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

Electrical Specifications

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

which need to be matched with the corresponding transformer; 

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

or else measures need to be taken. 

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

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

Motor-related parameters: 

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

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

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

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

Control specifications

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

and different stop modes and ramp times can be selected. 

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

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

of functions.

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

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

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

Communication specifications

Communication interface and protocol: 

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

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

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

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

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

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

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

Other specifications

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

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

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

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

Technical characteristics

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Application Scenario

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

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

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

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

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

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

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

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

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

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

ABB BSD Brushless Servodrives

Precautions for operation

Danger

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

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

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

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

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

Caution 

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

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

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

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

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

Precautions for transportation

Caution

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

Compulsory

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

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

Precautions for installation

Caution

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

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

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

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

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

Compulsory

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

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

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

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

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

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

Servo Motor Specifications

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

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

Servo amplifier specifications

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

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

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

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

ABB Baldor FlexDrive Servo Drives

Electrical Specifications

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

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

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

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

Control Specifications

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

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

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

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

Communication Specifications

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

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

Physical Specifications

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

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

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

Other specifications

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

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

Product Notice Intended use:

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

industrial power installations according to the standards EN60204 and VDE0160.

They are designed for machine applications that require variable speed controlled

three phase brushless AC motors.

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

— Home appliances

— Medical instrumentation

— Mobile vehicles

— Ships

— Airplanes

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

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

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

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

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

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

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

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

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

— System documentation must be available at all times.

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

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

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

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

PRECAUTIONS: Classifications of cautionary statements.

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

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

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

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

Electrical shock can cause serious or fatal injury.

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

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

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

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

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

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

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

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

ABB AC servo motors BSM Series

BSM Series Servo Motors

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

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

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

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

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

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

Motion Control Products

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

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

Introduction to Motion Control and PLC products

Solutions

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

performance Motion Control Drives, rotary servo motors, PLCs and

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

Choice

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

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

Quality, reliability & design

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

Experience

Technical knowledge is the key to solving customers’ needs.

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

demanded by the markets we serve. 

Application Scenarios

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

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

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

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

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

New BSD Series A complete range,

ABB Sace S.p.A. presents its new BSD servo system, a compact, high performance and easy product.

The BSD servo drive meets the needs of engineers, looking for high-performance, easy and reliable products, and buyers, who have lower and lower budgets to make their products competitive in today’s selective market.

ABB: A “made in Europe” brand, worldwide identified as a synonymous of reliability, quality and security. New BSD servo system by ABB Sace: the perfect partner for any of your application needs

Driver Specifications

• Range from 100 watt to 2 Kw

• Supply: 220 Vac

• Compact servo system and high performances

• Analog speed command +/- 10 Volt

• Analog torque command +/- 10 Volt

• Pulse train command up to 1 Mhz

• Serial encoders from 131.072 pulses/turn (standard

• Anti-vibration filter (patent pending)

• Auto-tuning

• Automatic off-set adjustment

• Notch filters

• Configurable simulated encoder output

• Software windows: BSD Configurator.

cutting edge

High Accuracy: Equipped with 131,072 pulses/revolution (17-bit) serial encoder, it can achieve high positioning accuracy and excellent rotational linearity even at low speeds, ensuring precise motor operation and meeting the requirements of applications with stringent positioning accuracy.

High adaptability: Two types of motors, low inertia (3000Rpm) and medium inertia (2000Rpm), with a variety of power options ranging from 100W to 2kW, can be adapted to different work requirements. Different power motors have different torque, speed, current and other parameters, which can meet diversified industrial applications, such as low-power motors for small equipment, high-power motors can be used for large machinery.

Good stability: the motor shaft is equipped with keys, which enhances the stability of the mechanical connection, reduces vibration and displacement during operation, and guarantees the stable operation of the equipment. With vibration resistance, it can withstand vibration of 5g (49m/s²), adapting to the working environment with vibration, reducing the impact of vibration on the performance and life of the motor.

Perfect matching function: the motors with brake have different braking torque, the excitation voltage is 24Vdc, the attraction time and release time are shorter, and the braking power is also different, which can provide suitable braking performance for different applications and ensure the equipment stops safely. Perfectly matched with BSD series servo drives, they work together to achieve the best performance.

Easy to install and use: The document lists the dimensions of each motor model in detail, which is convenient for layout and selection during equipment design and installation.

Applicable industrial scenarios

Scenarios requiring high-precision positioning: Since the motor is equipped with a serial encoder with 131,072 pulses/revolution, it has high positioning accuracy and excellent rotational linearity, which is an obvious advantage in the fields of electronics manufacturing and precision instrument manufacturing. For example, in the manufacture of electronic chips, where the positioning accuracy of components is extremely high, the motor ensures precise operation of the production equipment and improves product quality and productivity.

Scenarios with different requirements for torque and speed: the motors are classified into low inertia (3000Rpm) and medium inertia (2000Rpm), with power ranging from 100W to 2kW, and various torque and speed parameters. In the field of packaging machinery, different packaging tasks may require different torques and speeds. Low-power, high-rpm motors can be used for material conveying in small packaging equipment, while high-power motors with the right torque can meet the operational needs of large packaging machinery. In textile machinery, different processes require different torques and speeds of motors, and this series of motors can meet these variations.

Scenarios with braking requirements: motors with brakes have different braking torques, short attraction times and release times, and are suitable for occasions where frequent starting and stopping is required or where equipment is required to stop quickly. Such as cranes, lifts and other equipment, in the process of operation requires a reliable braking system to ensure safety, this series of motors with brake can meet this demand.

Scenarios that need to adapt to complex working environments: the motors can withstand vibration of 5g (49m/s²), and in some industrial environments where there is vibration, such as mining machinery, construction machinery and other fields, they can also operate stably to ensure that the equipment works normally and to reduce failures caused by vibration.

ABB Advant Controller 110

Advant® OCS Open Control System

Produktübersicht: Der Advant Controller 110 ist eine mittelgroße Verarbeitungsstation mit Steuerungs-, Regelungs- und Kommunikationsfunktionen für eine Vielzahl industrieller Szenarien, entweder als eigenständige Lösung oder als Teil eines Advant OCS-Systems. Sie führt Steuerungsaufgaben, Schrittlogik, Regelungs-, Zähl- und Berechnungsfunktionen aus und unterstützt die Ereignisprotokollierung mit hoher Verarbeitungsleistung und einer Programmierzykluszeit von nur 2 ms.

Programmierung und Bedienung: Die Advant Station 100 wird mit der grafischen Programmiersprache AMPL konfiguriert. AMPL basiert auf Funktionsblöcken, was die Erstellung von Anwendungen erleichtert, und das gedruckte Programm stimmt mit der Bildschirmanzeige zur Fehlerbehebung überein.

Prozesskonnektivität: Unterstützt eine breite Palette von S600-E/A-Geräten, die digitale und analoge Signale, einschließlich Gleich- und Wechselstromsignale, sowie intelligente Impulszähler verarbeiten können. Das Gerät ist in einem Metallgehäuse (IP20) untergebracht, und die Prozesskabel werden an der Vorderseite des Geräts angeschlossen, was eine saubere und platzsparende Lösung darstellt. Die Anschlussmöglichkeit von dezentralen E/As – Advant Fieldbus 100 für die S800 E/A-Serie und PROFIBUS für zusätzliche externe E/A-Stationen – ermöglicht darüber hinaus eine Vielzahl von Anlagentopologien.

Systemanbindung und Kommunikation: Als Bestandteil des Advant OCS-Automatisierungssystems unterstützt es eine Vielzahl von Kommunikationsprotokollen wie Advant Fieldbus 100, PROFIBUS, RCOM/RCOM + und MasterFieldbus usw. und kommuniziert mit anderen Steuerungen, dezentralen E/As, Bedienstationen und Drehzahlregelantrieben und kann über Modbus I und Siemens 3964R mit anderen Steuerungen, dezentralen E/As, Bedienstationen und Drehzahlregelantrieben verbunden werden. Über Modbus I- und Siemens 3964R-Schnittstellen kann er auch mit Leitsystemen anderer Hersteller 

kommunizieren.

Erweiterungsfähigkeit: Die Erweiterung kann durch das Einfügen von Modulen, das Hinzufügen kompletter E/A-Modulträger oder das Verbinden mehrerer Stationen und das Einstecken in ein dezentrales Steuerungssystem erfolgen, wobei ein Teil der Erweiterungen im laufenden Betrieb durchgeführt werden kann.

Zentraleinheitsoptionen: Drei Zentraleinheitsoptionen sind verfügbar: PM632 ist der Basisprozessor mit 256k Speicher; PM633 und PM634 verdoppeln die Verarbeitungsgeschwindigkeit und die Speicherkapazität, und PM634 verfügt über eine PROFIBUS-DP-Masterschnittstelle für die nahtlose Integration von PROFIBUS-Produkten.

Technische Spezifikationen: Abdeckung eines breiten Spektrums elektrischer Spezifikationen, wie z.B. verschiedene Arten von Eingangs- und Ausgangskanälen (digitale Eingänge, digitale Ausgänge, analoge Eingänge, analoge Ausgänge), jeweils mit unterschiedlichen elektrischen Parametern und Eigenschaften; mit einem breiten Spektrum an Kommunikationsschnittstellen, z.B. RS 232C für verschiedene Kommunikationsszenarien; sowie Hardware- und Softwareoptionen, z.B. Unterstützung verschiedener Kommunikationsprotokolle, Impulszählfunktionen, etc. Gleichzeitig werden Informationen zu den geltenden Schrankspezifikationen und Schutzklassen gegeben.

Zu seinem Funktionsumfang gehören: Steue rungsaufgaben, Schrittketten, Regelungen,Zählfunktionen und Berechnungen. Dank der quellorientierten Zeitstempelung unterstützt er sogar die Meldefolgenprotokollierung.

Er verfügt über eine RS 232-Schnittstelle für MODBUS I oder RCOM Datenfernüber tragung  und eine optionale Profibus Schnittstelle.

Er ist sowohl für die Einzelaufstellung als auch für den Einsatz in einem dezentralen Leitsystem geeignet. 

Er kann als autonome Station oder in Verbindung mit dem Advant OCS System eingesetzt werden.

Dank hoher Verarbeitungsleistung sind Programm-Zykluszeiten bis hinunter zu ms möglich – nicht nur in der Theorie, sondern auch in der Praxis.

Bei zukünftigen Erweiterungen der An lage kann auch der Advant Controller 110 aufgrund der Vielzahl an Erweiterungs möglichkeiten und der Online Program

mierung jederzeit beliebig ausgebaut werden.

Die Konfiguration erfolgt mit der graphischen Programmiersprache AMPL (ABB Master Programming Language) auf der Advant Station 100 Engineering Station.

Die Anwenderprogramme werden in einem nicht-flüchtigen, elektrisch löschbaren Speicher abgelegt, wodurch eine sofortige Neuprogrammierung möglich ist. Eine Batteriepufferung ist nicht erforderlich

Hardware Leistung

Zentraleinheiten: Es stehen drei Zentraleinheiten zur Verfügung: PM632, PM633, PM634, PM632 mit 16-MHz-Basisprozessor und 256 kB Programmspeicher, PM633 und PM634 mit 25-MHz-Basisprozessor und 512 kB Programmspeicher und PM634 mit einer PROFIBUS-DP-Hauptschnittstelle, die die Integration von Feldgeräten ermöglicht und zwei Einbauplätze erfordert. Das PM634 verfügt über eine PROFIBUS-DP-Hauptschnittstelle, die die Integration von Feldgeräten ermöglicht und zwei Einbauplätze erfordert.

Betriebsspannung: Unterstützt eine breite Palette von Versorgungsspannungen, einschließlich 48V DC (direkter Anschluss), 19,2 – 30V DC, 110 – 125/220 – 250V DC, 110/120/220/240V AC (47 – 450Hz), und mehr.

Eingangs- und Ausgangsspezifikationen

Digitaler Eingang: Verschiedene Arten und Anzahl von Kanälen. Zum Beispiel gibt es 32 Kanäle für 24 V DC (Potenzialanschluss DI610, gruppierte Potenzialtrennung DI620 usw.); 32 Kanäle für 60 V DC (gruppierte Potenzialtrennung DI622, DI652 usw.); und 16 Kanäle für 120 V AC (gruppierte Potenzialtrennung DI635, DI636 usw.). Einige Kanäle unterstützen Ereigniserkennung (Zeitstempel) oder Impulszählung.

Digitaler Ausgang: 24 V DC mit verschiedenen Spezifikationen, z. B. 32 Kanäle (maximal 200 mA, Kurzschlussschutz, Potenzialanschluss DO610), 16 Kanäle (maximal 2,4 A, Kurzschlussschutz, gruppierte Potenzialtrennung DO625) usw.; außerdem 16 Kanäle für Relaisausgang (Laststrom maximal 2 A, minimal 20 mA, Abschaltleistung AC 500 VA, DC 40 W).

Analogeingänge: Sie decken eine breite Palette von Messbereichen und Auflösungen ab. Zum Beispiel 16 Kanäle für ±10V/±20mA, 0 – 20mA (Gruppenpotentialisolierung, 12-bit Auflösung, Gleichtaktspannung und andere Parameter sind unterschiedlich); es gibt auch Kanäle für Pt100 oder Widerstandsmessung, Thermoelementmessung, jeder mit einem anderen Messbereich und Eigenschaften.

Analogausgänge: 16 Kanäle für 0 – 20mA (gruppiert potenzialgetrennt, 12-bit Auflösung, unterstützt verschiedene Spannungsausgangsbereiche) und 8 Kanäle (einzeln potenzialgetrennt, 12-bit Auflösung).

Kommunikationsspezifikationen

Interne Kommunikation: Unterstützt Kommunikationsprotokolle wie Advant Fieldbus 100, PROFIBUS, RCOM/RCOM+ und MasterFieldbus zur Kommunikation mit anderen ABB-Steuerungen, dezentralen E/A, Bedienstationen und Frequenzumrichtern. Bis zu 80 Stationen können über den Advant Fieldbus 100 angeschlossen werden, der Twisted-Pair-Koaxial- und Glasfaserkabel mit einer maximalen Buslänge von bis zu 1700 m je nach Kabelmaterial unterstützt.

Externe Kommunikation: Ausgestattet mit RS 232C-Schnittstelle zur Fernübertragung von MODBUS I- oder RCOM-Daten; über Modbus I- und Siemens 3964R-Schnittstellen ist auch die Kommunikation mit Steuerungen anderer Hersteller möglich.

Programmierung und Speicherung: Die Programmierung erfolgt auf der Basis von Funktionsblöcken mit der grafischen Programmiersprache AMPL und das Anwendungsprogramm wird in einem nichtflüchtigen, elektrisch löschbaren Speicher ohne Batteriepufferung gespeichert.

Weitere Spezifikationen: 5 Impulszähler für Frequenz-, Positions- und andere Messungen; optionale Hardware-Schnittstellenmodule, wie z. B. Advant Fieldbus 100-Schnittstellenmodul, MasterFieldbus-Schnittstellenmodul usw.; Softwareunterstützung für eine Vielzahl von Funktionen, wie z. B. Steuerung, Logik, Zeitsteuerung, Ereignisverarbeitung usw., aber auch Unterstützung einer Vielzahl von Kommunikationsprotokollen. Die Gehäuse der RM500-Serie sind in den Schutzarten IP21, IP41 und IP54 erhältlich, was den NEMA-Schutzklassen 1, 2 und 5 entspricht.

ABB ASTAT Manual  AST10_054 Crane motion controller

Basic Operating Parameters

Voltage range: The rated voltage of the control and thyristor modules is allowed to fluctuate within the range of -30% to +10% of the nominal value, and there are various operating voltages, such as 380 – 690V AC, etc., and different voltages are applicable to different models of modules.

Frequency range: The supported frequency is from -10Hz to +10Hz nominal, commonly 50Hz or 60Hz.

Temperature range: Control system modules can be operated continuously from -25°C (unheated) to +70°C, thyristor modules can be operated at +85°C (short periods without cooling), but the permissible current needs to be reduced at temperatures above +40°C or +55°C.

Isolation requirements: EN 60664, pollution class 4, 250V AC for control system modules and 630V AC for thyristor modules.

Control System Module Specifications

Models and characteristics: DARA 1000, DARA 1001, DARA 1010 and other models, some of which support different types of feedback (such as rotor frequency feedback, pulse encoder feedback, etc.), and integrated with a variety of interfaces, such as the RS232 interface for programming/monitoring, optocoupler interfaces for master-slave control, and so on.

Electrical parameters: the operating voltage is 115V or 230V AC 50/60Hz single phase, the power and current consumption of different models are different, such as the power of DARA 1000 is 100VA, and the current consumption of DARA 1010 is different under different loads.

Thyristor Module Specifications

Voltage and current rating: Covering a wide range of voltage, such as maximum 530V, 600V, 690V, etc.; current rating from 25A to 1000A, different models are suitable for different motor current ratings.

Other parameters: Thyristor modules are IP20 rated, come in different sizes and weights, and perform differently at different temperatures, e.g. need to be derated for high temperature environments.

Other module specifications

Overvoltage Protection Modules: Various models are available for different voltage levels, e.g. DASG 218 – DASG 223, for protection against voltage spikes, monitoring of voltage levels and phase sequence, with different sizes, weights and power consumption.

Cabin I/O modules: The DAPM 100 and DAPM 101 models are available for analogue and digital signal interfaces, respectively, with protection class IP20 and an operating temperature range of max. +55°C (plastic housing) or +70°C (metal housing).

Speed feedback modules: the DADT 100, for example, is used for speed feedback and rotor monitoring, with protection class IP20 and an operating temperature rating of +70°C, and is connected to the motor rotor and control system module via specific interfaces.

Communication-related specifications

Communication interface: Control system module with integrated RS232 channel, partial support for RS485 multi-drop systems, communication speed settable via jumpers up to 115200bps.

Communication protocols: A variety of communication protocols are supported, such as MMS (SattLink), COMLI, 3964R, etc., to meet different communication needs.

Load Related Functions

Load Measurement and Optimisation: Accurate measurement of load and a variety of load-based functions are achieved by connecting load sensors. Such as load cell linearisation for accurate measurement and calibration of different weights; torque-based load estimation function to estimate the load in specific situations; mass inertia compensation function to compensate for inertial mass effects in load measurement based on factors such as acceleration and gravity .

Overload and Speed Regulation: Complete overload protection logic, when the load exceeds the warning or stop limit, it will trigger the corresponding instructions and actions to protect the safety of the equipment. There is also a high-speed descending function (Cycle Time Reducer), which can increase the descending speed of the empty hook and shorten the working cycle under certain load conditions. At the same time, for different load conditions, it can achieve reasonable adjustment of the speed, such as limiting the lifting speed during light load to prevent the rope from shaking.

Brake-related functions

Brake control and monitoring: precise control and comprehensive monitoring of the braking process. According to the speed and direction signals, the braking can be applied at the right time, such as braking in time when the speed is close to zero or when the direction signal changes. It also has a brake delay function, which can delay the brake release in specific situations to reduce oscillation in motion. In addition, the on and off state of the brake is strictly monitored, and if the brake does not respond within the specified time, a fault will be triggered and appropriate measures will be taken .

Special brake compensation: For different types of brakes, a variety of compensation functions are provided. For example, for slow closing brakes, the load is kept stable electrically during the braking process; for slow opening brakes, the speed reference can be kept at zero before it opens, avoiding conflicts between the motor and the brake and current/torque spikes.

Speed Control Related Functions

Multiple speed control modes: Provides two modes of speed control and acceleration control. In speed control mode, the speed is precisely controlled by PID regulator, and the control parameters can be adjusted according to different working conditions. Acceleration control mode is more suitable for driver-controlled travelling movement, where the driver’s operation can directly affect the acceleration, and can be smoothly switched to speed control mode when encountering limit switches.

Speed reference and optimisation: The speed reference system supports a variety of inputs, including potentiometers or stepper main switches. The analogue reference can be shaped and acceleration and deceleration ramp times can be set to suit different conditions. In addition, a variety of speed-related optimisation functions are available, such as reducing speed when approaching limit switches, limiting the maximum speed to maintain the effectiveness of the speed controller, and automatically adjusting ramp times for weak power conditions.

Other special functions

Master-slave control function: In the master-slave control system, it is possible to achieve co-operation between different ASTATs. However, it is necessary to pay attention to the super-synchronous mode and the limitation conditions of shared movement, and at the same time, there are specific requirements for the setting of speed and limit switches, so as to ensure the synchronisation and safety of master and slave equipment in the process of movement.

Standby and Emergency Functions: There is a bypass function that enables standby mode in case of partial equipment failure, such as using one motor for rescue operations. There is also a quick-stop function, which allows electrical braking independently of the master switch in case of emergency, guaranteeing the safety of equipment and personnel .

ABB ASTAT A4 EN  Manual Crane motion controller.

ASTAT ® for industry!

ASTAT, with slip-ring motors, has become the leading technology for new heavy industrial cranes in the growth regions of the world.

In Europe, ASTAT is mostly used for retrofit installations or when normal industrial drives are unable to fulfil the requirements.

We supply ASTAT solutions for applications upto 4000 A or 4700 kVA.

The ASTAT Digital Crane Motion Controller has better control and information properties compared to earlier controllers. Equally important is the focus on quality of hardware components. 

The digital controller can be mounted on a steel plant crane in hot countries such as India without extra cooling or air conditioning. 

This capability provides additional benefits to worldwide industrial crane users.

The crane control system must withstand dirty, hot and cold environments in addition to difficult power supply systems. 

This has forced us to integrate functions like brake control, time relays, logic control and thermistor relays into the ASTAT controller. 

Generic products with the same robustness as the ASTAT controller are difficult to find. With this level of integration we offer a complete, fully tested motion control system.

Slip-ring motors may be produced with small internal rotor losses. This is important in crane applications with multiple motors and a high demand for good motion control. As well as being ideal for crane applications, slip-ring motors are low on maintenance with brushes being exchanged only every 5 to 10 years.

ASTAT uses the slip-rings for measurement of the rotor frequency and from this calculates the speed. In most cases no tachometer or pulse encoder is necessary.

The operator controls the crane motion, while all rotor contactors are optimized by ASTAT, as an integrated part of the current control. This results in dramatically reduced wear of contactors and crane mechanical parts. Crane maintenance costs will therefore be reduced.

Advantages with ASTAT ® :

• Fewer and better components result in more up-time.

• Operational diagnostics will speed-up fault tracing.

• Multipurpose spares will reduce parts in stock.

• The PC-program for maintenance can be installed in a ground level computer. Nobody has to visit the crane first to find the problem.

Digital ASTAT motion control is superior to other techniques and it increases the operational results to thElimits of the crane itself. 

For you as a user it will create:

• Increased productivity. 

The operator moves the crane without jogging, i.e. with one single movement.

• Prolonged lifetime. Smooth acceleration and retardation decreases torque peaks.

• Special functions reduce rope and brake wear.

• Satisfied operators. Motion control is possible down

to increments of only one cm. Try to do such a small step

without the ASTAT system!

• Excellent control features permit higher speed

during automatic control.

When to select ASTAT® ?

ASTAT is suitable for crane control in demanding

environments, when larger motor powers must be

handled, for retrofits or when automating one or more

cranes.

Applicable scenarios: suitable for demanding environments, occasions that need to handle larger motor power, crane renovation projects and scenarios that automate one or more cranes.

Technical specifications and features

Operating Limits: Voltage is allowed to fluctuate from -30% to +10% of the rated value, supports frequencies of 50Hz±10Hz, 60Hz±10Hz, operating temperature range of -25 (-40)ºC (unheated) to +70 (+85)ºC (un-cooled, for short periods of time), isolation in accordance with the EN60664 standard, pollution class 4.

Loads and Voltages: Supports a wide range of voltages such as 380 – 400V AC, 415V, 440 – 480V, 500 – 575V, 690V, etc.; Thyristor modules up to 690V (50/60Hz), currents ranging from 25A – 1000A (crane motor rated currents), continuous currents (AC – 1) higher than the rated currents.

Control system module: The control system module DARA 1001 supports 115/230V 50/60Hz single-phase voltage and is equipped with various interfaces, such as RS 232 interface for programming/monitoring, opto-coupler interface for master-slave control, digital input/output interfaces, motor PTC input interfaces, analogue input/output interfaces and so on.

Feedback module: The feedback module DADT1 is suitable for rotors with a rated rotor voltage of up to 600V.

Functions: Various functions including I/O unit and factory test, optional digital outputs, power supply information, motor information, limit switch functions, ASTAT configuration, rotor system, braking information, speed feedback, speed reference, speed regulation, speed monitoring, current/torque regulation, rotor resistance, etc. The setup is done from a PC, with Windows and COM1/USB port, with a two-digit display (00 – 99) for temperatures of -40 … + 85ºC.

Control modes and feedback: Reversible stator voltage control, with 0 – 3 rotor contactors, supporting two modes: scalar speed control or vector-based torque control. There are three options for speed feedback: rotor frequency, tachometer and pulse encoder.

Optional controls: Swing control system, positioning system for TCP/IP commands, four-rope grab crane control, and other optional features are available.

ABB Advant Controller 210

Product Overview: The Advant Controller 210 is a small, low-cost system in the Advant family that is configured and programmed via Advant Control Builder running on Windows NT. It integrates 10 binary inputs and 6 binary outputs, can be connected to a wide range of expansion units, and has a wide range of communication capabilities and functional features.

Functionality

Software Functions: Advant Control Builder provides a wide range of functions, including logic functions, PID adjustment, alarm handling functions, and communication with other systems.

Hardware Features: Compact design supports DIN rail mounting. Integrated digital I/O with removable screw terminals for power and I/O connections. Units with different I/O capacities are available to support various types of I/O devices, such as S200-E/A, S200L-E/A, S800-E/A, communication with other systems via RS232, and optional battery/real-time clock unit.

Hardware details

Central I/O system: 10 binary inputs and 6 binary outputs, rated voltage DC 24V, signals optically isolated, outputs short-circuit protected. External expansion units can be connected. The inputs are equipped with second-order low-pass filters.

Communication interface: Two RS232 channels are integrated and connected via RJ-45 connectors, one channel is equipped with full modem control signals, the other only with send/receive signals. The communication status is indicated by LEDs.

PROFIBUS-DP interfaces: CI724 as optional interface for connecting I/O units of the S800, S200 and S200L series with a transmission distance of 100 – 1200 m, CI274 as PROFIBUS-DP master, up to two installed.

Battery / real-time clock unit SB210: optional unit, powered by a lithium battery, capable of keeping the real-time clock running and storing the RAM contents for approx. one year. The battery should be replaced every year or when the voltage is too low.

Technical data

General parameters: Operating voltage DC 19.2 – 30V, current consumption varies between components. Isolation voltage AC 500V, operating temperature + 5°C to + 55°C, humidity 5 – 95% non-condensing, protection class IP20, CE and UL approved.

Central Unit (CPU): MC68332ACFC20 processor with 18.432MHz, 2MB RAM and 2MB Flash, various status indicators, support for different numbers of I/O units, real-time clock accuracy 100ppm.

Integrated I/O system: Inputs are of different types, with different electrical parameters and hardware filters. The outputs are clearly parameterised and protected against short-circuit and over-temperature.

Integrated communication channels: two RS232 channels with various protocols and baud rates, programmable data, parity and stop bits, cable length up to 15 metres.

PROFIBUS-DP interface unit CI274: DP master class 1, various transmission rates, status indicator, connection via 9-pin D-SUB connector.

Battery / real-time clock unit SB210: Li-ion battery 3.0V, 0.22Ah, real-time clock accuracy 100ppm.

Programming cable TK211: 9-pin D-SUB connector and 8-pin RJ-45 connector, length 3.0 metres.

Product models: PM210V0, PM210V04, PM210V08, PM210V16, corresponding to different I/O expansion capabilities.

Hardware specifications

Central unit (CPU)

Processor: Adopting MC68332ACFC20 processor with 18.432MHz, it can efficiently handle various control tasks and meet the real-time requirements of the system.

Memory: Equipped with 2MB RAM and 2MB Flash, which can store operating procedures, data and system configuration information.

Power supply interface: A removable 2-pin screw terminal block is used to connect to the DC 24V power supply, which is solidly connected and easy to install and maintain.

Status display: Green LED shows the status of power supply (PWR) and integrated communication channels, while red LEDs indicate the status of FAIL and STOP, so that users can keep abreast of the system’s operating conditions.

I/O connectivity: Supports different numbers of I/O units, from 0 to 16 central I/O units depending on the controller type.

Real Time Clock: 100ppm accuracy (approx. 1 hour/year), records system operation time and ensures time accuracy in control scenarios involving time sequences.

Dimensions and Weight: Dimensions B 282 x H 131 x T 67mm, weight 725g (without packaging) or 1165g (with packaging), easy to install in various industrial control cabinets.

Integrated I/O System

Input Specifications

Number and Logic: 10 binary inputs with positive logic, 6 of which are equipped with fast hardware filters to effectively filter noise in the input signal and improve the stability of the input signal.

Electrical parameters: ‘1’ signal input voltage DC 15V min. – DC 30V max. (rated DC 24V), ‘0’ signal input voltage < DC 6.0V; different input channels have different input current requirements, and corresponding standards for input impedance. The input impedance is standardised accordingly, e.g. max. 3.7kΩ or 6.2kΩ for some channels.

Filter: The inputs are equipped with second-order low-pass filters with time constants from 0.5ms to 32ms, which can be set individually by the software to flexibly adjust the filtering effect to suit different industrial environments.

Status display: Each input channel has a yellow LED to show the status, which is easy to monitor the input signal status visually.

Output Specifications

Number and logic: 6 binary outputs, positive logic.

Electrical parameters: ‘1’ signal output voltage is min. DC 19V, nom. DC 24V, max. DC 30V; Output current is max. 3A per unit, max. 600mA for a single ‘1’ signal, inrush current limit is 0.7A – 1.5A. Inrush current limit is 0.7A – 1.5A; ‘0’ signal output voltage has different limits under different loads, residual current < 0.5mA, voltage drop < DC 0.15V (under 600mA load current) when signal ‘1’ is on.

Protection Circuit: It is equipped with perfect protection circuit to shut down the output when the output is short-circuited or the temperature of the driver chip reaches about 160°C; when the +24V power supply is lower than DC 8V, all outputs will be shut down to effectively protect the safety of the equipment and circuits.

Time constant: output signal time constant 50µs < td < 200µs, depending on the load and voltage changes, to ensure the stability and accuracy of signal transmission.

Status display: yellow LEDs for each output channel indicate status, making it easy to monitor the outputs.

Integrated communication channels

Number and interfaces: 2 non-isolated RS232 channels are integrated, connected via 8-pin RJ-45 connectors, with a metal housing for the connection cable shield to reduce electromagnetic interference.

Communication protocols: Channel 0 supports MMS (SattLink) protocol, channel 1 supports COMLI, MMS (SattLink), 3964R and user-defined protocols to meet different communication requirements.

Status display: Transmit (TD 0, TD 1) and receive (RD 0, RD 1) status is displayed by green LED.

Baud rate: Channel 0 is fixed at 9600 Baud, channel 1 supports various baud rates from 75 to 38400 Baud, which can be set flexibly according to actual communication requirements.

Data format: Data bit can be set as 7 or 8 bits (standard 8 bits), parity can be selected as odd parity, even parity or no parity, stop bit can be set as 1 bit (standard) or 2 bits.

Cable length: The maximum length of communication cable is 15m, which limits the communication distance, and signal attenuation should be considered in practical applications.

PROFIBUS-DP Interface Unit CI274 (optional)

Type: DP master class 1, connects to I/O units of S800, S200 and S200L series to achieve distributed control.

Communication protocol: Adopts PROFIBUS-DP protocol to ensure efficient and reliable data transmission on the bus.

Transmission rate: Supports 9.6, 19.2, 93.75, 187.5, 500, 1500, 3000, 6000 or 12000kBit/s transmission rates, which can be selected according to the network size and data transmission requirements.

Isolation mode: no electrical isolation, use should pay attention to the electrical compatibility and anti-interference measures.

Status display: Red error LED, green Ready and Run LEDs on the front panel, and 3 LEDs for service purposes on the card, which are convenient for users to know the working status of the device.

Interface: Connects via a 9-pin D-SUB connector for easy physical connection to other devices.

Current Consumption: Internal DC 5V current consumption of 700mA typical.

Weight and Dimensions: Weight 45g, dimensions 54 x 86mm, compact size for easy installation in the limited space inside the controller.

Battery / Real-time clock unit SB210 (optional)

Battery: A 3.0V, 0.22Ah lithium battery (Model CR2430, UL Listed) maintains real-time clock operation and RAM contents for approximately one year, ensuring that the system maintains the time and part of the data in the event of a power failure.

Real Time Clock Accuracy: 100ppm (approx. 1 hour/year) to ensure system time accuracy.

Weight and dimensions: Weight 15g, dimensions 44×57mm, compact size, easy to integrate into the controller.

ABB Advant Fieldbus 100 User Manual

Product Overview

Advant Fieldbus 100 (AF 100) is a high performance fieldbus, which is used for:

• Communication between Advant Controllers

• Communication between Advant Controllers and S800 I/O Stations, AC 800M

controllers, AC 100 OPC Server, and the equipments developed and sold by

other ABB companies.

In an AF 100 bus, it is possible to reach up to 80 stations within a total physical

distance of up to 13300 meters (43300 feet).

Advant Fieldbus supports three transmission media:

• Twisted pair (Twp)

• Coaxial (RG59 and RG11)

• Optical media.

An AF 100 bus can be built up with all the three media, where a part of one kind of

media is a specific segment.

The following rules apply to the segments:

• To each twisted pair segment, 32 stations can be connected, and the maximum

segment length is 750 meters (2500 feet)

• The coaxial segment can be:

– 300 meters (1000 feet) with cable RG59 or

– 700 meters (2300 feet) with cable RG11.

• The optical media is only used in point-to-point communication, and it allows

the total length of a bus segment to be up to 1700 meters (5500 feet).

• If back-to-back coupled optical segments are used, it is possible to reach up to a

physical length of 13300 meters (43300 feet).

An Advant Fieldbus 100 may be installed with one or two physical bus lines (single or redundant media).

Two bus lines are chosen when increased availability is required.

The redundant bus line does not enhance the bus bandwidth when both the bus cables are operating.

Advant Fieldbus 100 Redundancy Concept

The Advant Fieldbus 100 redundancy concept contains:

• Media redundancy

• Communication interface redundancy

• S800 I/O Field Communication Interface redundancy.

When redundant media is used, redundancy must be maintained through the whole

bus (this comprises of the bus lines as well as connections of the stations to the bus).

Media Redundancy

The Media redundancy includes redundant cable and redundant modems. A media

redundant AF 100 is configured and connected as in Figure 1.

The maximum difference in cable length between the redundant cables must be less

than 1200 meters between any two stations throughout the whole bus.

Introduction to the concept

Communication interfaces: Connection of different types of devices, e.g. Advant Controller 70 with integrated twisted pair modem, Advant Controller 110 via CI626 or CI627. Some of the interfaces can be used as bus managers and participate in bus master functions.

Communication methods

Process data transfer: Managed via cyclic data packets (CDP), which are configured with parameters such as signal identification, cycle time, size and direction, and data is transferred cyclically.

Message transmission: Point-to-point communication for the transmission of identification, configuration data and events, based on event-driven, in the idle slots of the CDP communication.

Bus structure: consists of several segments, the different segments are connected via a modem. Each segment has a maximum length limitation, e.g. 300 metres for RG59 coaxial cable segments, 750 metres for twisted pair segments etc.

Configuration Methods

Communication Interface Configuration: Different communication interfaces are configured in different ways, e.g., CI520 and CI522 are used in Advant Controller 400 Series, which need to be set to operation status and will affect the scan table when adding, deleting or updating the sending DSPs .

Data Set Peripheral (DSP) Communication Configuration: The number of DSPs that can be handled by different controllers varies, e.g., about 4000 for Advant Controller 400 Series. Configuration requires the setting of relevant parameters, such as transmission interval, signal identification, etc.

Event set configuration: For the Advant Controller 110 or 70 to send time-stamped process events to the 400 Series, the EVS element needs to be configured on the sending and receiving side, which is realised via message transmission.

Installation start-up

Cable installation: Twisted pair, coaxial cable and optical fibre can be installed in different ways. For twisted-pair connection, attention should be paid to termination, grounding and minimum distance; for coaxial cable installation, termination and grounding should be carried out at both ends.

Device startup: The startup steps of each device are different, such as Advant Controller 70 startup needs to configure CDP and select station address; S800 I/O station needs to be configured and started by the superior controller after it is started.

Bus Expansion: Single media bus expansion can interfere with communication; redundant cables can be expanded one by one; changing the length of the logic bus requires restarting the bus and following specific steps.