Description
Detailed parameter table
| Parameter name | Parameter value |
| Product model | PCD235C101 3BHE057901R0101 |
| Manufacturer | ABB |
| Product category | Process control module |
| Rated voltage | 24 V DC ±10% |
| Power consumption | ≤10 W |
| Digital inputs | 16 (24 V DC, sinking/sourcing configurable) |
| Digital outputs | 8 (relay, 250 V AC/30 V DC, 5 A) |
| Communication interface | Ethernet (Profinet, Modbus TCP), RS485 (Modbus RTU) |
| Processing capacity | 32-bit RISC processor, 100 MHz |
| Memory | 512 MB RAM, 2 GB flash storage |
| Operating temperature | -25°C to 70°C |
| Dimensions | 160 mm × 100 mm × 75 mm |
| Mounting type | DIN rail mount (35 mm) |
| Protection rating | IP20, with enhanced EMI/EMC immunity |
| Certifications | IEC 61131-3, CE, UL, ATEX Zone 2 |
| Cycle time | ≤1 ms for basic logic operations |
ABB PCD235C101 3BHE057901R0101
Product introduction
The PCD235C101 3BHE057901R0101 is a high-performance process control module from ABB, designed to handle discrete control tasks in industrial automation systems. As a key component in ABB’s Advant OCS or AC 800M product families, this module specializes in digital signal processing, making it ideal for applications requiring rapid response to on/off control signals—such as manufacturing lines, material handling systems, and industrial machinery.
Unlike the UAD149A1501, which focuses on analog signal conversion, the PCD235C101 excels in managing digital inputs (e.g., from limit switches, photoelectric sensors) and driving digital outputs (e.g., relays, contactors). Its powerful processor and ample memory enable complex logic operations, while multi-protocol communication ensures seamless integration with both legacy and modern control systems. This versatility makes it a cornerstone of discrete manufacturing automation, where precise timing and reliable switching are critical.
Core advantages and technical highlights
High-density digital I/O
With 16 digital inputs and 8 relay outputs, the PCD235C101 can manage multiple discrete devices simultaneously. The inputs are configurable as sinking or sourcing, allowing direct connection to NPN or PNP sensors without additional hardware. For example, in an automotive assembly line, it can monitor 16 position sensors (detecting part presence) and control 8 robotic grippers via relay outputs, coordinating sequence timing with a cycle time under 1 ms to ensure precision.
Powerful processing capabilities
Equipped with a 32-bit RISC processor running at 100 MHz, the module executes complex ladder logic, structured text, and function block diagrams with minimal latency. Its 512 MB RAM and 2 GB flash storage support large program sizes and data logging—capabilities beyond the scope of analog-focused modules like the UAD149A1501. In a food packaging plant, this allows it to store production logs (e.g., package counts, fault timestamps) while running synchronization logic for filling and sealing machines.
Dual-network redundancy
The PCD235C101 features redundant Ethernet ports supporting Profinet and Modbus TCP, ensuring uninterrupted communication in mission-critical systems. If the primary network fails, it automatically switches to the secondary link within 50 ms—far faster than the UAD149A1501’s non-redundant setup. This redundancy is vital in wastewater treatment plants, where a communication outage could disrupt pump control and cause overflow incidents.
Hazardous area compatibility
With ATEX Zone 2 certification, the module operates safely in environments with potentially explosive atmospheres (e.g., paint booths, chemical storage areas). Its robust design resists corrosion from airborne contaminants, outperforming standard control modules in harsh conditions. In a pharmaceutical solvent processing area, it reliably controls ventilation fans and isolation valves without risking ignition.
Key differences from UAD149A1501 3BHE014135R1501
| Feature | UAD149A1501 | PCD235C101 |
| I/O type | Analog-focused (12 inputs, 6 outputs) | Digital-focused (16 inputs, 8 outputs) |
| Output type | 4-20 mA, 0-10 V | Relay (250 V AC/30 V DC) |
| Processing | Signal conversion | Complex logic, data logging |
| Communication | Single-network (with Profinet) | Redundant Ethernet + RS485 |
| Power consumption | ≤7 W | ≤10 W |
| Certifications | ATEX (general hazardous areas) | ATEX Zone 2 (explosive atmospheres) |
ABB PCD235C101 3BHE057901R0101
Typical application scenarios
Automated warehouse
The PCD235C101 controls conveyor belts, stacker cranes, and barcode scanners in a logistics center. Its 16 digital inputs monitor photoelectric sensors (detecting package presence) and limit switches (crane position), while 8 relay outputs activate motors and brakes. Using Profinet, it syncs with a warehouse management system to optimize sorting routes, with redundant Ethernet ensuring no data loss during peak operations.
Chemical batching system
In a batch processing plant, the module coordinates valve actuation and pump startup/shutdown. Digital inputs track flow switch status (valve open/closed), and outputs trigger relay-controlled pumps. Its ATEX Zone 2 certification allows installation near solvent storage, while Modbus RTU communication with a SCADA system logs batch completion times and fault events for regulatory compliance.
Metal stamping line
The PCD235C101 synchronizes press machines, feeders, and ejectors in a steel stamping facility. It uses digital inputs to detect material feed status and press position, executing logic to prevent machine collisions. The 1 ms cycle time ensures precise timing between feed and stamping operations, reducing scrap rates. RS485 communication with a human-machine interface (HMI) displays real-time production counts.
Related model recommendations
ABB UAD149A1501 3BHE014135R1501
Complements the PCD235C101 in mixed-signal systems, handling analog sensors (e.g., pressure, temperature) while the PCD235C101 manages digital devices. Together, they form a full-featured control solution for hybrid automation setups.
ABB CI854A 3BSE022469R1
Enhances Profinet redundancy, enabling the PCD235C101 to integrate with safety PLCs in SIL 2/3 applications (e.g., emergency stop systems).
ABB 3BHB003688R0101
Provides stable 24 V DC power, ensuring reliable operation of the module’s digital circuits and relays in fluctuating industrial grids.
ABB PM590-ETH
A compact PLC that pairs with the PCD235C101 for distributed control, ideal for large facilities requiring localized logic near machinery.
ABB TB857
Surge protection for both power and communication lines, shielding the module from electrical transients in industrial environments.
Installation, commissioning and maintenance instructions
Installation: Mount on a 35 mm DIN rail with 50 mm clearance for cooling. Connect 24 V DC power using 1.5 mm² cable, protected by a 3 A fuse. For digital I/O, use 0.75 mm² shielded cable (grounded at the module end) to minimize noise. In ATEX Zone 2 areas, ensure all wiring complies with EX regulations—use flame-retardant conduit and explosion-proof enclosures if needed.
Commissioning: Program using ABB’s Control Builder M software, implementing logic via IEC 61131-3 languages (ladder diagram, structured text). Configure redundant Ethernet by setting unique IP addresses for primary/secondary ports. Test failover by disconnecting the primary network and verifying <50 ms switchover. Calibrate input thresholds (24 V DC ±10%) using a multimeter to ensure reliable sensor detection.
Maintenance: Inspect quarterly for loose connections and dust buildup (use compressed air for cleaning). Test relay outputs annually with a load meter to verify contact integrity. Check redundant network status weekly via diagnostic software. Replace relays with ABB-approved parts only—never use higher-current relays, as they may exceed the module’s ratings. In ATEX areas, perform maintenance during shutdowns and use non-sparking tools.
Service and guarantee commitment
The PCD235C101 3BHE057901R0101 comes with a 5-year warranty, covering manufacturing defects and ATEX Zone 2 compliance. ABB’s technical support offers 24/7 assistance for critical applications, with on-site service available within 24 hours in regions with certified technicians.
Extended service contracts include annual software updates, redundancy testing, and relay contact inspection. ABB guarantees compatibility with future Profinet standards, ensuring the module remains integrable with evolving automation systems. This commitment underscores its role as a durable, future-proof component in industrial control networks.
