as to improve the production efficiency and the degree of automation.

ABB BSD Brushless Servodrives

Precautions for operation

Danger

1. Never touch components inside the servo amplifier as you may receive an electric shock. 

2. Make sure to ground the grounding terminals of the servo amplifier and the servomotor or you may receive an electric shock. 

3. Perform wiring and inspection after waiting 5 minutes after shutting off the power or you may receive an electric shock. 

4. Do not damage cables, subject them to undue stress, put any heavy object on them or pinch them as failure, damage or electric shock may result. 

5. Do not touch the rotating part of the servomotor during operation as you may be injured.

Caution 

 1. Use the specified combination of the servomotor and the servo amplifier or fire or failure may occur. 

 2. Do not use the system in a place where it is exposed to water, a corrosive atmosphere or flammable gas atmosphere, or beside a flammable item as fire or failure may result. 

 3. Be careful as the temperature of the servo amplifier, servomotor and peripheral devices is high and may cause burns. 

4. Do not touch the radiator of the servo amplifier, the regenerative resistor and the servomotor during power supply or soon after shutoff because they will be hot and may cause burns. 

5. When the surface temperature of the servomotor exceeds 70°C for the final product during operation of the servomotor, affix a caution label indicating its high temperature. 

Precautions for transportation

Caution

Do not hold the cable or the motor shaft during transportation as failure or injuries may result.

Compulsory

1. Overloading of products may result in the collapse of piles. Observe the instructions.

2. Use the servomotor eyebolt only for transportation of the servomotor not for transportation of the machine as failure or injuries may result.

Precautions for installation

Caution

1. Do not ride on the servomotor or put a heavy object on the servomotor as failure, damage, electric shock or injuries may result.

2. Close the exhaust opening to prevent entry of foreign matter or fire or electric shock may result.

3. Make sure to observe the installation directions or fire or failure may result.

4. Maintain the specified distance between the main unit and the control panel or other devices or failure may result.

5. Do not subject to strong impact or failure may result.

Compulsory

1. The servomotor shaft thru-hole is not waterproofed or oil-proofed.

Take necessary precautions for the machine to prevent entry of cutting oil into the servomotor or failure may result.

2. If the system is used in an environment where the servomotor is exposed to many water drips or oil drips, take precautions including a drip cover over the machine.

The servomotor itself can be subjected to a few splashes without serious consequences.

In an environment where there is much humidity or oil mist, perform wiring so that lead wires and connectors face downward or failure may result due to poor insulation or short-circuit.

3. Never modify the servomotor as a fire or failure may result.

Servo Motor Specifications

Low inertia series (3000r/min, 0.1 – 0.75KW): rated output from 0.1kW to 0.75kW, rated torque range 0.318 – 2.39N・m, maximum torque 0.955 – 7.17N・m, rated speed 3000r/min, maximum speed 5000r/min, moment of inertia between 0.0371×10 The moment of inertia is between 0.0371×10-⁴ – 0.853×10-⁴kg・m², the rated current is 0.85 – 4.8A, the maximum current is 2.55 – 14.4A. Protection class IP67 (except shaft seals and connectors), 17 bit serial encoder, insulation class B, continuous rated operation. Static friction torque, attraction time, release time and power consumption of motors with brake are also available.

Medium inertia series (2000r/min, 1.0 – 2.0kW): rated output 1.0 – 2.0kW, rated torque 4.77 – 9.55N・m, max. torque 14.3 – 28.6N・m, rated speed 2000r/min, max. speed 3000r/min, mass moment of inertia 15.14×10- ⁴ – ⁴ – ⁴ – ⁴. ⁴ – 31.6×10-⁴kg・m², rated current 6.4 – 12.3A, maximum current 19.2 – 36.9A. Protection class, encoder, insulation class, etc. are similar to those of the low inertia series, and the corresponding parameters are also available for motors with brake.

Servo amplifier specifications

Applicable motors and power supply: Suitable for servo motors with different power, the power supply is divided into main power supply and control power supply. The main power supply has single-phase and three-phase, voltage range AC200 – 230V (single-phase – 10% to +10%, three-phase – 15% to +10%), frequency 50/60Hz; control power supply is single-phase, AC200 – 230V, – 10% to +10%, 50/60Hz.

Control and Feedback: IGBT PWM sine wave control with 17-bit serial encoder (incremental) feedback. Speed control accuracy is 1:5000 (rated load) and speed fluctuation is specified for specific loads and temperature variations. Recommended load inertia has different limits for speed and position control, with an overload capacity of 300% for approximately 3 seconds.

Functions and protection: Position, speed and torque control functions, switchable by means of sequential input signals. Various auxiliary functions such as brake timing output, Z-phase offset, etc. are available. Various protection functions are available to detect faults such as over-current, over-speed, over-voltage, etc., and relevant information is displayed and set through 7-segment LEDs and 4 operation keys.

Environment and standards: The working environment is indoor, below 1000m above sea level, free of dust, corrosive gases and direct sunlight, pollution class 2, overvoltage category III. Ambient temperature – 10℃ to +55℃, humidity 10% – 90% non-condensing, can withstand a certain degree of vibration and shock. Complies with UL/cUL (UL508c) and CE (Low Voltage Directive EN50178).

ABB Baldor FlexDrive Servo Drives

Electrical Specifications

Input Voltage: Various specifications are available, such as 115VAC, 230VAC, 460/400VAC, etc. Different models are applicable to different voltage ranges with corresponding minimum and maximum voltage limits.

Input Frequency: Support 50/60Hz ±5% frequency.

Output parameters: output bus voltage, phase current, peak phase current, output power, output frequency, etc. vary by model. For example, some models have an output frequency range of 0 – 500Hz and efficiency greater than 95%.

Logic Power: For certain models (FDxAxxxx – xxx3), an external 20 – 30VDC logic power supply is required, and the input current and inrush current varies by model.

Control Specifications

Control Type: IGBT PWM sine wave control for precise motor control.

Feedback type: Supports resolver feedback (resolution is automatically set according to the speed, up to 14 bits) and encoder feedback (signal type RS422, maximum input frequency 125kHz).

Analogue Inputs: Analogue speed command and analogue torque command inputs from 0 – 10VDC or ±10VDC with 12 bit command signal resolution and 500ms update rate.

Pulse Inputs: Pulse/direction input signals from 12 – 29VDC, optically isolated, maximum input frequency 125kHz, cycle time 1ms.

Communication Specifications

Serial Interface: Supports RS232C (non-isolated, 9600 Baud) and RS485 (non-isolated, 9600 Baud) communication standards.

CAN bus (optional): Some models support CAN bus, following CAN_OPEN and DS301 protocols, with a default baud rate of 125kbit/second, which can be changed by AS1 switch setting or serial command.

Physical Specifications

Size and Weight: The size and weight of the drives vary from model to model, e.g., models A, B, and C are different from models E, G, and H. Models with the CAN option may have a slightly increased width.

Protection: IP20 rated to provide a degree of protection against dust and foreign objects.

Environmental Adaptability: Capable of operating over a range of altitudes, temperatures, and humidity. No derating is required up to 3300 feet (1000 metres) above sea level, and a percentage of derating is required above that; operating temperature range is 0 – 40°C, with derating required above 40°C, and a maximum ambient temperature of 50°C; storage temperature range is -25 – +70°C, and the humidity range is 10% – 90% non-condensing.

Other specifications

Regenerative Functions: Drives at different voltages have different parameters for regenerative functions such as switching threshold, rated/peak power, maximum regenerative switching current and maximum load inductance.

Installation Requirements: Pay attention to the connection method and tightening torque of each component when installing, for example, the tightening torque of the X1 connector is 0.5 lb – in (0.6Nm), and make sure to use the correct cables and connectors, and follow the relevant EMC installation requirements.

Product Notice Intended use:

These drives are intended for use in stationary ground based applications in

industrial power installations according to the standards EN60204 and VDE0160.

They are designed for machine applications that require variable speed controlled

three phase brushless AC motors.

These drives are not intended for use in applications such as:

— Home appliances

— Medical instrumentation

— Mobile vehicles

— Ships

— Airplanes

Unless otherwise specified, this drive is intended for installation in a suitable enclosure. 

The enclosure must protect the control from exposure to excessive or corrosive moisture, dust and dirt or abnormal ambient temperatures. 

The exact operating specifications are found in Section 7 of this manual.

The installation, connection and control of drives is a skilled operation,disassembly or repair must not be attempted.

In the event that a control fails to operate correctly, contact the place of purchase

Safety Notice : This equipment contains high voltages. Electrical shock can cause serious or fatal injury. 

Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.

This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. 

Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.

— System documentation must be available at all times.

— Keep non-qualified personnel at a safe distance from this equipment.

— Only qualified personnel familiar with the safe installation, operation and

maintenance of this device should attempt start-up or operating procedures.

— Always remove power before making or removing any connections to this contro

PRECAUTIONS: Classifications of cautionary statements.

WARNING: Indicates a potentially hazardous situation which, if not avoided,could result in injury or death.

Caution: Indicates a potentially hazardous situation which, if not avoided,could result in damage to property

WARNING: Do not touch any circuit board, power device or electrical connection before you first ensure that power has been

disconnected and there is no high voltage present from this equipment or other equipment to which it is connected.

Electrical shock can cause serious or fatal injury.

WARNING: Be sure that you are completely familiar with the safe operation of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury.

WARNING: Be sure all wiring complies with the National Electrical Code and all regional and local codes or CE Compliance. Improper wiring may cause a hazardous condition.

WARNING: Be sure the system is properly grounded before applying power.

Do not apply AC power before you ensure that grounds are connected. Electrical shock can cause serious or fatal injury.

WARNING: Do not remove cover for at least five (5) minutes after AC power is disconnected to allow capacitors to discharge. Electrical shock can cause serious or fatal injury.

WARNING: Improper operation of control may cause violent motion of the motor shaft and driven equipment. Be certain that unexpectedmotor shaft movement will not cause injury to personnel or damage to equipment. Peak torque of several times the rated motor torque can occur during control failure.

WARNING: Motor circuit may have high voltage present whenever AC power is applied, even when motor is not rotating. Electrical shock can cause serious or fatal injury.

WARNING: If a motor is driven mechanically, it may generate hazardous voltages that are conducted to its power input terminals. The enclosure must be grounded to prevent a possible shock hazard.

ABB AC servo motors BSM Series

BSM Series Servo Motors

BSM N Series: Low inertia, high dynamic performance, NdFeB magnetic material, peak torque up to four times the continuous torque. Available with a variety of feedback devices, protection ratings to IP54/IP55, cooling packages and optional holding brakes on some models. Torque ranges from 3.9 – 354 lb-in (0.45 – 40 Nm) for applications requiring high acceleration and accurate positioning.

BSM C Series: High inertia, economical, reliable magnetic design with three times the peak torque of continuous torque. Multiple feedback devices and optional configurations, IP54/IP55 rated, torque range of 10 – 1185 lb-in (1.2 – 134 Nm) for high inertia load matching equipment.

SSBSM Series: All stainless steel with IP67 protection and 1500 psi flushing conditions for use in harsh environments such as food and liquids. Available in standard and low inertia designs with a variety of feedback devices and optional holding brakes.

BSM 25/33 Series: Durable round housing, foot mountable, standard neodymium magnet design. Torque range of 18 – 138 lb-in (2 – 15.6 Nm) with light weight, small diameter, and high power output for speed control applications.

Motor sizing calculations: Determine motor requirements based on load mechanical characteristics (e.g. friction and inertia) and motion profiles. Calculation of load parameters for different drive modes (direct, gear, tangential, ball screw), calculation of acceleration torque, rms torque, current and temperature in combination with motor parameters, selection of suitable motor and drive.

Calculation of motor selection: Determination of motor requirements based on load mechanical characteristics (e.g. friction and inertia) and motion profiles. Calculate the load parameters under different drive modes (direct drive, gear drive, tangential drive, ball screw drive), calculate the acceleration torque, root mean square torque, current and temperature in combination with the motor parameters, and select the appropriate motor and drive.

Motion Control Products

Motion controllers: including NextMove ESB – 2 and NextMove e100, support multi-axis co-ordinated motion with various control methods and communication interfaces, suitable for multi-task control of simple motion applications.

Servo Drives: such as the MicroFlex series and MotiFlex series, with a variety of control modes and communication interfaces for single-drive and multi-axis systems, with some models incorporating safety features and energy sharing capabilities.

Introduction to Motion Control and PLC products

Solutions

ABB’s comprehensive range includes multi-axis Motion Controllers, high

performance Motion Control Drives, rotary servo motors, PLCs and

HMI – all designed to seamlessly interface with each other to provide acomplete motion solution. This allows you to optimize your design time,save development costs and minimize your time to market.

Choice

ABB firmly believes in offering our customers a range of productsto fit a variety of market needs. Whether this means delivering

a product from stock, designing a product for your specific application, accessing technical data, or how you place your order,we make it easy to do business with us. Our products are designed to handle a wide range of applications.

Quality, reliability & design

With ISO9001:2008 certification to assure conformity to customer requirements and quality standards, and by using the latest CAD tools and manufacturing techniques, ABB’s engineering teams work side-by-side through design, product development, manufacture and final test to make sure that total quality and reliability is built into and stays with each product throughout its long lifetime.

Experience

Technical knowledge is the key to solving customers’ needs.

Our extensive experience has been gained over many years through close customer contact from product development to field maintenance, providing invaluable feedback for our product development process – ensuring ABB Motion Control and PLC products meet the ease of use, flexibility and performance

demanded by the markets we serve. 

Application Scenarios

Food processing industry: This series of motors are constructed of stainless steel with laser-etched nameplates, which meets the hygiene standards of the food industry, such as FDA shaft seal and BISSC standards, which can effectively prevent bacteria adhesion and contamination, and is suitable for food processing, bakery machinery, beverage equipment, etc. In food packaging, the high precision positioning and stable operation of the motor can ensure the accuracy and efficiency of packaging. In food packaging, the motor’s high-precision positioning and stable operation can ensure the accuracy and efficiency of packaging; in bakery machinery, it can adapt to high temperature, humidity and other environments to ensure the continuous and stable work of the equipment.

Pharmaceutical industry: With IP67 protection level and full stainless steel shell, it can effectively resist the erosion and cleaning of chemical substances in the process of drug production, and meet the strict requirements of pharmaceutical environment on equipment hygiene and corrosion resistance. In pharmaceutical production equipment, such as pharmaceutical filling machines, pharmaceutical testing equipment, etc., its high-precision motion control can ensure the accuracy and quality of pharmaceutical production.

Liquid handling industry: all stainless steel material and good sealing makes it able to operate stably in liquid environment, which can be used in liquid conveying equipment, measuring and distributing equipment, and so on. In chemical liquid transfer pumps, it ensures that the motor is not damaged when it comes into contact with corrosive liquids, and at the same time guarantees the stability and precise control of the transfer process.

Places with high hygienic requirements: As it meets high hygienic standards, it can be used in medical equipment, catering equipment and other equipment with stringent hygienic requirements. In medical testing equipment, its high precision and reliability help to improve the accuracy of testing; in catering equipment, it can adapt to the frequent cleaning of the working environment to ensure the normal operation of the equipment.

Harsh corrosive environments: The motor’s stainless steel and highly protective design allows it to withstand flushing conditions of 1500 psi (103 bar), allowing it to be used in industrial environments where corrosive substances are present or where frequent flushing is required. In some chemical production plant, offshore equipment and other scenes, can resist the erosion of the harsh environment, to ensure the long-term stable operation of the equipment.