ABB UCD240A101 Industrial Controller Module

ABB UCD240A101 Industrial Controller Module

Product core positioning

The ABB UCD240A101 industrial controller module is a high-precision DC power supply and power management unit designed specifically for industrial automation systems. Its core functions include system power distribution, voltage regulation, status monitoring, and fault protection. It is the "power center" of the AC 800M series PLC and distributed control system. Compared to conventional industrial power modules, it has a wide input range, multiple stable outputs, and intelligent monitoring capabilities, which can directly provide reliable power supply for core components such as PM825 main CPU and TC820-1 temperature control module. At the same time, real-time interaction between power parameters and the main control system is achieved through an internal bus. Widely adaptable to scenarios with strict requirements for power supply stability, such as petrochemicals, electricity, and new energy, especially in systems that require redundant power supply or distributed power management, it is a key support for ensuring the continuous operation of equipment.

Key technical parameters

（1） Power input and output parameters

Input voltage range

100-240 VAC (wide AC input), supports 50/60 Hz frequency adaptation, input current ≤ 3 A

Output voltage specifications

24 VDC single channel stable output, output current 0-10 A, continuous output power up to 240 W

Output voltage accuracy

Load adjustment rate ≤± 0.5%, linear adjustment rate ≤± 0.1%, output ripple ≤ 50 mVp-p

Voltage regulation function

Supports adjustable output voltage of 22.5-28 VDC, with a step size of 0.1 V, suitable for different device power supply needs

Redundant support

Built in redundant diodes, supporting up to 4 modules in parallel redundant operation, automatic current sharing, and uninterrupted redundant switching

（2） Hardware and protection parameters

Size specifications

Width 48mm x height 175mm x depth 130mm, compatible with standard 35mm DIN rail installation, compatible with AC 800M module layout

Heat dissipation method

Natural heat dissipation+internal heat sink design, fanless operation, suitable for industrial environments with high dust levels

Environmental adaptability

Working temperature -10 ℃ to+60 ℃, storage temperature -40 ℃ to+85 ℃; Relative humidity ranging from 5% to 95% (no condensation); Vibration resistance level IEC 60068-2-6 (10-500 Hz, 5 g acceleration)

Protection level

Module body IP20, wiring terminal IP20, with dust-proof design

Protection function

Overvoltage protection (29.5 ± 0.5 VDC), overcurrent protection (11 ± 0.5 A), short circuit protection, over temperature protection (75 ℃± 5 ℃), automatically restored after fault elimination

（3） Monitoring and communication parameters

Status indication

Power input indicator light (green), normal output indicator light (green), fault alarm indicator light (red)

Communication interface

1 RS485 communication interface (supporting Modbus RTU protocol), data transmission rate adjustable from 9600-115200 bps

Monitoring parameters

Real time monitoring of input voltage, output voltage, output current, module temperature and other parameters with an accuracy of ± 1%

Alarm output

1-channel dry contact alarm output (normally closed/normally open configurable), response time ≤ 10 ms

Software compatibility

Supports ABB Control Builder M V6.0 and above versions, and can achieve parameter configuration and status monitoring through system software

Core performance advantages

Wide input and stable output capability: 100-240 VAC wide AC input range, suitable for power grid voltages in different regions around the world, especially for industrial sites with large voltage fluctuations (such as remote mining areas and Southeast Asian factories); The output accuracy of 24 VDC reaches ± 0.5%, with ripple below 50 mVp-p. It can provide interference free power supply for the high-precision analog acquisition circuit of TC820-1, avoiding measurement deviation caused by voltage fluctuations.

Flexible redundancy and high reliability design: support the parallel redundancy of four modules, and the automatic current sharing technology ensures the load balance of each module (current deviation ≤ 5%). When a module fails, the rest of the modules instantly make up the load, and there is no voltage drop during the switching process, so as to ensure the uninterrupted operation of key equipment such as PM825 redundant system; Built in multiple protection functions, quickly cut off output in case of overheating or overcurrent, automatically restore after fault elimination, reducing manual intervention costs.

Intelligent monitoring and fault warning: Communicating with the PM825 main CPU through the RS485 interface, real-time parameters such as output current and module temperature can be uploaded. When the output voltage deviates from the set value by ± 1 V or the temperature exceeds 70 ℃, the dry contact alarm is immediately triggered and fault information is uploaded, making it easier for operation and maintenance personnel to investigate in advance (such as load overload, poor heat dissipation) and avoid system shutdown caused by module damage.

Fanless and wide temperature operation adaptation: Natural heat dissipation design eliminates fan failure hazards and adapts to dusty environments such as metallurgy and cement; -The wide temperature range from 10 ℃ to+60 ℃ can be directly installed in outdoor control cabinets without air conditioning (such as outdoor terminal boxes in substations), without the need for additional temperature control equipment, reducing system integration costs.

Flexible voltage regulation and load adaptation: The output voltage can be adjusted from 22.5-28 VDC, and the power supply voltage can be fine tuned according to the aging condition of the equipment (such as the TC820-1 module that has been running for 5 years can increase the voltage by 0.5 V to ensure signal acquisition stability); The 10A high current output can simultaneously power 8 PM820-1 modules or 4 TC820-1 modules, reducing the number of power modules and simplifying cabinet wiring.

Typical application scenarios

Core power supply scheme for AC 800M system:

In the central control room of the petrochemical industry, UCD240A101 serves as the main power module to supply power to the control system composed of redundant PM825 CPU, TC820-1 temperature control module, and PM820-2 pulse counting module. By parallel redundancy of 2 UCD240A101, ensure uninterrupted power supply in case of single module failure; The module uploads real-time output current data to PM825. When the current suddenly increases (such as a short circuit in a TC820-1 module), overcurrent protection is immediately triggered and an alarm is triggered. PM825 synchronously cuts off the corresponding module control circuit to avoid fault propagation.

New energy charging station power management:

In the ABB high-power DC charging station system, UCD240A101 provides a stable 24 VDC power supply for the charging station control unit (including PLC, touch screen, communication module). Its wide AC input is adapted to the on-site power grid fluctuations of the charging station, and the 10A high current output can simultaneously drive the charging gun control circuit and status monitoring sensors; When the internal temperature of the charging station is too high, the over temperature protection function of UCD240A101 is linked to PM825 to cut off the charging output, ensuring equipment safety and meeting the high reliability power supply requirements of overseas charging stations.

Power supply for secondary equipment in substations:

In the 110 kV substation, UCD240A101 supplies power to the relay protection device, telemetry module, and TC820-1 transformer temperature control module. Using 3 modules in parallel redundancy, the output voltage is adjusted to 25.5 VDC to compensate for long-distance wiring losses; Upload the power parameters to the substation monitoring system through the RS485 interface. When the input voltage is below 100 VAC (power grid fluctuation), it will be alerted in advance and switched to the backup power supply to avoid power outages caused by relay protection devices.

Distributed power supply for metallurgical production lines:

In the steel rolling production line of the steel plant, each section of the rolling mill control cabinet is equipped with one UCD240A101, which supplies power to the local TC820-1 heating furnace temperature control module and frequency converter control circuit. The fanless design of the module is suitable for the dust environment in the workshop, and the overcurrent protection function can resist the current surge during motor start stop; Each module is connected to the central PM825 system through Modbus bus to achieve centralized monitoring of the power status of the entire production line, making it easy to quickly locate power supply faults in a certain section of the rolling mill.