Category: ABB

Aluminium applications

– AC 800PEC unit controller ↔ AC 800PEC master controller communicates via PEC – PEC fibre optic link

(100 μs)

– Can be independent of the main controller control unit

– Allows emergency operation (full smooth current control in emergency mode without AC 800PEC,

only in combination with DCS800 pre-magnetisation)

– Predictive maintenance functions can be included

– Open circuit, overcurrent, undervoltage and overvoltage protection packages included in software

– Newly developed OPC (Open Circuit Protection) stand-alone PLC (Programmable Logic Controller)

that can be used in conjunction with AC 800PEC main controller functions or

as a stand-alone protection during main board maintenance

– Controlled shutdown in the event of an event without immediate tripping → reduced disruption to the

production process

– Potline load fluctuation detection and load shedding integrated into the application software

– Load tap converter fast tap function to prevent DC current overloads during disturbances

– Special Potline-to-Earth Resistance Measurement System (PERMS) based on the AC 800PEC series

– Maximum power regulation

– Prevents excessive power consumption and supports your generator

– Maximum DC voltage regulation to stabilise the process

Preventive maintenance program

ABB has designed its maintenance schedule for all contactor

families, based on its technical knowledge of the products and

on its experience in the field.

The preventive maintenance program has the following main targets:

• Check the preservation and the efficiency status of the apparatus

• Anticipate the trend of deterioration of the contactors, signalling

the need for replacement of excessively worn out components,

where available, or suggest alternative solutions for bringing them up to date

• Increase the life cycle of the installation, proposing proactive

maintenance and replacing obsolete components.

Provided services

Considering the importance of the maintenance activity and

the required technical know-how, ABB guarantees professional

competence. Interventions are performed by ABB recommended

skilled technicians. After the inspection activities, ABB technicians

give all the indications related to the future maintenance needs and

any possible corrective actions, while releasing the final report.

Benefits

Preventive Maintenance creates value over the long-term by

• Providing the best management of maintenance costs, in

particular:– Less expensive direct costs of maintenance, by reducing

the charges due to urgent situations–  Less expensive indirect costs of the installation shut-down,

taking advantage of scheduled stops.

• Ensuring better efficiency and reliability of the equipment

• Extending the contactor’s life

• Guaranteeing the safety of the installation for longer time.

Provided services

Considering the importance of the maintenance activity and

the required technical know-how, ABB guarantees professional

competence. Interventions are performed by ABB recommended

skilled technicians. After the inspection activities, ABB technicians

give all the indications related to the future maintenance needs and

any possible corrective actions, while releasing the final report.

Features and benefits

Powerful

•  1000 V DC switching ratings (IEC).

•  UL (508) rated up to 600 V DC.

Flexible

•  Wide control voltage range (e.g. 100-250 V AC/DC) means

less versions covering the entire range.

•  PLC interface with 24 V DC / 10 mA for GAF/AF400…2050.

•  Ideal for remote and fast operation.

Efficient

•  The AF electronic coil interface reduces power consumption

5-10 times at holding compared to conventional contactors.

Reliable

•  The GAF contactor is based on the well proven AF contactor.

•  Less sensitive to voltage drops due to a drop-out voltage

of 55% of the lower nominal value along with 20 ms sag

and dip immunity. These features avoid the problems with

contactor chattering and welding.

•  Elimination of contact bounce and chattering allows for

increased reliability and service life.

Quiet

•  DC powered coil makes the contactor virtually noise free.

Easy

•  The external dimensions of the GAF contactors are the same

as corresponding AF contactors making it easy to order and install.

•  Existing add on accessories for A/AF range of three pole

contactors will fit the GAF contactors.

Profibus network characteristics

The Profibus network extension by means of signal segmentation and regeneration

is limited to a maximum of 32 nodes/partners (master/slave) per segment;

On the other hand, the entire network can have up to 126 nodes/partners.

If you need to increase the length of the bus or use more than 32 stations, you must use repeaters.

Any repeater is a ‘load’ on the bus. Each new segment introduced 

must be terminated at both ends of the segment, the maximum length

of which depends on the baud rate; however, standard procedure is to connect up to 30 loads per

segment.

The transmission method for Profibus DP is the RS485 interface

(according to the EIA standard) using shielded twisted-pair cables.

The simple RS485 twisted-pair transmission method is ideally

suited for linear/tree networks with high transmission speeds.

The Profibus must always be terminated with two terminals.

As shown in the figure below, either terminal must consist of three resistors;

The terminals must be fed with a voltage of 0 to 5 volts DC,

otherwise their resistance is not equal to the characteristic impedance of the cable.

With this structure, the voltage on the bus is fixed when there are no active devices.

According to the IEC 61158/EN 50170 standard, Profibus DP (decentralised periphery)

is typically used to connect decentralised peripheral devices with fast response times.

The standard specifies node distances of up to 300 metres with bit rates

ranging from 9.6 kbps to 12 Mbps, using standard cables and maintaining maximum operating speed.

Transmission method

The transmission method for Profibus DP is the RS485 interface

(according to the EIA standard) using shielded twisted-pair cables.

The simple RS485 twisted-pair transmission method is ideally

suited for linear/tree networks with high transmission speeds.

The Profibus must always be terminated with two terminals.

As shown in the figure below, either terminal must consist of three resistors;

The terminals must be fed with a voltage of 0 to 5 volts DC,

otherwise their resistance is not equal to the characteristic impedance of the cable.

With this structure, the voltage on the bus is fixed when there are no active devices.

FAU810 Specifications

Each flame analysis unit consists of two independent channels.

Each channel receives and processes one flame detector signal.

The two detectors can be any combination of the following designs:

– SF810 Flame Scanning Head

– All DFS flame scanning heads

– Flame Rod (Ion Flame Monitoring)

Each detector can be independently configured via the FAU810 pushbutton and display, 

the Flame Explorer engineering tool or Profibus.

The FAU810 can be powered by a single or redundant 24 VDC power supply (+/- 20%).

The FAU810 has a built-in diode auction for power isolation.

Two digital input channels are available for remote parameter switching.

One digital input per sensor.

(Example: Dedicated flame detector parameters can be customised to monitor coal or oil burning)

The FAU810 can be upgraded in the field based on official releases of

new product features through a proprietary firmware download tool.

Signalling an Unsafe Condition

A no flame condition occurs when the FAU810 logic determines that an unsafe condition exists.

Remote Monitoring

Extended setup, parameter archiving, group viewing, advanced diagnostics including flame raw data,

real-time and historical trending for up to 254 networked scanning heads.

Networking with the DTM is possible via the PC-based software package

Flame ExplorerTM or via any Profi Bus DP-V1 master remote control.

FAU810 Specifications

Each flame analysis unit consists of two independent channels.

Each channel receives and processes one flame detector signal.

The two detectors can be any combination of the following designs:

– SF810 Flame Scanning Head

– All DFS flame scanning heads

– Flame Rod (Ion Flame Monitoring)

Each detector can be independently configured via the FAU810 pushbutton and display, 

the Flame Explorer engineering tool or Profibus.

The FAU810 can be powered by a single or redundant 24 VDC power supply (+/- 20%).

The FAU810 has a built-in diode auction for power isolation.

Two digital input channels are available for remote parameter switching.

One digital input per sensor.

(Example: Dedicated flame detector parameters can be customised to monitor coal or oil burning)

The FAU810 can be upgraded in the field based on official releases of

new product features through a proprietary firmware download tool.

Gas Control

Control Method

Closed loop PID; temperature stabilized

Number of pressure zones

1 to 5

Filtration

2 μm at inlet, provided

Inlet Pressure

Minimum

Setpoint + 69 kPa (10 psig)

Maximum

1034 kPa (150 psig)

Range

0 to 100 psig, Bubble tight, non-venting

Gauges

Electronic readout

0.01 psig resolution; Setpoint resolution:

0.01 psig

Accuracy

0 to 50 psig: 1.7%

50 to 100 psig: 2.7%

Repeatability

±0.1 psig

Allowable Gases

H2. He, N2. Air, Ar

Quality

GC Grade. an optional air clean up unit is available for FID

burner air.

Flow adjustment

Oven mounted needle valves with external adjustment

Tube fittings

316 SS Gyrolok (std.); 316 SS Swagelok (optional);

1⁄16. ⅛, ¼ inch connections

Temperature programmed column oven

Oven shell material

Stainless Steel

Internal dimensions

225.8  Diameter x 108.8 mm Depth

(8.89  Diameter x 4.285 in. Depth)

Heat

Forced air

Temperature control method

Closed loop PID

Oven temperature

+ 30 to 289 °C (Settings and display in °C only)

(86 to 35 °F)

Setpoint resolution

1 °C

Analytical columns

Metal capillary, fused Silica capillary, or packed

Stainless Steel

Column oven cooling  (When required by the application)

At the end of the analysis cycle, the controller directs

vortex-cooled air into the inner column oven to rapidly

return this oven zone to the initial temperature, allowing

the next measurement cycle to begin.