ABB 3BHE032025R0101 for AC 800M – Seamless Drive Synchronization via Control Builder M
Description
The ABB 3BHE032025R0101,also known by its functional name PCD235A101,is a specialized Process and Drive Control Module designed for the AC 800M controller platform within ABB’s System 800xA architecture.It acts as a high-performance coordinator between the central PLC logic and ABB variable-speed drives(e.g.,ACS880,ACS800,ACS580),enabling precise speed,torque,and position control across complex industrial processes.
Unlike standard I/O modules,the PCD235A101 offloads drive-specific communication and synchronization tasks from the main CPU,reducing scan time and improving system determinism—especially critical in applications like extruders,winders,crushers,and marine propulsion systems.
Application Scenarios
At a steel rolling mill in Germany,engineers needed to synchronize 14 main drive motors across three stands with<2 ms jitter to prevent strip breakage.By deploying two ABB PCD235A101(3BHE032025R0101)modules—one per production line—they achieved nanosecond-level timestamp alignment over PROFIBUS DP using ABB’s proprietary DriveBus protocol.The PCD235A101 handled real-time torque sharing and load balancing,while the AC 800M CPU focused on interlocking and safety logic.Post-commissioning,mill throughput increased by 12%,and unplanned stops dropped by 35%.
Parameter
Main Parameters Value/Description
Product Model 3BHE032025R0101(Functional Name:PCD235A101)
Manufacturer ABB
Product Category Drive Coordination&Communication Module for AC 800M
Compatible Drives ABB ACS880,ACS800,ACS580,ACS1000(with firmware support)
Communication Interfaces•2×10/100 Mbps Ethernet(RJ45)
•1×PROFIBUS DP port(9-pin D-sub)
Supported Protocols ABB DriveBus,PROFIBUS DP-V1,MODBUS TCP,OPC UA Server
Drive Coordination Cycle Time As low as 0.5 ms(depending on network load)
Operating Temperature-25°C to+70°C
Mounting Method Plugs into AC 800M I/O base(e.g.,TK811V001,TB510V001)
Functional Safety Supports SIL 2 applications(when used in certified architecture)
Certifications CE,UL 61010-2-201,IEC 61508,IEC 61131-2,EN 61000-4-2/4/5(EMC)
Configuration Tool ABB Control Builder M(with DriveLib library)
Note:Requires AC 800M firmware v3.1 or later and DriveLib version 2.0+for full ACS880 functionality.
Technical Principles and Innovative Values
Innovation Point 1:Hardware-accelerated drive coordination—dedicated co-processor handles cyclic data exchange with drives,freeing the main CPU for higher-level logic.
Innovation Point 2:Time-synchronized control using IEEE 1588(PTP)over Ethernet or synchronized PROFIBUS cycles ensures multi-drive phase alignment.
Innovation Point 3:Integrated diagnostics provide real-time monitoring of drive status(e.g.,DC bus voltage,motor temperature,fault codes)directly in System 800xA HMI.
Innovation Point 4:Unified engineering—drive parameters,logic,and HMI are configured in a single Control Builder M project,eliminating tool fragmentation.
Application Cases and Industry Value
In a Norwegian offshore oil platform,the PCD235A101 coordinates six seawater injection pumps in a master-follower configuration to maintain constant pressure despite varying well demands.The module’s ability to auto-adjust follower speeds based on master load reduced energy consumption by 18%annually(~$220,000 savings).Its immunity to salt fog and vibration ensured zero drive communication failures over 3 years of operation.
Related Product Combination Solutions
ABB PM866A/PM867B(3BHB005245R0101):Host CPUs that work with PCD235A101 in redundant or simplex setups.
ABB ACS880-01/-04:Standard drives commonly controlled by PCD235A101.
ABB CI854A:PROFIBUS DP master module—used if additional non-drive DP slaves are present.
ABB GMKP2800-32IBY:Digital I/O for hardwired drive enable/fault signals.
ABB System 800xA Electrical Library:Visualizes drive performance,energy use,and health trends.
ABB DriveComposer Pro:Optional tool for advanced drive parameter tuning(though most settings are managed via Control Builder M).
Installation,Maintenance,and Full-Cycle Support
Installation involves inserting the PCD235A101 into an AC 800M I/O base and connecting it to drives via shielded PROFIBUS or Ethernet cables.Termination resistors and grounding follow ABB’s EMC guidelines.Configuration is done in Control Builder M using pre-certified DriveLib function blocks(e.g.,DRIVE_START,TORQUE_CONTROL).
Maintenance includes remote firmware updates,drive health dashboards in System 800xA,and LED indicators for link status and errors.In redundant systems,the module supports hot replacement.ABB provides lifecycle services including migration paths to newer platforms(e.g.,ABB Ability™System 800xA with AC 900F),cybersecurity patches,and global technical support for drive integration challenges.
Contact us for a customized solution—whether you’re optimizing a multi-motor line,implementing energy-efficient pump control,or building a safety-rated drive system with the powerful ABB 3BHE032025R0101 PCD235A101.
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