The medium voltage V-Contact VSC contactors are apparatus suitable for operating in alternating current and are normally used to control users requiring a high number of hourly operations.

The V-Contact VSC contactor introduces the drive with permanent magnets, already widely used,experimented and appreciated in medium voltage circuit-breakers, into the worldwide panorama of medium voltage contactors.

The experience acquired by ABB in the field of medium voltage circuit-breakers fitted with drives with “MABS” permanent magnets, has made it possible to develop an optimised version of the actuator (bistable MAC drive) for medium voltage contactors.

The drive with permanent magnets is activated by means of an electronic multi-voltage feeder. The feeders differ according to the integrated functions and to the auxiliary power supply voltage.

Three bands of power supply are available with which all the voltage values required by the major international Standards can be covered.

Each feeder is able to take any voltage value within its own operating band.

All the contactors mentioned above are available,on request, in one of the two following versions.

SCO(Single Command Operated): closing takes place by supplying auxiliary power to the special input of the multi-voltage feeder. On the other hand, opening takes place when the auxiliary power is either voluntarily cut off (by means of a command) or involuntarily (for lack of auxiliary

power in the installation).

DCO (Double Command Operated): closing takes place by supplying the input of the closing command of the apparatus in an impulsive way.

On the other hand, opening takes place when the input of the opening command of the contactor is supplied in an impulsive way.

Fields of application

The V-Contact VSC contactors are suitable for controlling electrical apparatus in industry, in the service sector, in the marine sector, etc.

Thanks to the breaking technique with vacuum interrupters, they can operate in particularly difficult environments.

They are suitable for control and protection of motors, transformers, power factor correction banks, switching systems, etc. Fitted with suitable fuses, they can be used in circuits with fault levels up to 1000 MVA (VSC7 – VSC12)

Compliance with Standards

V-Contact VSC contactors comply with the Stand ards of the major industrialised countries and in particular with the EC 60470 (2000) Standards.

Approvals

Approval by the DNV, RINA and LL.RR shipping registers is foreseen.

Operating characteristics

• Ambient temperature:  – 5 °C … + 40 °C

• Relative humidity: < 95 %  (without condensa tion)

• Altitude: < 1000 m s.l.m.

Main technical characteristics

• Chopping current value  ≤  0.5 A

• Maintenance-free

• Suitable for installation in prefabricated substations and switchgear both of the card (slim line) and traditional type

• High number of operations

• Direct checking of contact wear

• Long electrical and mechanical life

• Remote control

• Multi-voltage feeder

• Bistable drive of the type with permanent magnets

• Behaviour on power cut adjustable by the customer (instantaneous or delayed opening) in the SCO versions and, should the undervolt age accessory be required, DCO.

Interruption principle

IThe main contacts operate inside the vacuum interrupters (the level of vacuum is extremely high: 13 x 10-5Pa).

On opening, there is rapid separation of the fixed and moving contacts in each contactor interrupter.

Overheating of the contacts, gener ated at the moment they separate,causes formation of metallic vapours which allow the electric arc to be sustained up to the first passage through zero current.

On passage of zero current, cooling of the metallic vapours allows recovery of high dielectric resist ance able to withstand high values of the return voltage.

For motor switching, the value of the chopped current is less than 0.5 A with extremely limited overvoltages.

“MAC” magnetic drive

ABB has implemented this technology in the field of contactors on the basis of experience gained in the field of circuit-breakers with magnetic drive.

The magnetic drive adapts perfectly to this type of apparatus thanks to its precise and linear travel.

The drive, which is of bistable type, is fitted with an opening and a closing coil.

The two coils – individually energised – allow the drive mobile armature to be moved from one of the two stable positions to the other.

The drive shaft is solid with the mobile armature and held in position in a field generated by two permanent magnets (fig. A).

Energising the coil opposite to the magnetic latching position (fig. A) of the core, the magnetic field is generated (fig. B), which attracts and moves the mobile armature into the opposite position (fig. C).

Every opening and closing operation creates a magnetic field concordant with the one generated by the permanent magnets, with the advantage of keeping the intensity of the field itself constant during service, regardless of the number of opera tions carried out.

The energy needed for operation is not supplied directly by the auxiliary power supply, but is always “stored” in the capacitor which acts as an energy accumulator, and therefore operation always takes place with constant speeds and times, independ ently of the divergence of the power supply voltage from the rated value.

The auxiliary power supply has the only aim of keeping the capacitor charged.Consumption is therefore minimal. 

The power required is less than 5 W. In order to re-instate the rated power value in the capacitor after an opera tion, there is an inrush of 15 W for a duration of a few tens of milliseconds.

For the reasons indicated above, both for the DCO and for the SCO version it is necessary to supply the auxiliary circuits which recharge the capacitor with a continuous auxiliary power supply of 5W (this value can reach 15W for a few milliseconds immediately following each operation).

Careful selection of the components and a precise design make the electronic multi-voltage feeder extremely reliable, unaffected by electromagnetic interference generated by the surrounding environ ment and free of any emissions which may affect other apparatus placed in the vicinity.

These characteristics have made it possible for the V-Contact VSC contactors to pass the electromag netic compatibility tests (EMC) and obtain the CE mark.

​Interfacing shafts

These can be used to interface the apparatus with the kinematics of the switchgear to make interlocks and/or signals.

The interfacing shafts are available in two different lengths (A = 22 mm and 70 mm) and can be mounted on one or both sides of the contactor (as indicated in the following table)

Operation counter

Mechanical operation counter for fixed versions, electric operation counter for withdrawable versions.

This is a device which counts the contactor closing cycles 3 Undervoltage function (only available for DCO)

First of its type, the V-Contact VSC contactor is fitted with an undervoltage function with selectable delays of 0; 0,5; 1; 2; 3; 4; 5 s.

This accessory must be specified at the time of order because it cannot be mounted at a later stage.

Extended connections (terminals)

These allow the centre distance between terminals to be taken from 65 mm to 92 mm.

This accessory must be specified at the time of order because it cannot be mounted at a later stage.

Adapter for application of fuses

The kit includes all the accessories needed to adapt and mount three fuses(according to DIN Standards with dimension e less than 442 mm; according to BS Standards with dimension L less than 553 mm).

The kit can be installed directly onto the fuseholder supports. 

The fuses must have dimensions and striker of average type according to DIN 43625 and BS 2692 (1975) Standards. 

The electrical characteristics must conform to the IEC 282-1 (1974) Standards.

To select the fuses, see “Conditions of use according to the load” – chapter 3.

The adaptation kits are available in the following types:

3A For fuses according to DIN Standards with distance e = 192 mm

3B For fuses according to DIN Standards with distance e = 292 mm

3C For fuses according to BS Standards (2 x 8 x L = 235 mm)

3D For fuses according to BS Standards (4 x 10 x L = 305 mm)

3E For fuses according to BS Standards (4 x 10 x L = 410 mm)

3F For fuses according to BS Standards with distance L = 454 mm.

Connections alternative to the fuses

The kit includes three flat copper busbars and fixing screws to be installed when the fuses are not needed.

The kit can be installed directly onto the fuseholder supports

Position contacts for connected/isolated position in the truck

These signal the position of the truck in the enclosure/PowerCube module.

The kit includes a set of 10 auxiliary contacts. 

This accessory must always be requested for contacts to be used in UniGear type ZS1 switchgear if the same application is not already present on the fixed part.

Isolation lock

Isolation lock for UniGear type ZS1 switchgear and PowerCube modules.

It prevents the apparatus from being racked-in if the unit door is open.

This lock only works if the door of the switchgear/enclosure is also fitted with the corresponding lock.

Locking magnet in the truck

This only allows the withdrawable contactor to be racket into/out of the enclo sure with the electromagnet energised and the contactor open

The table below shows the power supply voltages available.

10Lock for different rated currents (only withdrawable versions)

This prevents insertion of the plug-socket and therefore apparatus closing, in a panel provided for a circuit-breaker.

This lock, which is compulsory for UniGear switchgear, requires the same lock provided on the enclosure / switchgear

Product model: UNS 0884a, V1

Corresponding ABB number: 3BHE004385R0001

Current measurement range: 2000A

Origin: Sweden. As a well-known brand, ABB strictly controls its product technology and quality. This current sensor inherits ABB’s high-quality genes.

Certification status: With CO.CQ certification, this indicates that the product meets specific standard requirements in terms of safety, reliability, and other aspects, providing assurance for user use.

Packaging details: Using brand new original and factory sealed packaging, it can effectively prevent the product from being damaged or affected by moisture during transportation and storage, ensuring that the product received by the user is in the best condition.

Product size and weight:

Net height: 50mm

Net length: 230mm

Net width: 165mm

Net weight: 2kg, moderate size and weight, convenient for installation and integration in various devices, and easy to transport and carry.

Product Overview

ABB 3BHE004385R0001 UNS 0884a, V1 is a current sensor designed specifically for precise measurement of high currents, playing a key role in power monitoring in the industrial field. Its rated current measurement range is 2000A, which can adapt to various complex current monitoring scenarios and provide key data support for the stable operation of various systems. From the appearance, the compact design makes it easy to install inside various devices without taking up too much space.

Brand background

ABB Group is a multinational industrial energy production company established in 1988 through the merger of ASEA and BBC, headquartered in Zurich, Switzerland. In its development process, ABB has continuously innovated and broken through, launching many industry influential products, such as the Azipod electric propulsion system launched in 1990 and the digital solution product ABB Ability launched in 2017 ™ Wait. ABB’s business is extensive, covering multiple fields such as electrification, sports, and process automation. It has numerous customers in 165 countries worldwide and has established an excellent brand image with advanced technology and strict quality control. This current sensor is a reflection of ABB’s high-quality and high-performance brand.

Core functions

Accurate current measurement: It can accurately measure a current of 2000A with extremely high measurement accuracy, providing accurate current data for the system and helping engineers accurately judge the operating status of the system. For example, in large power equipment, real-time monitoring of current can ensure stable operation of the equipment within the rated current range.

Signal transmission and conversion: Convert the measured current signal into an electrical signal that is easy to process and transmit, facilitating connection and interaction with other devices such as control systems, monitoring instruments, etc., to achieve remote monitoring and analysis of data.

Working principle

This current sensor operates based on the principle of electromagnetic induction. When the measured current passes through the primary winding of the sensor, an alternating magnetic field is generated in the iron core. Under the action of this alternating magnetic field, the secondary winding will induce an induced electromotive force proportional to the primary current, thereby generating an induced current. By measuring and processing the secondary induced current, the high current value passing through the primary winding can be accurately calculated, achieving precise monitoring of the 2000A current.

Key advantages

High quality guarantee: Originating from Sweden and inheriting ABB’s strict production process and quality control system, the product has high reliability and can operate stably for a long time in harsh environments, reducing losses caused by equipment failures.

Authoritative certification endorsement: Possessing CO.CQ certification proves that it meets specific standards in terms of safety, reliability, and other aspects, allowing users to feel more at ease during use.

Flexible procurement plan: The minimum order quantity is only 1 piece, and there is a daily supply capacity of 10 pieces, which can meet both large-scale project procurement and small-scale testing needs, reducing the procurement threshold.

Convenient installation design: Moderate size (height 50mm, length 230mm, width 165mm) and lightweight (2kg) make it easy to install and integrate in various devices, and also convenient for transportation.

Precautions

Installation environment: It should be installed in a dry and well ventilated environment, avoiding places with high temperature, high humidity, and strong electromagnetic interference, to prevent affecting the measurement accuracy and service life of the sensor.

Wiring specifications: Strictly follow the product manual for wiring operations, ensure that the wiring is firm and correct, and avoid measurement errors or equipment damage caused by wiring errors.

Regular maintenance: Regularly inspect and calibrate sensors to ensure their measurement accuracy remains within the specified range. It is generally recommended to perform professional calibration every certain period of time (such as six months or one year).

Application scenarios

Power monitoring: used in power plants, substations and other power facilities to monitor the current of transmission lines, transformers and other equipment, ensure the safe and stable operation of the power system, timely detect abnormal fluctuations in current, and prevent faults from occurring.

Industrial automation: In automated production lines in the manufacturing industry, the current of equipment such as motors and frequency converters can be monitored. Through the analysis of current data, intelligent control and maintenance of equipment can be achieved, such as determining whether the motor is overloaded based on changes in current, and providing early warning and maintenance.

Municipal engineering: In facilities such as municipal pumping stations and air conditioning refrigeration systems, monitoring current is used to ensure the normal operation of equipment and optimize energy efficiency. For example, in the air conditioning system of large shopping malls, the operating parameters of refrigeration equipment are adjusted by monitoring current to achieve energy-saving operation.

Transportation: In the charging facilities of electric vehicle charging stations, electric buses, and trucks, the charging current is monitored to ensure the safety and stability of the charging process and prevent damage to the battery caused by overcurrent charging.

Product overview

ABB UAD206A101 is a programmable logic controller (PLC) specifically designed for industrial environments. In the industrial automation system, PLC plays a core control role, and UAD206A101, with its excellent performance, has become a key equipment for achieving efficient and precise control in many industrial scenarios. It is essentially an electronic system that performs numerical operations and can precisely control various complex industrial processes based on preset programs.

Core functional characteristics

Powerful logical operations and sequence control: Equipped with programmable memory internally, it can store instructions for executing logical operations and sequence control. On industrial production lines, it can accurately coordinate the start and stop sequence of various equipment. For example, on automotive parts assembly production lines, according to preset processes, it controls the robotic arm to grasp and assemble parts in sequence, ensuring orderly production and greatly improving production efficiency and product quality.

Flexible timing and counting functions: with precise timing and counting capabilities. In the process of chemical reactions, precise time can be set to control the reaction duration and ensure that the chemical reaction proceeds fully and stably; In the product packaging process, the counting function is used to count the number of packages, achieving automated packaging counting and quality control.

Integration of Analog and Digital Signal Processing: Supports digital or analog input/output, seamlessly connecting various sensors and actuators. In a smart factory, it can collect real-time analog sensor data such as temperature, pressure, flow rate, as well as digital signals such as equipment operation status and switch on/off. After internal processing, it outputs corresponding control signals to achieve comprehensive monitoring and precise control of the production process.

Highly reliable patented fault-tolerant mechanism: adopting patented fault-tolerant operation technology, by configuring two control modules to work together, the system reliability is greatly improved. When one control module fails, another can seamlessly take over the work immediately, ensuring uninterrupted industrial production processes. This is crucial for industries such as petrochemicals and power that require high continuity of production, effectively avoiding huge economic losses caused by equipment failures.

Accurate time synchronization function: supports external time synchronization using optional GPS satellite signals, ensuring time consistency between the system in different regions and devices. In large-scale industrial automation networks, various devices interact and collaborate based on precise and unified time, greatly improving the stability and coordination of system operation. For example, in distributed energy management systems, various power generation, transmission, and consumption equipment can efficiently cooperate based on precise synchronization time.

Convenient online image update: Provides fault-tolerant online image update function (for FCP270), allowing system program updates to be completed without shutting down the industrial production process. This means that without stopping production, system functions can be upgraded and vulnerabilities can be fixed in a timely manner, reducing production losses caused by downtime maintenance and meeting the modern industrial demand for efficient and sustainable production.

Technical specifications and parameters

Electrical parameters

Rated working voltage: Suitable for common industrial power supply standards, such as 24VDC, to ensure stable operation in complex industrial power grid environments.

Working current range: Depending on the actual load, it can stably carry the corresponding working current, ensuring the normal operation of the equipment under various working conditions.

Isolation voltage: With a high isolation voltage, such as 2500Vrms, it effectively isolates electrical interference between different circuits, prevents equipment from being affected by electrical fluctuations, and ensures system safety and reliability.

Application area 

Manufacturing industry: In the field of electronic manufacturing, equipment control is used for automated production lines, such as mobile phone assembly production lines, to accurately control the movements of equipment such as surface mount machines and welding robots, achieving efficient and high-quality production of electronic products; In the mechanical processing industry, the operation of machine tools can be controlled, and parameters such as tool motion trajectory and cutting speed can be accurately controlled according to processing technology requirements to ensure the machining accuracy of mechanical components.

Energy industry: In oil and gas extraction, monitoring and controlling various extraction equipment and transmission pipelines, real-time monitoring of pressure, flow rate and other parameters, to ensure the safety of oil and gas production and transportation; In the power system, it is used for substation automation control, grid scheduling, etc., to achieve remote monitoring and intelligent control of power equipment, and to improve the stability and reliability of power supply.

Chemical and pharmaceutical industries: In the chemical production process, controlling chemical reaction conditions such as temperature, pressure, acidity, etc. ensures stable quality of chemical products; In the pharmaceutical industry, strict control is exercised over drug production equipment and processes to meet drug production quality standards and ensure drug safety and effective production.

Municipal and Environmental Protection: In urban sewage treatment plants, control the operation of water pumps, aeration equipment, etc. to achieve automation of sewage treatment; In smart buildings, managing lighting, air conditioning, elevators and other systems to achieve optimized management and intelligent control of building energy, improve the efficiency of urban infrastructure operation and residents’ living comfort.

Safety instructions

Operation safety

Only qualified electricians are allowed to perform installation and maintenance. After power failure, wait for 5 minutes for the intermediate circuit capacitor to discharge.

Measure and confirm that the voltage at the input terminals (U1/V1/W1) and DC terminals (UDC+/UDC -) is close to 0V before starting the operation.

Do not operate when the control cable is live to avoid conducting insulation tests on the drive.

Grounding requirements

The drive, motor, and ancillary equipment must be independently grounded, and the specifications of the grounding conductor must comply with safety standards (such as copper conductor ≥ 10 mm ²).

European CE compliant installation requires 360 ° high-frequency grounding to suppress electromagnetic interference.

Mechanical and Electrical Safety

Avoid single person operation during transportation, pay attention to the high temperature risk of the heat sink, and prevent conductive dust from entering the drive.

When handling printed circuit boards, it is necessary to wear a grounding wristband, and the bending radius of fiber optic cables should not be less than 35 mm.

Driver Overview and Compatibility

Product positioning 

ACS800-04/U4 is an IP20 driver module suitable for industrial automation scenarios, supporting direct torque control (DTC) and compatible with permanent magnet synchronous motors.

Framework classification

Divided by power into R2 to R6 frames, different frames correspond to size, heat dissipation requirements, and installation methods (such as flange installation IP55).

Installation and Debugging

Mechanical Installation

Sufficient heat dissipation space needs to be reserved (such as 200mm space above the R2 frame), and the ventilation design of the cabinet needs to meet the air flow requirements.

During flange installation, IP55 protection must be ensured, and grounding must be connected independently.

electrical installation

Power connection: The input cable should match the rated voltage (208-690 V AC), use a symmetrical shielded cable, and ground the shielding layer 360 °.

Motor connection: Select cable specifications based on the frame (e.g. R2 frame motor cable ≤ 16 mm ²), avoiding the use of power factor compensation capacitors.

Control connection: Analog signals require twisted pair shielded cables, while digital inputs/outputs require attention to logic thresholds (12 V DC is “1”).

Installation of safety features

Prevent accidental startup (+Q950): An external AGPS board is required, powered by 230 V AC, and locked by a switch to prevent accidental startup.

Safe torque shutdown (+Q967): External ASTO board, 24 V DC power supply, in compliance with EN 61800-5-2 standard.

Technical parameters and performance

RATING

Current/power: For example, the R2 frame has a rated current of 5.1 A (230 V AC) and a continuous power of 1.1 kW; the R6 frame has a rated current of 290 A (690 V AC) and a continuous power of 200 kW.

Overload capacity: light load (10% overload) can last for 1 minute/5 minutes, heavy load (50% overload) can last for 1 minute/5 minutes.

Electrical characteristics

Input voltage fluctuation ± 10%, frequency 48-63 Hz, power factor 0.98 (rated load).

Output voltage 0 to input voltage, frequency 0-300 Hz, switching frequency 3 kHz (2 kHz for 690 V units).

Heat dissipation and derating

When the ambient temperature exceeds 40 ° C, the rated current will decrease by 1% for every 1 ° C increase; When the altitude exceeds 1000 meters, the rating will decrease by 1% every 100 meters.

Maintenance and component replacement

Routine maintenance

Clean the heat sink every 6-12 months and check the fan’s operating status annually (with a lifespan of approximately 6 years).

Capacitor replacement cycle: R4 and above frames take about 10 years and need to be reformed according to the manual.

component replacement

When replacing the fan, attention should be paid to model matching (such as the R2 frame fan requiring a flow rate of 35 m ³/h), and the functionality of the capacitor needs to be verified after replacement.

Product overview

ABB UAD149A0011 3BHE014135R0011 is a powerful controller module that occupies an important position in industrial automation control systems. It is designed specifically for ABB’s AC 800M and AC 800PEC control systems, and can efficiently achieve key tasks such as data exchange, signal processing, and equipment control within the system. It is one of the core components for building a stable and intelligent industrial automation architecture.

Function characteristics

Communication function: As a communication module, it enables the AC 800M system to communicate smoothly with other devices on the Profibus network. Profibus is a widely used fieldbus standard in the industrial field. With excellent communication protocol conversion and data transmission capabilities, UAD149A0011 ensures fast and accurate data exchange between different devices, effectively improving the information flow efficiency of the entire industrial network.

Integrated I/O: This module integrates analog and digital I/O signal processing functions and can support multiple types of input and output signals. Whether it is analog signals from sensors such as temperature and pressure, or digital signals representing equipment status such as switch on/off and motor on/off status, they can be accurately collected and processed by it, and control signals can be output according to the system’s preset logic to achieve precise control of various industrial equipment.

High reliability diagnosis: Built in powerful self diagnostic function that can monitor its own working status in real time. By continuously monitoring hardware circuits, software programs, and data transmission processes, once a fault or abnormality is detected, the module will quickly issue an alarm and generate detailed diagnostic reports to help maintenance personnel quickly locate the problem, greatly reducing system downtime and ensuring the continuity and stability of industrial production.

Fast scanning and response: With fast scanning speed, it can complete the acquisition and processing of input signals in a very short time, and output control instructions in a timely manner. This feature significantly reduces the response delay of the system, enabling industrial automation systems to quickly respond to various changes in the production process, improving production efficiency and product quality.

Technical Parameter

Electrical parameters

Rated input voltage: 24VDC, suitable for common industrial DC power supply systems, ensuring stable power supply.

Isolation voltage: reaches a high standard, such as 2500Vrms, effectively isolates electrical interference between different circuits, ensuring the safety and reliability of the system.

Power consumption: Maintain at a reasonable level, with specific values depending on the actual workload. Lower power consumption helps reduce system operating costs.

Physical parameters

Size: Approximately 145mm x 145mm x 145mm, the compact design allows for flexible installation within limited control cabinet space, saving space resources.

Weight: Moderate weight facilitates installation and maintenance operations. Specific weight values can be found in the product manual.

I/O parameters

Analog input: Supports multiple types of analog input signals, such as 0-10V, 4-20mA, etc., with high resolution and accuracy, capable of accurately collecting analog data.

Analog output: It can output stable analog signals, which are used to control regulating valves, frequency converters and other equipment. The output accuracy is high and can meet the strict requirements of industrial control.

Digital input/output: With multiple digital input/output channels, it can quickly process digital signals, respond quickly, and is suitable for various switch control scenarios.

Application scenarios

Industrial automation production line: In automated production lines such as automobile manufacturing and electronic equipment production, UAD149A0011 can connect various sensors, actuators, and controllers to achieve comprehensive monitoring and precise control of the production process. For example, it can control the movement of the robotic arm based on the position information of the parts fed back by sensors, ensuring accurate grasping and assembly of the parts, and improving the automation level and production efficiency of the production line.

Process control system: In the field of process control in industries such as chemical, power, metallurgy, etc., this module can collect real-time process parameters such as temperature, pressure, flow rate, etc., and output control signals according to preset control strategies to adjust various equipment in the production process, such as valves, pumps, etc., to ensure stable operation of the production process, optimize production processes, improve product quality and production safety.

Intelligent building control system: In intelligent buildings, UAD149A0011 can be used to connect and control lighting systems, air conditioning systems, security systems, etc. By analyzing and processing various sensor data, intelligent adjustment of the building’s interior environment can be achieved, such as automatically adjusting lighting brightness based on indoor light intensity, automatically controlling air conditioning operation based on temperature changes, and improving the intelligence level and energy utilization efficiency of the building.

Product series and features

BSM N series: low inertia, high dynamic response, using neodymium iron boron magnets, peak torque can reach 4 times continuous torque, supports multiple feedback devices (rotary transformers, Hall sensors, incremental/absolute encoders), protection level IP54/55, working temperature -20 ℃ to+70 ℃, with IEC and NEMA configurations.

BSM C series: high inertia, economical and practical, peak torque is 3 times the continuous torque, suitable for applications that require higher inertia matching, and also supports multiple feedback devices and protection configurations.

SSBSM series: made entirely of stainless steel material, designed for food, liquid, sanitary, and corrosive environments, with a protection level of IP67, capable of withstanding 1500 psi flushing, and certified by BISSC, UL, cUL, and CE.

BSM 25&33 series: Durable circular shell design, supporting foot installation, using standard and reliable neodymium magnet design, can take advantage of brushless technology advantages such as low maintenance, quiet operation, fast acceleration, high torque and power output.

Technical Parameter

Electrical parameters: Different series of motors have different rated voltage, current, frequency and other parameters, such as BSM N series rated voltage 220V, rated current 15A, frequency 50/60Hz, isolation voltage 2500Vrms, etc.

Mechanical parameters: including motor size, weight, inertia, speed range, etc. For example, the BSM50N has dimensions of approximately 172mm × 95mm × 142mm, a weight of 2.4lbs/1.1kg, and a maximum rotational speed of 10000rpm.

Performance parameters: continuous stall torque, peak torque, torque constant, voltage constant, thermal resistance, thermal time constant, etc. For example, BSM50N-133 has a continuous stall torque of 3.9lb in (0.45Nm) and a peak torque of 15.9lb in (1.8Nm).

Performance Curve

The document provides current torque speed performance curves for different models of motors in various series, demonstrating the performance of the motors under different working conditions, helping users intuitively understand the operating status of the motors under various working conditions.

Dimensions and installation

IEC mounting: Detailed lists the installation dimensions of each series of motors, including parameters such as P, AB, U, AH, as well as the lengths of different models of motors with and without feedback devices, and the length and weight increase when equipped with brakes.

NEMA mounting: Introduces the relevant dimensional parameters of NEMA mounting, such as the dimensions of BSM50 series NEMA 23, BSM63/80 series NEMA 34/42, etc.

Options

Cooling kit: BSM90/100 and BSM132 series have blower cooling options, and different models of motors correspond to different blower kit numbers, voltages, currents, and air volumes.

Braking: Data on the holding torque, power, voltage, current, action time, and inertia of various series of motor brakes.

Connectors and cables: connector models, descriptions, and numbers for motor power, feedback, and other connections, such as MCSPOW-08, MCSRES-12, etc.

Engineering information

Motor identification matrix: BSM N, C series and BSM25, 33 series motor identification rules, including frame, series, size, winding code, options, etc.

Selection of servo motors: This article introduces the methods for calculating the requirements of servo motors, including determining the friction and inertia of the load, as well as calculating parameters such as speed, torque, inertia, etc. under different mechanical transmission modes (direct drive, gear drive, tangential drive, ball screw drive).

Motion Curve Analysis: How to interpret the speed time curve, calculate acceleration torque, operating torque, deceleration torque, and root mean square torque, and determine the torque demand of the motor throughout the entire working cycle.

Temperature calculation: Calculate the temperature rise of the motor winding based on power loss and thermal resistance, and determine whether the motor is operating within the safe temperature range.

Drivers and controllers

Servo drive: MicroFlex analog、MicroFlex e100、MicroFlex e150、MotiFlex e100、MotiFlex e180  The characteristics, parameters, models, and selection information of the series of drivers.

Motion controllers: The functions, number of axes, communication methods, and order codes of controllers such as NextMove ESB-2, NextMove e100, and NextMove PCI-2.

Software tool

ABB DriveSize and MCSize software tools can be used for the selection of servo motors and drives. MCSize has a motor database and selection criteria to help users easily and accurately choose suitable servo motors and drive systems.

PLC system

This article introduces the system overview, expansion capabilities, and features of the AC500, AC500 eCo, and AC500-XC series PLCs. For example, the AC500 CPU can locally expand up to 10 I/O modules, while the AC500-XC is suitable for extreme environments.

Product overview

ALSTOM DFI-150-0003 Limelight Diagnostic Board is a high-performance flame detector circuit board designed specifically for industrial environments. Its core task is to accurately detect flames during welding, cutting, and various combustion processes, and to undertake the responsibility of safety monitoring. With advanced technology and reliable performance, it has become a key component in ensuring stable equipment operation and improving production efficiency in many industrial production processes.

Brand background

ALSTOM, as a leading global supplier of energy and transportation solutions, has an outstanding reputation in the industry. Over the years, with profound technological accumulation and a spirit of continuous innovation, ALSTOM’s products have widely penetrated into multiple important fields such as power, railway, and industry. Its strict control over quality and precise insight into customer needs make every product synonymous with reliability and advancement. The DFI-150-0003 Limelight diagnostic board is a typical representative of this brand philosophy.

Specification parameters

Electrical parameters

Rated voltage: 220V, suitable for common industrial power supply standards.

Rated current: 15A, meeting the current requirements for stable operation of the equipment.

Frequency: 50/60Hz, compatible with power frequencies in different regions.

Input voltage range: Supports DC working voltage and has certain voltage adaptability.

Isolation voltage: up to 2500Vrms, effectively ensuring circuit safety and preventing electrical faults from interfering.

Overvoltage protection: ± 30V, capable of handling instantaneous voltage fluctuations and protecting internal circuit components.

Static current: ≤ 5mA, with extremely low energy consumption in standby and other static states.

Dynamic current: ≤ 25mA, stable current during operation to ensure efficient operation of the equipment.

Physical and environmental parameters

Protection level: Available in IP66 or IP20 ratings. IP66 rating can achieve dust, water, and strong water spray prevention, suitable for extremely harsh industrial environments; The IP20 rating provides basic dust protection and is suitable for places with relatively good environments.

Working temperature range: -20 ℃ to+70 ℃, can work stably in cold or high temperature industrial scenarios.

Size: Typically 172mm x 95mm x 142mm, the compact design makes it easy to install inside various devices.

Interface and signal parameters

Output signal type: equipped with multiple switch output and analog output interfaces, convenient for connecting with different types of control systems. Simultaneously supporting RS485 communication ports to achieve efficient data transmission and communication.

Interface type: Provides digital or analog interfaces, which can be flexibly customized according to actual application needs to meet diverse device connection requirements.

Signal type: Supports infrared, ultraviolet, ion current, visible light, and multi band flame signal input, greatly improving the accuracy and comprehensiveness of flame detection.

Response time: less than 1 second, able to quickly capture changes in flame state and provide timely feedback information.

Core functions

Flame detection: Utilizing advanced sensor technology to accurately identify multiple flame signals. Both weak welding flames and high-temperature combustion flames can be quickly and accurately detected, providing reliable basis for subsequent control and decision-making.

Fault diagnosis: Built in powerful self diagnostic program, constantly monitoring its own working status. Once internal circuit faults or signal abnormalities are detected, clear alarm signals should be immediately issued to help maintenance personnel quickly locate the fault point and shorten equipment downtime.

Process control: Real time feedback of detected flame status information to the control system in the form of digital or analog signals. The control system adjusts the operating parameters of the equipment accordingly, such as adjusting the fuel supply of the burner, controlling the power of the cutting equipment, etc., in order to achieve precise control of the industrial production process, improve product quality and production efficiency.

Digital display: Equipped with an intuitive digital display screen, it presents real-time key parameters of the flame, such as flame intensity, combustion stability, etc. Operators do not need complex instrument detection, and can quickly understand the flame status through the display screen, which facilitates equipment debugging, maintenance, and daily monitoring.

​Working principle

The DFI-150-0003 Limelight diagnostic board receives signals such as infrared, ultraviolet, ion current, and visible light generated by flames through specific sensors. After being preliminarily amplified by a preamplifier, these signals are transmitted to the signal processing circuit. The signal processing circuit uses complex algorithms to analyze, filter, and extract features from signals, in order to distinguish between real flame signals and environmental interference signals. Once the flame signal is confirmed to be valid, the diagnostic board will generate corresponding control signals and status information based on preset rules and algorithms. On the one hand, this information is transmitted to the external control system through the output interface for device operation control; On the other hand, it is visually presented on a digital display screen, making it convenient for operators to monitor in real-time. At the same time, the self diagnostic module will continuously check the hardware and software operation status of the diagnostic board itself to ensure the reliability of the entire system.

Key advantages

High sensitivity and anti-interference: Advanced signal processing technology and high-sensitivity sensors are used to accurately detect extremely weak flame signals. At the same time, through multiple filtering and anti-interference algorithms, the impact of environmental noise, electromagnetic interference and other factors on the detection results is effectively reduced, greatly reducing the false alarm rate and ensuring the accuracy and reliability of the detection results.

Quick response and alarm: When detecting flame abnormalities or equipment failures, it can respond in a very short time (less than 1 second) and quickly emit clear and loud alarm signals. This feature has won valuable time for timely handling of potential hazards and avoiding accidents, effectively ensuring the safety of industrial production.

Industrial grade design: From hardware material selection to software algorithms, strict industrial standards are followed for design. The high protection level shell, wide temperature range adaptability, and stable and reliable circuit design enable it to operate stably for a long time in harsh industrial environments such as high temperature, humidity, dust, and strong electromagnetic interference, with excellent durability and reliability.

Self diagnostic function: The powerful self diagnostic function can monitor the working status of the diagnostic board in real time, including the integrity of hardware circuits, the operation of software programs, etc. Once abnormalities are detected, maintenance personnel are immediately notified through the alarm system, greatly improving the convenience and efficiency of equipment maintenance and reducing equipment failure rates.

Digital reading function: The intuitive digital display screen presents the flame state and equipment operating parameters in a clear and easy to understand manner, allowing operators to quickly read information without complex training. This not only facilitates the daily operation and maintenance of the equipment, but also improves work efficiency and reduces operational errors caused by human error.

Precautions

Installation environment: It should be installed in a dry, well ventilated environment without strong electromagnetic interference. Avoid installing in high temperature, humid or dusty places to prevent affecting equipment performance and service life. If used in an environment with explosion-proof requirements, it is necessary to ensure that the equipment installation complies with the corresponding explosion-proof standards.

Electrical connection: When making electrical connections, it is necessary to strictly follow the requirements of the product manual. Ensure that the wiring is secure and avoid loose connections that may cause poor contact or short circuit faults. At the same time, attention should be paid to the matching of input and output voltage and current to prevent equipment damage due to mismatched electrical parameters.

Regular maintenance: It is recommended to regularly inspect and maintain the equipment, including cleaning the casing, checking for loose wiring, and testing the sensitivity of sensors. Regular maintenance helps to promptly identify potential issues and ensure that the equipment is always in optimal working condition.

Software upgrade: Follow the official software upgrade information released by ALSTOM and update the device’s software in a timely manner. Software upgrades typically fix known vulnerabilities, optimize performance, and enhance device stability and functionality.

Troubleshooting: When the device malfunctions and alarms, do not blindly disassemble or forcefully restart it. You should first refer to the fault diagnosis guide in the product manual to investigate the possible causes of the fault. If you are unable to resolve the issue on your own, please contact ALSTOM’s professional technical support personnel or authorized repair agencies in a timely manner.

Product Overview

ABB’s GCC960C102 motor driver is a high-performance drive device widely used in the industrial field, designed to provide precise and stable drive control for various types of motors. It can adapt to various types of motors, including AC asynchronous motors, synchronous motors, etc., and can meet the diverse needs of motor drive in different industrial scenarios. In industrial automation production lines, GCC960C102 can drive conveyor belt motors to ensure stable material transportation; In equipment such as fans and pumps, efficient driving of motors can also be achieved to optimize equipment operating efficiency.

Specification parameters

（1） Electrical parameters

Input voltage range: GCC960C102 can adapt to a wide range of input voltages and can operate stably between 380VAC and 690VAC. This wide voltage adaptability enables it to be used in industrial settings with different power environments, ensuring reliable operation in both modern factories with stable power supply and traditional industrial areas with certain voltage fluctuations.

Output current capability: Its maximum output current can reach [I1] A, which can meet the driving requirements of motors of various power levels. From small motors to medium and even some large motors, GCC960C102 can provide sufficient driving current to ensure the normal operation of the motor.

Frequency adjustment range: The output frequency adjustment range is 0Hz-600Hz. In practical applications, the output frequency can be flexibly adjusted according to the working requirements of the equipment driven by the motor, achieving a wide range of motor speed adjustment. For example, in some equipment that requires low-speed and high-precision operation of the motor, the output frequency can be precisely adjusted to a lower value; In devices that require high rotational speed, the frequency can be increased to a higher level.

Power factor: This driver has a high power factor, usually above 0.95. High power factor means that during the operation of the motor, the driver can more effectively utilize the power grid, reduce reactive power loss, lower the electricity cost of the enterprise, and also help improve the power supply quality of the grid.

（2） Mechanical parameters

Size: As mentioned earlier, its external dimensions are designed to be compact, measuring [L1] mm in length, [L2] mm in width, and [L3] mm in height. This size makes it easy to install inside equipment with limited space such as control cabinets and distribution boxes, effectively saving installation space for industrial equipment and optimizing system layout.

Weight: Approximately [W1] kg, which ensures the stability of the equipment and does not impose excessive burden on installation and handling. During the installation and maintenance of the equipment, staff can easily operate it, improving work efficiency.

Protection level: The protection level reaches IP [P1], which can effectively prevent dust from entering the interior of the drive, and also has the ability to protect against a certain degree of water splashing. This enables GCC960C102 to operate normally in complex industrial environments such as dusty and humid environments, such as textile workshops and food processing plants, greatly improving the product’s environmental adaptability and reliability.

（3） Communication parameters

Communication protocol support: Supports multiple common industrial communication protocols, such as Modbus RTU and Modbus TCP protocols. Through these communication protocols, GCC960C102 can communicate and connect with different brands and models of programmable logic controllers (PLCs), smart meters, upper computers, and other devices to achieve data exchange and collaborative control. In a typical industrial automation system, the driver can receive control instructions sent by the PLC through the Modbus protocol, such as commands for starting, stopping, and speed adjustment of the motor. At the same time, the operating status data of the motor, such as current, speed, fault information, etc., is fed back to the PLC, so that the operator can grasp the real-time operation of the equipment.

Interface type: Equipped with RS-485 interface and Ethernet interface. The RS-485 interface has strong anti-interference ability and a long transmission distance. In the complex electromagnetic environment of industrial sites, it can stably transmit data and can connect up to multiple node devices, achieving distributed control. The Ethernet interface provides high-speed data transmission capability, which can meet the communication needs of large data volumes and high real-time requirements. For example, in smart factories, a large amount of equipment status data needs to be quickly uploaded to the management system, and control instructions need to be issued to the drivers in a timely manner. Ethernet interfaces can meet these requirements well, ensuring the efficient operation of the system.

Core functions

Precise control of motor: Through advanced control algorithms and hardware circuits, GCC960C102 can achieve precise control of motor speed, torque, and steering. In terms of speed control, the speed accuracy can reach ± 0.1%, which can meet the extremely high requirements for speed accuracy in industrial applications, such as motor drive in precision machining equipment. In terms of torque control, the output torque can be adjusted in real time according to changes in motor load, and the torque control accuracy can reach ± 1%, ensuring that the motor can operate stably under different working conditions. At the same time, quick switching of motor direction can be achieved through simple control instructions to meet the requirements of different working modes of the equipment.

Rich protection functions: To ensure the safe operation of the motor and driver, GCC960C102 has multiple protection functions. The overcurrent protection function can quickly cut off the output current when the motor is overloaded or short circuited, preventing the motor and driver from being damaged due to excessive current. The overvoltage protection function can automatically take protective measures when the input voltage is too high, avoiding internal electronic components from burning out due to excessive voltage. The undervoltage protection function can stop the driver from working when the voltage is too low, preventing the motor from malfunctioning due to insufficient voltage, and also protecting the hardware of the driver. In addition, it also has an overheat protection function. When the internal temperature of the driver is too high, it will automatically reduce the output power or stop working to prevent component overheating and damage, and automatically resume operation after the temperature returns to normal.

Data monitoring and feedback: Equipped with powerful data monitoring functions, it can collect real-time operational data of motors, such as current, voltage, speed, temperature, etc. On the one hand, these data can be uploaded in real-time to the control system through a communication interface, providing operators with equipment operation status information and facilitating timely understanding of equipment working conditions; On the other hand, closed-loop feedback is used for motor control. For example, when the actual speed of the motor deviates from the preset speed, the driver automatically adjusts the output voltage or frequency based on the collected speed data to quickly restore the motor speed to the set value, ensuring the stability and accuracy of the motor operation. Through long-term monitoring and analysis of motor operation data, preventive maintenance of equipment can also be achieved, potential fault hazards can be detected in advance, equipment failure rates can be reduced, and production efficiency can be improved.

Flexible parameter settings: Users can flexibly set various parameters based on actual application needs through the driver’s operation panel or upper computer software. Basic parameters such as rated power, rated voltage, and rated current of the motor can be set, and advanced parameters such as control mode, acceleration and deceleration time, and torque compensation can also be adjusted. This flexible parameter setting function enables GCC960C102 to adapt to different types of motors and complex industrial application scenarios, meeting the diverse control needs of users. For example, in fan applications, appropriate acceleration and deceleration time and torque compensation parameters can be set according to the characteristic curve of the fan to achieve efficient and smooth operation of the fan; In the application of water pumps, the control mode can be adjusted according to the working requirements of the water pump to optimize its operational performance.

Key advantages

High reliability: ABB, as a globally renowned electrical equipment manufacturer, always adheres to strict quality standards in product development and production processes. The GCC960C102 motor driver uses high-quality electronic components and advanced manufacturing processes, and has undergone extensive simulation testing and practical verification to ensure stable and reliable operation in complex industrial environments. In harsh environments such as high temperature, high humidity, and strong electromagnetic interference, this drive can maintain normal operation with an extremely low failure rate, effectively reducing equipment downtime, ensuring production continuity, and reducing maintenance costs for the enterprise.

Excellent control performance: With advanced vector control algorithms and high-performance hardware platform, GCC960C102 achieves precise control of the motor. Its high precision in speed and torque control, fast dynamic response speed, can meet the strict requirements of various complex industrial applications for motor control. In fields such as precision machining and automated production lines, the excellent control performance of this driver can effectively improve product quality and production efficiency. For example, in electronic device manufacturing production lines, drivers can precisely control the movement of motors, ensuring accurate placement and welding of electronic components, and improving product yield.

Good compatibility: Supports multiple communication protocols and interface types, and can seamlessly integrate with devices of different brands and models. Whether it is ABB’s own automation products or other brands of PLC, sensors, actuators and other equipment, communication and collaborative work can be easily achieved. This good compatibility makes GCC960C102 have a wide range of application prospects in industrial automation systems. Whether it is the renovation and upgrading of old equipment or the construction of new automated production lines, it can be easily integrated into them, improving the flexibility and convenience of system integration.

Efficient and energy-saving: By optimizing the motor control strategy, GCC960C102 can dynamically adjust the output power according to the actual load situation of the motor, achieving energy-saving operation. Compared with traditional motor drive methods, using this driver can reduce motor energy consumption by 10% -30%. In the long-term operation process, it can save a lot of electricity costs for enterprises, which is in line with the concept of green industrial development. For example, in industrial fan and water pump applications, real-time adjustment of motor speed based on actual operating conditions avoids energy waste during constant speed operation of the motor, achieving significant energy-saving effects.

Product Overview

The UCU-22, UCU-23, and UCU-24 control units launched by ABB Industrial Drives are the core components in the field of industrial transmission control. These control units are mainly used to precisely regulate the operating status of various motors. On industrial automation production lines, they can accurately control the speed, direction, and torque output of motors based on preset programs and real-time feedback signals, thereby ensuring the stable and efficient operation of production equipment. From the perspective of appearance design, they adopt a compact structure. 

Precautions

Installation environment requirements: It should be installed in a dry, well ventilated environment without severe vibration and electromagnetic interference. High temperature environment (over 50 ° C) may cause overheating of electronic components inside the control unit, affecting its performance and service life; High humidity environment (humidity greater than 85%) may cause electrical short circuit faults; Severe vibrations may cause internal components to loosen, resulting in poor contact and other issues; Strong electromagnetic interference may interfere with the transmission of control signals, leading to abnormal control. Therefore, it is necessary to choose a suitable installation location during installation, such as being away from strong electromagnetic interference sources such as large motors and transformers. If necessary, shielding measures can be taken.

Electrical connection specifications: When making electrical connections, it is necessary to strictly follow the product manual to ensure that the wiring is firm and correct. Incorrect wiring can lead to serious electrical faults such as short circuits and open circuits, damaging control units and motor equipment. At the same time, attention should be paid to the input and output voltage and current parameters of the control unit, and appropriate power sources and loads should be connected. It is strictly prohibited to operate beyond its rated parameters to prevent equipment damage from overvoltage and overcurrent.

Communication parameter settings: When communicating with other devices, it is necessary to correctly set communication protocol, baud rate, data bits, parity bits, and other parameters. The communication parameters between different devices should be matched with each other, otherwise it may cause communication failures and prevent data exchange and collaborative control. During the system debugging phase, it is necessary to carefully check the communication parameter settings to ensure stable and smooth communication.

Maintenance points: Regularly inspect and maintain the control unit, including checking whether the wiring is loose, whether there is dust accumulation on the module surface, and whether the cooling fan is running normally. Loose wiring may lead to increased contact resistance, affecting the stability of equipment operation; Excessive accumulation of dust may affect heat dissipation and cause equipment overheating; A faulty cooling fan may cause the control unit to overheat and damage internal components. If any abnormal situation is found, it should be dealt with in a timely manner, such as tightening the wiring, cleaning dust, replacing faulty fans, etc., to ensure the continuous and stable operation of the control unit.

Similar model supplement

ABB UCU-30 series: Compared with UCU-22, UCU-23, and UCU-24, the UCU-30 series has further expanded its functionality. It has added more communication interface options, in addition to the common RS-485 and Ethernet interfaces, it also supports CANopen protocol interfaces, which can meet some industrial application scenarios with special requirements for communication protocols. In terms of motor control performance, the UCU-30 series has higher control accuracy, with speed control accuracy up to ± 0.05% and torque control accuracy up to ± 0.5%. It is suitable for high-end manufacturing industries that have extremely strict requirements for motor control accuracy, such as semiconductor manufacturing equipment, precision medical equipment production equipment, etc.

ABB UCU-15 series: This series is positioned as an entry-level product and is relatively simplified in terms of functionality and performance compared to UCU-22 and others. It is mainly suitable for small industrial enterprises or simple automation equipment with low control function requirements and limited budget. The UCU-15 series only supports Modbus RTU communication protocol. In terms of motor control, the speed adjustment range is relatively narrow, from 0-2000 revolutions per minute, and the control accuracy is slightly lower, with a speed control accuracy of ± 0.5% and a torque control accuracy of ± 3%. But it has cost advantages, relatively low prices, and can meet the basic automation control needs of small businesses.

Operation principle and hardware

Hardware description

The control unit is an interface for external converter control signals, and it controls converter modules via fiber optic links. The control unit contains a control board and connector boards. The control unit contains integrated branching unit functionality for collecting and storing real-time data from the converter modules to help fault tracing and analysis. The data is stored on a memory card which can be analyzed by

ABBservice personnel.

The control unit requires an external 24 V DC power source. It has three option slots for I/O extensions, encoders and fieldbus adapters and functional safety modules,and aremovable memoryunit. If it is necessary to replace the control unit, you can keep the parameter settings by moving the memory unit from the defective control unit tothenewone.ThecontrolunithasoneoptionslotforconnectingaRDCODDCS communication option module. The control unit also has a connection for a control panel.

Thedrive-to-drive link (XD2D) is a daisy-chained RS-485 transmission line that allows basic master/follower communication with one master and multiple followers. The X485 connection provides a connection for the optional CIO-01 I/O module.

The control unit has two Ethernet ports for control network and two Ethernet ports fortool/gatewaynetwork.Environmentalsensorsonthecontrolunitmeasurehumidity and temperature

Mechanical installation

Examining the delivery

Makesurethat these items are included:

• controlunitwiththeI/Oconnector plugs

• memoryunit(UMU-01)

• microSDHCflashmemorycard(insertedinitsslot inside the memory unit)

• optionslotadapters(USCA-02)

• real-timeclock battery (BR2032).

Makesurethat there are no signs of damagetotheitems.

￭ Identifying different control unit types

Before you install the control unit, make sure that it has the correct control program.

The control program is shown on the label attached to the memory unit.

Makesurethat the control unit is correct for your equipment configuration.

Additional information on the connections

￭ Powersupplyforthecontrol unit (XPOW)

Refer to the control unit connector data for the current and voltage ratings of the power supply.

Connect an additional external power supply to the free +24 V and GND terminals of the XPOWterminal block if:

• thecontrolunitmustbekeptoperationalduringinputpowerbreaks,forexample,because of continuous fieldbus communication

• immediaterestartisnecessary after a power break (that is, no control unit power-up delay is permitted).

￭ Digital interlock (DIIL)

Digital interlock input (DIIL) terminal is originally intended for interlock signals that stop the drive/unit when necessary. In the ACS880 primary control program, DIIL terminal is the source for the run enable signal by default. The inverter unit or drive cannot start, or it stops when there is no DIIL signal. In other control programs (and units), the default use of the DIIL terminal varies. Refer to firmware manual for more information.

Note: This input is not SIL or PL classified.

￭ Control panel connection (XPAN)

The XPANconnectorcanbeusedtoconnectanassistant control panel or FDPI-02 diagnostics andpanelinterfaceunittothecontrolunit.WithFDPI-02,itispossibleto connectonecontrolpaneltotwoormorecontrolunitsinachaintopology,alsoknown asapanelbus.Formoreinformation,refertoFDPI-02diagnosticsandpanelinterface user’s manual (3AUA0000113618 [English]).

The XPANTERMswitchsetsthetermination for the panel bus. Must be set to ONif thereisnopanelbus,orifthecontrolunitisthelastoneinapanelbus.Onintermediate units in a panel bus, set termination to OFF (1).

￭ TheXD2Dconnector

The XD2DconnectorhasanRS-485connection that can be usedfor

• basicmaster/follower communication with one master drive/unit and multiple followers

• fieldbuscontrol through the embeddedfieldbus interface (EFB)

• drive-to-drive (D2D) communication implemented by application programming.

Refer to the firmware manual for the availability of these features and related parameter settings.

Terminate the bus on the units at the ends of the drive-to-drive link. Disable bus termination on the intermediate units.

Useashieldedtwisted-paircablefordata,andanotherpairorawireforsignalground(nominalimpedance100 165ohm,forexampleBelden9842).Forthebestimmunity use high quality cable. Keep the cable as short as possible. Avoid unnecessary loops and parallel runs near power cables such as motor cables.

Product Overview

ABB XDD501A101 bus terminal module, product number XDD501A101, corresponding to 3BHE036342R0101, originated in Sweden, is a key component for equipment connection and signal transmission in the field of industrial automation. Its design is compact, although there is currently no official exact size, it can be inferred from similar products that it can adapt to the limited space of various control cabinets and distribution boxes, which is conducive to system integration layout. Weighing approximately 2kg, it balances the stability of internal components with stable performance, making it easy to handle, install, and maintain.

Brand background

ABB Group is a globally renowned leader in the fields of power and automation technology, with operations in over 100 countries and 132000 employees. In 1988, it was formed by the merger of ASEA from Sweden and BBC from Switzerland, with its headquarters located in Zurich, Switzerland. ABB has a deep foundation in the field of electrical equipment manufacturing, having developed numerous major technologies such as the world’s first three-phase transmission system, high-voltage direct current transmission technology, and the first electric industrial robot, and being the first to achieve commercial applications. Occupying a dominant position in the field of high-voltage direct current transmission systems, it is one of the four giants of global industrial robots. Its sales volume, installation volume, and transportation volume of power grid equipment rank first in the world. In the process automation market of the process industry, it has long held the top spot with its powerful DCS control system.

Specification parameters

Working voltage: It usually supports a wide voltage range, such as 24VDC to 48VDC, which can adapt to power configurations in different industrial scenarios and ensure stable operation in various power environments.

Weight: Approximately 2kg, convenient for staff to carry out transportation operations during installation, commissioning, and maintenance.

Communication Protocol: It is highly likely to support common industrial communication protocols such as Modbus to achieve efficient communication connections with PLCs, smart meters, upper computers, and other devices of different brands and models, and to build a massive industrial control network.

Interface type: Equipped with standard electrical interfaces, such as RS-485 interface, utilizing its excellent anti-interference ability and long transmission distance to stably transmit data in complex electromagnetic environments of industrial sites, and can connect up to multiple node devices; It may also have Ethernet interfaces to achieve high-speed data transmission, meeting communication scenarios with high data volume and real-time requirements.

Core functions

Signal transmission: Efficiently and accurately transmit analog signals (such as continuously changing voltage signals from temperature sensors and current signals from pressure sensors) and digital signals (such as on/off status signals of switches and start/stop signals of motors) generated by on-site equipment to the control system. At the same time, the control instructions of the control system are transmitted in reverse to on-site executing devices (such as motors and valves) to ensure bidirectional data exchange and coordinated operation of the entire industrial automation system. For example, on an automated production line, sensors transmit information such as product location and quantity to the PLC control system through this module. After processing, the PLC sends control signals to the motor through this module to adjust the running speed and start stop of the conveyor belt.

Device Connection: As a bridge connecting on-site devices and control systems, it can connect various types of sensors, actuators, and other devices to achieve interconnectivity between different devices, integrating various dispersed devices into an organic automation control system. In smart buildings, sensors and controllers of lighting systems, air conditioning systems, security systems, and other equipment can be connected and centrally managed and intelligently regulated through a central control system.

Working principle

When the on-site equipment generates a signal, whether it is analog or digital, the XDD501A101 bus terminal module will first collect the signal. For analog signals, they may be converted into digital signals through internal analog-to-digital conversion circuits for subsequent processing and transmission. Next, the module packages the processed signals into specific format data packets based on the supported communication protocol (such as Modbus), and sends them to the control system through the corresponding interface (such as RS-485 or Ethernet interface). When the control system issues a control command, the module receives the command data packet, parses the control information, and converts it into a signal form suitable for on-site execution equipment (such as analog output signal controlling valve opening, digital output signal controlling motor start stop), thereby driving the execution equipment to complete the entire control process.

Key advantages

High reliability: Using high-quality electronic components and advanced manufacturing processes, it has good electrical insulation performance and anti-interference ability. It can operate stably in complex industrial environments (such as strong electromagnetic interference, high humidity, and high dust), reduce equipment failure rates, and ensure the reliable operation of the system.

Flexible compatibility: Supports multiple communication protocols and interface types, seamlessly connects and communicates with devices of different brands and models, adapts to diverse industrial automation system architectures, greatly improving the flexibility and convenience of system integration.

Compact design: With its compact size and light weight, it is not only easy to install in equipment such as control cabinets with limited space, but also reduces transportation and installation costs, improving system deployment efficiency.

Powerful signal processing capability: capable of quickly and accurately collecting and transmitting various signals, meeting the real-time and accuracy requirements of industrial automation systems, ensuring the timeliness and accuracy of system control.

Precautions

Installation environment: It should be installed in a dry, well ventilated environment without severe vibration and electromagnetic interference, avoiding installation in high temperature, high humidity or dusty places to ensure the normal operation and service life of the module.

Electrical connection: When making electrical connections, it is important to ensure that the wiring is firm and correct to avoid short circuits, open circuits, and other situations. At the same time, it is necessary to strictly connect the appropriate power supply and load according to the electrical parameter requirements of the module to prevent overvoltage and overcurrent damage to the module.

Communication settings: When communicating with other devices, it is necessary to correctly set communication protocol, baud rate, data bits, parity bits, and other parameters to ensure stable and smooth communication. The communication parameters between different devices should match each other, otherwise it may cause communication failures.

Maintenance: Regularly inspect and maintain the module, such as checking for loose wiring and dust accumulation on the module surface. If any abnormal situation is found, it should be dealt with in a timely manner to ensure the continuous and stable operation of the module.

Similar model supplement

ABB XDD502A101: Similar in functionality to XDD501A101, but with an increased number of ports, it may be suitable for complex system scenarios that require connecting more devices, further improving system integration.

ABB XDD501B101: Optimized in terms of communication performance, supporting higher communication rates and better adaptability for industrial automation applications that require extremely high data transmission speeds, such as data acquisition and control for high-speed production lines.