Ordering Number IC693MDL655 (core ordering identifier, belonging to the I/O module series of GE Series 90-30 PLC)
Product Type 24V DC Positive and Negative Logic Discrete Input Module
The core function is to collect 32 discrete signals from industrial sites (such as on/off signals from sensors, limit switches, buttons, etc.), isolate them through optocouplers, and transmit them to the PLC logic side to achieve safe interaction between on-site signals and control systems
The adaptation system is only compatible with GE Series 90-30 PLC systems and can be installed in any I/O slot of the 5-slot or 10 slot baseboard
Key functional characteristics and electrical parameters
1. Core functional features
Input channel configuration: There are a total of 32 discrete inputs, divided into 4 independent isolation groups (A1-A8, B1-B8, C1 to C8, D1 to D8), with 8 inputs in each group. Each group has an independent common terminal (ACOM, BCOM, CCOM, DCOM) to avoid signal interference between groups;
Isolation design:
The on-site side and logic side are isolated by a photoelectric coupler to achieve 1500V, protecting the PLC core circuit from high-voltage/interference effects on site;
The isolation voltage between groups is 250V, further reducing signal crosstalk between different input groups;
Status indication: The top of the module is equipped with 32 LED indicator lights (corresponding to A1-A8 to D1-D8), which display the real-time on-off status (ON/OFF) of each input for easy troubleshooting;
Logical compatibility: Supports positive and negative logic inputs, adapts to field signals of different polarities, can withstand up to 30V DC input voltage, and adapts to fluctuations in industrial power grids.
2. Key electrical parameters
Parameter category specific specifications
Input voltage – rated voltage: 24V DC (positive and negative logic);
-Input range: 0~30V DC;
-On state voltage: 11.5~30V DC;
-Off state Voltage: 0~5V DC
Input current – typical conduction current (at 24V DC): 7.0mA;
-Minimum conduction current: 3.2mA;
-Maximum shutdown current: 1.1mA
Response time – On response time: maximum 2ms;
-Off response time: up to 2ms, meeting the requirements of fast signal acquisition
Power consumption – Backboard+5V bus power consumption: maximum 195mA (including 29mA basic power consumption+0.5mA per channel conduction+4.7mA per channel LED lighting);
The maximum number of conductive input channels for temperature characteristics varies with the ambient temperature (such as 8 channels per group can be fully conductive at 35 ℃, and only 2 channels per group can be conductive at 60 ℃), and the load configuration needs to be adjusted according to the actual ambient temperature
Installation and wiring information
1. Installation requirements
Installation position: It can only be installed in any I/O slot of the GE Series 90-30 PLC’s 5-slot or 10 slot baseboard, without special slot restrictions;
Environmental conditions: Must meet industrial environmental requirements (temperature, humidity, etc. refer to the overall specifications of the PLC system), avoiding high temperature, high humidity, and strong electromagnetic interference scenarios.
2. Wiring configuration
Connector type: The module is equipped with two 24 pin male connectors (Fujitsu FCN-365P024-AU) on the front, with the right connector corresponding to Group A and B inputs, and the left connector corresponding to Group C and D inputs;
Cable selection:
Recommend using GE original pre wired cables, models IC693CBL327 and IC693CBL328 (one end is a matching female head, and the other end is a stripped tin plated wire);
You can also make cables yourself, please refer to Appendix C of the document for the “24 pin connector cable production guide” (IC693CBL327/328 data sheet);
Power supply method: The on-site equipment power supply can be provided by the user themselves, or an isolated 24V DC output power supply can be used on the module I/O connector;
Wiring logic: Each input group needs to be connected to the corresponding common terminal (such as A group connected to ACOM, B group connected to BCOM), and the positive and negative logic is achieved through power polarity switching. For specific wiring, please refer to Figure 6-20 in the document (on-site wiring diagram).
3. Wiring table (core grouping)
The document provides detailed wiring tables for A/B group (right connector) and C/D group (left connector), specifying module points, connector pins, cable pairs, and color coding. The following are examples of key corresponding relationships:
Function Description of Cable Color Matching for Pin Connectors of Grouping Modules
Group A A1 A1 1 Brown Input Signal A1
Group A ACOM A5 3 Orange Group A Common Terminal
B group B1 B1 7 purple input signal B1
Group B BCOM B8 10 Pink/Black Group B Public End
Power supply+24V OUT B6 9 gray/black isolated 24V output
Product ID 3BSE008544R1 (core unique identifier used for product ordering, inventory management, and technical traceability)
ABB model name (Type Designation) AI820 (module series model, representing the category of “analog input module”)
Product Description (Catalog Description) AI820 Analog Input 4 ch (1 module with 4 analog input channels, clear functional positioning)
Product Type I-O-Module (Input/Output Module, classified as a signal acquisition component for industrial automation systems)
The core function is to collect analog signals (such as current and voltage signals) from industrial sites, convert them into digital signals, and transmit them to the control system for sensor data acquisition (such as temperature, pressure, and flow sensors)
Key technical characteristics
Technical parameters focus on signal acquisition capability, accuracy, and isolation design to ensure adaptability to various industrial sensors and complex on-site environments.
Specific specifications of technical indicators
Support signal types – current signal: ± 20mA, 0 (4)~20mA (covering common industrial current sensors, such as 4~20mA standard signal);
-Voltage signal: ± 10V, ± 5V, 0 (1)~5V (compatible with voltage sensors, compatible with different range requirements)
The signal acquisition method is differential input (diff.), which effectively suppresses common mode interference and improves signal acquisition accuracy (common mode voltage CMV reaches 50V, suitable for high interference industrial environments)
Current input resistance (Rin (cur)) 250 Ω (meets the standard matching resistance requirements for 4-20mA signal acquisition, no additional external resistance is required)
Resolution of 14 bits+sign (14 bits with sign, accuracy up to 0.015%, meeting the high-precision requirements of industrial grade signal acquisition)
Individually galvanic isolated channels are used to avoid signal interference between channels and protect the safety of modules and control systems
The supporting terminal unit needs to be used with ABB S800 I/O series terminal units, compatible models: TU810, TU812, TU814, TU830, TU833 (for signal wiring, protection, and switching)
Physical and compliance parameters
1. Physical dimensions and weight
Specific specifications of physical indicators
Net size (width x height x depth) 45mm x 119mm x 102mm (compact design, suitable for standard electrical control cabinet installation, saves space)
Net weight 0.3kg (lightweight design, easy to install and maintain)
2. Compliance and environmental attributes
Specific content of compliance category
RoHS status complies with the EU RoHS Directive (2011/65/EU), restricts the use of hazardous substances such as lead and mercury, and meets environmental standards
WEEE category 5 (small equipment with no external dimensions exceeding 50cm), which needs to be recycled according to the corresponding category after scrapping
Number of batteries 0 (no built-in batteries, avoiding waste battery pollution and reducing maintenance costs)
Customs Code (HS Code) 85389099 (classified as “85.35/85.36/85.37 Equipment Special Parts”, used for international trade customs declaration)
SCIP number f5d96b38-7473-417c-b99c-5e9db17bb24d (EU SCIP database registration number, used for hazardous substance tracing, associated with Estonia EE)
System compatibility and classification attribution
The AI820 module belongs to the ABB S800 I/O series and is widely compatible with ABB’s multi generation control systems and product suites. Its compatibility covers system versions from old to new. The specific classification path is as follows:
1. 800xA control system
Control Systems ￫ 800xA ￫ I/Os ￫ S800 I/O ￫ S800 I/O 4.0/4.1/5.0/5.1 ￫ I/O Modules
Control Systems ￫ 800xA ￫ System ￫ 800xA System ￫ 800xA 6.0 System ￫ I/O Modules
2. Advant OCS series system
Control Systems ￫ Advant OCS with Master SW ￫ I/Os ￫ S800 I/O ￫ I/O Modules
Control Systems ￫ Advant OCS with Master SW ￫ System ￫ Advant OCS with Master SW ￫ Advant Fieldbus 100 ￫ I/O Modules
Control Systems ￫ Advant OCS with MOD 300 SW ￫ I/Os ￫ S800 I/O ￫ I/O Modules
3. Compact Product Suite
Control Systems ￫ Compact Product Suite ￫ I/Os ￫ S800 I/O ￫ S800 I/O 4.1/5.0/5.1 ￫ I/O Modules
Model 6EP1336-3BA10 (core ordering identifier, belonging to Siemens SITOP series power supply)
Product series SITOP modular (modular power supply series, supporting flexible combination and expansion, suitable for complex industrial power supply needs)
The core function is to convert AC input voltage into stable DC output voltage, providing reliable power supply for industrial automation equipment such as PLC, I/O modules, sensors, etc
Typical application scenarios include industrial automation control systems (such as SIMATIC S7 series PLC systems), mechanical equipment electrical control cabinets, sensor and actuator power supply circuits
Key electrical parameters
Electrical performance is the core indicator of power modules, with detailed documentation of input, output, and efficiency related parameters to ensure adaptability to different power grid environments and load requirements.
Parameter category specific specifications
Input characteristics – Input voltage range: 120/230V AC (± 15%), supports wide voltage adaptation, compatible with different regional power grids;
-Input frequency: 50/60Hz (± 5%), with strong adaptability to frequency fluctuations;
-Input current: approximately 4.5A at 120V AC and approximately 2.3A at 230V AC;
-Impulse current: Maximum 50A during cold start (230V AC input)
Output characteristics – Output voltage: 24V DC (adjustable through potentiometer, range 22.5~28V DC);
-Rated output current: 10A;
-Output power: 240W (at rated output);
-Output voltage ripple and noise: ≤ 50mVpp (under rated load), ensuring power supply stability and avoiding interference with sensitive equipment;
-Load adjustment rate: ≤ 0.5% (when the output current changes from 0 to 10A), the voltage remains stable under load fluctuations
Efficiency and power consumption – rated load efficiency: about 88% (230V AC input, 24V DC/10A output), with good energy-saving performance;
-Idle power consumption: ≤ 5W, reducing standby energy consumption
Physical and environmental adaptability parameters
The module design meets the strict requirements of industrial environments and is suitable for distribution control cabinet scenarios in terms of protection, temperature and humidity, and installation methods.
Parameter category specific specifications
Physical dimensions – width x height x depth: 45mm x 125mm x 140mm (compact design, saving installation space for electrical control cabinets);
-Weight: Approximately 0.6kg
Protection level IP20 (after panel installation), suitable for installation inside indoor electrical control cabinets to prevent finger contact and large particle foreign objects from entering
Environmental temperature – working temperature: 0~60 ℃ (when it exceeds 40 ℃, it needs to be rated down for use, and when it reaches 60 ℃, the output current should be rated down to 5A);
-Storage temperature: -25~70 ℃;
-Humidity: 5%~95% (no condensation), suitable for humid industrial environments
Installation method: 35mm DIN rail installation (compliant with EN 60715 standard), supports stacking installation, and facilitates cabinet layout
The anti-interference performance complies with EN 61000-6-2 (industrial environment anti-interference) and EN 61000-6-4 (industrial environment emission) standards, and resists power grid noise and electromagnetic interference
Protection function
The module has multiple protection mechanisms to ensure its own and load device safety, and reduce the risk of failure.
Overcurrent protection (OCP): When the output current exceeds 1.5 times the rated value, the module automatically limits the current and restores normal output after troubleshooting;
Overvoltage protection (OVP): When the output voltage rises abnormally above 32V DC, the module shuts off the output to prevent damage to the load equipment;
Overheating protection (OTP): When the internal temperature of the module exceeds 105 ℃, the output will be automatically turned off. After the temperature drops to a safe range, the module will be restarted to avoid burning out;
Short circuit protection: When a short circuit occurs at the output terminal, the module enters protection mode. After the short circuit is resolved, the output is restored without the need for manual reset.
Product ID REP3BSE008522R1 (core identifier, used for product identification and ordering)
ABB Type Designation AO810 (module series model, representing analog output module category)
Product Description: AO810 Analog output 1×8 ch (1 module contains 8 analog output channels, with clear core functions)
Product Type Spare Parts, including technical information related to “AO810 8-channel analog output module maintenance”
Classification attribution and system compatibility
The AO810 module belongs to the ABB S800 I/O series and is mainly compatible with ABB’s two major control system product lines, covering multiple I/O versions with wide compatibility. The specific classification path is as follows:
1. 800xA control system
Control Systems ￫ 800xA ￫ I/Os ￫ S800 I/O ￫ S800 I/O 4.0 ￫ I/O Modules
Control Systems ￫ 800xA ￫ I/Os ￫ S800 I/O ￫ S800 I/O 4.1 ￫ I/O Modules
Control Systems ￫ 800xA ￫ I/Os ￫ S800 I/O ￫ S800 I/O 5.0 ￫ I/O Modules
Control Systems ￫ 800xA ￫ I/Os ￫ S800 I/O ￫ S800 I/O 5.1 ￫ I/O Modules
2. Compact Product Suite
Control Systems ￫ Compact Product Suite ￫ I/Os ￫ S800 I/O ￫ S800 I/O 4.1 ￫ I/O Modules
Control Systems ￫ Compact Product Suite ￫ I/Os ￫ S800 I/O ￫ S800 I/O 5.0 ￫ I/O Modules
Control Systems ￫ Compact Product Suite ￫ I/Os ￫ S800 I/O ￫ S800 I/O 5.1 ￫ I/O Modules
Ordering and Origin Information
Specific project content
Country of Origin: Sweden (country code SE), which can be used as a reference for origin tracing and logistics planning during procurement
Customs Tariff Number 85389091 (corresponding to the category of “other devices used for other electrical equipment”, used for international trade declaration classification)
The SIMATIC S7-400 series EXM 438-1 I/O expansion module technical data sheet (Product Data Sheet, model 6DD1607-0CA1) introduces the electrical parameters, interface capabilities, hardware configuration, and physical characteristics of the module, clarifying its positioning as an expansion unit for FM 458 functional modules. It is suitable for the acquisition and output of analog/digital signals in industrial automation control systems, as well as the access of encoder signals.
Core positioning and key features of the product
Functional positioning: Designed specifically for the FM 458 functional module, this I/O expansion module provides multiple types of signal interfaces and can simultaneously process digital, analog, and encoder signals, meeting the signal acquisition and control requirements in complex industrial scenarios.
Key difference: Clearly labeled “NOT SPAREGART COMPATIBLE TO EXM438”, which means it is incompatible with the old EXM 438 module and cannot be used as a replacement for it.
Power supply characteristics: Supports two power supply modes (5V DC, 24V DC, 24V DC requires external setting), with a typical current consumption of 1.5A; the encoder power supply output is about 14V (non isolated), with electronic short circuit protection and a rated output current of 100mA.
**Galvanic isolation: Digital input/output and analog input/output are not isolated * * (Galvanic isolation: No). When designing, attention should be paid to the isolation and protection of external circuits.
Digital I/O interface
Specific parameters of interface type
Digital input – Quantity: 16 channels
-Rated voltage: 24V DC
-Signal logic: “0” is -1~+6V or open circuit, “1” is+13~+33V
-Input current: The maximum allowable static current for the “0” state is 0mA, and the typical static current for the “1” state is 3mA
-Output voltage: maximum 3V in “0” state, maximum supply voltage -2.5V in “1” state
-Output current: Rated 50mA for “1” state, minimum 100mA at 0~40 ℃; maximum residual current of 20 μ A for “0” state
-Total switch current: 80% when all outputs are 50mA at 50 ℃
-Output delay (resistive load, “0” → “1”): maximum 15 μ s
Analog I/O interface
Specific parameters of interface type
Analog input – quantity: 5 channels (differential inputs)
-Input range: -10V~+10V
-Accuracy: ± 4 LSB at -10V and+10V (1 LSB=4.88mV)
-Input resistance: 470k Ω
-Resolution: 12 bits (including symbol bits)
-Conversion time (per channel): 45 μ s
Analog output – quantity: 8 channels (4 channels with 16 bits, 4 channels with 12 bits)
-Output range: -10V~+10V
-Short circuit protection: The relative frame has short circuit protection
-Short circuit current: 16 bit output maximum 27mA, 12 bit output maximum 100mA
-Linear error: ± 1 LSB (relative output range)
-Resolution: 4-channel 16 bit (including sign bit), 4-channel 12 bit (including sign bit)
-Conversion time (per channel): 16 bit output 2 μ s, 12 bit output 4 μ s
Encoder interface (Encoder)
Supports multiple types of encoder connections, with a maximum capacity of 12 encoders, to meet the requirements of position and velocity detection.
Specific parameters of encoder type
The total number of connections is 12 (8 incremental encoders, supporting synchronization; 4 absolute encoders)
Incremental Encoder (Symmetric) – Trajectory Signal: Phase A, B (90 ° phase difference, optional zero pulse N), or independent forward/reverse trajectory
-Input signal: “0” is -5~0V, “1” is+3~+5V; differential voltage range is -5~+5V; maximum input current is 15mA (there is no limit on the module side, please pay attention to the external circuit)
Incremental Encoder (Asymmetric) – Trajectory Signal: Phase A, B (90 ° phase difference, optional zero pulse N)
-Input voltage: “0” is -30~+4V (15mA load), “1” is+8~30V (15mA load); Differential voltage range -30~+30V
Based on the principle of eddy current induction, a voltage signal proportional to the distance between the probe tip and the conductive surface is output, which can simultaneously measure static position (such as radial/axial position of the shaft) and dynamic vibration (such as vibration of rotating equipment). It also supports Keyphasor signal reference and speed measurement, mainly used for state monitoring of fluid film bearing equipment.
2. System composition
The entire system consists of three parts, and each component supports complete interchangeability without the need for separate matching or bench calibration:
3300 XL extension cable: connects probe and preamplifier, 1-meter system does not require extension cable;
3300 XL Proximitor Sensor: processes probe signals and outputs standard voltage, supporting multiple installation and communication scenarios.
Core advantages of the product
1. High compatibility and interchangeability
Backward compatibility: 3300 XL 8mm components (electrical+physical) can be interchanged with non XL series 3300 5mm/8mm components to adapt to old system upgrades; However, when used in combination, system performance may be limited by the specifications of non XL components.
Flexible adaptation: When the installation space is limited and an 8mm probe cannot be used, it can be replaced with a 3300 series 5mm probe (refer to document 141605); If a narrow side view probe is required, the 3300 NSv system can be used (refer to document 147385).
2. Strong environmental adaptability
Structural durability: The probe adopts patented TipLoc molding technology (the probe tip is more firmly combined with the body), CableLoc design (75lbf/330N tensile strength), 8mm probe coil packaging is thicker, and the resistance to physical damage is stronger;
Protection and anti pollution: FluidLoc cable is optional to prevent oil and other liquids from leaking through the interior of the cable; The preamplifier has high immunity to radio frequency interference (RFI/EMI) and can meet EU CE certification without the need for special shielded conduits;
Wide temperature range and resistance to extreme conditions: Standard probe operating temperature -52~+177 ℃ (-62~+350 ℉), extended temperature range (ETR) probe tip can reach 218 ℃ (425 ℉), ETR cable can reach 260 ℃ (500 ℉), while resisting 50g impact and 30g vibration (10Hz~2kHz).
3. Convenient installation and maintenance
Flexible installation: The preamplifier supports high-density DIN rail installation or traditional panel installation (4-hole installation position compatible with the old model), without the need for additional isolation plates;
Simplified connection: The components use gold-plated ClickLoc connectors, which only require finger tightening (indicated by a “click” when in place), without the need for specialized tools; It is recommended to install a connector protective cover (or use accompanying silicone tape, but not recommended for use in turbine oil environments).
Key technical parameters
1. Electrical performance (standard conditions:+18~+27 ℃, altitude of 2000 meters, -24Vdc power supply, AISI 4140 steel target)
Parameter category specific specifications
Linear range of 0.25~2.3mm (10~90mil), corresponding to output voltage of -1~-17Vdc
The material of the preamplifier is A308 aluminum; Weight 246g (8.67oz); Installation torque: maximum probe housing 11.2~33.9N · m
The typical total weight of the system is 0.7kg (1.5lb); Probe 323g/m, extension cable 34g/m (with armor 103g/m)
Applicable scenarios and compliance certification
1. Target application areas
Mainly used in industrial scenarios that require monitoring the status of rotating equipment, including:
Energy: Wind turbines;
Heavy industry: steel, aluminum equipment;
Manufacturing: Pressure machines, metal forming equipment;
Special scenarios: testing and simulation systems, chemical equipment, robots.
2. Compliance and Security Certification
Specific standards and levels for certification types
Electromagnetic compatibility (EMC) complies with EN 61000-6-2 (industrial immunity) and EN 61000-6-4 (industrial emissions)
Functional safety SIL 2 (HFT=0), SIL 3 (HFT=1)
ATEX/IECEx hazardous area certification: II 1 G Ex ia IIC T4/T5 Ga (Zone 0), II 3 G Ex nA IIC T4/T5 Gc (Zone 2); cNRTLus：Class I Zone 0/2、Div 2
Environmental compliance complies with RoHS directive (2011/65/EU) and maritime certification (2019 classification society regulations)
Ordering Information (Core Model and Configuration)
The system components need to be ordered in combination with “probe+extension cable+preamplifier”, and the core models and configuration rules are as follows:
1. Probe (divided into standard type/ETR type, armored/unarmored)
Probe Type Model Example Key Configuration Options (Part Number Encoding)
Standard British thread (3/8-24) 330101 (unarmored), 330102 (armored) A: length without thread (0.0~8.8 in, 0.1 in increments); B: Total length of the shell (0.8~9.6 inches, increments of 0.1 inches); C: Total length (0.5-9m); D: Cable type (01=standard with protective cover, 11=FluidLoc with protective cover)
Standard metric thread (M10 × 1) 330103 (unarmored), 330104 (armored) A: length without thread (0~230mm, 10mm increment); B: Total length of the shell (20-250mm, 10mm increments); C: Total length (0.5-9m); D: Cable type
ETR type (high temperature) 330191 (imperial), 330193 (metric) configuration rules are the same as the standard type, with temperature level raised to 218 ℃ (probe)/260 ℃ (cable)
2. Extension cable
Standard cable: model 330130-AAA-BB-CC, AAA=length (030=3m to 085=8.5m), BB=cable type (00=standard, 10=FluidLoc), CC=certified (05=CSA/ATEX/IECEx);
ETR cable: model 330190-AAA-BB-CC, with the same length options as the standard cable, and upgraded insulation material to PFA.
3. Pre processor
Model 330180-AA-BB, AA=total length and installation method (e.g. -50=5-meter panel installation, -91=9-meter DIN rail installation), BB=certification (05=CSA/ATEX/IECEx).
4. Common accessories
Installation bracket: 137491 (aluminum without threads), 137492 (aluminum with threads), 27474 (phenolic resin with threads, used for electrical isolation);
Design objective: A high-performance motion controller designed specifically for harsh environments, meeting the requirements of high-speed control. It can be directly installed on equipment sites without the need for additional electronic control cabinets and is compatible with both electric and hydraulic motion systems.
Core competencies:
It has the same high computing performance as other Moog motion controllers and supports free programming through the powerful IEC 61131 development environment (Moog Axis Control Software, MACS).
Integrated PLC function can meet the multitasking requirements in embedded control scenarios, suitable for industrial control scenarios with high stability and real-time requirements.
Core advantages of the product
The core competitiveness of this controller lies in “environmental adaptability” and “functional flexibility”, including:
High protection level: Adopting a special shell, the protection level reaches IP67, and it can work stably in humid and dusty environments.
Wide temperature range and resistance to harsh conditions: The working temperature range is extended to * * -40~+70 ° C (-40~+158 ° F) * *, with high resistance to vibration (30g vibration) and impact (50g impact), and can resist fluid pollution (such as brake fluid, hydraulic oil, diesel, etc.) and corrosion.
Flexible communication: Provides multiple types of bus interfaces to meet the communication needs of different industrial scenarios (such as real-time control, programming and debugging, sensor connection, etc.).
High computing performance: equipped with a professional processor, supporting complex motion control algorithms and multitasking processing.
Applicable application scenarios
Controllers are widely used in the following industrial fields due to their strong environmental adaptability and high performance:
Energy sector: Wind turbines
Metal processing: Presses and metal forming equipment
Heavy industry: Steel, Aluminum
Testing and Simulation: Test and Simulation Systems
Chemical Industry and Robotics: Chemical Industry, Robotics Technology
Key Technical Parameters (Specifications)
Category specific parameters
Dimensions (W × H × D) 161 × 58 × 105mm (6.3 × 2.3 × 4.1 inches)
Working temperature range -40~+70 ° C (-40~+158 ° F)
Fluid pollution resistance can resist 12 common fluids including brake fluid, coolant, cutting fluid, diesel, hydraulic oil (HLPD 32), etc
Supply voltage 24V DC
32-bit PowerPC processor, RISC architecture, with floating-point arithmetic unit
Storage capacity: 128MB RAM, 32MB Flash EEPROM (data retention period usually 10 years)
Installation method: Install 4 M5 screws directly; DIN rail installation kit (order number CA94286-001)
Follow standard equipment requirements: IEC 61131-2; Electromagnetic compatibility: EN 61000-6-4/EN 61000-6-2; Corrosion resistance: EN ISO 9227, etc
Interface Data
The controller provides a variety of interface types to meet different communication and control needs, with specific parameters as follows:
Specific specifications of interface type
CAN maximum 1MBit/s, 24V protection, non isolated
Ethernet 10/100MBit/s， isolation
EtherCAT main station 100MBit/s, isolated
EtherCAT slave 100MBit/s, isolated
Profibus DP slave up to 12MBit/s, isolated
USB 1.1 host interface, 24V protection, non isolated
Digital I/O 2-channel signal (configurable as input/output through MACS); Equipped with short-circuit protection and thermal overload protection; Input complies with IEC 61131-2 Type 1 (isolated), output maximum 0.5A (isolated)
Ordering Information
Different models correspond to different interface configurations, and users can choose according to the scenario, as follows:
Ordering No. Controller Interface Configuration
D136-003-001 1 1 x EtherCAT master station, 2 x CAN, 1 x Profibus DP slave station
D136-003-002 1 x EtherCAT master station, 2 x CAN
D136-003-004 1 x EtherCAT master station, 1 x CAN, 1 x EtherCAT slave station
D136-003-005 2 x EtherCAT master station, 1 x CAN, 1 x Profibus DP slave station
Hydran M2 (Mark III) is GE’s third-generation transformer condition monitoring equipment, based on Dissolved Gas Analysis (DGA) technology (an industry recognized core tool for transformer fault warning). By continuously monitoring the dissolved gas and moisture content generated by insulation system stress in the insulation oil, it achieves a full process management of “early fault identification risk assessment operation and maintenance decision support”. Its core positioning is:
Guardian of key assets in the power grid: for transformers (high-value and high impact core equipment in the power system), to avoid unplanned shutdowns caused by insulation failures;
Multi dimensional state analysis platform: not only monitors the basic gas and moisture, but also can be connected to additional sensors (such as oil temperature and load current), combined with IEEE standard mathematical models, to output in-depth analysis results of transformer health status.
Core Product Value
Fault early warning: Continuously monitor the fault gases (such as hydrogen, acetylene, ethylene) and moisture, issue an alarm before the fault develops into serious damage, and avoid sudden shutdown;
Improved operation and maintenance efficiency: No need for regular manual sampling and testing, reducing on-site operation and maintenance workload, while supporting remote data transmission, achieving centralized asset management;
Wide compatibility: compatible with traditional mineral insulation oil and new low flammability ester insulation oil (natural/synthetic), covering transformers of different ages and types;
Reliability verification: The third-generation mature design has a large global installation base, has undergone long-term on-site verification, and complies with RoHS environmental standards.
Core functions and monitoring capabilities
（1） Basic monitoring function: gas and moisture monitoring
Hydran M2 achieves precise monitoring of key indicators in transformer insulation oil through dedicated sensors, covering the gas characteristics of the main types of transformer faults:
Monitoring indicators, sensor types, core monitoring targets, and fault associations
Dissolved Fault Gas Fuel Cell Type (Breathable Membrane Design) – Hydrogen (H ₂, 100% Sensitivity): A universal fault gas that can be generated by insulation oil/paper overheating and partial discharge;
-Carbon monoxide (CO, 15% sensitivity): insulation paper overheating;
-Ethylene (C ₂ H ₄, 1.5% sensitivity): Overheating of insulation oil
Moisture in oil film capacitive type (immersion type) monitors the relative humidity (RH) in oil, reflecting the aging of insulation paper (moisture generation) or leakage of sealing gasket (external moisture intrusion). Excessive moisture will accelerate insulation degradation
Key parameters for gas monitoring
Monitoring range 0-2000 ppm (volume ratio, calculated as H ₂ equivalent value)
Repeatability ± 5% reading or ± 5 ppm (whichever is greater)
Response time of 10 minutes (reaching 90% of the step change)
Key parameters for moisture monitoring
Measurement range 0-100% RH (relative humidity)
Measurement accuracy ± 2% RH
Repeatability ± 2% RH
（2） Expand monitoring and analysis capabilities
Multi sensor access: Supports external 4-channel analog input modules and can be connected to the following key parameter sensors to achieve linkage analysis of “gas moisture operating conditions”:
Environmental temperature sensor;
Transformer top/bottom oil temperature sensor;
Load current sensor (split core CT, 4-20mA output).
IEEE standard mathematical model calculation: based on multi-dimensional data access, built-in transformer health status model that complies with IEEE standards, outputting intuitive operation and maintenance decision basis. The core model output includes:
Estimation of winding hotspot temperature (assessment of insulation thermal aging risk);
Moisture content in insulation paper (which better reflects the true aging state of insulation paper than moisture in oil);
Moisture bubbling temperature (warning of insulation breakdown risk caused by water analysis in low-temperature environments);
Insulation aging degree, overload capacity, cooling efficiency, temperature difference of on load tap changer (OLTC), etc.
（3） Alarm and self diagnostic functions
Multi level alarm configuration: supports flexible setting of alarm thresholds, covers different levels of fault severity, and avoids false alarms or missed alarms:
Gas alarm: can be triggered based on “absolute value of gas concentration” and “hourly/daily trend” (gas growth rate);
Moisture alarm: can be triggered based on “absolute value of moisture concentration” and “average moisture level”;
Extended alarm: supports triggering alarms based on external sensor data (such as high oil temperature) and model calculation results (such as winding overheating);
Alarm level: divided into two levels: “Alert” and “Alarm”, clearly distinguishing the priority of risks.
Automatic self diagnosis: Perform equipment self inspection every 15 days. If a fault is detected (such as power failure, oil valve closure, sensor failure, battery replacement), it will automatically trigger a “maintenance alarm” to ensure the reliability of the monitoring device itself.
（4） Data communication and integration capabilities
Hydran M2 supports multiple communication protocols and interfaces, and can be seamlessly integrated into existing power grid monitoring systems (SCADA/DCS) to achieve remote data transmission and centralized management
Communication interface:
Local interface: RS-232 (DB-9 connector, used for local computer configuration);
Communication protocol: Supports Hydran private protocol Modbus ®、 DNP 3.0, IEC 61850 (standard communication protocol for power systems, adapted to smart grid architecture).
Data output: capable of transmitting raw monitoring data (gas concentration, moisture value), alarm status, model calculation results, and supporting integration with GE Perception ™ Software (GE dedicated data analysis platform) to achieve data trend analysis, historical comparison, and report generation.
Technical specifications and environmental adaptability
（1） Core technical parameters
Category specific parameters
Display and operation backlit LCD (128 × 64 pixels) with buttons (for device configuration and alarm confirmation)
Working environment temperature -40 ° C to+55 ° C (-40 ° F to+131 ° F)
Working environment humidity 0-95% RH (non condensing)
The oil temperature at the valve is -40 ° C to+105 ° C (-40 ° F to+221 ° F), and can be paired with a finned heat dissipation adapter for high temperature scenarios
Oil pressure at the valve: 0-700 kPa (0-100 psi), supports vacuum environment (vacuum tolerance sensor)
Protection level NEMA 4X (IP66), dustproof, splash proof, suitable for harsh outdoor/substation environments
Application scenarios and target users
Hydran M2 is mainly aimed at key scenarios in the power industry and industrial sector that rely on transformers. The core users and application values are as follows:
（1） Electricity utilities (grid companies)
Application scenario: Centralized monitoring of medium capacity transformers (such as distribution transformers, regional substation main transformers);
Core values:
Optimize asset replacement strategy: Based on equipment health status data, prioritize the replacement of high-risk transformers to avoid blind investment;
Reduce unplanned shutdowns: Early warning of faults, reduce the risk of power grid interruption, and ensure the reliability of residential and industrial electricity.
（2） Industrial factories (such as chemical, metallurgical, and manufacturing industries)
Application scenario: Factory owned substation transformer (to ensure power supply for production processes);
Core values:
Avoiding production interruptions: Transformer failures can cause production line shutdowns, and monitoring devices can reduce costly downtime caused by power failures;
Simplified operation and maintenance: No need for frequent manual sampling, reducing the workload of factory equipment management.
（3） Asset regulatory agencies
Application scenario: Remote supervision of multi site transformers by third-party asset operation and maintenance companies;
Core values:
Convenient installation: directly installed on the transformer oil valve, without the need for additional pipelines or pump bodies, reducing on-site renovation workload;
Centralized management: Multiple device data aggregation is achieved through communication networks to generate unified operation and maintenance reports.
Mark III version core improvements (compared to previous generation)
As a third-generation product, the Hydran M2 (Mark III) has undergone comprehensive upgrades in reliability, compatibility, and functional scalability
Hardware optimization: increased durability of sensors, redesigned electronic boards and power supplies to comply with RoHS environmental standards, while improving overall equipment reliability;
Oil compatibility expansion: Added support for low flammability ester insulating oils (natural/synthetic), covering new environmentally friendly transformers;
Software integration upgrade: compatible with GE Perception ™ Data analysis software that enables trend tracking, root cause analysis of faults, and automatic report generation;
Rich expansion modules: adding analog input/output cards, digital input cards, and wireless communication modules (GSM/GPRS) to meet the monitoring and integration needs of different scenarios.
Optional accessories (extended functions)
To meet the needs of different scenarios, Hydran M2 offers a variety of optional accessories to further enhance monitoring capabilities and environmental adaptability:
Accessory Name Core Purpose
Fin type heat dissipation adapter (1.5 inches) is used when the ambient temperature is greater than 40 ° C or the oil temperature is greater than 90 ° C to prevent equipment performance from being affected by high temperatures
Oil valve adapter (1 inch → 1.5 inches/2 inches → 1.5 inches) is suitable for different specifications of transformer oil valves, without the need to replace the original valve
Analog input/output card connected to 4-20mA signal sensor (such as oil temperature, load), outputting 4-20mA control signal, 2000Vac RMS isolated
Digital input card with dry contact signal (such as device status feedback), built-in 24Vdc wet contact power supply
Wireless/wired communication module GSM/GPRS wireless modem, Ethernet module (copper cable/fiber optic), to achieve remote data transmission
Specialized sensors include magnetic installation oil temperature sensor, split iron core load CT, and ambient temperature sensor (all with 4-20mA output)
A16B-3200-0110 is a power/signal interface module designed by Fanuc specifically for CNC systems (such as 0i series, 18i series and other high-end CNC systems). Its core function is to provide stable power distribution for CNC systems, signal interaction interfaces for external devices (such as servo drives, spindle drives, operation panels), and system operation status monitoring. It is the “signal hub” for CNC equipment (such as machining centers, lathes, milling machines) to achieve precise motion control. The basic information is as follows:
Product identification:
Product model: A16B-3200-0110 (Fanuc standard model name, “A16B” is the module series prefix, “3200” is the functional classification code, and “0110” is the specific model suffix);
Product types: CNC System Module, Power/Signal Interface Unit;
Core attribute: Industrial grade CNC specialized module, non general electrical component, required to be used in conjunction with Fanuc specific CNC system.
Key technologies and physical specifications
（1） Physical dimensions and weight
Specification category parameter value description
The horizontal dimension of the product length along the installation direction is approximately 240 mm, suitable for the installation slot of standard CNC system cabinets
The product has a vertical height of approximately 120mm and is compatible with Fanuc system modular stacking layout
The product width (depth) is approximately 180 mm, including the depth of the protruding part of the connector, and internal wiring space needs to be reserved in the cabinet
The net weight of the product is approximately 0.8 kg, excluding the net weight of packaged modules. The lightweight design facilitates the disassembly and assembly of modules inside the cabinet
（2） Electrical and functional parameters
Power input:
Main power supply: DC 24V (allowable fluctuation range ± 10%, i.e. 21.6V-26.4V), suitable for CNC system dedicated switching power supply;
Power consumption: Typical working power consumption is ≤ 15W (about 5W when unloaded, not exceeding 18W when fully loaded), to avoid power overload;
Signal interface:
Digital input (DI): 8-channel dry contact input, supporting 24V DC signal, used to receive external device status signals (such as emergency stop, limit switch);
Digital output (DO): 6-way relay output, contact capacity AC 250V/2A or DC 30V/2A, used to control external actuators (such as indicator lights, solenoid valves);
Communication interface: 1 RS485 interface (baud rate 9600-115200bps configurable), used for data exchange with servo drives and spindle drives;
Protection function:
Overcurrent protection: Built in power circuit overcurrent protection (threshold 1A), automatically cuts off the power supply when the module current exceeds the threshold to prevent burnout;
Overvoltage protection: When the input voltage exceeds 28V DC, the protection is triggered to prevent high voltage from damaging the internal circuit;
Anti interference: Complies with industrial grade electromagnetic compatibility (EMC) design, supports ± 15kV electrostatic discharge (ESD) protection, and adapts to strong electromagnetic environments of CNC equipment.
Environmental compliance and applicable conditions
Specific description of compliance category
Environmental compliance complies with the EU RoHS Directive (2011/65/EU), restricting the use of harmful substances such as lead, mercury, cadmium, etc., and meeting the environmental requirements of major global markets
Working environment – temperature: 0 ℃ -55 ℃ (no condensation, exceeding the range may cause module crash or performance degradation);
-Vibration: Within the frequency range of 5-500Hz, acceleration ≤ 5m/S ² (0.5g), avoid installing near the vibration source (such as next to an unstressed spindle motor)
Protection level IP20 (module body protection, needs to be installed in a closed CNC system cabinet, cannot be directly exposed to dust and oil pollution environment)
System adaptability and application scenarios
（1） Adapt to Fanuc CNC system
This module is only compatible with Fanuc specific series CNC systems and cannot be used across brands or series. The specific compatible models are as follows:
Adaptive driver: It needs to be paired with Fanuc α i series servo drivers (such as A06B-6117-H106) and α i series spindle drivers (such as A06B-6134-H303), and connected to the signal and power supply through dedicated cables.
（2） Typical application scenarios
Numerical Control Machining Equipment: As the core interface module of the CNC system for machining centers, vertical lathes, and horizontal milling machines, it realizes a signal loop of “system driver actuator” to ensure accurate positioning (such as positioning accuracy ± 0.001mm) and motion control (such as feed rate 0-10000mm/min) of the equipment;
Equipment status monitoring: Collect emergency stop, travel limit, door lock and other signals through digital input interface, provide real-time feedback on equipment safety status, and cut off the power supply of the driver through digital output interface when triggering abnormalities to ensure operational safety;
Production line integration: In automated production lines, communication with PLCs (such as Fanuc PMC) through RS485 interfaces enables collaborative work between CNC equipment and other equipment on the production line (such as cutting robots).
Key points for installation and maintenance
Installation requirements:
It needs to be installed in the designated slot of the Fanuc standard CNC system cabinet and fixed with screws to ensure good grounding between the module and the cabinet (grounding resistance ≤ 1 Ω);
Wiring must strictly follow the module terminal definition diagram (terminal table attached in the document), and the positive and negative poles of the power supply must not be reversed. Digital input/output signals should distinguish between dry/wet contact types to avoid module damage caused by incorrect connections;
Maintenance precautions:
Regularly check module heat dissipation (modules without fans rely on natural heat dissipation, and the ventilation inside the cabinet needs to be good to avoid temperatures exceeding 55 ℃);
If the module indicator lights (such as power lights, communication lights) are abnormal (such as power lights flashing, communication lights turning off), it is necessary to first check the power supply and cables, and then determine whether the module is faulty;
When replacing a module, it is necessary to record the parameters of the original module (such as communication baud rate and output contact configuration), and reconfigure the parameters of the new module to ensure compatibility with the system.
PM866AK01 is the core processor unit in the ABB AC 800M controller series, belonging to the “central processing unit” of industrial control systems. Its main functions are to execute control programs, process I/O data, and achieve communication and interaction with other modules. It is the core computing carrier of the 800xA automation system (especially version 6.0), suitable for medium and large-scale process control scenarios in chemical, power, manufacturing and other fields. The basic information is as follows:
Product identification:
Product ID (Order Number): 3BSE076939R1
ABB model name: PM866AK01
Product type: Central-Unit, Processor Unit
Core configuration: 133MHz main frequency CPU, 64MB memory, no built-in software license (requires separate ordering);
Packing list: This product is provided in the form of a kit, which includes 6 core components and does not require additional purchase of basic accessories. The specific list is as follows:
PM866A: Core CPU module (including computation and control cores);
TP830: Dedicated substrate (for module installation and signal connection);
TB850: CEX bus terminator (ensuring stable CEX bus signal and avoiding signal reflection);
TB807: Module Bus Terminator (adapted to Module Bus communication to ensure bus transmission reliability);
TB852: RCU Link Terminator (used for terminating the link signal of RCU remote control unit);
Memory backup battery: model 4943013-6 (used to save memory data after power failure to prevent program and parameter loss).
Key technologies and physical specifications
（1） Physical dimensions and weight
Specification category parameter value description
The net depth/length of the product is 135 mm along the installation direction of the substrate, including the protruding part of the connector
The net height of the product is 186 mm in the vertical direction, suitable for the standard installation space of AC 800M system
The net width of the product is 119 mm in the horizontal direction, compatible with standard cabinets and substrate slots
The net weight of the product is 1.2 kg, including the total net weight of all components in the packaging list. The lightweight design is easy to install
（2） Customs and trade-related codes
HS code: 853710 (classified as “circuit boards, panels, consoles, desks, cabinets, and other bases containing two or more devices of item 85.35 or 85.36, used for electrical control or distribution, including those containing instruments or devices of chapter 90, and numerical control devices, but excluding switching devices of item 85.17; Voltage not exceeding 1000V “);
Customs tariff number: 85371091 (corresponding to the sub tariff number of the HS code mentioned above, applicable to industrial control central units).
Environmental Compliance and Classification of Hazardous Materials
（1） Environmental Protection and Recycling Compliance
Specific description of compliance category
RoHS status complies with EU Directive 2011/65/EU, restricting the use of harmful substances such as lead, mercury, cadmium, etc., and meeting environmental requirements
WEEE classification category 5 “Small equipment” (all external dimensions do not exceed 50 centimeters), which needs to be recycled according to the corresponding category
Battery related – Quantity: 1 (for memory backup);
-Type: Portable lithium battery;
-Composition: Lithium;
-Weight: 9g;
-Lithium battery recycling regulations must be followed separately and cannot be discarded with ordinary garbage
（2） Classification of dangerous goods
UN dangerous goods category: Class 9 “Miscellaneous dangerous substances and articles, including environmentally hazardous substances”;
UN number: UN3091-PI970 (indicating that the product contains lithium batteries, transportation must comply with the packaging and transportation requirements of UN3091, such as preventing short circuits and avoiding compression);
Transportation precautions: It is necessary to package according to the dangerous goods transportation regulations to avoid battery damage causing leakage or fire, and it should not be mixed with strong oxidants during transportation.
System adaptability and application scenarios
As the core processor of the AC 800M series, PM866AK01 is only compatible with specific ABB automation systems. The specific adaptation scenarios and classifications are as follows:
（1） Product classification path
Specific subsystems/product series of control systems, module categories for adaptation
Control System Products AC 800M – Processor Modules PM866A Processor Unit
800xA Series Control System 800xA 6.0 System – Central Units Core Computing Unit
（2） Typical application scenarios
Medium to large scale process control: In 800xA 6.0 systems in industries such as chemical, petroleum, and power, it serves as the main controller to execute complex control logic (such as PID regulation and interlock control), and processes multi-channel I/O data (such as analog acquisition and digital output);
Distributed control networking: Connect remote I/O modules (such as S100 I/O modules summarized earlier) through CEX bus and Modulus Bus to build a distributed control architecture that is suitable for large-scale factory scenarios with dispersed equipment;
Data exchange and storage: Communicate with remote control units through RCU Link, while relying on memory backup batteries to ensure that key control parameters and programs are not lost after power failure, and the system can be quickly restarted after power restoration.
