ABB TC820-1 Industrial Control Module

ABB TC820-1 Industrial Control Module

Product core positioning

The ABB TC820-1 industrial control module is a specialized functional module in the AC 800M series PLC, focusing on temperature control and analog signal processing. It is designed for precise acquisition and closed-loop control of continuous parameters such as temperature, pressure, and liquid level in industrial sites. As an important functional supplement to the AC 800M system, it can seamlessly integrate with main processor modules such as PM825 and PM820-1, stripping the analog signal processing capability from the main CPU. This not only reduces the computational load of the main processor, but also improves the control accuracy of temperature and other parameters (such as ± 0.1 ℃). It is widely suitable for industries with strict temperature control requirements such as petrochemicals, metallurgy, and food processing, and is a key component for building high-precision industrial control circuits.

 Key technical parameters

（1） Signal acquisition and control parameters

Channel configuration

8 independent analog input channels+4 analog output channels, supporting separate configuration of input/output channels

Input signal type

Supports thermocouples (J, K, T, E, R, S, B types), thermistors (Pt100, Pt1000, Cu50), 4-20 mA/0-10 V standard analog signals

Input accuracy

Thermocouple: ± 0.1 ℃ (within the range of -200 ℃ to 1700 ℃); Thermal resistance: ± 0.05 ℃ (within the range of -200 ℃ to 850 ℃); Standard analog quantity: ± 0.02% of full scale

Output signal type

4-20 mA current output (load resistance ≤ 500 Ω), 0-10 V voltage output (load resistance ≥ 10 k Ω)

Control algorithm

Built in PID, fuzzy PID, adaptive PID algorithms, support manual/automatic control switching, configurable control cycle (10-1000 ms)

Filtering function

Configurable 1-1000 ms digital filtering, supporting sliding average and weighted average filtering methods to suppress signal noise

（2） Hardware and power supply parameters

Power supply specifications

Input voltage 24 VDC (allowable fluctuation range ± 10%), power consumption ≤ 4 W, compatible with AC 800M system power supply

Size specifications

Width 40mm x height 100mm x depth 160mm, consistent with PM820-1 and PM825 dimensions, compatible with standard 35mm DIN rail installation

Environmental adaptability

Working temperature -25 ℃ to+70 ℃, storage temperature -40 ℃ to+85 ℃; Relative humidity ranging from 5% to 95% (no condensation); Vibration resistance level IEC 60068-2-6 (10-500 Hz, 10 g acceleration), impact resistance level IEC 60068-2-27 (15 g, 11 ms)

Protection level

Module body IP20, wiring terminal IP40, dust-proof design to protect wiring parts

（3） Communication and compatibility parameters

Communication interface

1 AC 800M system internal bus interface, data transmission rate of 100 Mbps, real-time data exchange with the main processor

Protocol support

Compatible with internal protocols of AC 800M system, supporting third-party protocol forwarding such as Modbus and Profibus DP through the main processor

Software compatibility

Supports Control Builder M V5.0 and above versions, allowing for software configuration of channel parameters, control algorithms, and alarm thresholds

Core performance advantages

High precision temperature acquisition and control: The acquisition circuit is optimized for thermocouple and thermistor signals, with an accuracy of ± 0.05 ℃ - ± 0.1 ℃. Equipped with built-in adaptive PID algorithm, it can quickly respond to temperature fluctuations (such as controlling the temperature overshoot of chemical reaction kettle within 5% and shortening the stabilization time to 10 seconds), meeting the high temperature stability requirements of precision industrial production.

Multi signal type compatibility and flexible configuration: eight input channels can be configured as thermocouples, thermal resistors or standard analog quantity types respectively, and four output channels support current/voltage output switching. Different sensors and actuators can be adapted without changing modules (the same module can simultaneously collect the heating furnace thermocouple signal and pressure transmitter 4-20 mA signal), reducing the complexity of system integration.

Reduce the load on the main CPU and improve response speed: Independently undertake tasks such as analog signal acquisition, filtering, and PID operation. The main processor (such as PM825) only needs to receive control results and issue instructions, reducing the computational load by 30% -50%. At the same time, the local control cycle of the module is as short as 10 ms, which is 2-3 times faster than the centralized control response speed of the main CPU.

Strong anti-interference and stable operation capability: The input channel adopts differential isolation design, and the anti common mode interference voltage reaches 250 V, which can effectively resist electromagnetic interference generated by industrial field frequency converters and high-power motors; The module is equipped with overvoltage and overcurrent protection circuits to prevent module damage caused by sensor failures or wiring errors, with an average time between failures (MTBF) of over 80000 hours.

Convenient debugging and diagnostic functions: Through Control Builder M software, real-time data and PID parameter curves of each channel can be viewed online, supporting channel fault self diagnosis (such as thermocouple open circuit, thermal resistance short circuit, signal over range). Fault information is uploaded to the upper computer through the system bus, making it easy to quickly locate problems (such as heating furnace thermocouple disconnection can trigger an alarm within 1 second).

Typical application scenarios

Temperature control of reaction vessels in the petrochemical industry:

In the chemical intermittent reaction process, the TC820-1 module collects temperature signals from different areas of the reaction kettle (such as the temperature inside the kettle, jacket, and coil) through 8 thermocouple input channels. The built-in adaptive PID algorithm adjusts the steam valve opening of 4 output channels (4-20 mA control signal) according to the target temperature (such as 150 ℃), achieving precise temperature control (fluctuation ± 0.1 ℃). At the same time, the temperature data is uploaded to the PM825 main CPU to ensure stable reaction process and improve product quality consistency.

Heating furnace temperature control system in metallurgical industry:

In the steel rolling heating furnace of the steel plant, the TC820-1 module collects temperature signals from multiple thermal resistors (Pt100) inside the furnace (such as preheating section, heating section, and homogenization section temperature), and controls the output power of the gas valve or electric heating tube through fuzzy PID algorithm to avoid steel oxidation or deformation caused by sudden temperature rise and drop; Simultaneously supporting collaboration with the PM820-2 pulse counting module, dynamically adjusting the heating furnace temperature based on the rolling mill speed (pulse signal) to adapt to different rolling rhythm requirements.

Sterilization temperature control in the food processing industry:

In the dairy sterilization production line, the TC820-1 module collects the temperature of the sterilization tank through a thermocouple (target 85 ℃, maintained for 15 seconds), and controls the steam heating valve, cold water valve, stirring motor speed, and conveyor belt speed through four output channels, achieving closed-loop temperature control throughout the "heating insulation cooling" process; The fault diagnosis function of the module can monitor the status of the thermocouple in real time. If there is a disconnection, it will immediately trigger an alarm and switch to the backup heating circuit, avoiding the flow of unsterilized products into the next process.

Temperature monitoring of transformers in the power industry:

In the substation transformer, the TC820-1 module collects transformer winding, iron core, and oil temperature signals through Pt100 thermistor. When the temperature exceeds the threshold (such as winding temperature of 105 ℃), it outputs a 4-20 mA signal to control the cooling fan to start; At the same time, the temperature data is uploaded to the power grid monitoring system through the PM825 main CPU, which supports remote viewing of temperature curves and historical data, early warning of transformer overheating faults, and ensures the safe operation of equipment.

Selection and usage precautions

（1） Key selection points

Select based on signal type and channel quantity:

If simultaneous acquisition of thermocouple, thermistor, and standard analog signals is required, TC820-1 (8-in 4-out, multi signal compatible) should be selected as the preferred option; If only a single type of signal is required (such as only thermocouples), it can be compared to other simplified models in the same series (such as TC810) to reduce costs.

A single module can support up to 8 inputs and 4 outputs. If the channel requirements exceed this range, multiple TC820-1 can be connected in parallel to the AC 800M system, supporting up to 32 module extensions (256 inputs and 128 outputs).

Confirm control accuracy and algorithm requirements:

If the control accuracy requirement is ≤± 0.1 ℃ (such as precision chemical engineering, food sterilization), the high-precision acquisition and adaptive PID of TC820-1 can meet the requirements; If it is a general temperature monitoring (accuracy ± 1 ℃), lower order models (such as TC800) can be selected.

Software and system compatibility:

It is necessary to ensure that the firmware version of the AC 800M main processor is ≥ V5.0 and the Control Builder M software version is ≥ V5.0, in order to avoid module parameter configuration or data exchange issues caused by version incompatibility.

（2） Installation and wiring precautions

Installation environment requirements:

Install the PM825 and PM820-1 modules side by side on DIN rails, with a 5-10 mm gap reserved between modules for heat dissipation; Avoid installation near heat sources (such as heating furnaces, transformers) or in humid environments (relative humidity>95%). If unavoidable, install a cooling fan or waterproof cover; When the distance from strong electromagnetic interference sources (such as frequency converters) is ≥ 0.5 meters, the input signal line adopts twisted pair shielded wire, and the shielding layer is grounded at one end (grounding resistance ≤ 4 Ω).

Wiring specifications:

Thermocouple wiring: Use compensating wires (such as KC compensating wires for K-type), with the positive and negative polarities strictly corresponding to the module terminals, to avoid measurement deviation caused by reverse connection; Extend the length of the cable to ≤ 100 meters to reduce signal attenuation.

Thermal resistance wiring: Use three wire or four wire wiring (Pt100 recommends four wire wiring) to avoid measurement errors caused by wire resistance; Wire cross-sectional area ≥ 0.5 mm ² to reduce line losses.

Power and output wiring: Connect 1A fuses in series in the power circuit, and install surge protectors between the output channel and actuators (such as valves and fans) to prevent voltage surges from damaging the module; Separate the wiring of output signal lines from input signal lines to avoid signal interference.

（3） Key points for use and maintenance

Parameter configuration optimization:

According to the sensor type, configure channel parameters (such as thermocouple type, thermal resistance scale, filtering time). It is recommended to set the filtering time to 1-3 times the signal cycle (such as 50 Hz interference, filtering time of 20-60 ms) to avoid data fluctuations caused by insufficient filtering or response delays caused by excessive filtering; The PID parameters need to be adjusted according to the characteristics of the controlled object (such as furnace inertia and lag time), and can be automatically optimized through the software's "self-tuning" function.

Regular calibration and maintenance:

Use a standard signal generator (such as thermocouple calibrator, precision resistance box) to calibrate the input channel accuracy every quarter. If the deviation exceeds ± 0.2 ℃, zero and gain correction must be performed through software; The output channel can measure 4-20mA/0-10V signals through a multimeter to ensure that the output accuracy meets the standard.

Every six months, check whether the wiring terminals are loose, whether the compensating wires are aging, and whether the shielding layer is well grounded. Especially in scenarios with high vibration (such as metallurgical rolling mills and chemical reaction vessels), it is necessary to strengthen the frequency of terminal tightening to avoid signal interruption caused by poor contact.

Fault handling and data backup:

If the module has an alarm (such as channel failure or communication interruption), first check the fault code through Control Builder M (such as "E01" indicating thermocouple open circuit), and then investigate the sensor, wiring, and power supply; Regularly backup module parameter configuration (channel type, PID parameters, alarm threshold), and if the module is replaced, the configuration can be quickly restored to reduce downtime.