I. Overview
The ABB LD810HSEEX 3BSE091722R1 is an explosion-proof high-performance Ethernet interface module specifically designed for hazardous industrial environments. As a core communication component of the ABB AC 800M series Distributed Control System (DCS), it is positioned as a "distributed control network access terminal for explosive environments". Its core function is to enable high-speed Ethernet communication between on-site equipment and the AC 800M controller in hazardous areas with explosive gases or dust, facilitating the transmission of real-time control commands, collection of equipment status data, and feedback of fault information. Meanwhile, relying on the dual explosion-proof design of intrinsic safety and flameproofing, it ensures safe operation in hazardous areas.
With high communication speed, strong anti-interference capability, wide environmental adaptability, and flexible system compatibility, this module is well-suited for industrial fields with explosion risks such as petrochemicals, natural gas extraction, coal chemical industry, and pharmaceuticals. It serves as a key network connection unit for the ABB AC 800M control system to achieve "centralized control - distributed execution - safe communication" in hazardous environments.
Its application scenarios accurately match the industrial control communication needs in hazardous environments:
In the petrochemical field, as the communication core of the on-site control layer for catalytic cracking units in refineries, it is deployed in explosion-proof control cabinets. It connects on-site flameproof pressure transmitters, temperature sensors, and explosion-proof actuators, uploads real-time process parameters (such as reaction temperature and catalyst pressure) to the AC 800M controller via HSE Ethernet, and issues adjustment commands from the controller simultaneously. With a communication delay of ≤5ms, it ensures precise control of the catalytic cracking reaction process.
In the natural gas extraction field, it is used for networking the control system of wellhead gas production platforms. The module connects wellhead pressure monitoring equipment and emergency shut-off valves through explosion-proof wiring, and transmits wellhead data to the central control room using a redundant communication design. It maintains stable communication even under hazardous conditions such as excessive methane concentration, providing protection for safe wellhead extraction.
In the coal chemical industry, it is adapted to the gasifier control scenario of coal-to-olefins units. While withstanding high temperatures and high dust levels, it realizes real-time transmission of key parameters such as gasifier temperature and liquid level, and supports communication compatibility with third-party explosion-proof instruments, ensuring the continuous and stable operation of the gasification process.
As a dedicated explosion-proof communication module for the AC 800M system, it supports seamless connection with the CI854 communication module and HMI (Human-Machine Interface) within the system. It achieves high-speed data interaction through the HSE industrial Ethernet protocol, meeting the strict requirements of "high safety, low latency, and high reliability" for communication in hazardous environments.
In terms of hardware architecture and system compatibility, the LD810HSEEX 3BSE091722R1 adopts a hardware architecture of "explosion-proof reinforced housing + core communication unit + safety monitoring module". Its core consists of a high-performance Ethernet communication chip, an intrinsically safe signal conditioning circuit, a flameproof power management unit, a fault diagnosis module, and redundant communication interfaces.
The module is equipped with 2 independent HSE Ethernet interfaces, supporting 100Mbps full-duplex transmission. It uses explosion-proof RJ45 terminals and is compatible with explosion-proof shielded network cables, enabling device-level redundant communication. When the primary communication link fails, the backup link switches automatically within 1ms to ensure communication continuity. It has a built-in HSE protocol stack, compatible with the IEC 61158 standard, supporting seamless conversion with the PROFINET protocol of the AC 800M controller. It is also compatible with the Modbus TCP protocol, allowing direct connection to third-party explosion-proof instruments and equipment.
In terms of explosion-proof performance, the module has obtained dual explosion-proof certifications (ATEX and IECEx), with an explosion-proof rating of Ex d IIC T6 Ga/Ex tD A21 IP66 T80℃. The flameproof housing is made of high-strength cast aluminum alloy, treated with surface anodization, which can withstand the impact of explosive gas explosions. The intrinsically safe circuit adopts a current-limiting and voltage-limiting design to ensure no electric sparks or high temperatures sufficient to ignite explosive mixtures are generated during signal transmission.
For communication optimization, it has a built-in 256KB data cache unit, supporting batch data processing and cache-and-forward. When the network fluctuates temporarily, untransmitted data is cached (cache duration is configurable from 0 to 30s) and automatically retransmitted once the network is restored. It uses an industrial-grade Gigabit Ethernet chip, supporting 1,000 data interactions per second to meet the demand for high-concurrency control.
Relying on the explosion-proof reinforced design, the module uses wide-temperature-tolerant components (-40℃~80℃), corrosion-resistant terminals, and anti-vibration mounting structures. It complies with the IEC 60068-2 series of environmental adaptability standards and can operate stably in hazardous industrial sites with high temperature, high humidity, strong corrosion, and strong electromagnetic interference.
II. Technical Parameters
III. Functional Features
1. Dual Explosion-Proof Design for Hazardous Environments
The LD810HSEEX 3BSE091722R1 adopts a dual explosion-proof design of "flameproof housing + intrinsically safe circuit" and has obtained authoritative explosion-proof certifications (ATEX and IECEx) with an explosion-proof rating of Ex d IIC T6 Ga/Ex tD A21 IP66 T80℃. It can be safely used in Zone 1/2 explosive gas environments and Zone 21/22 explosive dust environments.
The flameproof housing is made of high-strength cast aluminum alloy, formed by integral die-casting and treated with surface anodization. With a housing wall thickness of ≥10mm, the flameproof joint adopts a spigot structure with a gap of ≤0.1mm, which can effectively withstand the 1.5MPa impact pressure generated by explosive gas explosions and prevent flame leakage. The housing surface is coated with an anti-corrosion layer, which can resist acid and alkali corrosion media commonly found in the petroleum and chemical industries, with a service life of over 10 years.
For the intrinsically safe circuit, both the internal communication circuit and power circuit of the module adopt a current-limiting and voltage-limiting design, equipped with an intrinsically safe power module with an output voltage of ≤24V and an output current of ≤100mA. This ensures no electric sparks or high temperatures exceeding the ignition threshold are generated in abnormal conditions such as short circuits or overloads. The signal transmission uses intrinsically safe shielded twisted-pair cables, combined with explosion-proof RJ45 terminals, forming a complete intrinsically safe communication link. In addition, the module is equipped with an explosion-proof breather valve, which can balance the air pressure inside and outside the housing, avoid housing deformation caused by temperature changes, and prevent dust and liquid intrusion, further improving explosion-proof reliability.
2. High-Speed Redundant Communication for Control Real-Time Performance
The module is equipped with 2 independent HSE Ethernet interfaces, supporting 100Mbps full-duplex high-speed transmission. It uses the IEC 61158 standard HSE protocol, enabling direct establishment of a high-speed communication link with the AC 800M controller. The transmission delay is ≤5ms for a single control command and ≤30ms for a batch of 100 data items, meeting the real-time requirements for precision control in hazardous environments.
It supports a redundant communication link design. Through configuration software, the 2 interfaces can be configured into primary-backup mode: the primary interface is responsible for normal data transmission, while the backup interface monitors the status of the primary link in real time. When the primary link fails (such as disconnection, signal attenuation, or excessive interference), the backup link switches automatically within 1ms without data loss during the switching process, ensuring the continuous transmission of control commands and status data.
It has a built-in 256KB high-speed data cache unit, supporting batch data caching and forward. When the network fluctuates temporarily due to interference, it can cache up to 2,000 data items (cache duration configurable from 0 to 30s via configuration software), and automatically retransmit the cached data once the network is restored, avoiding the loss of process data.
Using an industrial-grade Gigabit Ethernet chip combined with efficient data processing algorithms, it supports 1,000 data interactions per second and can connect up to 32 on-site explosion-proof devices simultaneously, meeting the high-concurrency demand for centralized communication of multiple devices. For example, in the control of coal chemical gasifiers, the module uploads data from 32 temperature and pressure sensors to the AC 800M controller and issues adjustment commands to 20 actuators via dual-link redundant communication, with a stable transmission delay of less than 5ms, ensuring the gasifier temperature control accuracy reaches ±0.5℃.
3. Strong Anti-Interference & Environmental Adaptability for Stable Operation
The module adopts a triple anti-interference design of "multiple shielding + signal filtering + electrical isolation", enabling stable operation in high-interference scenarios of hazardous environments.
In terms of electromagnetic shielding, a 0.5mm-thick copper foil shielding layer is laid inside the flameproof housing. Combined with the electromagnetic shielding effect of the housing, the overall shielding effectiveness is ≥80dB, complying with the IEC 61000-4-3 RF radiation immunity standard (20V/m), which can resist strong electromagnetic radiation interference generated by equipment such as frequency converters and high-voltage motors. The communication interfaces are equipped with common-mode filters and differential-mode filters, which can filter out 50/60Hz power interference and high-frequency noise, increasing the signal-to-noise ratio of communication signals by more than 60%.
In terms of electrical isolation, photoelectric isolation technology is used to achieve electrical isolation between the communication interfaces and the core circuit, with an isolation voltage of ≥2.5kVrms. This effectively blocks ground loop interference and common-mode interference, preventing on-site high-voltage signals from impacting the core communication circuit.
In terms of environmental adaptability, the module uses wide-temperature-tolerant components (-40℃~80℃), with core chips adopting industrial-grade wide-temperature models. Combined with a low-temperature startup circuit and high-temperature heat dissipation design, it can operate stably in extremely cold natural gas wellheads or high-temperature refinery units. With a protection level of IP66 and waterproof and dustproof terminals, it can withstand high-humidity and high-dust environments, even short-term spray washing. Its anti-vibration performance meets the 10g acceleration requirement of the IEC 60068-2-6 standard, allowing direct installation in explosion-proof control cabinets near vibration sources such as pumps and compressors without additional shock absorption measures.
4. Comprehensive Status Monitoring & Fault Diagnosis for Improved O&M Safety
The module is equipped with comprehensive operating status monitoring and fault diagnosis functions, using a dual mechanism of "hardware monitoring + software diagnosis" to monitor the module's operating status in real time. Meanwhile, considering the special nature of O&M in hazardous environments, it optimizes fault early warning and location capabilities.
In terms of hardware, the front of the module is equipped with an explosion-proof LED indicator group, including a power indicator (steady green for normal power supply), two communication status indicators (steady green for normal interface, blinking for data transmission, steady red for interface fault), an explosion-proof status indicator (steady blue for normal explosion-proof circuit), and a system status indicator (steady green for normal system, blinking yellow for network fluctuation, steady red for system fault). The indicators adopt an explosion-proof packaging design to avoid electric spark generation, allowing maintenance personnel to quickly determine the module's operating status through the indicators.
In terms of software, the operating parameters of the module (including communication speed, data transmission volume, fault records, explosion-proof circuit status, and power voltage) can be read remotely via the ABB Control Builder M configuration software. It supports automatic fault alarm: when faults such as communication failure, abnormal explosion-proof circuit, power fluctuation, or data transmission timeout occur, it can send an alarm signal to the AC 800M controller via the HSE protocol and record fault codes (e.g., "ERR02: Primary Communication Interface Fault", "ERR08: Abnormal Explosion-Proof Circuit"). The controller can trigger on-site audible and visual alarms or remotely notify maintenance personnel.
Considering the inconvenience of on-site troubleshooting in hazardous environments, the module supports remote diagnosis. Maintenance personnel can remotely test communication links and calibrate interface parameters via configuration software, completing most fault troubleshooting tasks without entering hazardous areas, thus improving O&M safety and efficiency.
5. Flexible Compatibility & Convenient Configuration for Reduced System Integration Costs
The module has excellent system compatibility, supporting seamless connection with ABB AC 800M, Advant Controller 800, and other series controllers. It can work in collaboration with other components in the system, such as the CI854 communication module, AI810 analog input module, and AO810 analog output module, forming a complete control solution for hazardous environments.
It is also compatible with third-party explosion-proof equipment and supports the Modbus TCP protocol, allowing direct connection to explosion-proof PLCs, instruments, and actuators of brands such as Siemens and Rockwell without additional protocol conversion modules, reducing system integration costs.
In terms of configuration, it supports ABB Control Builder M V6.0 and above configuration software, providing a graphical configuration interface. It allows intuitive configuration of communication parameters (IP address, subnet mask, gateway), redundancy mode, data mapping relationship, cache parameters, and alarm thresholds without writing underlying code, improving configuration efficiency by 70%. For example, via the configuration software, the module's IP address can be quickly set to 192.168.1.10, Interface 1 configured as the primary communication link (PROFINET protocol), Interface 2 as the backup link (Modbus TCP protocol), and data from address 0x0001 of the third-party explosion-proof pressure transmitter mapped to address DB1.DBW0 of the AC 800M controller, making the configuration process simple and efficient.
In addition, the module supports parameter backup and restoration. Configuration parameters can be exported as encrypted files for backup via the configuration software. When replacing the module, parameters can be imported directly without reconfiguration
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