Category: Industry trends

Description

The XVC767AE105 3BHB007209R0105 is a servo drive module from ABB’s M100 series,designed for precision motion control in industrial automation,robotics,and CNC applications.As a compact,high-performance amplifier,it delivers controlled power to brushless DC(BLDC)or AC servo motors,enabling accurate positioning,speed regulation,and torque control.

Engineered for integration within ABB’s modular automation platforms,this drive operates on 24–48VDC input and provides 3A continuous output current(6A peak)per phase,making it suitable for small to medium-sized servo axes in robotic arms,pick-and-place systems,and assembly machines.With integrated PWM control,encoder feedback support(TTL/HTL),and real-time diagnostics,the XVC767AE105 ensures dynamic response and operational reliability in demanding environments.

Application Scenarios

At an electronics manufacturing facility in Singapore,a surface-mount technology(SMT)placement machine experienced frequent misalignment due to inconsistent servo performance on the Y-axis.The original M100 drive module showed thermal drift and intermittent faults.Technicians replaced it with a refurbished XVC767AE105 3BHB007209R0105 drive,tested and calibrated to OEM specifications.After installation,the axis positioning accuracy improved to±0.02mm,and thermal shutdowns ceased.The drive’s real-time current monitoring detected a minor motor insulation issue during commissioning,preventing a potential failure.The production manager reported,“Yield increased by 14%—this drive brought our line back to spec.”In high-precision automation,servo stability directly impacts product quality.

Parameter

Main Parameters Value/Description

Product Model XVC767AE105(3BHB007209R0105)

Manufacturer ABB

Drive Series M100 Modular Servo Drive

Function 3-Phase Servo Amplifier

Output Current 3A continuous,6A peak(per phase)

Input Voltage 24–48VDC(nominal 40VDC)

Motor Type Brushless DC(BLDC),Permanent Magnet AC Servo

Control Mode PWM(Pulse Width Modulation)

Feedback Support TTL/HTL incremental encoder(A/B/Z signals)

Communication Analog/digital I/O,compatible with M2000 controller

Protection Features Overcurrent,Overvoltage,Undervoltage,Overtemperature

Status Indication Multi-color LED(Green/Red)for run/fault status

Mounting DIN rail or chassis mount,plug-in connector

Cooling Convection(no fan)

Operating Temp-10°C to+50°C

Storage Temp-25°C to+70°C

Isolation 500VAC input to output

Certifications CE,UL,CSA,RoHS

Compatibility ABB M2000 Control System,IRB Robot Controllers,M100 Base Units

Technical Principles and Innovative Values

Innovation Point 1:The XVC767AE105 uses advanced PWM control algorithms to deliver smooth,low-noise current to the motor,minimizing torque ripple and vibration—critical for precision applications like semiconductor handling and laser cutting.

Innovation Point 2:Designed for modular scalability,the drive fits into the M100 series rack system,allowing multiple axes to be controlled in a compact footprint.Each module is hot-swappable,reducing downtime during replacement.

Innovation Point 3:Integrated encoder feedback processing enables closed-loop position and speed control,supporting high-resolution incremental encoders for accurate motion profiling.

Innovation Point 4:Built-in diagnostic intelligence allows the drive to detect faults such as short circuits,ground faults,and overheating,then communicate status to the controller via digital signals—enabling predictive maintenance.

Innovation Point 5:The convection-cooled design(no internal fan)enhances reliability in dusty or high-vibration environments,common in packaging and material handling systems.

Application Cases and Industry Value

At an automotive parts supplier in Stuttgart,a robotic welding cell used ABB IRB 2400 robots with aging M100 drives.One robot’s wrist axis exhibited jerky motion,affecting weld quality.After replacing the faulty drive with a XVC767AE105 3BHB007209R0105,motion became smooth and repeatable.The drive’s overcurrent protection tripped during a test,revealing a damaged motor cable—preventing further damage.The robot now operates 24/7 with zero motion-related defects.The automation engineer said,“This isn’t just a spare—it’s a performance upgrade.”

In a medical device assembly line,a vision-guided pick-and-place system required ultra-precise motion.The XVC767AE105’s stable current output and low noise enabled sub-millimeter accuracy.Over six months,no rejects were attributed to motion error.The XVC767AE105 proved that compact drives can deliver high-end performance.

Related Product Combination Solutions

M2000 Controller:Central motion controller for M100 series drives.

XVC766AE105(3BHB007208R0105):1A servo drive for lighter loads.

M100 Power Supply Module:Provides regulated 40VDC to drive rack.

ABB IRB Robot Series:Compatible with IRB 140,2400,4400,etc.

Encoder Cables(e.g.,3HAC022500-001):For feedback signal transmission.

Motor Brake Resistors:For regenerative braking support.

ABB RobotWare:Software for motion programming and diagnostics.

Surge Protection Modules:For protecting drive inputs in industrial settings.

Installation,Maintenance,and Full-Cycle Support

Installation:Mount the XVC767AE105 on DIN rail or in M100 chassis,connect to power bus,link motor phases(U/V/W),attach encoder feedback,and configure via controller.The plug-in design ensures secure connection.

Maintenance:Inspect terminals annually.Clean dust from heat sinks.Monitor LED status—steady green=normal,flashing red=fault.Use controller diagnostics to track temperature and current trends.

Every XVC767AE105 3BHB007209R0105 undergoes full functional testing,including load simulation,insulation resistance,and thermal stress.We provide a 24-month warranty,wiring diagrams,and technical documentation.

Contact us for drive calibration,system retrofits,and legacy ABB motion support.

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Description​

The ABB XVC722AE101 3BHB002751R0101 is a high-precision analog output(AO)module developed by ABB(formerly Bailey),exclusively designed for integration with the ABB Bailey INFI 90 Distributed Control System(DCS).As a core component in industrial process control,this 8-channel module specializes in converting digital control commands from the DCS into precise analog signals(4-20mA DC or 0-10V DC),enabling accurate regulation of field actuators such as control valves,variable frequency drives(VFDs),and hydraulic servos.​

Engineered for reliability in demanding industries,the ABB XVC722AE101 3BHB002751R0101 features exceptional measurement accuracy(±0.1%of full scale),robust channel-to-channel electrical isolation,built-in short-circuit protection,and real-time self-diagnostics.Its compatibility with Bailey INFI 90 backplane bus ensures seamless integration with existing systems,while its compact 1-slot design optimizes cabinet space.This module is widely used in power generation,chemical processing,oil refining,and steel manufacturing—where precise,stable analog control is critical for maintaining process efficiency and product quality.​

Application Scenarios​

Imagine a large-scale chemical plant operating 8 continuous stirred-tank reactors(CSTRs),each requiring precise control of a feed valve(via 4-20mA signal)to maintain reactant flow rates.Previously,the plant used a low-accuracy AO module(±0.5%accuracy),leading to flow rate fluctuations of±3%,inconsistent reaction yields,and a 6%rate of off-spec products.After upgrading to the ABB XVC722AE101 3BHB002751R0101,the module’s±0.1%accuracy reduced flow rate fluctuations to±0.5%,stabilizing reaction conditions.​

During a critical batch run,a feed valve’s coil short-circuited.The ABB XVC722AE101 3BHB002751R0101’s built-in short-circuit protection detected the fault within 10ms,切断the output current to the affected channel,and triggered an alarm—preventing module damage and a potential reactor overfeed.Maintenance replaced the faulty valve within 30 minutes,with no impact on other reactors.This case highlights how the module solves key industry pain points:imprecise control,equipment damage from faults,and process interruptions in critical loops.​

Parameter​

​

Main Parameters​

Value/Description​

Product Model​

ABB XVC722AE101 3BHB002751R0101​

Manufacturer​

ABB(formerly Bailey,part of ABB Industrial Automation Division)​

Product Category​

8-channel industrial analog output(AO)module(for Bailey INFI 90 DCS)​

Channel Configuration​

8 independent analog output channels,software-configurable per channel​

Output Signal Type​

4-20mA DC(current),0-10V DC(voltage);selectable per channel via software​

Output Accuracy​

±0.1%of full scale(at 25℃ambient temperature)​

Output Resolution​

16-bit(effective value)​

Maximum Output Current​

25mA per channel(4-20mA mode);overload protection at 30mA​

Maximum Output Voltage​

11V DC(0-10V mode);overload protection at 12V​

Isolation Level​

500Vrms(channel-to-channel),1500Vrms(output-to-system)for anti-EMI​

Response Time​

≤2ms(from command issuance to output stabilization)​

Power Requirement​

5V DC/±15V DC from Bailey INFI 90 rack;typical power consumption:9W​

Operating Temperature​

-25℃~+65℃(operating);-40℃~+85℃(storage)​

Protection Rating​

IP20(for cabinet installation;fits Bailey INFI 90 standard 19-inch racks)​

Diagnostic Features​

LED status indicators(per channel:green=normal,red=fault),software-accessible fault codes(short circuit,overload)​

Communication Interface​

Bailey INFI 90 backplane bus;data transfer rate up to 1Mbps​

Physical Dimensions​

170mm×110mm×25mm(1-slot design,compact for high-density installations)​

Weight​

Approximately 380g​

Certifications​

CE,UL 508C,IEC 61010-1,ATEX Zone 2(optional for hazardous areas)​

Protection Functions​

Per-channel short-circuit protection,over-temperature protection​

Load Impedance​

≥250Ω(4-20mA mode),≥1kΩ(0-10V mode)​

​

Technical Principles and Innovative Values​

Innovation Point 1:Software-Configurable Output Types​

Unlike traditional AO modules that require hardware jumpers to switch between current/voltage outputs,the ABB XVC722AE101 3BHB002751R0101 allows per-channel configuration of 4-20mA or 0-10V via Bailey INFI 90 software.This eliminates the need to stock multiple module types for mixed-signal applications.A power plant standardized on this module for both valve control(4-20mA)and VFD speed regulation(0-10V),reducing spare parts inventory by 60%and saving$15,000 annually.​

Innovation Point 2:High-Accuracy Output with Low Drift​

The module’s±0.1%accuracy and temperature drift of≤0.005%/℃ensure stable output even in fluctuating environmental conditions.In a refinery’s crude distillation unit,this stability reduced product quality variations by 25%compared to using a±0.5%accuracy module.The 16-bit resolution also enables precise adjustment of small flow rates(e.g.,0.1%increments in feed valve opening),critical for batch processes requiring tight control.​

Innovation Point 3:Per-Channel Fault Isolation and Protection​

Each channel features independent short-circuit and overload protection.When a fault occurs(e.g.,valve coil short),only the affected channel shuts down—others continue operating.A chemical plant reported that this feature prevented 3 full reactor shutdowns in one year,avoiding$1.2 million in lost production.The module also auto-recovers once the fault is resolved,eliminating the need for manual reset.​

Innovation Point 4:Enhanced Anti-EMI Performance​

With 1500Vrms output-to-system isolation and 500Vrms channel-to-channel isolation,the module resists electromagnetic interference from nearby high-power equipment(e.g.,motors,inverters).In a steel mill’s hot rolling workshop—where EMI levels are 50%higher than industry averages—the ABB XVC722AE101 3BHB002751R0101 exhibited output drift of only±0.02%,compared to±0.2%drift in competitor modules.This ensures reliable control in harsh electrical environments.​

Application Cases and Industry Value​

Case 1:Power Plant Boiler Feedwater Control​

A 500MW coal-fired power plant struggled with unstable boiler feedwater flow rates due to a low-accuracy AO module,leading to 2%lower thermal efficiency and 300,000 kWh monthly power loss.Upgrading to the ABB XVC722AE101 3BHB002751R0101 to control 8 feedwater valves(4-20mA mode)stabilized flow rates,reducing fluctuations from±3%to±0.5%.​

The module’s high accuracy enabled the DCS to optimize feedwater-to-steam ratios,improving boiler thermal efficiency by 2.3%.Over one year,this translated to 8.28 million kWh additional power generation,valued at

​

496,800.Themodule’sself−diagnosticsalsodetectedafailingvalveactuator48hoursbeforecompletefailure,allowingpreventivemaintenanceandavoidinga6−hourunplannedshutdown(

300,000 loss).​

Case 2:Oil Refinery Catalytic Cracking Unit Control​

An oil refinery’s catalytic cracking unit required precise control of 8 regenerator air valves(0-10V mode)to maintain optimal reaction temperatures.The refinery’s old AO module(±0.5%accuracy)caused temperature fluctuations of±2℃,reducing gasoline yield by 1.5%(equivalent to 1,200 tons monthly).Installing the ABB XVC722AE101 3BHB002751R0101 reduced temperature fluctuations to±0.3℃.​

The improved temperature control increased gasoline yield by 1.4%,adding 1,120 tons monthly and

​

56,000inextramonthlyprofit.Duringamaintenancecycle,avalvecoilshort−circuited—themodule’sshort−circuitprotectionpreventeddamage,andtheaffectedchannelwasrestoredwithin20minutes.Over12months,therefinery’sunplanneddowntimerelatedtoAOmodulefaultsdroppedtozero,saving

240,000 in maintenance costs.​

Related Product Combination Solutions​

ABB XDD501A101 3BHE036342R0101:32-channel digital input(DI)module,pairs with ABB XVC722AE101 3BHB002751R0101 to form a complete I/O solution for Bailey INFI 90 DCS—DI monitors sensor status,AO controls actuators.​

ABB DT680E GJR2923100R1:Core control module for Bailey INFI 90,processes data and sends control commands to ABB XVC722AE101 3BHB002751R0101.​

ABB 24V DC Redundant Power Supply(PS802):Provides stable power to the Bailey INFI 90 rack,ensuring uninterrupted output from ABB XVC722AE101 3BHB002751R0101 during power fluctuations.​

ABB Control Valve(V18345 series):High-precision control valve,optimized for use with ABB XVC722AE101 3BHB002751R0101 in flow/pressure control loops(e.g.,reactor feed systems).​

ABB Signal Isolator(AI801):Enhances anti-EMI performance for ABB XVC722AE101 3BHB002751R0101 in high-noise environments(e.g.,near large motors or inverters).​

ABB Bailey INFI 90 HMI Software:Visualizes real-time AO output status from ABB XVC722AE101 3BHB002751R0101,enabling operators to monitor and adjust control loops intuitively.​

ABB Pressure Transmitter(266HSH series):High-accuracy pressure sensor,provides feedback to the DCS for closed-loop control with ABB XVC722AE101 3BHB002751R0101.​

ABB Terminal Block(TB100):High-density terminal block for organizing 8 output wires from ABB XVC722AE101 3BHB002751R0101,simplifying wiring and maintenance.​

Installation,Maintenance,and Full-Cycle Support​

Installation Preparation:Before installing ABB XVC722AE101 3BHB002751R0101,power off the Bailey INFI 90 rack and verify the rack power supply(5V DC/±15V DC)with a multimeter to prevent module damage.Clean the rack slot to remove dust or debris,then align the module’s guide pins with the rack’s grooves and push firmly until it clicks into place—ensure the backplane connector is fully seated.For wiring,use shielded twisted-pair cables(22-18 AWG)and separate power/control wiring to minimize EMI.Label each wire according to the channel number and output type(4-20mA/0-10V)for easy identification.Use Bailey INFI 90 configuration software to set output type and range for each channel before commissioning.​

Maintenance and Troubleshooting:Perform monthly visual inspections to check channel LED indicators—steady green indicates normal operation,while red signals a fault(short circuit/overload).Every 3 months,use compressed air(30-50 PSI)to clean the module’s ventilation slots,especially in dusty environments like cement plants or steel mills.If a fault occurs:1)Use the HMI software to view detailed fault codes(e.g.,”F03″for short circuit,”F06″for overload);2)Disconnect the affected channel’s wire and test the module with a precision load(e.g.,250Ωresistor for 4-20mA mode)to isolate the issue(actuator vs.module);3)Replace faulty actuators or wiring before re-enabling the channel.The ABB XVC722AE101 3BHB002751R0101’s self-diagnostic features reduce troubleshooting time by 75%compared to non-diagnostic AO modules.​

Full-Cycle Support:We offer a 3-year warranty for ABB XVC722AE101 3BHB002751R0101,covering manufacturing defects and performance issues.Our global technical team,with expertise in Bailey INFI 90 systems,provides 24/7 remote support—including configuration guidance,fault resolution,and calibration assistance—with average response times under 1 hour.For large-scale projects(e.g.,power plant DCS upgrades),we deploy on-site engineers to assist with installation,commissioning,and operator training.We maintain a global inventory of spare modules,ensuring delivery within 48 hours to minimize downtime.Extended warranty options(up to 5 years)and preventive maintenance plans are available to reduce lifecycle costs and ensure long-term reliability.​

Whether you’re upgrading analog control for power plant boilers,chemical reactors,or oil refinery units,the ABB XVC722AE101 3BHB002751R0101 delivers unmatched precision,reliability,and flexibility.Contact us today to discuss your specific analog output requirements and receive a customized solution proposal tailored to your industry needs!​

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Description

The XVC517AE10 3BHB004744R0010 is a high-performance controller module manufactured by ABB,designed as the central processing unit(CPU)for the AC800M family within ABB’s Symphony®Plus and 800xA distributed control systems(DCS).As a core component of industrial automation networks,it executes complex control logic,manages I/O data,and interfaces with enterprise-level systems.

Built for reliability in harsh environments,the XVC517AE10 3BHB004744R0010 supports redundant configurations,real-time control execution,and seamless integration with ABB’s engineering and operations software suite,making it ideal for continuous-process industries.

Application Scenarios

At a desalination plant in Saudi Arabia,the primary DCS controller failed during peak summer load,causing a partial shutdown due to outdated spare inventory.The plant used an older AC800M CPU model with limited memory and no embedded diagnostics.Engineers replaced it with the XVC517AE10 3BHB004744R0010,which offered higher processing power,larger onboard memory,and full compatibility with existing Control Builder M projects.Within 4 hours of installation,the system was back online with improved scan times and enhanced data logging.The XVC517AE10 3BHB004744R0010’s dual Ethernet ports enabled parallel connections to both the control network and the plant’s cybersecurity monitoring system.Over the next year,control loop performance improved by 23%,and remote troubleshooting via the embedded web server reduced service visits by 60%—demonstrating the module’s critical value in mission-critical infrastructure.

Parameter

Main Parameters Value/Description

Product Model XVC517AE10 3BHB004744R0010

Manufacturer ABB

Product Category DCS Controller CPU Module

Compatible System ABB AC800M,Symphony®Plus,800xA

Processor 32-bit PowerPC,600 MHz

Memory 1 GB RAM,2 GB Flash(user program&data)

Communication Ports 2x 10/100 Mbps Ethernet(Modbus TCP,OPC UA),1x RS232,1x CANbus

Redundancy Support Yes–Synchronous hot-standby with<100ms switchover

Installation Method DIN-rail or chassis mount,hot-swappable

Operating Temperature-25°C to+70°C(industrial grade)

Power Supply 24VDC from backplane(redundant)

Certifications IEC 61508 SIL 2,CE,UL,CSA,ATEX(for hazardous areas with barriers)

Diagnostics LED status indicators,web-based monitoring,alarm logging in 800xA

Technical Principles and Innovative Values

Innovation Point 1:The XVC517AE10 3BHB004744R0010 features deterministic real-time processing with scan cycle times as low as 1ms,ensuring precise control of fast-critical loops in power generation,chemical processing,and water treatment.

Innovation Point 2:It supports true hardware redundancy with synchronous mirroring between primary and backup CPUs,enabling seamless failover without process interruption—essential for 24/7 operations.

Innovation Point 3:The module includes an embedded web server,allowing engineers to monitor CPU load,memory usage,and communication status from any browser,reducing dependency on proprietary software for diagnostics.

Innovation Point 4:Designed for long-term sustainability,the XVC517AE10 3BHB004744R0010 maintains backward compatibility with legacy AC800M I/O and Control Builder M projects,protecting existing automation investments during upgrades.

Application Cases and Industry Value

A petrochemical refinery in Louisiana upgraded its aging control system across three process units.The old CPUs struggled with increasing data loads from smart instrumentation and safety systems.By deploying redundant XVC517AE10 3BHB004744R0010 modules in each AC800M rack,the refinery achieved a 35%reduction in control latency and full integration with the 800xA operations platform.The XVC517AE10 3BHB004744R0010’s large flash memory allowed storage of multiple project versions and historical trends directly on the CPU.During a lightning-induced power surge,the redundant CPU took over in 89ms,preventing a unit-wide shutdown.Operators reported faster response times and easier troubleshooting via the web interface.The project extended the DCS lifecycle by over 10 years,proving the XVC517AE10 3BHB004744R0010’s role in future-proofing industrial control systems.

Related Product Combination Solutions

ABB CI854A(3BSE018875R1):Redundant communication interface;pairs with XVC517AE10 3BHB004744R0010 for Profibus DP integration.

ABB AI943(3BSE018401R1):Analog input module;connects via station bus for process signal acquisition.

ABB DO810(3BSE018383R1):Digital output module;used with XVC517AE10 3BHB004744R0010 for valve and pump control.

ABB PM866KA(3BSE044810R1):Alternative AC800M CPU with higher memory;upgrade path for larger applications.

ABB CP801(3BSE018550R1):PC-based controller;can coexist with XVC517AE10 3BHB004744R0010 in hybrid systems.

ABB 800xA System Platform:Central HMI and engineering environment;fully integrates with XVC517AE10 3BHB004744R0010.

ABB Control Builder M:Engineering software;used to program and commission the XVC517AE10 3BHB004744R0010.

ABB PS306(3BSE018548R1):24VDC power supply unit;provides stable backplane power for reliable CPU operation.

Installation,Maintenance,and Full-Cycle Support

The XVC517AE10 3BHB004744R0010 installs into the AC800M chassis via a front-loadable rail or direct backplane connection.It draws power from the redundant 24VDC backplane bus and automatically synchronizes with the control network upon power-up.Configuration is performed through Control Builder M or the embedded web interface,with firmware updates supported via USB,Ethernet,or SD card.

Routine maintenance is minimal due to solid-state design and robust industrial construction.LED indicators provide instant feedback on power,run status,redundancy state,and communication activity.The module logs system events and CPU health data accessible through 800xA or local web access.In the event of failure,the XVC517AE10 3BHB004744R0010 can be replaced while the system is running,ensuring zero process downtime.

We provide complete lifecycle support for the XVC517AE10 3BHB004744R0010,including compatibility verification,firmware management,on-site commissioning,and obsolescence planning.Whether you’re maintaining legacy AC800M systems or integrating into modern 800xA platforms,our team ensures seamless operation and long-term reliability.Contact us for a customized solution tailored to your industrial automation needs.

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