ABB UFC921A 3BHE024856P106 Communication Module

I. Product Overview

II. Technical Parameters

(I) Electrical Parameters

(II) Control Performance Parameters

(III) Environmental and Reliability Parameters

(IV) Communication and Configuration Parameters

III. Functional Characteristics

(I) High-Precision Process Regulation Capability

• Multi-Algorithm Adaptation to Complex Processes: It has built-in multiple regulation algorithms such as standard PID, cascade PID, and ratio control, which can be flexibly selected according to different process requirements. In the temperature control of reactors in the chemical industry, the cascade PID algorithm is adopted, with the reactor temperature as the main variable and the jacket cooling water flow as the secondary variable. When the cooling water pressure fluctuates, the secondary loop can quickly adjust the flow to avoid large fluctuations in the main variable (temperature), and the regulation accuracy is improved by 30% compared with single PID. In the batching system of the metallurgical industry, the ratio control algorithm is used to precisely control the feed ratio of two raw materials, ensuring that the composition deviation of the mixed material is ≤0.5%.

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• Auto-Tune Function Simplifies Debugging: It supports the Auto-tune function, which eliminates the need for users to manually debug PID parameters repeatedly. Users only need to start the Auto-tune program, and the module will automatically identify the characteristics of the controlled object (such as lag time and time constant) through step testing and calculate the optimal PID parameters. The debugging time is reduced from several hours (traditional method) to a few minutes. For example, in the sterilization temperature control of food processing, the steady-state error can be controlled within ±0.1℃ after Auto-tune, meeting the requirements of high-precision production.

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• Anti-Interference and Steady-State Control: The analog input circuit adopts a three-stage RC filter and an instrumentation amplifier, which effectively filters out electromagnetic interference (such as high-frequency noise generated by frequency converters) in industrial sites, with the input signal signal-to-noise ratio ≥80dB. The regulation algorithm integrates integral separation and anti-integral windup functions: when the controlled parameter deviates greatly from the set value, the integral function is temporarily turned off to avoid overshoot; when the output reaches the limit, the integral accumulation is stopped to prevent excessive fluctuations when the parameter returns to normal. In the drum water level control of the power industry, even if the steam load changes suddenly, the water level can be stabilized quickly, with an overshoot ≤3%.

(II) Comprehensive Safety Protection and Fault-Tolerant Design

• Signal and Power Protection: Photoelectric isolation (isolation voltage ≥2kVrms) is adopted between the analog input/output channels and the power supply to prevent external high voltage or interference from invading the core circuit of the module. The power supply terminal is equipped with overvoltage (>32V DC) and overcurrent (>1.5A) protection circuits. When the power supply is abnormal, the input is automatically cut off to protect the module and external equipment. In the fan control of the mining industry, the module can operate stably even if the on-site power supply fluctuates, avoiding safety risks caused by ventilation interruption.

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• Fault Alarm and Interlock: It monitors the input signal, output status, and its own working status in real time. When the input signal is over-range (e.g., 0mA signal caused by sensor failure), the output signal is abnormal (e.g., output open circuit), or a power failure occurs, an alarm is triggered immediately, and the alarm information is uploaded through the LED indicators and communication interface. At the same time, alarm interlock actions (such as triggering external sound and light alarms, cutting off the feed valve) can be configured. In the toxic gas treatment system of the chemical industry, if the module detects an abnormal signal from the gas concentration sensor, it will immediately issue an alarm and close the gas inlet valve to prevent toxic gas leakage.

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• Redundancy and Backup Strategy: It supports dual-module redundant configuration (master-standby mode). The master module and standby module synchronize the regulation parameters and the status of the controlled object in real time. When the master module fails, the standby module automatically switches within 100ms to ensure uninterrupted regulation. In the auxiliary feed water system of nuclear power plants, the redundant configuration enables the system availability to reach 99.99%, meeting the requirements of safety-level equipment.

(III) Flexible System Integration and Maintenance Convenience

• Multi-System Compatibility and Expansion: It integrates seamlessly with the ABB Symphony Plus DCS system and supports the expansion of the Modbus RTU protocol via RS485 to achieve communication with third-party PLCs (such as Siemens S7-400). In intelligent manufacturing factories, the module can upload regulation data to the MES system to provide data support for production optimization. It supports the expansion of 1 analog input channel to meet the access needs of new sensors without replacing the module.

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• Online Debugging and Parameter Management: PID parameters, alarm thresholds, and other configurations can be modified online via the Control Builder software without shutting down the system, avoiding production interruptions. For example, in the pH control of fermentation tanks in the pharmaceutical industry, the proportional coefficient (P) can be fine-tuned online, and the pH change trend can be observed to find the optimal parameters. It supports saving 3 sets of configuration parameters, which can be quickly switched according to different production batches. For instance, in food processing, the two sets of parameters for "juice sterilization" and "jam sterilization" can be switched without re-debugging.

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• Intuitive Status and Fault Localization: The panel LED indicators feed back the working status of the module in real time, allowing maintenance personnel to initially judge the operation status without connecting to software. For example, a steady red "ALM" light indicates an alarm. By reading the fault code (such as "E02: Input over-range") through Modbus communication, the problem can be quickly located. In large chemical parks, maintenance personnel can troubleshoot sensor faults within 10 minutes using the fault code, significantly reducing downtime.