Description

The ABB XV C768 AE116 3BHB007211R0116​is a high-precision,high-isolation current sensing module manufactured by ABB,designed for integration into advanced medium-voltage drive systems,power converters,and industrial control panels.This model belongs to the ABB XV C700 series of current measurement modules,renowned for their accuracy,fast response,and reliability in demanding power control environments.Engineered for use in high-performance variable frequency drives(VFDs),static excitation systems,and converter modules,the XV C768 AE116​provides highly linear,low-noise,and galvanically isolated current feedback to the main control unit.

Application Scenarios

In a large steel processing plant,the main rolling mill drive system requires precise torque control to maintain product quality and prevent equipment damage.The ABB XV C768 AE116​continuously monitors the motor current in real-time,providing accurate feedback to the drive controller.When an overload condition occurs due to material thickness variations,the module’s fast response time(<1.5µs)enables the system to quickly adjust the drive output,preventing motor overheating and production downtime.This scenario demonstrates how the XV C768 AE116​addresses the critical need for reliable current monitoring in harsh industrial environments,ensuring process stability and protecting valuable equipment.

Parameter

Main Parameters

Value/Description

Product Model​

ABB XV C768 AE116 3BHB007211R0116​

Manufacturer​

ABB

Product Category​

Current Measurement Instrument

Measurement Principle​

Hall-effect based isolated current sensing

Nominal Input Current​

±200 A nominal(up to±500 A peak)

Measurement Range​

Bipolar measurement for AC/DC current

Output Signal​

±10 V or 4–20 mA analog output

Resolution​

12-bit(4096 steps)

Full Accuracy​

±0.2%of full scale

Response Time​

<1.5µs

Bandwidth​

DC to 150 kHz

Isolation Voltage​

4000 Vrms(input to output)

Power Supply​

24 VDC±10%

Power Consumption​

≤3 W

Operating Temperature​

-10°C to+70°C

Dimensions​

100×120×25 mm

Weight​

0.3 kg

Certifications​

CE,RoHS,IEC 61010-1

Technical Principles and Innovative Values

The ABB XV C768 AE116​incorporates several innovative technologies that set it apart from conventional current sensors:

Innovation Point 1:Advanced Hall-Effect Sensing Technology

The module utilizes a Hall-effect based isolated current sensing principle that enables precise measurement of both AC and DC currents without physical contact with the primary circuit.This non-intrusive measurement approach ensures complete galvanic isolation up to 4000 Vrms,protecting both the measurement system and operators from high-voltage hazards.

Innovation Point 2:High-Speed Signal Processing Architecture

With a response time of less than 1.5 microseconds and bandwidth extending from DC to 150 kHz,the XV C768 AE116​can accurately capture fast-changing current transients and harmonics.This capability is crucial for modern drive systems that require real-time control of motor torque and speed,particularly in applications with rapid load changes.

Innovation Point 3:Dual Output Configuration

The module provides both±10 V voltage output and 4–20 mA current output options,offering flexibility for integration with various control systems.This dual-output capability allows the XV C768 AE116​to interface seamlessly with PLCs,DCS systems,and standalone controllers without additional signal conditioning.

Innovation Point 4:Temperature-Stable Performance

Featuring low temperature drift(<70 ppm/°C)and reinforced insulation,the module maintains measurement accuracy across the entire operating temperature range(-10°C to+70°C).This thermal stability ensures reliable performance in industrial environments with significant temperature variations.

Application Cases and Industry Value

Case Study 1:Steel Mill Main Drive System

A major steel producer in Europe upgraded their main rolling mill drive system with the ABB XV C768 AE116​current measurement modules.The installation involved replacing outdated current transformers with the new Hall-effect sensors across six main drive motors,each rated at 2.5 MW.The results were significant:the plant achieved a 30%reduction in drive-related downtime due to improved overload detection capabilities.The fast response time of the XV C768 AE116​enabled the system to detect and respond to material jams within milliseconds,preventing motor damage and reducing maintenance costs by approximately€50,000 annually.Additionally,the improved measurement accuracy(±0.2%vs.the previous±1.0%)allowed for better torque control,resulting in more consistent product quality and reduced material waste.

Case Study 2:Renewable Energy Converter Station

A 100 MW wind farm converter station in North America implemented the ABB XV C768 AE116​modules for DC current monitoring in their power conversion units.The harsh environmental conditions,including temperature extremes and high humidity,required robust measurement devices.The modules’4000 Vrms isolation and wide operating temperature range proved ideal for this application.Over a two-year operational period,the system maintained 99.98%availability,with zero module failures reported.The precise current feedback enabled optimal power transfer efficiency,contributing to an estimated 2%increase in energy yield compared to the previous measurement system.

Related Product Combination Solutions

The ABB XV C768 AE116​works seamlessly with several complementary products to form complete automation solutions:

ABB ACS6000 Medium-Voltage Drives

The XV C768 AE116​is fully compatible with ABB’s ACS6000 drive platform,providing precise current feedback for torque control and motor protection.The combination enables high-performance variable speed control in demanding industrial applications.

ABB ACS1000 Low-Voltage Drives

For lower voltage applications,the XV C768 AE116​integrates with ACS1000 drives to deliver accurate current monitoring and overload protection in compact drive packages.

ABB MEGADRIVE-LCI Systems

In large synchronous motor applications,the module provides excitation current feedback for precise control of motor torque and power factor.

ABB PM866K01 AC800M Controller CPU

The high-resolution analog output of the XV C768 AE116​interfaces directly with ABB’s AC800M control system,enabling advanced process control algorithms and data logging.

ABB DI810 Digital Input Module

For system integration,the DI810​module provides digital input capabilities to complement the analog current measurements from the XV C768 AE116.

ABB DO810 Digital Output Module

This module offers digital output functionality for control signals,working in conjunction with the current feedback provided by the XV C768 AE116.

ABB AI810 Analog Input Module

For applications requiring additional analog inputs,the AI810​module expands the system’s measurement capabilities alongside the XV C768 AE116.

Installation,Maintenance,and Full-Cycle Support

Installation and Commissioning

The ABB XV C768 AE116​is designed for straightforward installation with both baseplate and panel mounting options.The compact dimensions(100×120×25 mm)and lightweight construction(0.3 kg)facilitate easy integration into existing control panels and drive cabinets.The module requires a 24 VDC power supply(±10%)and provides both voltage and current output options for flexible system integration.During commissioning,the factory-calibrated settings ensure immediate operation,though fine-tuning adjustments are available through software configuration if required for specific application needs

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