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High-reliability binary input (BI) module for ABB’s Advant OCS (Open Control System), designed to interface with digital sensors and switches in large-scale industrial processes. It converts discrete electrical signals (e.g., from limit switches, contactors) into digital data for the system’s processor unit (e.g., HIEE300900R0001), enabling real-time monitoring of device status in mission-critical applications like power generation and petrochemical plants.
- System Compatibility: Exclusive to ABB Advant OCS platform; integrates with Advant Controller 450/460 racks via backplane communication.
- Input Channels: 16 isolated binary inputs (channels 1-16), individually configurable for different signal types.
- Input Specifications:
- Voltage range: 24V DC (18-30V DC) — compatible with standard industrial sensors.
- Input type: Sinking (NPN) or sourcing (PNP) via software configuration.
- Response time: ≤1ms (for critical signals) to 10ms (configurable via processor).
- Isolation: Channel-to-channel isolation (2.5kV AC, 1min) and channel-to-backplane isolation (5kV AC, 1min) — prevents ground loops in large systems.
- Power Supply: 24V DC from Advant OCS rack backplane; power consumption ≤8W (all channels active).
- Env: -10°C~+50°C, 5%-95% RH (non-condensing); IP20 (rack-mounted in control cabinets).
- Dimensions: 160mm (W) × 130mm (H) × 220mm (D); weight ~1.2kg (fits standard Advant OCS 19-inch racks).
- Discrete Signal Acquisition: Converts physical on/off signals (e.g., valve open/close, motor run status) from 16 industrial devices into digital data (0/1) for the processor unit.
- Signal Conditioning: Filters noise from input signals (via configurable RC filters) to prevent false triggers in high-EMI environments (e.g., near motors or inverters).
- Diagnostics: Provides channel-level fault detection (e.g., open circuit, overvoltage) and transmits status to the processor — indicated by LED per channel (green = active, red = fault).
- Redundancy Support: Works in redundant rack configurations — if primary module fails, backup module automatically takes over without data loss.
- High Isolation: Robust channel-to-channel isolation prevents interference between signals, critical for large systems with distributed sensors (e.g., power plant turbine control).
- Fast Response: ≤1ms response time captures critical events (e.g., emergency stop signals) without delay, enhancing process safety.
- Configurable Flexibility: Software-adjustable input type (sinking/sourcing) and response time eliminate the need for hardware modifications, simplifying integration with diverse sensors.
- Seamless System Integration: Optimized for Advant OCS processors — uses proprietary backplane communication for deterministic data transfer (no latency spikes).
- Power Generation: Monitors status of circuit breakers, valve position switches, and emergency stops in turbine control systems — 16 channels handle multiple discrete signals from the turbine enclosure.
- Petrochemical Plants: Tracks contactor states, flame detectors, and pressure switch alarms in reactor units — isolation prevents ground loop interference from nearby high-voltage equipment.
- Water Treatment: Reads level switch signals (high/low) from storage tanks and pump run/fail status in filtration systems — diagnostics alert operators to faulty sensor wiring.
- Metallurgy: Monitors limit switches on rolling mill conveyors and hydraulic valve status in steel production — fast response ensures timely detection of jam conditions.
- Rack Compatibility: Verify compatibility with Advant Controller 450/460 racks (backplane version ≥v3.0); older racks may not support full diagnostic functions.
- Wiring: Use 0.5-1.5mm² twisted-pair cables for inputs; torque terminals to 0.8-1.2N·m. Keep input wiring separate from high-voltage cables (≥240V) to avoid noise.
- Configuration: Set input type (sinking/sourcing) via Control Builder M software to match sensor type — mismatched settings cause incorrect signal reading.
- Redundancy Setup: In redundant systems, ensure primary/backup modules have identical firmware (v4.1+) — firmware mismatches disrupt failover.
- Environmental Control: Install in climate-controlled cabinets; avoid condensation (use cabinet heaters in humid areas) to prevent isolation degradation.
- Testing: Periodically test input channels with a signal generator (24V DC) to verify response — untested channels may hide wiring faults.
The structure and details of the product:

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