ABB BN5930: High-Resolution Counter Module for Advant Controller 31 (AC 31)

Product Description

The ABB BN5930 is a specialized high-resolution counter and frequency measurement module designed for the ABB Advant Controller 31 (AC 31) and MasterPiece 200 family of programmable logic controllers. This module is engineered for applications requiring precise counting of high-speed digital pulses or accurate frequency measurement. The ABB BN5930 typically interfaces with sensors such as rotary encoders, proximity switches, or turbine flow meters to monitor parameters like production count, rotational speed (RPM), or flow rate. Its high-speed input capability and dedicated processing logic make it far superior to standard digital inputs for these demanding tasks. The reliable performance of the ABB BN5930 is essential for accurate data acquisition in process control and production monitoring systems.

Product Parameters

• Product Type: High-Speed Counter / Frequency Module
• Manufacturer: ABB
• Part Number: BN5930
• Compatible Controller: Advant Controller 31 (AC 31), MasterPiece 200
• Number of Channels: Typically 1 or 2 independent high-speed counter channels.
• Input Type: Digital pulse input, often with support for quadrature (A/B phase) encoders for direction sensing.
• Count Frequency: Capable of counting very high frequency pulses (e.g., in the kHz range), specific to the module’s design.
• Functions: Up/down counting, frequency measurement, period measurement, and comparison for generating internal signals.
• Outputs: May include dedicated high-speed digital outputs for control based on count values.
• Power Supply: Powered from the AC 31 rack’s backplane.

Advantages and Features

The primary advantage of the ABB BN5930 is its dedicated hardware for high-speed counting, which operates independently of the main PLC scan cycle. This ensures accurate capture of every pulse, even at very high speeds where a standard input might miss counts. The module often features flexible counting modes (e.g., single-direction, quadrature) and built-in comparison functions that can trigger outputs directly, enabling fast response for applications like cut-to-length or registration control. Its integration with the AC 31 system allows the counted values to be easily accessed by the main control program for display, logging, and higher-level logic. The robust design of the ABB BN5930 ensures reliable operation in industrial environments with electrical noise.

Application Cases in Various Fields

This module is used in applications requiring precise motion or flow monitoring. In Packaging and Converting Machinery, the ABB BN5930 counts encoder pulses for precise length measurement of web materials (paper, plastic, metal) for cutting or printing registration. Within Automotive Manufacturing, it monitors the speed of rotating tools or counts parts on a high-speed assembly line. For Flow Measurement, it counts pulses from a turbine flow meter to calculate totalized flow in water, chemical, or oil applications. It is also used in Textile Machinery for yarn speed control and in Printing Presses for synchronization.

Comparisons with Competing Products

Compared to using standard PLC inputs with software-based counting, the ABB BN5930 offers vastly superior speed and accuracy, as it uses dedicated hardware counters. Competing PLC systems from Siemens (FM 350 counter module for S7-300) or Allen-Bradley (High-Speed Counter module for PLC-5/SLC 500) offered similar dedicated functionality. The ABB BN5930 is distinguished by its specific integration into the AC 31 software and hardware environment. For legacy AC 31 systems, it is the optimal, system-native solution for high-speed counting, whereas modern systems often integrate this functionality directly into the CPU or use high-speed I/O on a fieldbus network.

Selection Suggestions and Precautions

1. Sensor Compatibility: Ensure your pulse-generating sensor (encoder, proximity switch) provides a signal compatible with the ABB BN5930‘s input requirements regarding voltage level (e.g., 24V DC), waveform, and frequency. Using an incompatible sensor will result in missed counts.
2. Configuration in Programming Software: The module is not plug-and-play. It must be correctly configured in the AC 31/MasterPiece programming software (e.g., ABB MasterTool). Parameters such as counting mode, preset values, and filter settings must be defined.
3. Wiring and Noise Immunity: High-speed signals are susceptible to noise. Use shielded, twisted-pair cables for sensor connections and ground the shield at the controller end only to prevent ground loops and ensure signal integrity for the ABB BN5930.
4. Counting Range and Rollover: Understand the counting range (e.g., 32-bit) of the ABB BN5930. For very long-running counts, implement logic in the main PLC program to handle counter rollover (when the count value resets after reaching its maximum) to maintain accurate totalization.
5. Physical Slot and Addressing: The module occupies a specific slot in the AC 31 rack. Its I/O addresses are determined by this slot position. Document this addressing, as it is required to access the count values from the main control program. Replacing the module requires ensuring the new unit is in the same slot.