The ABB 3BHL000389P0101 is a high-performance safety expansion module specifically engineered to enhance the functionality of ABB’s ACS800 and ACS880 series variable frequency drives (VFDs), working in tandem with safety-integrated control modules like ABB 3BHL000388P0101 to scale safety system capabilities. This SIL 3-certified module expands the number of safe input/output (I/O) channels, enabling integration of additional safety devices such as emergency stops, safety interlocks, and light curtains in complex industrial environments. As a critical extension of ABB’s functional safety ecosystem, ABB 3BHL000389P0101 maintains the highest safety integrity while providing flexible configuration options, ensuring compliance with global safety standards without compromising drive performance or system responsiveness.
Designed for rugged industrial use, ABB 3BHL000389P0101 features robust electromagnetic compatibility (EMC) shielding, wide environmental tolerance, and redundant signal processing, ensuring reliable operation amid voltage fluctuations, vibration, and extreme temperatures. Its plug-and-play integration with ABB’s flagship drive platforms and safety control modules simplifies system expansion, allowing for seamless upgrades of existing safety setups or customization of new installations to meet specific application requirements. Whether deployed in safety-critical sectors such as automotive manufacturing, oil and gas, or power generation, ABB 3BHL000389P0101 delivers industry-leading safety scalability and operational continuity, solidifying its position as an indispensable component for complex safety-integrated drive systems.
Scalable Safe I/O Capacity: ABB 3BHL000389P0101 adds 8 safe digital inputs and 4 safe digital outputs, expanding the safety system’s ability to integrate multiple safety devices such as emergency stop buttons, safety gates, and pressure sensors. This scalability eliminates the need for separate safety controllers, reducing system complexity and cost while maintaining SIL 3 integrity.
Seamless Integration with ABB Safety Ecosystem: Designed to work seamlessly with ABB 3BHL000388P0101 safety control module and ABB ACS800/ACS880 drives, ABB 3BHL000389P0101 offers plug-and-play compatibility with no custom firmware modifications. It communicates via ABB DriveBus and PROFIsafe, ensuring synchronized safety logic between the expansion module, base control module, and drive system.
Configurable I/O Flexibility: The module’s safe inputs and outputs are configurable as PNP or NPN, supporting diverse safety device types and wiring configurations. This flexibility allows system designers to adapt ABB 3BHL000389P0101 to specific application requirements, from simple emergency stop setups to complex interlocking systems.
Robust Safety and Industrial Durability: Certified to SIL 3 (IEC 61508) and EN ISO 13849-1 Category 4, ABB 3BHL000389P0101 maintains the highest safety integrity in critical applications. Its rugged design includes EMC shielding, surge protection (up to 2 kV), and resistance to dust, vibration, and temperature extremes, ensuring reliable performance in harsh industrial environments.
Advanced Diagnostic Capabilities: ABB 3BHL000389P0101 provides channel-level fault monitoring, real-time integrity checks, and detailed event logging, enabling rapid troubleshooting of safety system issues. Operators can access diagnostic data via the drive’s HMI or ABB DriveStudio Software, ensuring quick resolution of faults and maintaining compliance with safety regulations.
Application Fields
ABB 3BHL000389P0101 is tailored for scaling safety-integrated drive systems in industries where complex safety configurations are required to protect personnel and processes. In the automotive manufacturing sector, it is widely used in robotic assembly lines, paint shops, and conveyor systems, expanding the number of safety interlocks and emergency stops to cover large work areas with multiple access points. The module’s compatibility with PROFIsafe also makes it ideal for integration with distributed safety systems in automotive plants, ensuring synchronized safety logic across multiple drive units.
In the oil and gas industry, ABB 3BHL000389P0101 enhances safety systems for offshore platform pumps, pipeline compressors, and refinery agitators, enabling integration of additional safety sensors (e.g., pressure, temperature, gas detection) to trigger safe shutdowns in hazardous conditions. It is extensively employed in power generation plants, expanding safety I/O for boiler feed pumps, turbine auxiliary drives, and flue gas desulfurization systems to meet strict safety compliance requirements (e.g., NERC CIP, IEC 61511).
In pharmaceutical and food processing facilities, ABB 3BHL000389P0101 supports complex safety interlocking for mixing equipment, packaging lines, and material handling systems, ensuring safe access to machinery during maintenance while maintaining production continuity. It also finds applications in mining and mineral processing (hoist systems, mill drives) and water treatment plants (large pump stations), where scaling safety I/O enables coverage of distributed equipment and remote operating areas. For renewable energy projects such as offshore wind farms, ABB 3BHL000389P0101 expands safety capabilities for wind turbine pitch drives and solar tracker systems, integrating additional emergency stop and access control devices to protect maintenance personnel.
Related Products
ABB 3BHL000388P0101: Safety-integrated drive control module, the primary base module paired with ABB 3BHL000389P0101 for expanded safe I/O capabilities.
ABB 3BHE042816R0101: Ultra-high-power medium-voltage power module, designed to work with ABB 3BHL000389P0101 in safety-critical ACS880 drive systems.
ABB ACS880-37: Next-generation medium-voltage drive platform that integrates ABB 3BHL000389P0101 and base safety modules for complete safety-integrated solutions.
ABB AC500-S Safety PLC: Safety controller that communicates with ABB 3BHL000389P0101 via PROFIsafe for centralized safety system management in large-scale applications.
ABB 3BHL000383P0101: PROFIsafe communication module, enhancing ABB 3BHL000389P0101’s connectivity with distributed safety networks.
ABB DriveStudio Software: Configuration tool for programming, diagnosing, and monitoring ABB 3BHL000389P0101 and associated safety systems.
ABB 3BHE035301R0001: High-power medium-voltage power module, a core companion to ABB 3BHL000389P0101 in safety-critical ACS800 drive systems.
ABB 3BHL000386P0101: Drive redundancy module, enabling fault-tolerant safety configurations when paired with ABB 3BHL000389P0101 and base safety modules.
ABB 3BHE033068P106: Mid-range power module, ideal for pairing with ABB 3BHL000389P0101 in medium-power safety-integrated drive setups.
ABB 3BHL000390P0101: Advanced safety expansion module with analog safe I/O, offering extended functionality for ABB 3BHL000389P0101-based systems.
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