Application Scenarios

In a large water treatment plant,motorized valves,pump status signals,and analog sensors are distributed across vast distances.Running individual cables from each device to a central control room is impractical.Instead,local I/O clusters are installed near equipment groups.The ABB PFEA111-65​serves as the communication hub for one such cluster.It is mounted on a DIN rail alongside various S800 I/O modules(like digital input cards for pump run feedback and analog input cards for flow meters).The PFEA111-65​connects to these modules via a local high-speed serial bus,aggregates their data,and transmits it over a single,robust Profibus DP cable running back to the central AC 800M controller.Its value lies in drastically reducing wiring costs,simplifying network architecture,and providing a standardized,reliable interface for distributed process data acquisition and control.

Parameter

Main Parameters

Value/Description

Product Model​

PFEA111-65​(Order Code:3BSE050090R65)

Manufacturer​

ABB

Product Category​

Fieldbus Adapter/Communication Interface

Compatible System​

ABB S800 I/O,designed for use with AC 800M controllers or other Profibus masters.

Fieldbus Protocol​

Profibus DP-V1 slave.

Data Transfer Rate​

Configurable,up to 12 Mbps.[Allows optimization for speed vs.distance]

Number of Connected I/O Modules​

Supports connection to multiple S800 I/O modules(specific max.depends on configuration and data volume).

Address Setting​

Via rotary switches on the front.[For setting the Profibus slave address]

Diagnostic Indicators​

LEDs for power,module status,and bus communication status.

Power Supply​

Requires 24V DC power for operation.

Key Feature​

Translates between the Profibus DP network protocol and the internal S800 I/O bus.

Technical Principles and Innovative Values

Innovation Point 1:Deterministic Data Gateway with Advanced Diagnostics:​The PFEA111-65​is more than a simple protocol converter.It operates as a deterministic data manager for its local I/O cluster.It cyclically polls the connected S800 I/O modules,packages the data efficiently,and ensures its timely delivery on the Profibus network according to the master’s polling cycle.It also performs comprehensive diagnostics on the local I/O bus and its own status,reporting any faults directly on its LEDs and back to the Profibus master for centralized alarm management,enabling rapid fault localization.

Innovation Point 2:Seamless Integration with the S800 I/O Ecosystem:​Its design is optimized for the S800 I/O architecture.It communicates with the I/O modules via ABB’s high-speed,proprietary local bus,ensuring fast and reliable data exchange.Configuration is streamlined within ABB’s engineering tools(like Control Builder),where the entire I/O station—including the PFEA111-65​and all attached modules—is configured as a single unit.This deep integration reduces engineering effort and eliminates complex parameter mapping.

Innovation Point 3:Robust and Simple Field Configuration:​Designed for industrial environments,the module features robust connectors and clear diagnostic LEDs.The Profibus slave address is set via intuitive rotary switches,eliminating the need for a software tool for basic commissioning.This simplicity is crucial for field technicians during installation,replacement,or troubleshooting,allowing them to quickly verify or change the station address without a laptop.

Application Cases and Industry Value

Case Study:Automotive Paint Shop Conveyor Control System

A car manufacturer’s paint shop uses an extensive overhead conveyor system.Hundreds of photo-eyes,encoders,and pneumatic valves control the precise movement and spacing of car bodies.A centralized control architecture would mean thousands of long,costly wires.

Solution&Implementation:

Distributed control nodes were placed along the conveyor.Each node consisted of an ABB PFEA111-65​Profibus adapter connected to a mix of S800 digital I/O modules.The PFEA111-65​gathered all local sensor data(position,presence)and executed output commands(for stops and lifts)received from a central Siemens S7 PLC acting as the Profibus master over a single trunk cable.

Results and Value Delivered:

Massive Reduction in Wiring Costs and Complexity:​The use of PFEA111-65​nodes reduced the home-run wiring to the main cabinet by over 70%,saving significantly on cable,conduit,and installation labor.The clean,modular design also simplified documentation.

Enhanced System Flexibility and Scalability:​Adding a new conveyor section simply required installing another node with a PFEA111-65​and extending the Profibus cable.The modular S800 I/O made it easy to adapt the mix of digital and analog points at each node.

Improved Maintainability:​Technicians could localize faults to a specific node using the Profibus master’s diagnostics.They could then go to that node and use the PFEA111-65’s LEDs and the connected I/O module status to quickly pinpoint the failed device(sensor,module,or fuse).

Related Product Combination Solutions

S800 I/O Modules(e.g.,DI:DSDO451,DO:DSQC679,AI:AI810):​These are the various input and output modules that connect directly to field devices and are managed by the PFEA111-65.

S800 I/O Power Supply(e.g.,PS801):​Provides the necessary 24V DC power to the rack where the PFEA111-65​and other S800 I/O modules are mounted.

ABB AC 800M Controller(e.g.,PM803)with Profibus Master Module(CI854):​A typical system configuration where the AC 800M controller,equipped with a Profibus master communication interface,acts as the master for multiple PFEA111-65​slave nodes.

Third-Party Profibus Master(e.g.,Siemens S7-400 with DP Master):​The PFEA111-65​is an open Profibus DP-V1 slave and can equally be used with non-ABB masters,making it a versatile gateway for integrating ABB S800 I/O into other automation ecosystems.

Profibus Network Components:​Includes Profibus cables,connectors,repeaters,and terminators required to build the physical network connecting the master to the PFEA111-65​slaves.

ABB Control Builder or 800xA Engineering:​The configuration software used to define the I/O configuration for the S800 station headed by the PFEA111-65​and to map the process data to the Profibus telegram.

TB850 Terminal Base Unit:​The mounting base onto which the PFEA111-65​and other S800 modules are snapped,providing the electrical connection to the field wiring.

Installation,Maintenance,and Full-Cycle Support

Installation involves mounting the PFEA111-65​on a DIN rail(via a TB base unit),connecting the 24V DC power,and attaching the Profibus DP cable to its 9-pin D-sub connector.The slave address is set using the rotary switches.The connected S800 I/O modules are then snapped into place on adjacent bases.Configuration is done offline in ABB’s engineering software,where the modules are added,addressed,and the Profibus data exchange is defined.The configuration is then downloaded to the master controller,which propagates it to the PFEA111-65.

Routine maintenance is minimal.The LEDs(PWR,COM,OK,I/O BUS)provide immediate health status.A failure is often indicated by the OK LED being off or flashing.Troubleshooting involves checking power,verifying the Profibus address and cable/termination,and reviewing diagnostics on the master station.The module supports hot-swapping(if the bus and system are designed for it)or can be replaced during a brief shutdown.It is crucial to note the slave address before removing an old unit to configure the replacement identically.

We provide comprehensive lifecycle support for the ABB PFEA111-65 3BSE050090R65​and related S800 components.Our services include verifying module compatibility with your master system,supplying new or fully tested refurbished units,and assisting with configuration and diagnostics.We can also supply the associated S800 I/O modules,bases,and network components to support your complete distributed I/O solution.