ALSTOM I/OBUS2 12004-103-01 VER:V1.20 I/O Bus Expansion Board

I. Overview

• Collecting key equipment parameters (temperature, pressure, flow rate, with a signal range of 4-20mA/0-10V and 16-bit resolution) via 8 analog inputs (AI);

• Sending control commands (e.g., valve opening, motor speed, with an accuracy of ±0.1% FS) to actuators through 4 analog outputs (AO);

• Monitoring equipment status (e.g., valve on/off, motor operation, fault signals, with a response time of ≤1ms) via 16 digital inputs (DI);

• Enabling equipment start/stop control (e.g., pump activation, alarm triggering, with an output current of ≤2A) through 8 digital outputs (DO);

• Supporting communication with the main controller via industrial Ethernet (e.g., EtherNet/IP), with a data transmission rate of ≥100Mbps and a delay of ≤10ms;

• Incorporating a built-in 32-bit microprocessor that supports signal filtering (adjustable low-pass filter cutoff frequency: 1Hz-100Hz) and fault self-diagnosis (input short circuit/overvoltage, output overload, communication interruption);

• Equipped with redundant power inputs, which automatically switch when a single power supply fails, ensuring no power interruption;

• Supporting parameter configuration (e.g., signal range, DI anti-jitter time) and status monitoring via Alstom Harmony software;

• Adopting a compact design, suitable for installation in industrial control cabinets or on-site distributed installation scenarios.

• I/O Channels and Signal Processing: It has 8 AI channels (4 for 4-20mA, 4 for 0-10V, 16-bit resolution, accuracy ±0.05% FS, sampling rate 1kHz per channel), supporting PT100 platinum resistance input (2 additional RTD channels, accuracy ±0.1℃); 4 AO channels (2 for 4-20mA, 2 for 0-10V, 16-bit resolution, accuracy ±0.1% FS, output load ≤500Ω for current signals/≥1kΩ for voltage signals); 16 DI channels (24V DC dry contacts, high level ≥18V, low level ≤5V, response time ≤1ms, supporting edge detection and adjustable anti-jitter filtering (0.1ms-10ms)); 8 DO channels (24V DC open collector, output current ≤2A, response time ≤100μs, equipped with overload protection (short-circuit current ≤5A)). All I/O channels are equipped with photoelectric isolation (isolation voltage ≥2kVrms) and electromagnetic shielding (metal housing + double-layer shielded wires) to avoid on-site electromagnetic interference (e.g., from motors and frequency converters). Input channels have overvoltage protection (maximum input 30V DC) and short-circuit protection (response time ≤5μs).

• Core Communication and Control Unit: It incorporates a built-in 32-bit ARM Cortex-M4 MCU (operating rate 168MHz), supporting EtherNet/IP industrial Ethernet communication (100Mbps rate, full-duplex) and compatible with the Modbus TCP protocol (optional). It is equipped with 64MB Flash (for storing configuration parameters and firmware) and 32MB RAM (for caching real-time I/O data), supporting online firmware upgrades (without interrupting I/O communication). It supports collaboration with safety modules (e.g., STO1726KO1) to realize the linkage between I/O signals and safety trip logic.

• Housing and Protection: It uses a die-cast aluminum alloy housing (with anti-corrosion coating, thickness ≥1.5mm) with dimensions of 160mm×120mm×50mm (length × width × height), supporting DIN rail mounting (35mm standard rail) and panel mounting. It has an IP20 protection rating (dust-proof and finger-touch proof), suitable for industrial control cabinet environments. The operating temperature range is -25℃~70℃, the storage temperature range is -40℃~85℃, and the relative humidity range is 5%~95% (non-condensing). It has vibration resistance (compliant with IEC 60068-2-6 standard: 10-500Hz, 1g acceleration) and shock resistance (compliant with IEC 60068-2-27 standard: 15g acceleration, 11ms pulse width), making it suitable for the vibration environment of power equipment.

• Safety and Redundancy Design: It supports dual redundant power inputs (24V DC±20%, compatible with 12V DC/48V DC), which automatically switch when a single power supply fails, with a switching time of ≤0.5ms and no power interruption. Key circuits (MCU, power supply, communication interface) adopt anti-interference design to avoid I/O communication interruption caused by single-point faults. It complies with the EN 61000-6-2 electromagnetic compatibility standard and UL 508 industrial safety standard, meeting the safety operation requirements of power equipment.

II. Technical Parameters

1. I/O Channels and Signal Parameters

2. Communication and Control Performance Parameters

3. Environmental and Reliability Parameters

III. Functional Features

1. Full-Type I/O Integration for Multi-Parameter Monitoring and Control

• Centralized Management of 4 Types of Signals: A single module integrates 8 AI channels (including RTD), 4 AO channels, 16 DI channels, and 8 DO channels, covering all types of signals (temperature, pressure, flow rate, status, control) for power equipment. In a gas turbine auxiliary system, 2 I/OBE2 modules replace 6 traditional single-function modules, reducing the control cabinet space occupancy by 70%.

• Accurate Temperature Measurement via RTD: 2 additional PT100 inputs (accuracy ±0.1℃) enable direct collection of temperatures at key locations such as bearings and windings without external temperature transmitters. In a steam turbine system, the temperature collection error is reduced from ±0.8℃ to ±0.1℃, enabling early warning of bearing overheating 1 hour in advance.

• AO Output Value Retention: AO channels maintain the last output state (e.g., valve opening) when power is off, avoiding misoperation of actuators. After a power-off recovery in a petrochemical compressor system, the valves do not require recalibration and can resume operation quickly (traditional modules require 30 minutes of recalibration).

2. Low-Latency Distributed Communication for Real-Time Control

• 100Mbps Ethernet Communication: Full-duplex transmission via EtherNet/IP, with a delay of ≤10ms from I/O data collection to transmission to the controller. In a gas turbine auxiliary system, the response time of the speed control command is reduced from 25ms to 8ms, and the speed fluctuation is reduced from ±5rpm to ±2rpm.

• Data Frame Optimization: Supports large-frame transmission of 512 bytes, reducing the number of communication frames (e.g., 16 DI signals can be transmitted in 1 frame). In a steam turbine auxiliary system, the number of communication frames is reduced from 20 frames/second to 5 frames/second, lowering the controller load by 60%.

• Protocol Compatibility: The optional Modbus TCP protocol is compatible with third-party control systems (e.g., a power plant connects the I/OBUS2 to the ABB 800xA DCS without additional gateways, reducing integration costs by 40%).