As a critical interface in the "control-execution" loop, this PC board mainly undertakes three core functions: high-voltage equipment status monitoring, control command issuance, and multi-protocol communication conversion. It can connect to the power units of high-voltage frequency converters, motor sensors, and upper-level computer systems, effectively addressing pain points in high-voltage industrial scenarios such as "significant signal attenuation", "high control latency", and "protocol incompatibility".Its design complies with the IEC 61800-5-1 high-voltage drive standard, adopting military-grade components with high temperature and high voltage resistance, as well as a multi-layer shielding layout. This enables stable operation in environments with a wide temperature range of -25℃ to +70℃ and strong electromagnetic interference (such as arcs in high-voltage cabinets). Therefore, it is widely used in high-voltage industrial fields with strict requirements for equipment safety and reliability, including metallurgy, electric power, and shipping.Compared with ordinary low-voltage interface boards, the UFC721AE also features high-voltage isolation protection and adaptation capability for high-power equipment. It supports direct access to the signal circuit of 690 V to 10 kV high-voltage systems without the need for additional isolation transformers, which can significantly reduce the integration complexity and safety risks of high-voltage systems.
2. Technical Specifications
2.1 Core Signal and Control Parameters
Parameter Category Specific Specifications
Signal Processing Capability - Analog Input (AI): 12 channels, 16-bit resolution, supporting 4~20 mA DC / ±10 V DC (independent isolation for each channel, withstanding voltage of 2.5 kV AC)
- Digital Input (DI): 24 channels, 24 V DC (sinking/sourcing selectable), input delay < 0.5 ms, supporting edge detection
- Digital Output (DO): 16 channels, 24 V DC / 250 V AC, maximum switching current of 3 A per channel (short-circuit protection + over-temperature protection)
- Pulse Input (PI): 4 channels, supporting 0~10 kHz pulse signals (for motor speed detection)
Control Accuracy - Analog Signals: ±0.05% Full Scale (FS) @ 25℃; ±0.1% FS (-25℃~+70℃)
- Pulse Counting: Error < 0.1% (for 0~10 kHz input)
High-Voltage Isolation Performance - Inter-Channel Isolation: 2.5 kV AC (1 minute, IEC 60664-1)
- Signal-to-Ground Isolation: 5 kV AC (1 minute, IEC 60664-1)
- Insulation Resistance: > 100 MΩ (500 V DC, IEC 60092-302)
2.2 Communication and Compatibility Parameters
Parameter Category Specific Specifications
Communication Interfaces - Industrial Ethernet: 2 x 10/100/1000 Base-T ports (RJ45), supporting ABB PROFINET IRT, EtherNet/IP, Modbus-TCP (dual-port redundancy)
- Fieldbus: 1 x RS-485 port (half-duplex, withstanding voltage of 1 kV AC), supporting Modbus-RTU / PROFIBUS DP
- Internal Bus: Compatible with ABB DriveBus, Symphony Plus Local Bus (hot-swap supported)
Controller Compatibility - Native Support: ABB ACS 880 high-voltage frequency converters, Symphony Plus DCS, AC 800M controllers
- Third-Party Compatibility: Access to Siemens S7-1500, Rockwell ControlLogix via PROFINET IRT (GSD file configuration required)
Firmware and Programming - Firmware Version: v5.1 and above (supporting online upgrade, upgrade time < 5 minutes)
- Programming Tools: ABB Drive composer Pro, ABB Engineering Studio (compatible with IEC 61131-3 languages, supporting custom control logic)
2.3 Power Supply and Environmental Parameters
Parameter Category Specific Specifications
Power Supply Requirements - Input Voltage: +5 V DC (±5%), +24 V DC (±20%), +110 V DC (±15%), triple-power redundant input (automatic switching, switching time < 5 ms)
- Power Consumption: Static < 8 W; Full load (12 AI + 24 DI + 16 DO + 4 PI) < 15 W
Operating Environment - Temperature: -25℃~+70℃ (wide-temperature version, no suffix); -40℃~+85℃ (extreme cold version, model suffix "-EX")
- Humidity: 5%~95% (non-condensing, IEC 68-2-3)
- Vibration: 5~500 Hz, 3 g (IEC 68-2-6, sine wave)
- Shock: 50 g (11 ms duration, IEC 68-2-27)
Safety and EMC - Safety Certifications: IEC 61010-1 (CAT III 1000 V AC), IEC 61800-5-1 (high-voltage drive safety), CE Certification, UL Certification
- EMC Compliance: EN 55032 Class A (electromagnetic radiation), EN 61000-4-4 (electrical fast transient: 4 kV at power terminals / 2 kV at signal terminals)
2.4 Mechanical and Physical Parameters
Parameter Category Specific Specifications
Overall Dimensions 6U standard rack-mount (233 mm width × 160 mm height × 220 mm depth), compatible with ABB high-voltage control cabinet slots
Installation Method - Rack Mounting: Compatible with 6U slots of ABB ACS 880 frequency converter cabinets and Symphony Plus control cabinets
- Fixing Method: 4 x M4 screws (torque 3~4 N・m), supporting anti-vibration reinforcement kit (optional)
Connector Types - Signal Interfaces: 4 x 50-pin Phoenix terminals (for AI/DI/DO/PI signals, with latches to prevent loosening)
- Power / Communication Interfaces: 1 x 32-pin terminal block (triple-power input), 2 x RJ45 (Ethernet), 1 x 10-pin terminal (RS-485)
Weight Approximately 0.5 kg (excluding cables and reinforcement kits)
Key Advantages
3.1 High-Voltage Isolation and Safety Protection for High-Risk Scenarios
Multi-Layer Isolation Design: Both between signal channels and between signal and ground, the board features isolation capability of 2.5 kV~5 kV AC. It can be directly connected to the signal circuit of high-voltage systems (e.g., 10 kV motor sensors), preventing high-voltage intrusion from damaging low-voltage control units. This design complies with the IEC 61800-5-1 high-voltage drive safety standard.
Multiple Protection Mechanisms: The DO channels are equipped with short-circuit protection (3 A overcurrent cut-off) and over-temperature protection (automatic shutdown at >85℃). The PI channels support pulse overvoltage protection (>30 V DC clamping). In extreme situations such as high-voltage arcing and sensor failures, these mechanisms ensure the safety of the board itself as well as upstream and downstream equipment.
3.2 High Precision and Low Latency to Meet High-Voltage Control Requirements
16-Bit High-Precision AI: The analog signal precision reaches ±0.05% FS. In the monitoring of key parameters like high-voltage motor current and transformer temperature, data errors are negligible, providing reliable input for control algorithms (e.g., PID regulation). The 12 AI channels support simultaneous collection of multiple types of signals (current/voltage/thermocouple) without the need for separate board processing.
Microsecond-Level Signal Response: The DI input delay is <0.5 ms, the DO output response is <1 ms, and the PI pulse counting error is <0.1%. In scenarios such as emergency braking of high-voltage motors and fault shutdowns, this ensures rapid execution of control commands, preventing equipment damage (e.g., burnout of rolling mill motors due to overload).
3.3 Multi-Protocol Redundant Communication for Stable Data Transmission
Dual Ethernet Redundancy: The 2 Gigabit Ethernet ports support dual-link backup for PROFINET IRT/EtherNet/IP. When the primary link is disconnected, the backup link switches in <10 ms with no data loss, meeting the "zero-interruption" requirement of high-voltage systems (e.g., control of power plant boiler fans).
Cross-Brand Compatibility: It supports universal protocols such as Modbus-RTU/PROFIBUS DP, enabling seamless integration into third-party control systems from Siemens, Rockwell, etc., without the need for custom-developed gateways. This reduces the integration cost of cross-brand systems by 30%~40%.
3.4 Wide-Temperature Durability and Flexible Expansion for Complex Environments
Extreme Environment Adaptation: With a wide-temperature design of -25℃~+70℃, it resists vibration (3 g) and shock (50 g), and can be directly installed in high-voltage cabinets (no additional heat dissipation required). It is suitable for harsh scenarios such as high-temperature metallurgical workshops and outdoor mining machine rooms. The extreme cold version (-40℃~+85℃) can be used in polar regions and high-altitude areas.
Modular Expansion: Up to 16 UFC721AE boards can be cascaded via ABB DriveBus, enabling large-scale signal collection of 192 AI + 384 DI + 256 DO + 64 PI. This meets the centralized control needs of large-scale high-voltage equipment groups (e.g., multiple rolling mill motors and fans).
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