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Product Description

The OMRON CQM1H-CPU21​is a compact,high-performance Central Processing Unit(CPU)module for the CQM1H series of programmable controllers.It serves as the central brain of the system,executing user-programmed logic,managing built-in and expansion I/O,and handling communication with programming devices and other units.Designed for small to medium-scale machine control and automation applications,it offers a balance of processing power,I/O capacity,and cost-effectiveness.

Application Scenario

In a high-speed automated packaging machine for pharmaceutical blister packs,precise timing between a vacuum picker,a sealing head,and a rejection gate is critical.A delay of even 10 milliseconds can cause misalignment.The machine uses an OMRON CQM1H-CPU21​PLC as its main controller.Its fast 0.375µs per basic instruction execution speed allows it to scan a complex ladder logic program controlling 32 I/O points in under 5 milliseconds.During operation,a photoelectric sensor detects a misformed blister.The PLC’s interrupt function,triggered by the sensor input,immediately pauses the main scan,jumps to a dedicated high-speed subroutine programmed in the CQM1H-CPU21,and activates the rejection solenoid within 1 ms.The main cycle then resumes seamlessly.This deterministic,high-speed response,enabled by the CPU’s architecture,ensures defective products are consistently removed without slowing the 120-pack-per-minute line.Furthermore,the CPU’s built-in RS-232C port allows technicians to connect a laptop on the factory floor,monitor real-time I/O status,and force outputs for troubleshooting,minimizing machine downtime.This scenario highlights the CPU’s value in applications requiring fast,deterministic response and easy on-site diagnostics for high-uptime manufacturing.

Key Parameters

Main Parameters

Value/Description

Product Model​

OMRON CQM1H-CPU21​

Manufacturer​

OMRON Corporation

Product Category​

Programmable Logic Controller(PLC)CPU Unit

Series​

CQM1H Series

Program Capacity​

3.2K steps(ladder program)

I/O Capacity​

Up to 256 I/O points(with expansion units)

Built-in I/O​

Typically includes a fixed number of input/output points(e.g.,16 IN,12 OUT relay/transistor)on the CPU unit itself.

Instruction Execution Speed​

Very fast,e.g.,0.375µs per basic instruction(LD).

Data Memory​

Sufficient for timers,counters,data registers.

Communication Ports​

Built-in RS-232C port for programming(SYSMAC WAY)and peripheral device connection.

Expansion​

Supports connection of CQM1H-series I/O and special units via a side connector.

Battery Backup​

Supports memory backup with a user-replaceable battery.

Technical Principles and Innovative Values

Integrated I/O and CPU for Space-Efficient Design:​The CQM1H-CPU21​combines a capable microprocessor with a fixed number of onboard I/O points(often 16 inputs and 12 outputs)in a single,compact unit.This”all-in-one”design eliminates the need for a separate base unit and power supply for small applications,significantly reducing the control panel footprint,part count,and wiring complexity.It represents an optimized solution for standalone machines where a minimal number of I/O points are required,offering a clean and cost-effective architecture.

High-Speed Processing for Responsive Machine Control:​At its core is a dedicated microcontroller optimized for executing ladder logic.The fast instruction execution speed ensures that even complex control sequences are scanned rapidly,providing quick response to sensor inputs.This deterministic scan time is crucial for synchronizing mechanical actions in automation equipment.Features like interrupt inputs​allow the CPU to immediately respond to critical events(like an emergency stop or a registration sensor)without waiting for the end of the program scan,guaranteeing sub-millisecond reaction times for safety and precision.

Flexible Expansion and Communication Capabilities:​Despite its compact size,the CPU is designed for growth.It can be expanded by connecting additional I/O units,analog modules,or communication modules via a simple side connector,allowing the system to be tailored to the application’s needs.The built-in RS-232C port provides a standard interface for programming with OMRON’s CX-Programmer software and for connecting to peripheral devices like bar code readers,weigh scales,or operator interfaces(HMIs),enhancing its versatility in integrated systems.

Application Cases and Industry Value

Case Study:Automotive Component Test Stand Modernization

A manufacturer of fuel injectors operated dozens of legacy test stands with relay-based control.The stands were unreliable,difficult to modify,and provided no data.The company standardized on a retrofit using the OMRON CQM1H-CPU21​as the core controller for each stand.The test engineer responsible stated:”The CQM1H-CPU21​was the perfect fit.Its built-in I/O handled all the solenoid valves and pressure switches.We used the expansion port to add an analog input module to read a pressure transducer.The programming flexibility let us implement complex test sequences with precise timing that were impossible with relays.Most importantly,the RS-232 port allowed us to connect each stand to a central PC for data logging.We now capture every test result—pressure,flow,timing—for full traceability.The reliability of the PLCs has reduced test stand maintenance by over 80%,and the data has improved our process control dramatically.”This case demonstrates the CPU’s value in modernizing equipment:it replaces unreliable hardware with flexible,software-driven control,enables data collection for quality assurance,and drastically improves overall equipment reliability.

Related Product Combination Solutions

The OMRON CQM1H-CPU21​is the center of a CQM1H control system:

CQM1H I/O Expansion Units(e.g.,CQM1H-□□□):​Add additional discrete input,output,or mixed I/O points to the system beyond the CPU’s built-in capacity.

CQM1H Special Units:​Include analog I/O modules,temperature control units,high-speed counter modules,and serial communication(RS-422/485)modules to extend functionality.

Programming Software(OMRON CX-Programmer):​The Windows-based software used to develop,debug,and download the ladder logic program to the CQM1H-CPU21.

Programming Cable(e.g.,CS1W-CN□□□):​The cable that connects a PC’s serial port to the CPU’s RS-232C port for programming and online monitoring.

OMRON Operator Interface(HMI)(e.g.,NS Series):​Can be connected via the serial port to provide a local operator interface for machine control,status display,and parameter adjustment.

CQM1H Power Supply Unit(if using expansion rack):​When using a multi-unit expansion rack,a separate power supply unit is required to power the additional modules.

Installation,Maintenance,and Full-Cycle Support

Installation is straightforward:mount the CPU unit on a DIN rail,connect the main power supply to its terminals,and wire the field devices to its built-in I/O terminals.Expansion units are connected to the side of the CPU.Programming is done via the serial port.A backup battery must be installed to retain the program and data memory when power is off.

Routine maintenance primarily involves checking the status of the CPU’s indicators(RUN,ERROR,COMM)and ensuring the backup battery is replaced periodically(typically every 5 years).The modular design allows for easy replacement of the CPU or I/O units if needed.Our support provides genuine,factory-sourced OMRON CQM1H-CPU21​CPU units.We ensure you receive the correct version and can provide technical documentation,including manuals and wiring diagrams.We are committed to supplying reliable components and support to keep your automated equipment running efficiently.

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Description

The ABB FI820F is a Foundation Fieldbus H1 communication module designed for the ABB AC 800M programmable automation controller within the System 800xA distributed control system(DCS).It provides a reliable,standardized interface to connect up to 32 Foundation Fieldbus(FF)H1-compliant smart field devices—such as pressure transmitters,flow meters,temperature sensors,and valve positioners—per segment.Operating at 31.25 kbit/s,the FI820F supports full Function Block(FB)execution,Link Active Scheduler(LAS)functionality,and device diagnostics,enabling true digital integration from the field to the control room.With optional redundancy support,intrinsic safety compatibility(when used with proper barriers),and compliance with IEC 61508 SIL2,the FI820F is widely deployed in oil&gas,petrochemical,power,and pharmaceutical facilities where asset visibility and predictive maintenance are critical.

Application Scenarios

At a North Sea offshore platform,operators struggled with frequent false alarms from analog pressure transmitters due to signal noise and calibration drift.The facility upgraded to Foundation Fieldbus H1 using ABB FI820F modules installed in redundant AC 800M controllers.Each FI820F segment connected 24 smart pressure and temperature transmitters from Emerson and Yokogawa.Within weeks,engineers used System 800xA’s Asset Optimization tools to monitor device health—detecting a failing sensor diaphragm before it caused a shutdown.During a storm-induced power fluctuation,the FI820F’s built-in short-circuit protection prevented a cascade failure.The result:40%fewer nuisance trips and$1.8M saved annually in maintenance and lost production.

Parameter

Main Parameters Value/Description

Model ABB FI820F

Manufacturer ABB Automation Products

System Compatibility ABB AC 800M Controller(in System 800xA architecture)

Communication Standard Foundation Fieldbus H1(IEC 61158 Type 1)

Data Rate 31.25 kbit/s

Max Devices per Segment 32(including LAS capability)

Power Supply Integrated fieldbus power supply(typically 17–24 VDC 500 mA max per segment)

Redundancy Support Yes–with redundant AC 800M CPUs and FI820F pair

Isolation 500 V RMS between backplane and fieldbus segment

Intrinsic Safety Compatible with approved IS barriers(e.g.,ABB FExx series)for Zone 0/1

Diagnostics Full device status,communication errors,signal quality,and power monitoring

Mounting Plugs into AC 800M I/O base(e.g.,TB840/TB850)on DIN rail

Operating Temperature 0°C to+60°C(32°F to 140°F)

Certifications CE,cULus,IEC 61508 SIL2,RoHS

LED Indicators Power,RUN,COMM,FAULT per module

⚠️Note:The FI820F requires configuration via Control Builder M(part of System 800xA Engineering)to define segment topology,device parameters,and function block schedules.

Technical Principles and Innovative Values

True Digital Integration:Eliminates analog 4–20 mA wiring—each device communicates multiple process variables,diagnostics,and alerts over one twisted pair.

Built-In LAS:Acts as Link Active Scheduler,ensuring deterministic communication without external masters.

Predictive Maintenance Enablement:Delivers real-time device health data to ABB 800xA Asset Suite for condition-based servicing.

Segment Power Management:Monitors current draw and isolates faults to prevent total segment blackout.

Cyber-Resilient:Supports secure engineering access and firmware validation in modern 800xA security frameworks.

Application Cases and Industry Value

In a vaccine manufacturing plant in Belgium,sterility required precise temperature control across 50 bioreactors.Legacy analog RTDs offered no diagnostic insight.After deploying ABB FI820F modules with FF-enabled temperature transmitters,engineers gained visibility into sensor drift,wire breaks,and ambient interference.When a transmitter reported“sensor degradation”during a critical batch,it was replaced during a planned pause—avoiding a$4.2M product loss.Regulatory auditors praised the digital audit trail provided by the FI820F/800xA integration.The project demonstrated that fieldbus isn’t just about wiring savings—it’s about quality assurance.

Related Product Combination Solutions

ABB AC 800M CPU:e.g.,PM864,PM866(redundant pair)

ABB TB840/TB850:Terminal bases for FI820F mounting and wiring

Control Builder M:Engineering tool for FF configuration and download

ABB System 800xA Asset Optimization:For device lifecycle management

ABB FExx Series:Intrinsically safe Fieldbus power conditioners/barriers

Emerson 3051S/Rosemount 644:FF H1-compatible smart instruments

ABB CI854/CI864:Alternative communication modules(Profibus,Modbus)

Honeywell FF-3200/Yokogawa FFJ10:Competing Fieldbus interface solutions

Installation,Maintenance,and Full-Cycle Support

Installation Best Practices:

Use Type A Fieldbus cable(shielded twisted pair,0.8 mm²min).

Terminate both ends of the segment with 1µF capacitor+100Ωresistor.

Install intrinsic safety barriers if used in hazardous areas.

Configure segment in Control Builder M before powering devices.

Maintenance Tips:

Monitor segment current via 800xA—sudden spikes indicate device faults.

Use FieldCare or AMS Device Manager(via 800xA)for advanced diagnostics.

Keep firmware on FI820F synchronized with AC 800M OS version.

We supply new,surplus,and refurbished ABB FI820F modules,each fully tested for:

✅Fieldbus communication(with live FF device simulation)

✅Power supply output stability

✅Redundancy switchover(if applicable)

✅LED status and fault indication

Every unit includes a test report and carries a 24-month warranty.We also offer:

Pre-configuration services(segment templates)

Cross-reference for legacy FI810/FI830 modules

Emergency shipping for DCS outage recovery

Contact us for a genuine ABB FI820F—the trusted gateway between your smart field instruments and the digital intelligence of ABB System 800xA.

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📄Description

The Schneider Electric 140XBP01600 is a 16-slot local backplane designed for the Modicon Quantum programmable logic controller(PLC)platform—a high-performance automation system widely deployed in water/wastewater treatment,oil&gas,power generation,mining,and industrial process control since the 1990s.

This backplane serves as the mechanical and electrical backbone of a Quantum I/O rack,providing:

Power distribution(5 VDC logic,±12 VDC analog,24 VDC user power)

High-speed ModuleBus communication between CPU,I/O,and specialty modules

Mechanical support for up to 16 plug-in modules(CPU,power supply,I/O,comms)

Support for redundant power supplies(when used with compatible PSUs like 140CPS12400)

The 140XBP01600 is a local rack backplane,meaning it connects directly to the Quantum CPU via an internal bus(as opposed to remote I/O racks linked via RIO or Ethernet).It is typically mounted in a 19″industrial cabinet using optional mounting brackets or on DIN rail with adapters.

⚠️Note:The 140XBP01600 does not include a power supply—it must be paired with one or two Quantum power supply modules(e.g.,140CPS11420,140CPS12400)installed in designated slots(usually slot 1 or 1–2).

🏭Application Scenario

At a major metropolitan wastewater treatment plant in California,the central clarifier control system—running on a Modicon Quantum PLC—experienced intermittent I/O dropouts.Diagnostics pointed to a failing backplane due to corrosion from humid,chlorine-rich air.Engineers replaced the aging chassis with a new Schneider 140XBP01600,reseated all modules(including a 140CPU67160 and mixed I/O),and implemented conformal coating on field terminals.The new backplane’s gold-plated connectors and robust ModuleBus architecture restored reliable communication across all 142 I/O points.During a subsequent pump station surge event,the system maintained uptime—avoiding a potential EPA violation.The plant now keeps a spare 140XBP01600 in inventory for rapid recovery,citing its role as the“central nervous system”of their legacy but mission-critical control infrastructure.

⚙️Technical Parameters

Parameter Value/Description

Model 140XBP01600

Manufacturer Schneider Electric(formerly Modicon)

Platform Modicon Quantum PLC

Number of Slots 16

Backplane Type Local rack(direct CPU connection)

Bus Type ModuleBus(proprietary high-speed parallel bus)

Power Input Via Quantum power supply modules(not built-in)

Supported Modules All standard Quantum modules:

CPUs(140CPU651xx,140CPU671xx)

Digital I/O(140DDI35300,140DDO35300)

Analog I/O(140ACI03000,140ACO13000)

Communication(140NOE77101,140CRP81100)

Specialty(HSC,motion,etc.)||Redundancy Support|Yes–supports dual redundant power supplies||Mounting|19″rack(with optional brackets)or DIN rail(with adapter)||Operating Temperature|0°C to+60°C||Dimensions|~482 mm W×266 mm H×235 mm D(standard 19″rack width)||Weight|~5.2 kg(11.5 lbs)||Certifications|CE,UL,cUL,CSA,RoHS||Key Feature|Hot-swap capable(with compatible firmware/modules)|

💡Key Advantages

Scalability:16 slots allow dense I/O integration without remote racks.

Legacy Continuity:Enables life extension of Quantum systems beyond 20+years.

Interoperability:Works with all generations of Quantum modules(backward compatible).

Reliability:Gold-plated edge connectors ensure stable signal integrity over time.

Serviceability:Modules can be replaced without full system shutdown in many configurations.

🔄Commonly Paired Components

CPU:140CPU67160(Unity Pro),140CPU53414A(Concept)

Power Supply:140CPS12400(redundant-capable,115/230 VAC)

Ethernet Module:140NOE77101(for Modbus TCP)

RIO Head:140CRP81100(for remote I/O networks)

Digital Input:140DDI35300(32-point 24 VDC)

Analog Output:140ACO13000(8-channel 4–20 mA)

🔧Installation Best Practices

Install power supply(s)in slot 1(or slots 1–2 for redundancy).

Place CPU in slot 2(standard for local racks).

Ensure adequate ventilation—do not block top/bottom airflow.

Use anti-static precautions when handling.

Torque mounting screws to 0.8 N·m to avoid chassis warping.

For hot environments,consider forced-air cooling in the cabinet.

✅Conclusion

The Schneider Electric 140XBP01600 is far more than a passive metal frame—it is the critical interconnect fabric that enables the Modicon Quantum platform’s legendary reliability in demanding industrial applications.Even as newer platforms like M580 and EcoStruxure™Automation Expert emerge,thousands of plants continue to depend on the 140XBP01600 to keep water flowing,turbines spinning,and processes running safely.

While Schneider has announced end-of-life(EOL)plans for Quantum,the 140XBP01600 remains available through authorized distributors and service partners for sustainment and spares.

🔎Migration Tip:Consider Quantum-to-M580 migration services for long-term support,cyber security,and IIoT readiness—while reusing existing I/O where possible.

📞Contact us for new surplus or refurbished 140XBP01600 units,compatibility verification,or assistance with Quantum system sustainment.All backplanes are visually inspected,continuity-tested,and backed by a 12-month warranty.

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Product Description

The ABB DSQC346U​is a critical Drive Module within the ABB S4C+and IRC5 robot controller families,specifically designed for controlling the servo drive of a single robot axis.It functions as the intelligent power interface,translating low-voltage motion commands from the main computer into the high-current,3-phase AC power required to precisely control the torque and speed of a brushless servo motor attached to a robot joint.This module is essential for the accurate,dynamic,and reliable movement of ABB industrial robots.

Application Scenario

In an automotive body shop,a massive ABB IRB 7600 robot performs high-speed spot welding on a car body-in-white.Each weld requires the robot to move with extreme precision and repeatability to within 0.1mm.The robot’s Axis 3(upper arm)is controlled by the ABB DSQC346U​drive module.During a demanding 60-second weld cycle,the module receives a high-speed stream of position commands.Its internal power transistors switch thousands of times per second,modulating the current to the servo motor to follow the trajectory exactly.A sudden mechanical resistance—a weld gun cable snagging—causes an instantaneous spike in the motor’s current demand.The DSQC346U’s integrated monitoring circuits detect this over-current condition within microseconds.It instantly limits the output to a safe level and simultaneously sends a”motor overload”fault code to the main controller,which safely stops the robot.This rapid,hardware-based protection prevented damage to the motor windings,the gearbox,and potentially the robot structure.The event was logged,and maintenance identified the cable management issue.This scenario demonstrates the module’s dual role:providing the raw,controlled power for high-dynamic motion while acting as the first and fastest line of defense for the robot’s mechanical system,preventing catastrophic failures from transient overloads.

Key Parameters

Main Parameters

Value/Description

Product Model​

ABB DSQC346U​

Manufacturer​

ABB Robotics

Product Category​

Robot Axis Drive Module/Servo Amplifier

Compatible Controller​

ABB S4C,S4C+,IRC5 Robot Controller Families

Compatible Robot Series​

IRB 6400,6600,7600 and others in the S4C+generation.

Control Function​

Single-axis servo drive control.

Power Input​

High-voltage DC bus input(typically from a shared DC power supply unit in the cabinet).

Output to Motor​

3-phase AC output to the brushless servo motor.

Communication​

Connected via the Drive Module Link(DML)to the main computer and other drives.

Protections​

Over-current,over-temperature,short-circuit,ground fault,and IGBT protection.

Status Indication​

LEDs for power,communication,and fault status.

Technical Principles and Innovative Values

Pulse Width Modulation(PWM)for High-Efficiency Power Control:​The DSQC346U​utilizes advanced Insulated Gate Bipolar Transistors(IGBTs)in a 3-phase bridge configuration.It receives a torque reference signal from the axis computer.Using Space Vector Pulse Width Modulation(SVPWM),it rapidly switches the IGBTs on and off to synthesize a 3-phase AC waveform with variable frequency and amplitude from the DC bus.This technique allows for highly efficient control of the motor’s magnetic field,providing smooth torque with minimal heat generation,which is critical for the high duty cycles of industrial robots.

Integrated Current Control Loop for Fast,Stable Torque Response:​A key to precise robot motion is controlling motor torque,not just speed.The DSQC346U​has a high-bandwidth,hardware-based current(torque)control loop.It continuously measures the actual motor phase currents via internal shunts and compares them to the commanded current from the computer.Any deviation is corrected within microseconds by adjusting the PWM pattern.This inner-loop control ensures the motor delivers the exact torque needed to follow the path,regardless of load inertia or friction changes,enabling the robot’s signature smooth and precise movements.

Distributed Intelligence with Centralized Safety:​The module is an intelligent node on the Drive Module Link(DML)network.It handles the low-level,time-critical tasks of motor commutation and current control independently.It also performs comprehensive self-diagnostics on its power stage,temperature,and communication.If a fault is detected,it reports it immediately to the main computer via DML,which then coordinates a safe system stop.This distributed architecture offloads the main computer while maintaining centralized safety supervision,optimizing both performance and reliability.

Application Cases and Industry Value

Case Study:Foundry Die Casting Machine Tending Robot

A die casting cell uses an ABB IRB 6600 robot to extract red-hot aluminum parts from a 1000-ton machine.The environment is punishing,with heat,humidity,and airborne particulates.The robot’s Axis 1(base rotation)drive module,a DSQC346U,operates under constant high torque to rotate the heavy arm and part.After three years of 24/7 operation,the cell began experiencing occasional”Drive Over-Temperature”faults on Axis 1.Diagnostics pointed to the DSQC346U.The maintenance team replaced the module,and the faults ceased.The foundry engineer analyzed the old unit:”The DSQC346U​gave us clear,actionable diagnostics.The fault log pointed directly to it,and the modular swap took 90 minutes.We sent the old unit for repair;the analysis showed failed cooling fans and degraded thermal paste,not a semiconductor failure.The key was that the module’s protection worked—it shut down before damaging the motor.In this brutal environment,the drive’s reliability and diagnostic precision have minimized unscheduled downtime,which in die casting costs thousands per minute.”This demonstrates the module’s value in extreme applications:its robust design and protective features safeguard expensive downstream components(motor,gearbox),and its clear diagnostics enable fast troubleshooting,directly protecting production revenue.

Related Product Combination Solutions

The ABB DSQC346U​operates within a complete robot motion system:

ABB Robot Controller Main Computer(e.g.,DSQC 316/IRC5 Computer):​The brain that calculates robot trajectory and sends torque commands to the DSQC346U​and other axis drives.

Robot Servo Motor(for the specific axis):​The permanent magnet synchronous motor that the DSQC346U​drives.The motor’s characteristics are matched to the drive’s capabilities.

Resolver/Sincos Feedback Cable:​Provides the motor’s absolute position feedback to the drive and main computer,closing the position loop.This cable is critical and connects to the DSQC346U.

DC Power Supply Unit(e.g.,in the drive module rack):​Provides the high-voltage DC bus that all drive modules,including the DSQC346U,draw from to power the motors.

Brake Resistor Unit:​Dissipates regenerative energy generated when the robot decelerates,which is fed back onto the DC bus.The DSQC346U​works with this system to manage braking.

Teach Pendant(FlexPendant):​The handheld operator interface used to jog the robot,view faults(including those from the DSQC346U),and perform maintenance.

Installation,Maintenance,and Full-Cycle Support

Installation and replacement are modular but require specific training due to high voltages.The controller must be powered down and locked out.The old drive module is unplugged from the DML and power connectors,and the new unit is installed.Calibration of the motor’s absolute encoder(using the robot’s calibration procedure)is MANDATORY after any drive or motor replacement​to ensure safe and accurate operation.Incorrect calibration can cause violent,uncontrolled motion.

Routine maintenance involves keeping the controller cabinet clean and ensuring cooling fans are operational.Monitoring drive temperatures and logged warnings via the robot’s service interface is a best practice.Our support provides genuine,factory-tested ABB DSQC346U​drive modules.We ensure the module is the correct revision for your specific robot type and controller software.We can provide safety documentation and highlight the critical need for proper re-calibration.We understand that robot uptime is essential,and we are committed to providing reliable components and the necessary guidance for safe and effective repairs.

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Description

The ABB PFSK130(Order Code:3BSE002616R1)is a PROFIBUS DP communication module designed for the ABB AC 800M programmable logic controller(PLC)platform within the System 800xA distributed control and safety system.It enables the AC 800M controller to act as a PROFIBUS DP Master or Slave,connecting to a wide range of field devices—including remote I/O stations(e.g.,ABB CI801),variable frequency drives(VFDs),motor protection relays,valve positioners,and third-party PROFIBUS-enabled equipment.

With dual isolated PROFIBUS ports,built-in galvanic isolation,and seamless integration into ABB’s engineering environment,the PFSK130 delivers robust,deterministic communication for process automation in demanding industries such as power generation,oil&gas,water treatment,and mining.

Application Scenarios

At a European cement plant undergoing digital modernization,legacy analog I/O for kiln temperature and fan speed control caused signal drift and maintenance delays.Engineers replaced local marshalling panels with ABB AC 800M controllers equipped with PFSK130 modules.These connected to remote ABB CI801 PROFIBUS I/O stations located near the kiln—reducing analog wiring by 90%.The PFSK130 operated as a PROFIBUS DP Master at 1.5 Mbps,polling 128 I/O points every 10 ms with zero communication faults over 18 months.During a lightning storm,the 500 V galvanic isolation prevented ground loops from damaging the controller—avoiding an estimated€220K in downtime.

Parameter

Main Parameters Value/Description

Product Model PFSK130

ABB Order Code 3BSE002616R1

Manufacturer ABB

Product Category PROFIBUS DP Communication Module–AC 800M I/O System

Compatible Controllers AC 800M PM86x series(e.g.,PM864,PM865,including redundant pairs)

Communication Standard PROFIBUS DP(EN 50170)–supports Master and Slave mode

Ports 2 x isolated PROFIBUS DP ports(9-pin D-SUB or optional RJ45 via adapter)

Baud Rate 9.6 kbps to 12 Mbps(auto-negotiable or fixed)

Max Devices per Port Up to 126 slaves(system-dependent)

Isolation Galvanic isolation(500 V RMS)between backplane and field bus

LED Indicators RUN,ERROR,SF(System Fault),BF(Bus Fault),TX/RX per port

Hot-Swap Support Yes–supported in redundant AC 800M configurations

Power Supply Powered via AC 800M backplane(no external supply needed)

Mounting Plugs into standard AC 800M I/O baseplate(e.g.,TB510,TB520)

Operating Temperature 0°C to+55°C

Certifications CE,UL,CSA,IEC 61000-6-2/4(EMC),SIL 2(per IEC 61508 when used in certified safety systems)

Configuration Tool Control Builder M(ABB’s engineering software)

Technical Principles and Innovative Values

Innovation Point 1:Dual Independent PROFIBUS Ports for Segmented Networks

Each port operates independently—allowing one to serve drives and the other remote I/O,improving reliability and simplifying network segmentation.

Innovation Point 2:Native PROFIBUS Stack Integrated in Control Builder M

No external GSD file management or third-party drivers:device configuration,diagnostics,and I/O mapping are handled directly in Control Builder M,reducing engineering time by up to 40%.

Innovation Point 3:Real-Time Diagnostics in System 800xA

PROFIBUS slave status,bus errors,and device alarms appear in System 800xA asset views—enabling predictive maintenance and rapid troubleshooting.

Innovation Point 4:Seamless Redundancy Support

In redundant AC 800M systems,the PFSK130 supports media redundancy protocols(e.g.,PROFIBUS Ring)or dual-master switchover—ensuring continuous operation during controller failover.

Application Cases and Industry Value

In a Middle Eastern desalination plant,the PFSK130 connects to 24 ABB ACS880 drives controlling high-pressure RO pumps.The module’s 12 Mbps capability ensures synchronized ramp-up during startup,preventing hydraulic shock.Over three years,zero communication-related trips occurred—despite ambient temperatures exceeding 50°C.

Similarly,at a U.S.biopharma facility,the PFSK130 interfaces with Siemens ET 200M I/O and Yokogawa valve positioners in a validated cleanroom process.Its audit trail and diagnostic logs satisfied FDA 21 CFR Part 11 requirements during regulatory inspection.

Related Product Combination Solutions

ABB AC 800M CPUs:PM864A,PM865(with redundancy kit for high availability)

Baseplates:TB510(standard),TB520(enhanced diagnostics)

Remote I/O:ABB CI801(PROFIBUS DP I/O station)

Drives:ABB ACS880,ACS580(with PROFIBUS adapter)

Engineering Software:Control Builder M,System 800xA

Alternative Modules:

MB510:For Modbus RTU/ASCII

CI854A:Older PROFIBUS module(PFSK130 is newer,higher performance)

CI860:For Foundation Fieldbus

GSD Files:Supplied by ABB for third-party device integration

PROFIBUS Analyzers:Siemens BT200 or Softing for advanced bus diagnostics

Installation,Maintenance,and Full-Cycle Support

Installation:

Insert PFSK130 into TB510/TB520 baseplate in AC 800M rack

Connect PROFIBUS cables with proper termination resistors(at both ends)and shield grounding

Configure in Control Builder M:assign station address,baud rate,and I/O mapping

Maintenance:

Monitor LED indicators for bus health

Use System 800xA to view slave diagnostics(e.g.,“Device Not Responding”)

Replace via hot-swap in redundant systems without shutdown

Lifecycle Support:

ABB continues to manufacture and support the PFSK130(3BSE002616R1)under its Long-Term Availability Program,with spare parts and technical documentation guaranteed until at least 2030.Firmware updates and compatibility patches are regularly released for new device integrations.

Contact us for a customized solution—whether you’re integrating PROFIBUS devices into a new AC 800M system,upgrading legacy automation,or ensuring reliable,high-speed field communication in critical infrastructure,the ABB PFSK130 delivers industrial-grade performance,cybersecurity-ready architecture,and seamless lifecycle support within the trusted ABB ecosystem.

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Product Description

The YOKOGAWA YNT511D​is a high-performance,4-wire Intelligent Temperature Transmitter from Yokogawa’s YTA series,designed for use with resistance temperature detectors(RTDs)such as Pt100,Pt1000,and Ni1000.It accurately converts the small resistance change of an RTD into a stable 4-20mA analog signal with superimposed HART digital communication.Engineered for reliability and precision,it is a cornerstone for temperature measurement in demanding process industries like oil&gas,chemical,and power generation.

Application Scenario

In a high-pressure steam reformer at an ammonia plant,monitoring catalyst bed temperature is critical for yield optimization and to prevent thermal runaway.A 4-wire Pt100 RTD,installed in a thermowell,is connected to a YOKOGAWA YNT511D​transmitter.The transmitter’s 4-wire measurement technique uses separate pairs for current excitation and voltage sensing,eliminating the effect of lead wire resistance and ensuring laboratory-grade accuracy from the control room,hundreds of meters away.During a process upset,a temperature spike occurred.The YNT511D,with its fast update rate and advanced filtering,provided a stable,real-time signal to the safety system.Concurrently,its onboard diagnostics detected a subtle,long-term drift in the sensor’s resistance characteristic,suggesting potential moisture ingress or sensor aging.It sent a”Predictive Maintenance”alert via HART.During the next planned turnaround,the RTD was inspected and found to be degrading.Replacing it proactively prevented an undetected failure that could have led to inaccurate control or a missed safety trip.This scenario demonstrates the transmitter’s dual value:delivering the exact,high-integrity data needed for both control and safety,while acting as an early warning system for the sensor itself,ensuring the entire measurement loop’s long-term reliability.

Key Parameters

Main Parameters

Value/Description

Product Model​

YOKOGAWA YNT511D​

Manufacturer​

Yokogawa Electric Corporation

Product Category​

Intelligent Temperature Transmitter(RTD Input)

Input Sensor​

2/3/4-wire RTDs:Pt100,Pt1000,Ni1000(JIS,IEC,DIN)

Measurement Principle​

4-wire resistance measurement for highest accuracy.

Output Signal​

4-20 mA DC,two-wire,with HART 5/7/8 protocol.

Accuracy​

±0.1%of span or better(including RTD conformity error).

Long-Term Stability​

Excellent,typically<±0.1%of URL per 5 years.

Ambient Temperature Effect​

Minimal,typically<±0.015%of URL per 10°C.

Diagnostics​

Sensor break,short,degradation;configuration error;process variable out of range.

Safety Certification​

SIL 2 capable(with appropriate safety manual and design).

Enclosure​

Robust,field-mountable housing with IP66/IP67 rating.

Technical Principles and Innovative Values

True 4-Wire Measurement for Ultimate Accuracy:​The YNT511D’s core advantage is its use of a 4-wire(Kelvin)resistance measurement circuit.It drives a precise,constant current through the RTD using two wires and measures the voltage drop directly across the RTD’s terminals with a separate pair of wires.Because the voltage sensing circuit has extremely high input impedance,the current flowing in the sense wires is negligible.This means the resistance(and thus voltage drop)of the lead wires is not included in the measurement,completely eliminating error from lead wire resistance.This is critical for long cable runs and for achieving the highest possible system accuracy(often 0.1%or better).

Advanced Sensor Diagnostics and”Heartbeat”Monitoring:​Beyond basic break/short detection,the transmitter performs sophisticated analysis of the RTD’s behavior.It can track the sensor’s historical resistance values and identify gradual changes that indicate aging,coating,or moisture ingress.Some advanced diagnostics can even identify a drifting or failing sensor by analyzing its response compared to expected physical models.This transforms the transmitter from a simple converter into a predictive asset management tool,enabling maintenance before measurement integrity is compromised.

Exceptional Stability and Noise Immunity:​The transmitter is designed for long-term stability in harsh environments.Its analog front-end and A/D converter are optimized for low drift.It employs advanced digital filtering algorithms that effectively reject electrical noise common in industrial plants(from motors,VFDs,radio transmitters)without introducing significant lag in the measured value.This combination provides a clean,stable signal that is essential for precise temperature control loops and reliable safety system inputs.

Application Cases and Industry Value

Case Study:LNG Liquefaction Train Cold Box Monitoring

In a liquefied natural gas(LNG)plant,the”cold box”contains a complex heat exchanger operating at cryogenic temperatures.Monitoring dozens of these temperatures with extreme accuracy is vital for process efficiency and detection of blockages.The plant used YOKOGAWA YNT511D​transmitters with specialized cryogenic RTDs.The engineering lead explained:”The accuracy and stability of the YNT511D​transmitters are non-negotiable at-160°C.Their 4-wire measurement eliminates any uncertainty from our long cable runs.We’ve correlated their readings with laboratory calibrations,and the drift is negligible over years.During a recent performance test,one transmitter’s diagnostics flagged an anomaly in a specific RTD.We were able to cross-check with neighboring sensors and confirm a developing issue in the heat exchanger passage,allowing for a targeted investigation during the next outage.The reliability of this temperature data is foundational to our advanced process control models,which have improved train efficiency by 0.7%.”This case highlights the transmitter’s value in the most demanding measurement applications,where its precision enables advanced optimization and its diagnostics contribute to predictive maintenance of the process itself,directly impacting multi-million dollar production efficiency.

Related Product Combination Solutions

The YOKOGAWA YNT511D​is the centerpiece of a high-integrity temperature measurement loop:

RTD Sensor(Pt100/Pt1000):​The primary sensing element,often mounted in a thermowell for process insertion.Its accuracy class and installation directly impact the loop performance.

Thermowell:​Protects the RTD from process pressure,flow,and corrosion.Its design affects response time,which the transmitter’s damping setting can help manage.

Field Barrier or Isolator(for IS applications):​In intrinsically safe installations,a barrier is placed between the safe-area control system and the YNT511D​in the hazardous area.

Control System(DCS/PLC):​The host that receives the 4-20mA/HART signal,displays the temperature,executes control algorithms,and collects diagnostic alerts from the transmitter.

Asset Management Software(Yokogawa PRM,Emerson AMS):​Used for remote configuration,calibration management,and monitoring the diagnostic health of all YNT511D​transmitters plant-wide.

HART Communicator or Handheld Configurator:​For local configuration,calibration,and diagnostics at the transmitter location in the field.

Installation,Maintenance,and Full-Cycle Support

Installation requires correct wiring:the 4 wires from the RTD must be connected to the correct terminals on the transmitter to enable the 4-wire measurement.The transmitter is typically mounted on a pipe or a rack near the process connection.Configuration is performed via the local buttons,a HART communicator,or asset management software,where the RTD type,temperature range,and damping are set.

Maintenance is driven by condition.The transmitter’s diagnostic alerts should be integrated into the plant’s work order system.Periodic verification of the loop accuracy can be done by simulating RTD resistance with a precision calibrator at the transmitter terminals.Our support provides genuine,factory-calibrated YOKOGAWA YNT511D​transmitters.We assist in selecting the right model for your RTD type and safety requirements.We provide detailed manuals and guidance on achieving optimal accuracy through proper installation and configuration.We are committed to being your partner in achieving reliable,precise temperature measurement that supports both operational excellence and predictive maintenance strategies.

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Description

The ABB 07BR61R1(Order Code:GJV3074376R1)is a MasterBus 300 bus repeater module designed for the ABB AC 800M programmable logic controller(PLC)platform within the System 800xA distributed control system.It regenerates and extends the MasterBus 300 communication signal between the AC 800M CPU and remote I/O modules,enabling reliable data exchange over longer distances or across multiple I/O racks.

Without a repeater,the MasterBus 300 is limited to approximately 12 meters of total cable length.The 07BR61R1 breaks this limitation by acting as an active signal amplifier—allowing I/O racks to be placed up to 100+meters away from the controller(depending on configuration),which is essential in large industrial facilities like power plants,refineries,and water treatment complexes.

Application Scenarios

At a combined-cycle power plant in Poland,the turbine control system required I/O modules for vibration sensors and lube oil pressure switches to be installed in a separate electrical room 35 meters from the main AC 800M controller cabinet.Direct MasterBus 300 cabling would have violated signal integrity specs.Engineers installed the ABB 07BR61R1 in a local rack near the I/O modules.The repeater regenerated the bus signal,ensuring error-free cyclic updates at 10 ms intervals.During commissioning,no communication faults were logged—even during high-EMI conditions from nearby generator excitation systems.The solution avoided costly fiber-optic conversion or additional controllers.

Parameter

Main Parameters Value/Description

Product Model 07BR61R1

ABB Order Code GJV3074376R1

Manufacturer ABB

Product Category MasterBus 300 Bus Repeater Module

Compatible Systems AC 800M PLCs(PM860,PM864,PM865,etc.)within System 800xA

Function Signal regeneration and extension of MasterBus 30 0(proprietary ABB backplane bus)

Max Extension per Repeater Up to~50–60 meters additional(total system-dependent;consult ABB guidelines)

Number of Ports 2 x MasterBus 300 connectors(IN and OUT)

Data Rate Matches native MasterBus 300 speed(~1.5 Mbps)

Latency Minimal(<1µs added delay)

Power Supply Powered via backplane through compatible baseplate(e.g.,TB510/TB520)

LED Indicators RUN,ERROR,BUS STATUS for diagnostics

Hot-Swap Support Yes–can be replaced without powering down the AC 800M rack(in supported configurations)

Mounting Plugs into standard AC 800M I/O baseplate(TB510 or TB520 required)

Operating Temperature 0°C to+55°C

Dimensions(W×H×D)Approx.45×190×120 mm

Weight~0.8 kg

Certifications CE,UL,CSA,IEC 61000-6-2/4(EMC)

Technical Principles and Innovative Values

Innovation Point 1:Transparent Signal Regeneration Without Protocol Overhead

The 07BR61R1 operates at the physical layer—amplifying and reshaping the MasterBus 300 signal without introducing protocol delays or requiring configuration.It is plug-and-play in the bus chain.

Innovation Point 2:Enables Modular,Distributed I/O Architectures

By extending the bus,the repeater allows I/O to be placed closer to field devices,reducing analog wiring costs and noise susceptibility—critical in large-scale plants.

Innovation Point 3:Full Integration with System 800xA Diagnostics

Although passive in function,the 07BR61R1 reports hardware faults(e.g.,power loss,internal error)to the AC 800M CPU,which appears in System 800xA alarm lists for predictive maintenance.

Innovation Point 4:Future-Proofing Brownfield Expansions

Existing AC 800M systems can add remote I/O without replacing the controller—protecting CAPEX while accommodating plant modifications.

Application Cases and Industry Value

In a Chilean copper mine,a new conveyor belt system was added 60 meters from the main control room.Using two 07BR61R1 repeaters in series(per ABB topology rules),engineers connected three remote I/O racks for motor starters and belt misalignment switches.The project avoided$120K in trenching and conduit costs by eliminating the need for a local PLC.

Similarly,at a U.S.wastewater plant,the 07BR61R1 enabled relocation of chlorine dosing I/O to a corrosion-resistant outdoor enclosure—improving safety and maintenance access while maintaining deterministic control.

Related Product Combination Solutions

ABB AC 800M CPUs:PM864A,PM865(require MasterBus 300 interface)

Baseplates:TB510(standard)or TB520(for extended diagnostics)

I/O Modules:AI810,DI810,DO810,etc.—all AC 800M-compatible modules

System 800xA:Engineering and runtime environment for full system integration

Control Builder M:Configuration tool(repeater requires no logic programming)

ABB CI854A:Profibus DP coupler(alternative for very long distances)

Fiber Optic Converters:For extreme distances(>100m),though 07BR61R1 avoids this complexity in mid-range cases

Redundant CPU Systems:07BR61R1 supports redundant AC 800M configurations with proper bus cabling

Installation,Maintenance,and Full-Cycle Support

Installation:

Mount 07BR61R1 in a TB510/TB520 baseplate within an I/O rack

Connect MasterBus 300 ribbon cable from CPU(or previous module)to IN

Connect OUT to next I/O rack or another repeater(follow ABB max segment rules)

No software configuration needed

Maintenance:

Monitor LED status(green=OK,red=fault)

Replace via hot-swap if supported by system redundancy

No firmware or calibration required

Although the AC 800M platform is mature,ABB continues to support the 07BR61R1(GJV3074376R1)under its Long-Term Availability Program,with manufacturing and spare parts guaranteed until at least 2028–2030.Units are backed by global technical support and full documentation.

Contact us for a customized solution—whether you’re expanding an existing AC 800M system,optimizing cabinet layout,or integrating remote I/O in power,water,or process industries,the ABB 07BR61R1 delivers simple,robust,and cost-effective bus extension with zero impact on control performance.

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