ABB FPX86-9345-B 3BHL000986P0006 Controller Module

ABB FPX86-9345-B 3BHL000986P0006 Controller Module

Product Overview

The ABB FPX86-9345-- B 3BHL000986P0006 controller module is an intelligent core control unit launched by ABB for high-end industrial control scenarios. It belongs to the FPX series high-performance controller product line and is mainly used in the core control links of large industrial units (such as gas turbines, steam turbines), distributed control systems (DCS), and complex process industries. It undertakes comprehensive control tasks such as equipment operation status monitoring, multivariable logic operation, accurate instruction output, fault warning and diagnosis. This module integrates advanced multi-core processor technology, high reliability hardware architecture, and flexible software configuration platform. It can achieve millisecond level control response in harsh industrial environments such as high temperature, high vibration, and strong electromagnetic interference. It is a key core component to ensure the safe, efficient, and continuous operation of large-scale industrial systems, and is widely used in fields such as power, energy, metallurgy, aerospace, etc. that require strict control accuracy and reliability.

Core Features

1. Multi core parallel processing and super strong computing power

The module is equipped with a high-performance multi-core industrial grade processor, integrating floating-point arithmetic unit (FPU) and digital signal processing unit (DSP), with multitasking parallel processing capability. The core operation frequency can reach 1GHz, and a single cycle can complete complex PID adjustment, fuzzy control and other algorithm operations. In response to the multi variable coupling control requirements of large-scale industrial systems, the module is equipped with a dedicated control algorithm library that supports up to 32 independent PID loop controls, feedforward controls, and adaptive controls. The control accuracy can reach ± 0.01%, and real-time monitoring data from hundreds of sensors can be processed to quickly output precise control instructions, ensuring that the industrial process is stable in optimal working conditions.

2. High redundancy and high reliability design

To meet the operational requirements of "zero downtime" in large-scale industrial systems, the module adopts a fully redundant design architecture, including power redundancy, processor redundancy, communication redundancy, and I/O interface redundancy. The core circuit uses military grade wide temperature element devices, with a working temperature range covering -40 ℃ to 85 ℃, and excellent vibration resistance (in accordance with MIL-STD-810G standard) and impact resistance. At the same time, the module is equipped with a dual hardware watchdog circuit and a real-time fault diagnosis system, which can comprehensively monitor its own circuit, external interfaces, and connected devices. When a fault occurs, it can complete the fault location and trigger redundant switching within 5ms, with a switching time of less than 10ms, ensuring that control tasks are not interrupted and greatly improving the reliability of system operation.

3. Rich interfaces and flexible expansion capabilities

The module is equipped with extremely rich interface resources, covering analog input/output (AI/AO), digital input/output (DI/DO), pulse input/output (PI/PO), and various industrial communication interfaces. Among them, the AI interface supports multiple signal types such as 4-20mA, 0-10V, thermocouples, and thermal resistors, totaling 24 channels; AO interface 16 channels, supporting 4-20mA current output; 32 DI interfaces, supporting dry contacts and PNP/NPN signals; There are 16 DO interfaces, including two types: relay output and transistor output. In terms of communication, it integrates 2 Gigabit Ethernet interfaces (supporting PROFINET and EtherNet/IP protocols), 4 RS485 interfaces (supporting Modbus RTU/TCP protocols), and 2 CANopen bus interfaces, which can flexibly interface with DCS systems, upper computer monitoring platforms, and various intelligent devices on site. In addition, the module supports modular expansion, which can be connected to I/O expansion modules, communication expansion modules, etc. through a dedicated expansion bus. It can be expanded to a maximum of 256 I/O points to meet the control needs of industrial systems of different scales.

4. Intelligent diagnosis and convenient operation and maintenance functions

The module has powerful intelligent diagnostic capabilities, which can not only monitor its own operating status, but also obtain the operating parameters of connected devices through communication interfaces, achieving full chain fault diagnosis of "controller device". Diagnostic information includes sensor faults, line disconnections, equipment overload, communication abnormalities, etc., which can be output through status indicator lights, buzzers, and communication interfaces. In terms of operation and maintenance, it supports parameter configuration, program download, online monitoring, and debugging through ABB's dedicated configuration software (such as Control Builder M). The software interface provides visual process monitoring charts, data trend curves, and fault log query functions. At the same time, the module supports remote operation and maintenance, and engineers can remotely access the module through Ethernet to complete program upgrades, parameter modifications, and troubleshooting without the need to go to the site, greatly reducing operation and maintenance costs and time.

5. High compatibility and standardized design

The module strictly follows international industrial control standards (such as IEC 61131-3) and supports multiple programming languages such as ladder diagram (LD), functional block diagram (FBD), structured text (ST), etc., making it easy for engineers to develop and port programs. Its interface and communication protocol are highly compatible and can be seamlessly integrated into mainstream DCS systems such as ABB AC 800M and System 800xA, while also enabling interconnection with industrial equipment from other brands such as Siemens and Rockwell. Standardized design not only reduces the difficulty of system integration, but also provides convenience for subsequent system upgrades and expansions, protecting users' initial investment.

Key technical parameters

Core processor

Multi core industrial grade processor with a clock speed of 1GHz

control accuracy

±0.01%

Number of PID loops

Support 32 independent PID loops

Analog input (AI)

24 channels, supporting 4-20mA/0-10V/thermocouple/thermistor, accuracy ± 0.05%

Analog Output (AO)

16 channels, 4-20mA, load capacity ≤ 600 Ω, accuracy ± 0.1%

Digital Input (DI)

32 channels, dry contact/PNP/PNN, response time ≤ 0.1ms

Digital Output (DO)

16 channels, 8 relay outputs (AC 250V/5A), 8 transistor outputs (DC 24V/2A)

Pulse Input (PI)

8 channels, frequency range 0-100kHz

communication interface

2 Gigabit Ethernet (PROFINET/EtherNet/IP), 4 RS485 (Modbus RTU/TCP), 2 CANopen

working power supply

DC 24V ± 20% or AC 110/220V ± 10%, dual power redundancy, power consumption ≤ 30W

Operating Temperature

-40℃ ~ 85℃

Storage temperature

-55℃ ~ 100℃

Protection level

IP20 (module level), compatible with IP67 explosion-proof control cabinet

Dimensions (length x width x height)

220mm × 160mm × 50mm (excluding installation accessories)

Anti-interference performance

Compliant with IEC 61000-4-2/3/4/5/6 standards

Redundant switching time

≤10ms

Applicable scenarios

The ABB FPX86-9345-- B 3BHL000986P0006 controller module, with its outstanding performance and high reliability, plays a core control role in multiple key industrial fields:

-In the field of electric energy, it is used for gas turbine and steam turbine control systems in thermal power plants and nuclear power plants to achieve speed regulation, load distribution, start stop control, safety protection, and fault diagnosis of the units, ensuring stable and efficient power generation of the generator units and responding to dynamic changes in grid loads.

-In the field of metallurgy and steel, the control system is applied to core production processes such as blast furnace ironmaking, converter steelmaking, and continuous casting and rolling. It accurately controls key process parameters such as furnace temperature, pressure, and liquid level, coordinates the collaborative work of multiple equipment, improves the quality of metallurgical products, and reduces energy consumption.

-In the field of petrochemicals, it is used as a control system for large-scale refining units, chemical reaction vessels, and oil pipelines to achieve precise control of reaction and transmission processes. It has explosion-proof design and can work stably in flammable and explosive environments, ensuring the safety and continuity of chemical production.

-In the field of aerospace, it undertakes core control tasks in aircraft engine test benches and spacecraft ground simulation systems, with high precision and reliability characteristics, and can simulate equipment operating conditions under extreme conditions, providing precise control support for the research and testing of aerospace equipment.

-In the field of municipal engineering, it is used as an automated control system for urban sewage treatment plants and water treatment plants to achieve full monitoring and automatic adjustment of the water treatment process, including water quality testing, pump start stop, and chemical dosing, to ensure the quality of urban water supply and sewage treatment.

-In the field of ship and ocean engineering, it is suitable for control systems of ship power systems and oil and gas extraction equipment on offshore platforms. It has anti salt spray and anti vibration characteristics, and can work stably in harsh marine environments, ensuring the safety of ship navigation and the smooth progress of marine resource extraction.

Precautions for use

1. Installation specifications: The module should be installed in a control cabinet that meets the protection level requirements. The installation location should be away from high temperature heat sources, humid areas, strong magnetic fields, and corrosive gases to ensure good ventilation. The module spacing should not be less than 80mm to facilitate heat dissipation. For explosion-proof scenarios, it is necessary to select a matching explosion-proof control cabinet to ensure that the installation complies with explosion-proof standards (such as ATEX, IECEx). During installation, use specialized guide rails or fixed bolts to tighten to avoid loosening of interfaces or damage to components caused by vibration.

2. Wiring requirements: Strictly distinguish power circuits, signal circuits, and load circuits according to the product wiring manual. Strong and weak current circuits should be wired separately with a spacing of not less than 150mm to avoid cross interference. When wiring, wires that meet the specifications should be selected to ensure that the cross-sectional area of the wire matches the current. The wiring terminals should be tightened to prevent signal distortion or equipment failure caused by poor contact. It is recommended to use shielded twisted pair cables for sensor signal lines, with one end of the shielding layer reliably grounded (grounding resistance ≤ 3 Ω).

3. Power configuration: Prioritize the use of dual power redundant power supply to ensure seamless switching between one power supply and the other in case of a power failure. The power supply voltage should meet the module specifications, and the ripple factor should be less than 0.5% when powered by DC 24V; A regulated power supply is required for AC power supply. Install surge protectors and fuses (recommended specification 3A) at the power input end to prevent module damage from power surges or short circuits.

4. Program development and debugging: Before program development, it is necessary to clarify the control requirements, select a suitable programming language based on the IEC 61131-3 standard, and conduct offline simulation testing after completion to verify the correctness of the logic. During online debugging, the control circuit should be gradually put into operation to avoid putting all control tasks into operation at once. During the debugging process, it is necessary to monitor the operating status of the modules and promptly handle any abnormal situations. After the program debugging is completed, it needs to be backed up to prevent program loss.

5. Redundant configuration and testing: If redundant configuration is used, the redundant parameters must be correctly set in the configuration software, including the switching conditions between primary and backup modules, data synchronization methods, etc. Before the system is put into operation, a redundancy switching test is required to simulate the main module failure scenario, check whether the backup module can take over the control task within the specified time, and ensure that the redundancy function is normal.

6. Daily maintenance: Regularly inspect the module, check the status indicator lights, wiring terminals, cooling fans and other components to confirm that there are no abnormalities. Clean the dust on the surface of the module and inside the control cabinet once a month, and check the fastening of the wiring terminals once a quarter to prevent oxidation or loosening. Regularly backup module parameters and control programs for easy fault recovery.

7. Fault handling: When a module malfunctions, the fault information should first be obtained through the status indicator light and configuration software to preliminarily locate the cause of the fault. Before maintenance, the module power must be cut off and anti-static tools must be used to avoid static electricity damaging the core chip. For redundant systems, the backup module can be switched first, and then the faulty module can be repaired or replaced. For complex faults, please contact ABB professional technicians and do not disassemble the internal circuits of the module by yourself.