ABB UFC921A101 3BHE024855R0101

Description

Detailed parameter table

ABB UFC921A101 3BHE024855R0101

Product introduction

The ABB UFC921A101 3BHE024855R0101 is a rugged Process Interface Unit (PIU) engineered for demanding industrial control environments, particularly in high-voltage power generation, petrochemical, and heavy manufacturing sectors. As a key component in ABB’s Advant OCS and Symphony Plus control systems, this module serves as the critical link between field instruments and central controllers.

With 8 analog inputs, 16 digital inputs, 4 analog outputs, and 8 digital outputs, the UFC921A101 3BHE024855R0101 excels at consolidating diverse sensor data—such as pressure, temperature, and valve positions—while issuing precise control signals to actuators. Its robust isolation and wide temperature tolerance make it ideal for environments with electrical noise and extreme conditions, ensuring reliable operation in power plant boiler control loops, turbine monitoring systems, and chemical reactor skids. The module’s multi-protocol support enables seamless integration into both legacy and modern automation architectures, solidifying its role as a versatile interface solution.

Core advantages and technical highlights

Enhanced signal integrity: The UFC921A101 3BHE024855R0101 features 2.5 kVAC channel-to-bus isolation, eliminating ground loops in high-voltage environments like coal-fired power plants. In boiler control applications, this isolation prevents voltage transients from damaging sensitive control systems while maintaining 0.1% input accuracy—critical for regulating steam pressure within ±0.5 psi tolerances.

Dual redundancy support: Designed for mission-critical systems, the module supports hot-swappable installation and redundant power supplies. In a nuclear power plant’s safety system, operators can replace the UFC921A101 without shutting down the loop, ensuring uninterrupted monitoring of radiation detectors and emergency shutdown valves.

Broad protocol compatibility: With native Profibus DP and Modbus RTU, plus optional Ethernet/IP, the UFC921A101 3BHE024855R0101 bridges legacy and smart sensors. In a refinery upgrading from analog to digital flow meters, it simultaneously communicates with old 4-20 mA transmitters and new HART-enabled devices, avoiding costly system overhauls.

Harsh environment resilience: Conformal coating and -20°C to +70°C operation make the UFC921A101 suitable for unconditioned spaces like offshore oil platforms. Its resistance to vibration (10 g peak) and humidity (95% non-condensing) ensures reliable performance in turbine enclosures where traditional interface modules fail prematurely.

Typical application scenarios

Power plant turbine control: In a combined-cycle gas turbine (CCGT) plant, the UFC921A101 3BHE024855R0101 monitors 8 thermocouples measuring turbine exhaust temperatures (analog inputs) and 12 limit switches detecting valve positions (digital inputs). It sends 4-20 mA signals to fuel control valves (analog outputs) and triggers alarm relays (digital outputs) during overspeed conditions. The module’s fast 1ms response time ensures the turbine control system can adjust fuel flow within critical milliseconds to prevent damage.

Chemical reactor automation: For a batch reactor producing pharmaceutical intermediates, the UFC921A101 interfaces with pressure transmitters, pH sensors, and level switches. It converts their signals to digital data for the DCS, which calculates setpoints. The module then outputs 4-20 mA signals to control the reactor’s heating jacket and agitation speed, maintaining reaction temperatures within ±0.1°C—essential for meeting FDA purity standards.

Metallurgical process control: In a steel mill’s continuous casting line, the UFC921A101 3BHE024855R0101 handles inputs from infrared temperature sensors (mold temperature) and water flow meters (cooling circuits). It activates digital outputs to adjust spray nozzles and sends analog signals to speed controllers for the casting machine. Its rugged design withstands electromagnetic interference from arc furnaces, ensuring precise control of slab solidification rates.

Related model recommendations

UFC911A101: A compact 4-input/2-output variant of the UFC921A101 3BHE024855R0101, ideal for small-scale loops like pump skids where full I/O capacity isn’t needed.

CI854A: ABB’s Profibus DP redundant interface module that pairs with the UFC921A101 in safety-critical networks, providing dual communication paths to prevent single-point failures.

AI830: 8-channel analog input module with HART support, used alongside the UFC921A101 when connecting smart transmitters requiring configuration access.

DO820: 16-channel digital output module that expands the UFC921A101’s relay capacity, useful in large-scale alarm systems for power plant control rooms.

SPBRC410: Redundant power supply unit that ensures uninterrupted operation of the UFC921A101 in nuclear safety systems, meeting IEC 61508 SIL 3 requirements.

ABB UFC921A101 3BHE024855R0101

Installation, commissioning and maintenance instructions

Installation preparation: Mount the UFC921A101 3BHE024855R0101 on a grounded 35mm DIN rail in a NEMA 4 enclosure when installed in dusty or wet areas. Use twisted-pair shielded cables (0.5-1.5mm²) for analog signals, terminating shields at both ends to reduce noise. Verify 24 VDC power with ±15% tolerance and isolate from high-voltage cables (minimum 300mm separation). Configure input type (NPN/PNP) via DIP switches before power-up to prevent damage.

Maintenance suggestions: Inspect quarterly for loose terminals and dust buildup—clean with compressed air (5 bar max). Calibrate analog inputs annually using a precision signal generator; follow ABB’s 3-point calibration procedure (0%, 50%, 100% of range). If communication errors occur, check Profibus termination resistors (120Ω) and verify baud rate matches the DCS (9600-12Mbps). Replace faulty modules with genuine ABB spares to maintain SIL compatibility—use anti-static tools during handling.

Service and guarantee commitment

ABB warrants the UFC921A101 3BHE024855R0101 for 3 years against defects in materials/workmanship, including free replacement of failed units. Customers receive 24/7 technical support via ABB’s global helpdesk, with average response times under 2 hours for critical issues.

The module is backed by ABB’s lifecycle management program, providing firmware updates for 10 years post-launch and spare parts availability for 15 years. Optional on-site commissioning services include loop checks and DCS integration verification. For nuclear applications, ABB offers IEC 61513 compliance documentation and periodic safety audits, ensuring regulatory compliance throughout the product’s lifespan.