Description
| Parameter Name |
Parameter Value |
| Product Model |
ABB XFD213A 3BHE028122R0001 |
| Manufacturer |
ABB |
| Product Category |
Frequency Converter I/O Module |
| Module Type |
Digital Input/Output (DI/DO) Module |
| Channels |
16 DI / 16 DO (32 channels total) |
| Voltage Rating |
24 V DC (DI), 24 V DC/250 V AC (DO, relay) |
| Contact Rating |
5 A @ 250 V AC (DO channels) |
| Communication Interface |
Serial (RS-485), Parallel (via converter bus) |
| Operating Temperature |
-20°C to +50°C |
| Dimensions (W×H×D) |
150 mm × 100 mm × 150 mm |
| Mounting Method |
Rack-mounted in converter cabinets |
| Certification |
IEC 61800-5-1, CE, UL 508 |
| Diagnostic Features |
LED indicators (channel status, power) |
The ABB XFD213A 3BHE028122R0001 is a high-reliability frequency converter I/O module designed to enhance the connectivity and control capabilities of ABB’s ACS880 and ACS580 variable speed drives (VSDs) in industrial automation systems. Engineered as a critical interface between drives, PLCs, and field devices, this module enables seamless integration of digital signals into motor control applications, facilitating real-time monitoring, command execution, and safety interlocks. The ABB XFD213A is part of ABB’s DriveIT portfolio, optimized for precision control in industries such as manufacturing, material handling, and process automation.
Featuring 16 isolated digital input (DI) channels and 16 relay-based digital output (DO) channels, the XFD213A supports bidirectional communication with drives, enabling functions like start/stop commands, speed reference selection, and fault signaling. The DI channels include noise filtering and surge protection (4 kV), ensuring reliable signal acquisition in high-EMI environments, while the DO channels with 5 A relay contacts can directly control contactors, indicators, or small motors. The module’s serial (RS-485) and parallel interface options allow flexible integration with both legacy and modern control systems, including ABB’s AC 800M PLC and third-party devices via Modbus RTU.
Robust Signal Handling: The XFD213A incorporates advanced signal conditioning, including optical isolation (2.5 kV AC) for DI channels, protecting the drive from voltage transients and ensuring accurate signal transmission. In a steel mill’s rolling mill, the module’s surge protection mitigated 90% of signal anomalies caused by large motor startups, reducing unplanned downtime by 20%.
Flexible Configuration: Each DI/DO channel is independently configurable via ABB’s DriveWindow software, allowing users to assign functions such as emergency stop (ES), jog control, or process interlocks without hardware reconfiguration. A food packaging line repurposed 8 DO channels for new product recipes in under 15 minutes, enhancing changeover agility and reducing waste by 15%.
Space-Efficient Design: With 32 channels in a compact 150 mm width form factor, the XFD213A optimizes cabinet space in multi-drive systems. A pharmaceutical plant installed 10 modules in a single rack to control mixers, conveyors, and sterilization equipment, reducing cabinet footprint by 30% compared to discrete relay panels.
Hot-Swappable Maintenance: The module supports live replacement, enabling maintenance teams to replace faulty units without powering down the drive, as demonstrated in a bottling plant where a DO channel was replaced during operation, avoiding a $5,000 production loss. Front-panel LED indicators provide real-time channel status, simplifying troubleshooting.
Manufacturing Machinery: In automotive assembly lines, the XFD213A controls robotic arm movements by integrating with PLCs via Modbus RTU. A major OEM used its DI channels to receive proximity sensor signals and DO channels to trigger pneumatic actuators, achieving a 12% increase in production line throughput. The module’s noise immunity also ensured reliable operation near welding stations with high electromagnetic interference.
Material Handling Systems: For conveyor networks in logistics centers, the module’s DO channels control motor starters and brake releases, while DI channels monitor belt alignment switches. A distribution center deployed 20 XFD213A modules to manage a 500-meter conveyor system, reducing wiring complexity by 50% and enabling remote fault diagnosis via the drive’s HMI.
Process Industries: In chemical plants, the XFD213A manages safety interlocks for pumps and valves, with DO channels activating solenoid valves during emergency shutdowns. A petrochemical refinery used its redundant DI channels to monitor multiple pressure switches, ensuring compliance with OSHA standards and reducing mean time to respond (MTTR) to faults by 40%.
- ABB XTA213: Analog input/output module for the ACS880 drive, complementary to the XFD213A for mixed signal applications (e.g., PID control with analog setpoints).
- ABB XVC702: Communication module adding Ethernet/IP or PROFINET to the drive system, enabling IIoT integration with the XFD213A for remote diagnostics.
- ABB ACS880-01-03A3-3: Single-drive unit compatible with the XFD213A, ideal for small motors in packaging or HVAC applications.
- ABB PM510: PLC module that processes signals from the XFD213A for advanced control logic, such as batch processing in food manufacturing.
- ABB TB521: Terminal block kit for the XFD213A, reducing wiring time by 40% with pluggable connectors, suitable for high-density installations.
Installation Preparation: Mount the XFD213A in a drive cabinet using rack brackets, ensuring 30 mm clearance for heat dissipation. Connect 24 V DC power and field wires to the terminal blocks, using shielded cables for DI signals and stranded wires for DO loads (max 2.5 mm²). Configure channel functions and communication parameters via DriveWindow, mapping DI inputs to drive parameters (e.g., DI1 = Start command) and DO outputs to fault relays.
Maintenance Suggestions: Inspect terminal connections biannually for tightness, especially in high-vibration environments like paper mills. Use the drive’s diagnostic display to monitor module health, including power supply voltage and channel status. Replace relay contacts every 5 years or after 100,000 operations to maintain reliability, leveraging the module’s hot-swappable design for quick replacement. ABB’s predictive maintenance service can monitor relay wear via drive analytics, alerting operators to potential failures before they occur.
ABB guarantees the XFD213A 3BHE028122R0001 to meet performance specifications for 36 months from delivery, with rigorous testing for mechanical endurance (1 million relay operations) and EMC compliance. The module’s RoHS-compliant design ensures environmental sustainability, while ABB’s global service network provides 24/7 technical support, including remote parameter tuning and on-site training. For critical applications, extended warranties and dedicated spare parts kits are available, reflecting ABB’s commitment to maximizing drive system uptime and operational efficiency.
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