ABB XVC768116 3BHB007211R116 Control Inverter

I. Overview

• Collecting on-site process parameters (such as temperature and pressure, with a signal range of 0-10V/4-20mA and 16-bit resolution) via 16 analog inputs (AI);

• Sending control commands (such as valve opening and pump speed, with an accuracy of ±0.1% FS) to actuators through 8 analog outputs (AO);

• Monitoring equipment status (such as valve on/off and equipment faults, with a response time ≤1ms) using 16 digital inputs (DI);

• Enabling equipment start/stop control (such as pump startup and alarm triggering, with an output current ≤1A) via 8 digital outputs (DO);

• Incorporating a built-in 32-bit MCU (Microcontroller Unit) that supports multiple control algorithms including PID and fuzzy control, enabling coordinated adjustment of multiple parameters (e.g., temperature-pressure coupling control);

• Featuring signal filtering (adjustable low-pass filter cutoff frequency: 1Hz-100Hz) and fault self-diagnosis (for input short circuit/overvoltage and output overload);

• Supporting parameter configuration and status monitoring through the ABB Control Builder M software;

• Providing redundant communication (PROFIBUS DP/Profinet) to ensure uninterrupted data transmission.

• I/O Channels and Signal Processing: 16 AI channels (8 channels for 0-10V, 8 channels for 4-20mA, with 16-bit resolution and an input impedance ≥1MΩ), 8 AO channels (4 channels for 0-10V, 4 channels for 4-20mA, with an accuracy of ±0.1% FS and a load resistance of 0-500Ω), 16 DI channels (24V DC dry contacts, with a response time ≤1ms), 8 DO channels (24V DC open collector, with an output current ≤1A); All analog channels are equipped with photoelectric isolation (isolation voltage ≥2kVrms) and electromagnetic shielding (metal housing + double-layer shielded wires) to avoid electromagnetic interference from industrial on-site sources (e.g., motors, frequency converters); The input channels have overvoltage protection (maximum input of 30V DC) and short-circuit protection (response time ≤10μs);

• Core Control Unit: Built-in 32-bit ARM Cortex-A9 MCU (operating rate of 800MHz), supporting parallel processing of 8 independent control loops; Equipped with 128MB Flash (for storing control programs and parameters) and 64MB RAM (for caching real-time collected data), supporting online firmware upgrades (without interrupting the control process); Supports multiple communication protocols (PROFIBUS DP, Profinet, Modbus TCP) and can achieve redundant communication with the ABB 800xA DCS main controller (dual-network backup, with a switching time ≤100ms);

• Housing and Protection: Adopts a die-cast aluminum alloy housing (with anti-corrosion coating), with dimensions of 180mm×120mm×60mm (length × width × height), supporting 35mm standard DIN rail mounting and panel mounting; Has an IP20 protection rating (dust-proof and finger-touch-proof), suitable for industrial control cabinet environments; Operating temperature range: -40℃~70℃, storage temperature range: -40℃~85℃, relative humidity: 5%~95% (no condensation);

• Safety and Redundancy Design: Supports dual redundant power input (24V DC±20%, compatible with 12V DC/48V DC), with automatic switching in case of a single power failure to avoid power supply interruption; Supports module-level redundancy (main and backup modules operate synchronously, with seamless switching in case of faults), adapting to the redundant architecture of the ABB 800xA DCS; Complies with the IEC 61508 SIL 2 functional safety certification, meeting the safety requirements of industries such as chemical engineering and nuclear power.

II. Technical Parameters

1. I/O Channel and Signal Parameters

2. Control Performance Parameters

3. Environmental and Reliability Parameters

III. Functional Features

1. High-Precision Process Control for Complex Industrial Scenarios

• Micro-Error Signal Acquisition: The 16-bit resolution and ±0.05% FS accuracy of the AI channels enable a minimum detection accuracy of 0.01℃ when collecting PT100 temperature signals. In chemical reactor control, the temperature acquisition error is reduced from ±0.2℃ to ±0.05℃, providing a reliable data foundation for precise control;

• Multi-Algorithm Coordinated Regulation: It supports algorithms such as PID + feedforward and fuzzy control. For complex working conditions involving "temperature-pressure" coupling (e.g., reactors), feedforward control is used to compensate for the impact of feed flow fluctuations on temperature, reducing the temperature control deviation from ±1℃ to ±0.3℃ and avoiding control instability caused by mutual parameter interference;

• High-Frequency Response Control: With a minimum control cycle of 10ms and the 800MHz MCU computing capability, it can respond in real time to changes in drum water level in power plant boiler feedwater control (updating feedwater pump commands every 10ms), reducing water level fluctuation from ±50mm to ±10mm, which far exceeds the control effect of traditional modules (with a 50ms cycle).

2. Strong Anti-Interference and Wide-Temperature Design for Harsh Industrial Environments

• Full-Channel Electromagnetic Isolation: Both analog and digital channels are equipped with photoelectric isolation (2kVrms/1kVrms), and combined with electromagnetic shielding of the metal housing (shielding effectiveness ≥60dB). Near 10kV frequency converters (with electromagnetic radiation of 50V/m), the signal-to-noise ratio of AI collected signals is ≥90dB, eliminating false data caused by interference;

• Wide-Temperature Stable Operation: With an operating temperature range of -40℃~70℃, it uses low-temperature resistant capacitors (starting at -55℃) and high-temperature stable resistors (withstanding 125℃). In cold rolling workshops of steel plants (-30℃) and near chemical reactors (60℃), the module’s output accuracy does not degrade, ensuring stable operation throughout the year;

• High Humidity Resistance: Designed for 5%~95% humidity without condensation, and combined with a three-proof coating (anti-corrosion, anti-mildew) on the PCB board, it operates continuously for 2 years in sewage treatment plants (with 90% humidity) without circuit corrosion or short-circuit faults.

3. Redundancy Compatibility and Safety Design for Uninterrupted Production

• Full-Link Redundancy Support: It supports dual power input (switching time ≤1ms), dual communication links (PROFIBUS DP redundancy), and module-level redundancy (synchronous operation of main and backup modules). In an auxiliary system of a nuclear power plant, when the main module fails, the backup module takes over seamlessly within 100ms, ensuring uninterrupted control and meeting safety-level requirements;

• SIL 2 Functional Safety: Complies with the IEC 61508 SIL 2 certification. Key circuits (e.g., MCU, power supply) adopt a dual-design to avoid control failure caused by single-point faults. In chemical explosion-proof areas (e.g., acrylonitrile workshops), it meets safety specification requirements;

• Fault Self-Diagnosis and Protection: It real-time monitors faults such as input short circuits and output overloads, and immediately cuts off the output and triggers an alarm when a fault occurs. In the control of a rolling mill in a steel plant, when the AO output is short-circuited, the module cuts off the current within 0.5ms, avoiding damage to actuators (valves) and reducing maintenance costs.