ABB MPRC086444-003 Measurement Processing Board

Description

General Specifications

• Product Type: Measurement Processing Board (MPRC)
• Compatible Systems: ABB AC 800 Series DCS, Symphony Plus Systems
• Form Factor: Single PCB Assembly, Rack-Mountable
• Weight: Approximately 0.7 kg
• Dimensions: 67.5 mm (W) × 122.5 mm (L)
• Protection Class: IP20 (for internal cabinet installation)
• Certifications: CE, UL 508, IEC 61131-2
• Isolation Rating: 1.9 kV AC for 1 second or 1.6 kV AC for 1 minute (between field circuits and control ground)

Electrical Specifications

• Power Input: 24 V DC (operating range: 10 – 30 V DC)
• Internal Output Voltage: 5 V DC
• Output Current Capacity: Up to 2 A
• Channel Configuration: 32 total signal channels
  • Analog Input Channels: 16 channels
  • Digital Input/Output Channels: 16 channels
• Analog Input Signal Ranges: ±10 V DC, ±20 mA, ±50 mA
• Digital Signal Ratings: 24 V DC logic level
• Data Resolution: 16-bit analog-to-digital conversion
• Sampling Rate: Up to 100 kHz per channel
• Communication Interfaces: Parallel backplane bus for DCS integration
• Power Consumption: Maximum 20 W

Mechanical & Environmental Specifications

• Mounting: Standard 19-inch rack mounting via carrier module
• Operating Temperature: -20°C to +60°C
• Storage Temperature: -40°C to +85°C
• Relative Humidity: 5% – 95% RH (non-condensing)
• Shock Resistance: 25G (11 ms, IEC 60068-2-27)
• Vibration Resistance: 2G (10 – 200 Hz, IEC 60068-2-6)
• Cooling Method: Passive (natural convection)
• EMC Compliance: IEC 61000-4 series (industrial EMC standards)

Memory & Data Features

• Integrated B-RAM: Battery-backed static RAM for critical data retention
• Data Retention: Maintains process data and configuration for > 5 years (power-off)
• Non-Volatile Storage: On-board flash memory for firmware and configuration
• Real-Time Clock: Integrated RTC for time-stamped data logging

Protection & Filtering

• Transient Voltage Suppression: On-board filters for RFI/EMI immunity
• Overvoltage Protection: Clamps on all input channels
• Overcurrent Protection: Electronic fusing per channel
• Reverse Polarity Protection: On power input lines
• Ground Loop Isolation: Full galvanic isolation between field and system

Functional Features

1. High-Precision Multi-Channel Signal Acquisition

   Simultaneously processes 16 analog and 16 digital channels with 16-bit resolution. It supports direct connection to various sensors, transmitters, and switches, delivering high-fidelity data capture with ±0.05% full-scale accuracy.
2. Integrated Signal Conditioning

   Features built-in amplification, filtering, and linearization circuits. This eliminates the need for external signal conditioning modules, ensuring clean, stable signals even in electrically noisy industrial environments.
3. High-Speed Real-Time Processing

   Employs a dedicated high-performance processor for on-board data computation, filtering, and conversion. This reduces latency and offloads the main DCS CPU, enabling faster control loop response times.
4. Galvanic Isolation & Noise Immunity

   Provides 1.9 kV AC reinforced isolation between all field-side channels and the control system bus. This protects the control system from high-voltage transients, ground loops, and electrical interference, ensuring data integrity.
5. Non-Volatile Data Retention

   Integrated battery-backed RAM (B-RAM) securely stores critical process parameters, calibration data, and event logs during power outages, preventing data loss and enabling seamless system restart.
6. Comprehensive Diagnostic Capabilities

   Includes self-diagnostic routines for continuous monitoring of channel health, power status, memory integrity, and communication. Faults are reported via LED indicators and system bus for predictive maintenance.
7. Robust Industrial Design

   Constructed with high-grade components on a multi-layer FR-4 PCB with conformal coating. It operates reliably in extreme temperatures, high humidity, and high-vibration environments typical of heavy industry.
8. Seamless System Integration

   Designed as a plug-and-play module for ABB’s AC 800 and Symphony DCS platforms. It features a native backplane interface for direct integration, ensuring compatibility with system software and engineering tools.
9. Flexible Configuration

   Fully configurable via ABB’s control builder software. Users can define channel ranges, scaling, filtering, and alarm thresholds to meet specific application requirements.
10. Long-Term Reliability

    Designed for continuous 24/7 operation with a mean time between failures (MTBF) exceeding 90,000 hours, minimizing downtime and maintenance costs.

Application Scenarios

• Power Generation & Transmission

  Deployed in thermal, hydro, and wind power plants for precise monitoring of generator voltages, currents, temperatures, and vibration. It provides critical data for excitation control and grid stability systems.
• Oil & Gas Industry

  Used in upstream drilling, pipeline compressor stations, and refinery process units. It measures pressure, flow, level, and temperature signals for safe and efficient operation of distillation columns, pumps, and reactors.
• Chemical & Pharmaceutical Manufacturing

  Ensures accurate measurement and control of batch processes, including pH, conductivity, flow, and analytical signals. It supports compliance with strict quality and safety standards.
• Metals & Mining

  Integrated into control systems for steel rolling mills, smelters, and mineral processing plants. It handles high-speed measurements for motor control, furnace temperature regulation, and material handling.
• Water & Wastewater Treatment

  Manages analog and digital signals for pump control, flow metering, level measurement, and water quality analysis in municipal and industrial water systems.
• Marine & Offshore

  Certified for marine applications, providing reliable signal processing for ship propulsion, dynamic positioning, and offshore rig control systems in corrosive and high-vibration environments.
• Cement & Glass Production

  Operates in high-temperature and dusty environments, monitoring kiln temperatures, raw material feed rates, and exhaust gas emissions for optimal production efficiency.
• Paper & Pulp Industry

  Controls and measures variables such as moisture content, stock consistency, and tension in paper machines, ensuring product quality and production throughput.