Year: 2025

Product overview

ABB PU516 Engineering Board PCI (Product ID: 3BSE013064R1) is a communication module designed specifically for the industrial control field, belonging to the ABB Advant series hardware products. It is equipped with one MB300 interface and one RS-232 port, suitable for 5V 32-bit 33MHz PCI bus, built-in 16MB memory, mainly used for data transmission and communication connection in industrial control systems, and is a key component of Advant OCS and other system engineering configurations. This product is exempt from the restrictions of the 2011/65/EU (RoHS) directive and meets compliance requirements in specific industrial scenarios.

Basic information

Product identification: Product ID is 3BSE013064R1, ABB model name is PU516, catalog description is PU516 Engineering Board PCI, replacement part number is EXC3BSE013064R1.

Product Description: This product is a PU516 engineering board with one MB300 and one RS-232 port, suitable for 5V 32-bit 33MHz PCI bus, equipped with 16MB memory. In addition, this component is exempt from the 2011/65/EU (RoHS) scope, as per Article 2 (4) (c), (e), (f), and (j), with reference to document 3 BSE088609 – EU DECLARATION OF CONFORMITY – ABB Advant Master Process Control System。

Technical and physical parameters

Dimensions: The net depth/length of the product is 126mm, the net height is 18mm, and the net width is 324mm.

Weight: The net weight of the product is 0.38kg.

HS code: 853890, belongs to parts that are only or mainly applicable to devices listed in heading 85.35, 85.36, or 85.37, other categories.

Customs tariff number: 85389091.

​Classification information

Belonging to Control System Products – Control&Communication – Advance Common Hardware – Advance Common – Communication Modules – PU516 MasterBus 300 Interfaces – PU516 MasterBus 300 Interface.

It also belongs to Control Systems Advant OCS with Master SW Engineering Advant Station 100 Engineering Board – PCI Communication Modules.

The product type is Communication-Module.

Core functions

Communication interface expansion: Connect to the MasterBus 300 network through the MB300 interface, supporting high-speed data exchange between industrial control devices; The RS-232 port can be used to connect debugging devices or external terminals for local configuration and data transmission.

Data caching and processing: 16MB of memory can temporarily store and transmit data, reducing communication latency and ensuring continuous transmission of real-time data in industrial control systems.

PCI bus adaptation: Compatible with 5V 32-bit 33MHz PCI standard, it can be directly inserted into the PCI slot of industrial computers or control hosts to achieve hardware integration with the system.

Precautions

Installation environment: It should be installed in a dry and ventilated control cabinet to avoid dust, corrosive gases, and severe vibrations. The working environment temperature should comply with the general standards for industrial grade equipment (usually recommended -10 ℃ to 60 ℃).

Bus adaptation: Ensure that the host PCI bus is 5V 32-bit specification to avoid hardware damage caused by voltage or bit mismatch.

Interface protection: The RS-232 interface is designed for non isolation, and it is recommended to install lightning protection or surge protection devices when connecting external devices, especially in outdoor or strong electromagnetic interference environments.

Compliant use: Although exempt from RoHS restrictions, it is necessary to confirm whether the usage scenario complies with relevant environmental regulations in the region to avoid illegal applications.

Maintenance: Regularly check whether the connection between the board and the PCI slot is loose, clean the interface dust, and ensure good communication contact.

Similar model supplement

ABB PU515: Belonging to the Advant series communication board, the difference lies in the interface configuration. PU515 may only support MB300 interface, without RS-232 port, suitable for scenarios that do not require serial communication, and the price is relatively low.

ABB CI854: Modern industrial Ethernet communication module, supporting protocols such as PROFINET, with higher speeds, suitable for new systems that require high-speed network communication. Compared with PU516, the interface and protocol are more advanced, but the compatibility with the old Advant system is weaker.

Product Overview

The ABB 5SHX10H6004 control signal processing module is a core component designed specifically for industrial automation and power system fields, mainly used for precise processing and conversion of various complex control signals. In industrial automation processes, sensors generate a large number of signals of different types and characteristics, such as analog signals, digital signals, etc. This module can quickly collect, filter, amplify, and convert these signals into standard signal formats that can be recognized and utilized by the control system, thereby ensuring the stable operation of the automation system. In the power system, it can be used to analyze and process signals related to the operation status of the power grid, assist in the monitoring and control of the power system, and ensure the reliability and safety of power supply.

Specification parameters

Input signal type: Supports analog signal input, with a typical voltage range of -10V to+10V and a current range of 4mA to 20mA. It is compatible with the output signals of various common sensors; Simultaneously supporting digital signal input, it can recognize standard TTL/CMOS level signals and adapt to signal output of different logic circuits.

Signal processing accuracy: For analog signal processing, it has an analog-to-digital conversion accuracy of 16 bits or even higher, ensuring that even small changes in the signal conversion process can be accurately captured, effectively reducing signal distortion; In terms of digital signal processing, it can achieve nanosecond level signal response and processing, meeting the stringent requirements for high-speed signal processing.

Processing speed: With a high-speed processor core, it can perform millions of signal processing operations per second, quickly analyze and convert input signals, and adapt to applications with high real-time requirements in industrial automation and power systems, such as fast speed control of motors, rapid detection and response of power system faults, etc.

Communication interface: equipped with multiple standard communication interfaces, such as RS-485 interface, supporting half duplex communication mode, with a communication distance of over kilometers, suitable for long-distance, multi node industrial field communication; The Ethernet interface supports TCP/IP protocol, which enables high-speed and stable data transmission, facilitates data interaction with the upper computer or other intelligent devices, and facilitates remote monitoring and system integration.

Working temperature range: Designed to adapt to a wide range of working environment temperatures, generally from -20 ℃ to 70 ℃, it can maintain stable working performance in common high and low temperature environments in industrial production, ensuring reliable operation in different regions and working conditions.

Power supply voltage: Supports 24V DC power supply, with good power adaptability, allowing the power supply voltage to fluctuate within a certain range (such as ± 10%) without affecting the normal operation of the module. At the same time, it has complete power filtering and overvoltage/overcurrent protection functions to ensure the safe operation of the module in complex power environments.

Core functions

Signal acquisition and conditioning: capable of simultaneously acquiring multiple analog and digital signals, filtering and processing the collected analog signals to remove noise interference, and amplifying the signals appropriately through amplifiers to achieve a suitable level range for analog-to-digital conversion; For digital signals, level matching and anti-interference processing are performed to ensure the integrity and accuracy of the signal.

Analog to Digital Conversion: Built in high-performance analog-to-digital converters (ADCs) and digital to analog converters (DACs). ADC can accurately convert analog signals into digital signals, facilitating subsequent digital signal processing and analysis; DAC can convert digital signals into analog signals for driving actuators that require analog control signals, such as motor speed controllers, valve controllers, etc., to achieve precise control of industrial equipment.

Signal analysis and processing: Using advanced digital signal processing algorithms to analyze the collected signals, such as spectral analysis, time-domain analysis, etc. Through spectrum analysis, harmonic components in the signal can be identified to determine whether there are abnormalities in the power system; Time domain analysis can be used to monitor the changing trends of equipment operation status, such as motor speed fluctuations, equipment vibration, etc., providing a basis for equipment fault diagnosis and preventive maintenance.

Communication and data transmission: Through its rich communication interfaces, the processed signal data is packaged and sent to the upper computer or other devices according to specific communication protocols, while also receiving control instructions from the upper computer, achieving remote control and data exchange. In industrial automation production lines, it can work in conjunction with programmable logic controllers (PLCs), distributed control systems (DCS), etc. to build a complete automation control system.

Precautions

Installation environment: It should be installed in a dry, well ventilated, non corrosive gas and dust free place, avoiding direct sunlight. The ambient temperature should be maintained within the operating temperature range specified by the product to prevent module performance from being affected by high or low temperatures. At the same time, it is necessary to stay away from strong electromagnetic interference sources, such as large motors, transformers, etc., to avoid interfering with signal transmission and processing.

Electrical connection: When making electrical connections, it is necessary to strictly follow the requirements of the product manual. Ensure that the specifications of the input and output signal lines and power lines are appropriate, the connections are secure, and avoid issues such as looseness, short circuits, or open circuits. Special attention should be paid to the correctness of the power polarity to prevent damage to the module due to power connection. At the same time, it is necessary to ensure good grounding, and the grounding resistance should meet the requirements of relevant standards to improve the anti-interference ability and safety of the system.

Parameter setting: Before being put into use, professional technicians need to correctly set various parameters of the module according to actual application needs, such as sampling frequency, signal range, communication baud rate, etc. Improper parameter settings may lead to signal processing abnormalities, communication failures, and other issues. After setting up, carefully check the parameters to ensure accuracy.

Maintenance: Regularly inspect and maintain the module to check for any damage to the appearance of the equipment and aging of the connecting cables. Regularly clean the dust on the surface of the module to prevent the accumulation of dust from affecting heat dissipation and electrical performance. At the same time, regular performance testing and calibration of modules should be conducted based on usage to ensure that they are always in optimal working condition. For some vulnerable parts, such as filter capacitors, communication interface chips, etc., they should be replaced regularly according to their service life.

Fault handling: When a module generates a fault alarm, the relevant equipment should be immediately stopped and the cause of the fault should be analyzed by referring to the product manual based on the fault indicator light or fault code. Do not forcefully restart the module until the fault has been resolved, in order to avoid more serious damage. For some simple faults, such as loose cables, incorrect parameter settings, etc., they can be self checked and resolved; For complex faults, it is recommended to promptly contact ABB’s professional technical support personnel for maintenance and handling.

Product Overview

ABB PPE091A101 medium voltage frequency converter is a key power control equipment launched by ABB for applications in the medium voltage field. Medium voltage frequency converters are crucial in the industrial field as they can accurately adjust the speed of motors, thereby better adapting their operation to actual production needs. This product, with advanced technology and reliable performance, is widely used in many industries, effectively promoting the efficiency and intelligence of industrial production.

Brand background

ABB, as a global leader in the fields of power and automation technology, has a profound foundation. Since its merger with BBC in 1988, ASEA has had a presence in over 100 countries worldwide, bringing together 110000 professionals under its umbrella. For over 130 years, ABB has continuously innovated and created numerous classic products and cutting-edge technologies in the fields of power and automation. In the field of medium voltage frequency converters, ABB has always led the industry trend with years of accumulated rich experience and strong research and development capabilities. Its products are highly trusted by global users for their excellent quality, stable performance, and outstanding energy-saving effects.

Specification parameters

Rated voltage: Common medium voltage range, such as 3-11kV, can be customized according to actual application scenarios to meet the power adaptation needs of different industrial environments.

Rated power: Covering a wide range of power, from several hundred kilowatts to several megawatts, it can adapt to motors of different scales and load requirements. Whether it is small industrial equipment motors or key drive motors for large factories, PPE091A101 products with suitable power levels can be found to match them.

Frequency range: The output frequency can usually be flexibly adjusted within the range of 0-120Hz or even wider to meet the speed requirements of the motor under different working conditions. For example, in industrial production, the motor speed can be accurately adjusted according to changes in production processes to ensure the stability and efficiency of the production process.

Input characteristics: The input voltage allows for a certain range of fluctuations and can generally adapt to voltage changes of around ± 10%, ensuring stable operation even when there are certain fluctuations in the grid voltage. At the same time, the input power factor is relatively high, reaching above 0.95, effectively reducing the reactive power demand on the power grid and lowering the burden on the power grid.

Output characteristics: The output voltage waveform has high quality and low harmonic content, which can effectively reduce the heating and vibration of the motor and extend its service life. The output current has good overload capacity and can withstand 150% -200% of the rated current in a short period of time to cope with instantaneous high load situations during the production process.

Communication interface: Supports multiple common communication protocols, such as Modbus, Profibus DP, and Ethernet communication protocols, making it easy to integrate with factory automation systems, achieve remote monitoring, parameter setting, and fault diagnosis functions, and enhance the intelligent management level of industrial production.

Core functions

Precise speed regulation: Through advanced control algorithms, the motor speed can be precisely adjusted, with a speed regulation accuracy of ± 0.01%. According to the production process requirements, the motor can achieve smooth acceleration, deceleration, and stable operation, meeting the strict requirements for motor speed in different production processes.

Energy saving and consumption reduction: dynamically adjust the output power of the motor based on the actual load situation of the motor. Under light load conditions, reducing the operating frequency and voltage of the motor significantly reduces energy consumption. Through practical application verification, compared with traditional fixed speed operation mode, the energy-saving effect can reach 20% -50%, effectively helping enterprises reduce operating costs.

Motor protection: It has comprehensive motor protection functions, including overcurrent protection, overvoltage protection, undervoltage protection, overheating protection, and ground fault protection. When abnormal motor operation is detected, it can quickly act to cut off the circuit, avoiding further damage to the motor due to faults, greatly improving the reliability and safety of motor operation.

Process control integration: It can seamlessly integrate with various process control systems, receive control signals from the upper computer, such as 4-20mA analog signals, digital signals, etc., automatically adjust motor operating parameters according to real-time needs in the production process, achieve automatic control of the entire production process, and improve production efficiency and product quality.

Working principle

The ABB PPE091A101 medium voltage frequency converter mainly operates based on the AC-DC-AC frequency conversion principle. Firstly, the medium voltage AC power input from the power grid is converted into DC power by a rectifier, which usually uses thyristor rectification or diode rectification to convert the AC power into relatively smooth DC power. Next, the DC power is converted into AC power with adjustable frequency and voltage through an inverter. The inverter is the core component of the frequency converter, which precisely controls the frequency and voltage amplitude of the output AC power by controlling the on and off time of power switching devices (such as IGBT), in order to achieve precise control of motor speed and torque. Throughout the entire process, the control system monitors the operating parameters of the motor in real-time, such as current, voltage, speed, etc., and dynamically adjusts the rectifier and inverter according to preset control strategies to ensure stable and efficient operation of the motor.

Product Overview

ABB Control UNIT SYN 5201A-Z, V277 3BHB006714R0277 is a control unit launched by ABB for synchronous and parallel operations, belonging to the ABB SYNC HROTACT series products. This product features a dual channel configuration, with one channel monitoring the operation of the other, greatly improving operational safety. It can be used to ensure precise timing and control in complex industrial systems and plays an important role in the field of industrial automation.

Product Usage

Mainly used to ensure precise timing and control in complex industrial systems, it is a key component in industries such as power generation, telecommunications, and industrial automation, where precise synchronization is crucial.

​

Performance characteristics

Rich communication interfaces: Supports logically independent dual Profibus DP buses, can set dip switches to specific communication rates or adaptively, can flexibly choose 1-2 Profibus DP electrical interfaces and 1-2 155 Mbps fiber optic interfaces, supports redundant dual network and fiber ring network topologies.

Long communication distance: Fiber optic communication distance exceeds 20 kilometers, with a 155 Mbps high-speed optical interface, which can better support long-distance reliable transmission of burst data.

Clear status indication: equipped with 5 dual color LED status indicator lights, with fiber optic link and power failure relay output alarm function.

Good protection performance: The electrical interface has 4000V lightning protection, 1.5A overcurrent, and 600W surge protection, meeting industrial design standards and passing EMC testing certification. Adopting DC (12-36V) wide redundant dual power supply, with reverse protection function, protection level of IP30, and shell reinforced with corrugated aluminum material.

Easy installation: Using standard industrial 35mm guide rail installation method, it is convenient to install in the control cabinet.

Technical parameters:

Safety level: PL e, SIL 3- SIL CL 3- PL e – Cat. 4.

Input/output: There are 8 digital inputs, 2 OSSD PNP outputs (400 mA at 24 VDC) with short circuit, overload, and reverse polarity protection, 2 PNP status outputs (100 mA), and 4 test outputs.

Working temperature: -10 ℃ to 55 ℃, storage temperature: -20 ℃ to 85 ℃.

Power supply: 24V DC ± 20%.

Dimensions: Approximately 108mm × 22.5mm × 114.5mm, gross weight of approximately 206.8g.

Key advantages

High security: With a dual channel design, one channel monitors the operation of the other channel, greatly improving the safety during the operation process and reducing the risk of system abnormalities caused by equipment failures.

Wide applicability: It not only supports 50/60Hz standard power grid, but also supports 16 2/3Hz frequency, suitable for various types of power generation equipment and complex power grid environments, whether it is conventional power plants or some special industrial self owned power plants.

Accurate synchronization performance: With advanced digital technology and precise algorithms, high-precision frequency and voltage matching and synchronization operations can be achieved, effectively improving the stability and reliability of power grid operation, reducing power fluctuations and equipment losses caused by poor synchronization.

Powerful communication capability: supports multiple communication protocols, facilitates integration with various devices, achieves intelligent management and remote control of the system, and can meet the needs of different users for centralized monitoring and management of the system.

High reliability: Complies with industrial design standards and has passed EMC testing certification. The electrical interface has 4000V lightning protection, 1.5A overcurrent, 600W surge protection, and adopts DC (12-36V) wide redundant dual power supply with reverse protection function. The protection level is IP30, and the shell is reinforced with corrugated aluminum material, which can operate stably in harsh industrial environments.

Precautions

During the installation process, it is necessary to strictly follow the instructions in the product manual to ensure the correct installation position and avoid equipment damage or performance degradation caused by improper installation. Special attention should be paid to the firmness and correctness of electrical connections to prevent problems such as short circuits or open circuits.

Before use, carefully inspect the appearance of the equipment for any damage and ensure that all components are complete. At the same time, it is necessary to confirm whether the parameters of the input power supply are consistent with the equipment requirements, in order to avoid irreversible damage to the equipment caused by power problems.

During operation, regular inspections of the equipment should be carried out to observe whether the operating status indicator lights are normal and whether there are any abnormal noises or heating phenomena. If any abnormalities are found, the machine should be stopped immediately for troubleshooting. Do not forcefully restart the equipment until the fault is resolved.

When setting and maintaining equipment parameters, it must be operated by professional personnel and carried out in the event of a power outage to prevent safety accidents or equipment failures caused by misoperation. At the same time, after the operation is completed, carefully check the parameter settings to ensure that they are correct and error free.

The device should be stored in a dry, ventilated, and non corrosive gas environment, avoiding direct sunlight and strong electromagnetic interference. If the device is not used for a long time, it is recommended to conduct regular power on checks to ensure that the device is functioning properly.

Similar model supplement

SYN5200A-Z: also belongs to the ABB SYNC HROTACT series products, similar to SYN 5201A-Z, designed for industrial automation synchronous control. The working voltage is 24V DC, and the communication protocol supports Ethernet/IP, Profibus, and Modbus. The difference lies in that its performance parameters such as processor speed may differ from SYN 5201A-Z, and there may also be differences in input and output capacity. For example, SYN5200A-Z may support a different number of I/O points in certain application scenarios, and users can choose according to their specific system requirements and budget.

ABB SYN5201a-Z, V217: This is also an automatic synchronization device, belonging to the SyncHROTACT 5 series product line. Compared with SYN 5201A-Z, V277, the input voltage range (measured input U1, U2) is 50 to 130 VAC (rated), and the auxiliary power supply (AC/DC) is 24-250 V DC, 100-230 V AC. There are differences in some detailed parameters, and there may also be differences in applicable conditions such as working environment temperature. For example, its working environment temperature is+5 to+70 ° C, and users need to choose it reasonably according to their actual usage environment and working conditions.

Product Overview

ABB PXAH 401 Operator Unit (model: 3BSE017235R1) is an operation unit applied in the field of industrial automation. It plays a key role in connecting operators and industrial equipment in the industrial production process. Operators can monitor the real-time operation status of equipment through this unit, easily control the industrial process, and provide strong support for the efficient and stable operation of industrial automation systems.

Specification parameters

Input voltage: 24VDC

Working temperature range: -40 ℃ to 85 ℃

Communication Interface: Equipped with Ethernet interface for high-speed data transmission and network connection, RS232/485 interface can adapt to different communication protocol devices to achieve serial communication, and also has USB interface for convenient data storage and device debugging

Memory capacity: 512MB RAM for running programs and processing data, 1GB Flash for storing system programs, configuration files, and historical data, etc

Display screen size: typically 7 inches or larger, providing users with a clear visual interface for operation

Resolution: 800 x 640 pixels, ensuring clarity and readability of displayed content

Protection level: IP20, can effectively prevent dust in general indoor environments, providing basic protection for internal circuits of equipment

Functional Features

Multiple signal interfaces: Supports multiple signal input and output interfaces, including digital and analog signals, and can be connected to various sensors, actuators, and other devices to achieve the acquisition and control of various signals in industrial processes.

Rich control logic: Supports multiple control logics and algorithms, suitable for complex industrial control tasks, and can accurately control and adjust industrial processes according to different process requirements and control strategies.

High computing performance: It has high-performance computing capabilities, such as real-time analysis of 100000 level measurement point data in power dispatch systems, with a response time of less than 50ms, and can quickly process large amounts of real-time data, meeting the requirements of industrial automation systems for data processing speed and accuracy.

Redundant security design: Adopting redundant security measures such as dual machine hot standby design, the unplanned downtime is reduced from an average of 20 hours per year to 1.5 hours, improving the reliability and stability of the system and reducing production interruptions and losses caused by equipment failures.

Strong scalability: Through ABB’s CP600 series expansion module, up to 2048 I/O points can be connected, which can be flexibly expanded according to actual application needs, covering all scenario requirements from single machine control to whole plant integration.

Good environmental adaptability: With IP65 protection design, dustproof and waterproof, it can be directly installed in outdoor control cabinets, adapt to harsh industrial environments, and ensure stable operation under various complex working conditions.

Convenient human-computer interaction: Provides operators with an intuitive user interface that can display various process variables such as temperature, pressure, flow rate, etc., and allows operators to manually operate or adjust control parameters through a touch screen, facilitating real-time monitoring and control of industrial processes.

Industrial Internet compatibility: Built in OPC UA server can directly connect to MES and ERP systems to realize the transparency of production data, lay the foundation for digital factories, and facilitate enterprises to realize the informatization and intelligent management of production processes.

​Application area 

Pulp and paper industry: Used for pulp production lines and paper machine control, it can monitor and adjust parameters such as pulp concentration, flow rate, and paper machine speed in real time to ensure stable paper quality and improve production efficiency.

Power system: used in power plants and substations to monitor and control the operating status of equipment such as generators, transformers, and switchgear, achieve power dispatch automation, and ensure the stable operation and reliable power supply of the power system.

Metallurgical industry: used for monitoring and control of production processes such as steel and non-ferrous metals, such as blast furnace ironmaking, converter steelmaking, continuous casting and rolling, etc. It can accurately control parameters such as furnace temperature, pressure, liquid level, composition, etc., improve product quality and production efficiency, and reduce energy consumption and costs.

Manufacturing industry: used for process control and automation management of production line equipment, such as automotive manufacturing, mechanical processing, electronic equipment manufacturing, etc. It can achieve automated control of the start stop, speed adjustment, material conveying and other operations of various equipment on the production line, improve production efficiency and consistency of product quality.

Energy system: Used for energy scheduling and monitoring systems, such as smart grids, photovoltaic power stations, energy storage systems, etc., it can achieve real-time monitoring and optimized scheduling of energy production, transmission, distribution, and usage processes, improve energy utilization efficiency, and reduce energy consumption and costs.

Chemical industry: used for monitoring and control of chemical production processes, such as temperature, pressure, and flow control of reaction vessels, liquid level and temperature control of distillation towers, etc., which can ensure the safe and stable operation of chemical production processes, improve product quality and yield, and reduce environmental pollution.

Oil and gas industry: used for monitoring and controlling processes such as oil extraction, refining, and natural gas transportation, such as wellhead oil extraction equipment control, refining unit control, natural gas pipeline pressure and flow control, which can improve production efficiency, reduce production costs, and ensure production safety.

Pharmaceutical industry: used for monitoring and controlling the pharmaceutical production process, such as the operation control of drug production equipment, drug quality testing, inventory management of raw materials and finished products, etc., to ensure that the drug production process complies with GMP standards, improve drug quality and production efficiency.

Key advantages

High reliability: High quality electronic components are selected and advanced redundancy design concepts are adopted to ensure stable operation of equipment in harsh industrial environments such as high temperature, high humidity, and strong electromagnetic interference, reducing the probability of equipment failure and minimizing production losses caused by equipment downtime.

Usability: Equipped with a simple and user-friendly human-computer interaction interface, supporting multilingual operations, both experienced professional engineers and first-time operators can quickly get started and easily complete various operational tasks.

Scalability: Based on the modular design concept, this operating unit is easy to upgrade and expand the system. Users can flexibly add functional modules or expand communication interfaces according to actual production needs to adapt to the constantly changing requirements of industrial automation control.

Precautions

Installation environment: It should be installed in a dry, well ventilated environment without strong electromagnetic interference, avoiding direct sunlight and severe vibration to ensure the normal operation and service life of the equipment.

Power supply: Ensure stable input power supply, meet the specifications of 24VDC, and prevent equipment damage or abnormal operation caused by power fluctuations or abnormalities.

Regular maintenance: It is necessary to regularly clean the equipment, check whether the communication interface connection is secure, and regularly backup important data to ensure stable operation and data security of the equipment.

System Overview

Positioning: Plantguard is a safety instrumented system that complies with international safety standards such as IEC 61508 and IEC 61511, designed specifically for safety critical control in industrial processes. It is used to monitor hazardous conditions and trigger protective measures (such as emergency shutdown and energy cut-off), reduce accident risks, and ensure the safety of personnel, equipment, and the environment.

Core objective: To achieve Safety Instrumented Function (SIF) through highly reliable hardware architecture and software functionality, supporting safety integrity level requirements from SIL 1 to SIL 3.

System architecture

Hardware Architecture

Adopting modular and redundant design to ensure high availability and fault tolerance:

Controller: Based on the AC 800M series safety controllers (such as PM865, PM867, etc.), it supports safety architectures such as 1oo2 (1 out of 2) and 2oo3 (2 out of 3), meeting different SIL level requirements.

I/O module: including safety input/output modules (such as AI801S, DI801S, DO801S), with signal isolation and diagnostic functions, supporting multiple on-site signals (4-20mA, switch values, etc.).

Communication network: Adopting redundant industrial Ethernet (such as PROFINET, Ethernet/IP) and fieldbus (such as PROFIBUS DP) to ensure the security and real-time transmission of data, supporting integration with DCS, PLC and other systems.

Software architecture

Based on a unified engineering platform, simplify configuration and maintenance:

Engineering tool: Use Control Builder M software for safety logic configuration, supporting programming methods such as Function Block Diagram (FBD) and Ladder Diagram (LD), and built-in safety function block library (such as emergency stop and interlock logic).

Diagnosis and monitoring: System status monitoring, fault diagnosis, and event recording are achieved through Operator Station or Asset Optimization software, supporting online maintenance and testing without affecting the operation of safety functions.

Core functions and advantages

Safety function

Support custom security logic to implement safety controls such as emergency shutdown (ESD), fire and gas monitoring (F&G), burner management (BMS), etc.

Equipped with online testing and partial trip testing (PST) functions, reducing parking maintenance time and improving system availability.

integration capability

It can seamlessly integrate with ABB’s AC 800M process control system, Panel 800 operator panel, etc., achieving synergy between safety and process control.

Support open protocols (such as OPC UA, Modbus) for easy communication with third-party systems (such as ERP, MES), forming a complete industrial security ecosystem.

Compliance and reliability

Compliant with international standards such as IEC 61508 (SIL 1-3) and IEC 61511, certified by authoritative organizations such as T Ü V and EXIDA.

The hardware has a high mean time between failures (MTBF), supports redundant design and hot plugging, ensuring that a single point of failure does not affect system operation.

Application scenarios

Plantguard is widely used in industrial fields with strict safety requirements, including:

Petrochemical and natural gas processing (such as refineries and LNG plants);

Pharmaceuticals, food and beverage (such as hazardous material processing);

Energy industry (such as power plants, new energy projects);

Chemical and metallurgical industries (such as high-temperature and high-pressure reaction processes).

Customer Value

Risk reduction: By implementing reliable safety controls, the incidence of accidents can be reduced, in compliance with regulatory requirements.

Efficiency improvement: Online testing and diagnostic functions reduce downtime and improve production continuity.

Full lifecycle support: from engineering design, installation and debugging to operation and maintenance upgrades, providing full technical support to ensure long-term stable operation of the system.

Product overview

Positioning: AC 800M 6.0 is a high-performance modular controller hardware platform that can achieve various process and industrial automation control functions through programming. It is suitable for various industrial scenarios and can serve as an independent controller or undertake local control tasks in the control network.

Core composition: It consists of hardware components such as processor unit, communication interface, power supply unit, battery backup unit, etc. Some high integrity systems also require special modules such as SM810/SM811/SM812.

Hardware components and functions

Processor Unit

Category: Including PM851/PM851A、PM856/PM856A、PM858、PM860/PM860A、PM861/PM861A、PM862、PM864/PM864A、PM865、PM866/PM866A、PM867、PM891  There are differences in performance and configuration among different models, such as PM891 using MPC8270 microprocessor with a running speed of 450MHz, which is about three times the performance of PM864.

Function: Includes microprocessor, RAM memory, real-time clock, LED indicator lights, initialization button, etc., responsible for running firmware and application programs, and controlling the operation of the entire system. Support redundant configuration, with a primary backup switching time of less than 10ms, and the process output remains frozen during switching.

Communication interface

Diverse types: including RS-232C（CI853）、PROFIBUS DP（CI854/CI854A/CI854B）、MasterBus 300（CI855）、S100 I/O（CI856）、INSUM（CI857）、DriveBus（CI858）、FOUNDATION Fieldbus HSE（CI860） Multiple interfaces are available to expand the communication capabilities of the processor unit, supporting different protocols and device connections.

Function: Implement communication between the controller and external devices, networks, such as connecting remote I/O, fieldbus instruments, drivers, etc.

Power and battery backup

Power supply units, such as SD831, SD832, SD833, SD834, etc., are switch mode power converters that convert AC or DC inputs into stable 24V DC outputs. They support redundant configurations and need to be used in conjunction with voting units (such as SS823, SS832).

Battery backup: includes internal batteries (some models) and external batteries (SB821, SB822), used to provide backup power for memory and real-time clock in case of power failure. SB822 is a rechargeable lithium battery, while PM891 only supports external battery backup.

Other Components

CEX Bus interconnect units, such as BC810 and BC820, are used to divide CEX Bus into independent segments, improve system availability, and support redundant communication interfaces.

SM modules: SM810, SM811, SM812 are used for intelligent monitoring of high integrity controllers. SM811 and PM865, SM812 and PM867 can form a 1oo2 structure, supporting SIL3 applications respectively.

Technical Parameter

Processor performance: Different models of processors have different microprocessor models, operating frequencies, memory capacities, etc. For example, PM864/PM865 uses the 96MHz MPC862 microprocessor, while PM891 uses the 450MHz MPC8270 microprocessor.

Communication capability: Supports multiple communication protocols and rates, such as PROFIBUS DP supporting 9.6kbit/s-12000kbit/s, Ethernet ports supporting 10/100Mbit/s, etc.

Power parameters: The input voltage range, output voltage, and rated current of the power supply vary. For example, the SD831 has an input of 100-240V AC or 110-300V DC and an output of 24V DC/3A.

Environmental parameters: working temperature, storage temperature, humidity, etc. The working temperature range is usually -25 ° C to+60 ° C (some models may vary), and the relative humidity is 5% -85% without condensation

Product overview

The Panel 800 Version 6 series is a user-friendly, intuitive, and ergonomic operator panel designed to be compact, space saving, and equipped with advanced features. It supports process and equipment control through function keys next to the screen or touch LCD display screens, making it suitable for process monitoring and operation in industrial automation scenarios.

Product classification and core parameters

This series is divided into three categories: standard panels, high-performance panels, and reinforced panels. The specific models and parameters are as follows:

Category, Model, Display Screen Size, Resolution and Proportion, Core Configuration Size (W × H × D, mm), Protection Level (Front/Rear), Operating 

Temperature Range

Standard panel PP871 4.3 “480 × 272 (16:9) ARM9 processor (400MHz), 128MB memory 145 × 103 × 49 IP66/IP20-10~+60 ° C

PP874 7 “800 × 480 (16:9) Same as above 204 × 143 × 49 IP65/IP20 Same as above

PP877 10.4 “640 × 480 (4:3) Same as above 280 × 228 × 51 Same as above

PP874K/PP877K 7 “/10.4” with button operation as above, other models are slightly larger than PP874/PP877 and the same as above

High performance panel PP882 12.1 “1280 × 800 (16:10) Intel Atom processor (1.1GHz), 1GB memory 340 × 242 × 79 IP65/IP20-10~+50 ° C

PP885 15.4 “Same as above 410 × 286 × 83 Same as above

Reinforced panel PP880R 7 “800 × 480 (16:9) 1.0GHz Intel Atom, 3.5GB storage 204 × 143 × 73 IP66/IP20-30~+70 ° C

PP885R/PP886H 15.4 “1280 × 800 (16:10) 1.0/1.6GHz Intel Atom 410 × 286 × 83 Same as above

Common parameters:

Interaction mode: resistive touch (million touch cycles) or button operation (million press cycles).

Interface: All are equipped with Ethernet (RJ45), USB 2.0, RS232/RS422/485 serial ports, and support SD card expansion storage.

Power supply: 24VDC (18-32VDC), power consumption varies from 3.6W to 28W depending on the model.

Communication function

Supports multiple industrial communication protocols and drivers, and can be integrated with mainstream PLCs and control systems, including:

ABB proprietary protocols: COMLI (master/slave), Control Network MMS, Freelance 2016, etc.

Universal protocols: Modbus (ASCII/RTU/TCP, master/slave), Profinet, Ethernet/IP, OPC DA/UA, etc.

Third party agreements: Siemens S7 series, Schneider Uni Always, Rockwell DF1, etc., covering nearly 50 types of drivers.

Product Overview

Series positioning: System proS enclosed starters include direct online (D.O.L.) starters and dual speed starters, including non combination and combination types, suitable for 1-phase and 3-phase motor control, with a maximum CSA/UL horsepower rating of 7.5 to 125HP at 600VAC.

Core features: Compact and space saving design, pre wired indicator light components and control transformer kit for easy on-site modification and installation, anti misoperation design for terminals, all connection terminals can prevent accidental contact, and necessary terminal blocks and wiring are also included. The starter can be controlled through external holding contacts.

Starter type and specifications

1-phase starter

Non combination: Divided by contactor size (AF09, AF16, AF30, AF52, AF80), corresponding to different CSA motor switch currents and maximum motor horsepower ratings (120V and 240V), and providing models of different housing types (Type 1, Type 4/12, Type 4X).

Combination type: including types of fuse isolation switches and non fuse isolation switches, also divided according to the size of the contactor, corresponding to different motor parameters and housing models.

3-phase starter

Non combination type: There are types such as irreversible, reversible, and dual speed (2 windings and 1 winding), divided according to the size of the contactor (AF09, AF16, AF30, AF52, AF80, AF140), corresponding to the maximum motor horsepower rating at different voltages, and providing models of different housing types.

Combination type: including types of fuse isolation switches, non fuse isolation switches, and MCP circuit breakers, divided by contactor size, corresponding to different motor parameters and housing models.

Core parameters and selection

Coil voltage: Provides multiple options such as 24-60V, 48-130V, 100-250V, 250-500V, etc., which can be distinguished by the last digit of the catalog number.

Overload relay: Class 10 adjustable overload relay is used, and different contactor sizes correspond to different models of overload relays. The current setting range and cable range are different, and the selection should be based on the motor parameters.

Catalog number explanation: The number includes information such as housing type, combination method, starter type, contactor size, coil voltage, overload selection, indicator light components, auxiliary contacts, etc. The specific model can be determined according to the needs.

Attachment

Indicator light components: There are various types, including combinations with buttons and indicator lights, switches and indicator light combinations in different positions, etc., which can be installed by customers or factories. They are suitable for different types of starters and come in versions such as 130V and 24V, with different functions and identifications.

Transformer kit: Divided by contactor size and VA rating, there are options such as 50VA and 100VA. The input (primary) voltage ranges from 120-600V, and the output (secondary) voltage is 24V and 120V. It can be factory installed.

Technical data and installation

Technical parameters: Main protection, contactor, maximum overload, combined short-circuit current, AC1 and AC3 rated current, and corresponding horsepower of single-phase and three-phase motors for different types of starters.

Size specifications: Dimensions (height, width, depth) of starters of different types (non combination, combination) and different housing types (Type 1, Type 4/12, Type 4X).

Electrical diagram: including electrical wiring diagrams for direct online starters, single-phase 2-pole starters, reversible starters, dual speed 2-winding starters, etc., as well as electrical diagrams for indicator light components.

Product Overview

Series positioning: The Tmax T7 series is a high current model in ABB molded case circuit breakers, covering a current range of 630A-2500A, designed to meet the needs of high reliability, high breaking capacity, and compact design in industrial distribution systems.

Product types: including distribution circuit breakers (with thermal magnetic or electronic release), motor protection circuit breakers, etc., suitable types can be selected according to different application scenarios.

Core technical parameters and performance

Breaking capacity: At 480V AC voltage, the breaking capacity can reach 150kA, which can effectively deal with short-circuit faults and ensure system safety.

Release type:

Thermomagnetic release: Provides overload and short circuit protection, with relatively fixed parameter settings, suitable for conventional protection scenarios.

Electronic release devices (such as PR231/P, PR232/P, etc.): have more precise protection functions, support multiple protection curves, and can provide precise protection against overload, short circuit, grounding faults, etc. Some models also support communication functions (such as Modbus RTU), making remote monitoring and management easier.

General parameters: protection level IP54, insulation level F, temperature rise level B (some models are F), operating temperature range -25 ℃ to+70 ℃, storage temperature -40 ℃ to+70 ℃, in compliance with multiple international standards such as IEC 60947-2.

Installation and Configuration

Installation method: Supports fixed installation, plug-in installation, and pull-out installation. Multiple installation methods can meet different cabinet design and maintenance needs. Some models can be converted to different installation methods through conversion kits.

Connection method: Provides multiple terminal types, including front wiring, rear wiring, multi cable terminals, etc., suitable for copper and aluminum cables, making it easy to connect with different lines.

Accessories: Equipped with a variety of accessories such as auxiliary contacts, undervoltage release, shunt release, remote control mechanism, residual current release, etc., the circuit breaker function can be expanded according to actual needs.

Application and Authentication

Application scenarios: Widely used in industrial power distribution systems, large building power distribution, energy industries, and other fields, it can be used for main power distribution, feeder line protection, and protection of large motors.

Certification: Compliant with multiple international standards such as UL 489, CSA C22.2, IEC, and some models have been certified by classification societies (such as ABS, RINA, etc.) to ensure the applicability of the product in different regions and industries.