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ABB SDCS-CON-3 (3ADT310300R0001) Control Board  

1. Key Parameters

• Product Model: SDCS-CON-3
• Order Code: 3ADT310300R0001
• Product Series: ABB SDCS-CON Control Boards (High-Performance Drive Controllers, Compatible with ACS600/ACS800 Series)
• Core Function: Executes advanced drive control algorithms (vector control, direct torque control); processes real-time motor data (current, speed, torque); enables industrial network communication (PROFIBUS, Modbus); manages drive parameters and fault diagnostics; supports firmware updates and remote configuration
• Electrical Specifications:

  Parameter	Details	Performance Metrics
  Power Supply	- Input Voltage: 24V DC ±10% (from drive internal power supply) - Current Consumption: ≤300mA (normal operation); ≤500mA (during firmware update) - Power Consumption: ≤7.2W (24V DC × 300mA)	Integrates seamlessly with drive power systems, eliminating external wiring
  Control Performance	- Processing Speed: 32-bit microprocessor (100 MHz clock speed) - Control Modes: Vector control (with/without encoder), V/f control, torque control - Speed Regulation: ±0.01% (vector control with encoder); ±0.1% (sensorless vector) - Parameter Storage: 2000+ configurable parameters (non-volatile memory)	Enables precise speed/torque control for high-performance applications (e.g., 1000kW motors with ±1rpm accuracy)
  Communication Protocols	Built-in: PROFIBUS DP, Modbus RTU; Optional: Ethernet/IP, PROFINET (via SDCS-COM modules) - Baud Rate: 9.6 kbps~12 Mbps (PROFIBUS); 9.6 kbps~115.2 kbps (Modbus) - Data Transfer Rate: Up to 12 Mbps (PROFIBUS DP for real-time control)	Seamless integration with PLCs (Siemens S7, ABB AC800M) and SCADA systems
  I/O Interfaces	- Analog Inputs: 4× differential (0~10V DC / 4~20mA, 16-bit resolution) - Analog Outputs: 2× (0~10V DC / 4~20mA, 16-bit resolution) - Digital Inputs: 8× optically isolated (24V DC, 0.1A max) - Digital Outputs: 4× relay (250V AC / 30V DC, 2A) + 4× transistor (24V DC, 0.5A)	Supports diverse sensor inputs (encoders, pressure transducers) and actuator control signals
  Fault Diagnostics	- Fault Logging: 200+ fault codes with timestamps; stores last 50 fault events - Diagnostic Data: Real-time motor current, voltage, speed, temperature, and drive efficiency - Alarm Outputs: 2× dedicated fault relays (NO/NC configurable)	Enables predictive maintenance and rapid fault resolution (e.g., identifying bearing wear via torque ripple analysis)
  Isolation Ratings	- Control to Power: 2kVrms (1min dielectric test) - I/O to Communication: 1kVrms (1min dielectric test) - Signal to Ground: 500Vrms (1min dielectric test)	Protects sensitive control circuits from high-voltage transients in power drive systems

• Mechanical Specifications:
  • Housing Material: Aluminum alloy (electromagnetic shielding + heat dissipation); FR4 circuit board (flame-retardant)
  • Dimensions (W×H×D): 150mm × 200mm × 30mm (mounts in drive control compartment via guide rails)
  • Mounting: Hot-swappable (replaceable without drive shutdown); Secured via 4 captive screws (compatible with ACS600/ACS800 drive chassis)
  • Weight: Approximately 350g
  • Connectors: 1× 64-pin DIN 41612 (power/I/O), 1× 9-pin D-sub (PROFIBUS), 1× 9-pin D-sub (Modbus), 1× USB (configuration/firmware)
  • LED Indicators:
    • Power (PWR): Green (24V DC normal); Red (power fault)
    • Status (STS): Green (drive ready); Flashing green (running); Red (fault)
    • Communication (COM): Green (PROFIBUS active); Yellow (Modbus active); Red (communication error)
    • I/O (IO): Green (I/O signals normal); Red (I/O fault)
• Environmental Ratings:
  • Operating Temperature Range: -10℃~+60℃ (14℉~140℉)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Humidity Tolerance: 5%~95% RH (non-condensing, 40℃; suitable for industrial environments)
  • Vibration Resistance: 10~500Hz, 1g acceleration (IEC 60068-2-6; No data loss or control deviation)
  • EMC Compliance: EN 61800-3 (industrial environment immunity); EN 55011 (Class A emissions) | Resists noise from high-power drive circuits and industrial grids |
• Compliance Standards: IEC 61131-3 (industrial control programming), EN 60947-5-1 (drive controllers), UL 508C (industrial safety), CE, RoHS, IEC 61508 (SIL 1 capable for safety-related functions)

2. Key Features

• Multi-Drive Compatibility: Designed for ABB ACS600 and ACS800 series drives (10kW~2MW)—provides a unified control platform for medium-to-high power drives, simplifying inventory management and technician training across diverse industrial applications.
• Advanced Vector Control Algorithms: Delivers precise speed and torque regulation (±0.01% accuracy with encoder)—enables high-performance control of demanding loads such as extruders, winders, and precision conveyors, where tight speed tolerance is critical to product quality.
• Dual-Protocol Communication: Built-in PROFIBUS DP and Modbus RTU support seamless integration with industrial networks—facilitates real-time data exchange with PLCs and SCADA systems (e.g., transmitting motor torque data to a Siemens S7-1200 PLC for process optimization).
• Hot-Swappable Design: Allows replacement without shutting down the drive (≤5-minute swap time)—minimizes downtime in 24/7 industrial processes (e.g., steel rolling mills, continuous production lines) where unplanned stoppages cost thousands per minute.
• High-Resolution I/O: 16-bit analog I/O ensures accurate signal processing—enables precise control via external sensors (e.g., 4~20mA pressure transducers for pump pressure control) and reliable feedback to monitoring systems.
• Extensive Fault Diagnostics: 200+ fault codes and historical logging (50 events) enable root-cause analysis—technicians can quickly identify issues like motor bearing wear (via increased current ripple) or power supply instability, reducing troubleshooting time by 60%.
• EMI Shielding & Rugged Construction: Aluminum alloy housing provides electromagnetic shielding (reducing interference from drive power circuits) and mechanical durability—withstands harsh industrial environments (vibration, temperature fluctuations, electrical noise) common in heavy manufacturing.

3. Application Fields

• Heavy Industry Drive Control: Primary application—control of ACS600/ACS800 drives in demanding environments:
  • Metallurgical Processes: Controls 500kW ACS800 drives for steel rolling mill motors; Vector control maintains ±1rpm speed accuracy, ensuring uniform strip thickness, while PROFIBUS communication syncs with mill PLCs for coordinated operation.
  • Mining Conveyors: Manages 200kW ACS600 drives for long-distance ore conveyors; Advanced torque control prevents belt slippage during startup, and fault diagnostics alert to overload conditions (e.g., rock jams) before drive damage occurs.
• Manufacturing & Processing: Precision control for production machinery:
  • Plastic Extruders: Controls 100kW ACS800 drives for extruder screws; Torque regulation (±2% accuracy) maintains consistent melt pressure, while Modbus communication transmits process data to a batch control system for recipe optimization.
  • Paper Machine Calenders: Manages 300kW ACS800 drives for calender rolls; High-resolution analog inputs receive thickness sensor signals, enabling real-time adjustment of roll speed to maintain paper gsm (grams per square meter) uniformity.
• Energy & Utilities: Control of large-scale utility equipment:
  • Power Plant Pumps/Fans: Controls 400kW ACS600 drives for boiler feedwater pumps; Vector control adjusts speed to match boiler demand, reducing energy consumption by 25% vs. fixed-speed operation, while fault logs track bearing temperature trends.
  • Water Treatment Aerators: Manages 75kW ACS800 drives for aeration blowers; Modbus communication integrates with SCADA to adjust blower speed based on dissolved oxygen levels, optimizing treatment efficiency and reducing energy use.
• Material Handling & Logistics: Control of heavy-duty material systems:
  • Port Cranes: Controls 600kW ACS800 drives for crane hoist motors; Torque control prevents load swing during lifting, while hot-swappable design allows control board replacement without crane shutdown (critical for 24/7 port operations).
  • Automated Storage/Retrieval Systems: Manages 50kW ACS600 drives for warehouse stacker cranes; High-precision speed control (±0.1%) ensures accurate positioning of pallets, while PROFIBUS communication syncs with warehouse management systems.

4. Precautions

• Drive Compatibility (Critical): Use exclusively with ABB ACS600 and ACS800 series drives—Never install in non-ABB drives or older ABB models (e.g., ACS500); Incompatible hardware will cause communication failures, incorrect drive operation, or permanent damage. Verify drive model against board specifications.
• Installation & Hot-Swapping:
  • Power Safety: Wear insulated gloves (1000V-rated) during hot-swapping—Internal drive capacitors retain charge (up to 900V DC) even with control power off. Wait 5 minutes after disconnecting control power before removing the board to discharge residual voltage.
  • Static Protection: Handle the board only with grounded wrist straps—Static discharge can damage the 32-bit microprocessor and other sensitive components. Store the board in anti-static packaging when not installed.
  • Connector Alignment: Align board connectors with drive receptacles before pressing firmly—Misalignment bends pins, causing intermittent connections or complete failure. Ensure captive screws are fully loosened before removal/installation.
• Configuration & Calibration:
  • Parameter Backup: Backup drive parameters to a USB drive before replacing the board—Parameters are stored in non-volatile memory on the board; Failure to backup will require reconfiguration from scratch, causing extended downtime.
  • Encoder Calibration: For vector control with encoders, perform encoder alignment after installation—Incorrect alignment causes speed/torque ripple, reducing motor efficiency and increasing wear. Use ABB Drive composer software for automated calibration.
• Fault Handling & Maintenance:
  • Fault Code Interpretation: Always reference fault codes (via LED display or Drive composer) before troubleshooting—Generic "no communication" faults may indicate loose connectors, not board failure. Clean connectors with compressed air before replacing the board.
  • Firmware Compatibility: Use only ABB-approved firmware versions (via USB update)—Mismatched firmware (e.g., ACS600 firmware on an ACS800 drive) disables critical safety features and causes erratic operation. Verify firmware compatibility in the user manual.
• Environmental Limitations:
  • Temperature & Contamination: Keep drive compartments clean and within -10℃~+60℃—Dust accumulation on the board reduces heat dissipation (causing overheating), while temperatures above 60℃ degrade processor performance. Use air filters on drive enclosures in dusty environments.
  • Electrical Noise: Install the drive in a shielded enclosure when used near high-voltage equipment—Excessive electrical noise (e.g., from nearby transformers) can corrupt communication signals, causing false faults. Ensure proper grounding (≤0.5Ω) of drive cabinets.
• Safety Compliance:
  • SIL 1 Configuration: For safety-related applications, configure safety functions via ABB Safety software—Incorrect configuration (e.g., disabling emergency stop logic) invalidates SIL 1 compliance, increasing safety risks. Have a certified safety engineer verify settings.
  • Lockout/Tagout: Follow lockout/tagout procedures when working on drives with this board—Even with control power off, main drive power can energize hazardous components. Never rely solely on the control board for isolation

The structure and details of the product：

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