ABB 3BHL000986P3105 is a high-performance safety-integrated control module specifically engineered for seamless integration with ABB’s ACS800 and ACS880 series variable frequency drives (VFDs), serving as a core component in functional safety systems for mission-critical industrial automation. This advanced module combines SIL 3-certified safety logic with robust control capabilities, enabling essential safety functions while maintaining precise drive operation, making ABB 3BHL000986P3105 an indispensable solution for environments where personnel safety and process continuity are paramount. As a flagship offering in ABB’s safety control ecosystem, ABB 3BHL000986P3105 bridges the gap between safety compliance and operational efficiency, supporting global safety standards while ensuring compatibility with existing ABB drive infrastructure. Its design prioritizes reliability and flexibility, allowing for easy integration into both new installations and legacy system upgrades, solidifying its position as a trusted choice for industrial safety applications worldwide.
Technical Specifications
Parameter Name
Parameter Value
Product Model
ABB 3BHL000986P3105
Manufacturer
ABB
Product Type
Safety-Integrated Control Module
Rated Supply Voltage
24 VDC (±15%)
Safety Integrity Level
SIL 3 (per IEC 61508)
Compatible Drives
ABB ACS800, ACS880 series VFDs
Communication Protocols
ABB DriveBus, PROFINET, PROFIsafe, Modbus RTU/TCP
Safe I/O Interfaces
6 safe digital inputs, 3 safe digital outputs (configurable PNP/NPN)
Operating Temperature Range
-15°C to +55°C
Storage Temperature Range
-40°C to +85°C
Protection Class
IP20 (module level)
Physical Dimensions (W×H×D)
142 mm × 190 mm × 76 mm
Weight
1.8 kg
Safety Standards Compliance
IEC 61508, EN ISO 13849-1 (Category 4)
Processing Speed
80 µs per safety control cycle
Main Features and Advantages
ABB 3BHL000986P3105 stands out with its SIL 3 certification, ensuring the highest level of safety integrity for critical applications where hazardous motion could lead to severe consequences. This certification, combined with compliance to EN ISO 13849-1 Category 4, validates the module’s ability to reliably detect faults and initiate safe shutdowns, protecting personnel, equipment, and processes. The module’s seamless compatibility with ABB ACS800 and ACS880 drives eliminates the need for custom adaptations, enabling plug-and-play integration that reduces installation time and configuration complexity— a key advantage for both new projects and retrofit applications.
Equipped with 6 safe digital inputs and 3 configurable safe digital outputs, ABB 3BHL000986P3105 offers flexible connectivity for a range of safety devices, including emergency stop buttons, safety interlocks, and light curtains. Its support for PROFIsafe and other industrial communication protocols facilitates seamless integration with safety PLCs and supervisory systems, enabling centralized safety management and real-time status monitoring. Advanced diagnostic capabilities are another core strength: ABB 3BHL000986P3105 provides detailed fault logging, integrity checks, and event timestamping, allowing for rapid troubleshooting and ensuring compliance with safety regulations through comprehensive audit trails.
Rugged industrial design ensures ABB 3BHL000986P3105 performs reliably in harsh environments, with EMC shielding, surge protection up to 2 kV, and a wide operating temperature range. This durability makes it suitable for use in demanding settings, from high-vibration manufacturing floors to temperature-fluctuating energy facilities, without compromising safety or control performance.
Application Fields
ABB 3BHL000986P3105 is tailored for safety-critical drive systems across diverse industries where compliance with strict safety standards and uninterrupted operation are non-negotiable. In the manufacturing sector, it is widely deployed in automotive assembly lines, robotic workcells, and packaging machinery, providing safe torque off (STO) and safe stop functions that enable secure human-machine interaction while maintaining production efficiency. The module’s compatibility with ABB drives makes it an ideal choice for steel mills and metal processing plants, where it safeguards rolling mill drives and continuous casting machines from hazardous motion during maintenance or fault conditions.
In the energy industry, ABB 3BHL000986P3105 plays a critical role in power generation facilities (coal-fired, gas, and nuclear), controlling boiler feed pumps, turbine auxiliary drives, and flue gas systems to ensure safe shutdowns in emergency scenarios. It is also extensively used in renewable energy projects, such as offshore wind farms and solar plants, where it protects wind turbine pitch drives and solar tracker systems, supporting remote maintenance and maximizing uptime. The oil and gas sector benefits from ABB 3BHL000986P3105’s robust design, with applications in offshore platform pumps, pipeline compressors, and refinery agitators, where it withstands harsh environmental conditions while ensuring compliance with industry safety regulations.
Additionally, ABB 3BHL000986P3105 finds applications in pharmaceutical and food processing facilities, where it enables safe access to mixing equipment and conveyor systems, and in water and wastewater treatment plants, safeguarding large pump stations and aeration systems. Its versatility and safety integrity make it a trusted solution for any application requiring reliable, compliant safety control for medium-voltage drives.
Related Products
ABB 3BHL000388P0101: A complementary safety-integrated control module with similar SIL 3 certification, offering additional safety functions like Safe Stop 1 (SS1) for enhanced application flexibility.
ABB 3BHL000389P0101: Safety expansion module designed to work with ABB 3BHL000986P3105, adding 8 safe digital inputs and 4 safe digital outputs for complex safety configurations.
ABB 3BHE042816R0101: Ultra-high-power medium-voltage power module, optimized for use with ABB 3BHL000986P3105 in ABB ACS880 drive systems for high-demand industrial applications.
ABB ACS880-37: Next-generation medium-voltage drive platform that fully integrates ABB 3BHL000986P3105 for complete safety-integrated drive solutions.
ABB AC500-S Safety PLC: Safety controller that communicates with ABB 3BHL000986P3105 via PROFIsafe, enabling centralized safety system management in large-scale automation setups.
ABB 3BHL000386P0101: Drive redundancy module, compatible with ABB 3BHL000986P3105 to create fault-tolerant safety configurations for mission-critical applications.
ABB 3BHE035301R0001: High-power medium-voltage power module, a core companion to ABB 3BHL000986P3105 in ABB ACS800 drive systems for medium-to-high power requirements.
ABB DriveStudio Software: Configuration and diagnostic tool specifically designed to program, monitor, and troubleshoot ABB 3BHL000986P3105 and associated safety systems.
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