ABB PCD235A101

ABB PCD235A101

Product Brief:​

The PCD235 is ABB’s compact standalone controller​ for applications that don’t need a full AC 800M + S800 I/O rack — e.g., boiler auxiliary (ID/FD fan control, sootblower sequencing), water treatment package, compressor skid, small batch process.

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Category: SKU: ABB PCD235A101

Description

ABB PCD235A101

  • Technical Specifications (typical PCD235A101 — verify against label):
    • Power Supply: 24 V DC (18–30 V), typ. 8–12 W
    • Onboard DI: 8/12/16 × 24 V DC (wet/dry selectable per group) — debounce 0–127 ms
    • Onboard DO: 4/6/8 × Relay SPDT (2 A @ 250 V AC) or Transistor (0.5 A @ 24 V DC) — model dep.
    • Onboard AI: 2/4 × 0–10 V / 4–20 mA (12-bit)
    • Onboard AO: 2 × 4–20 mA (12-bit)
    • Communication Ports:
      • Eth: 10/100 Base-TX (RJ45) — Modbus TCP Server/Client, optionally IEC 61850 (firmware opt)
      • RS-232: D-sub 9 (service / local HMI)
      • RS-485: Screw terminals or D-sub — Modbus RTU Master/Slave
    • Program Memory: ≥512 kB user logic; retain variables battery-backed
    • Battery: CR2032 or Varta cell on CPU — retains retentive vars ≥5 yr
    • LEDs: Run, Err, I/O Active, Com, Link (Eth)
    • Mounting: DIN rail 35 mm (compact ~90×100×70 mm)
    • Operating Temp.: 0 °C to +55 °C (–20 °C to +70 °C storage)
    • Certifications: CE, UL, cUL, GL (marine some versions)
  • Functional Features:
    • Integrated I/O eliminates need for separate I/O rack for small skids
    • Web server (some FW) — view process values via browser
    • Time sync via NTP/SNTP (Ethernet) or IRIG-B (if ext. option)
    • Expandable via Modbus RTU to remote small I/O drops (e.g., ABB S200 / S500 remote I/O)
    • Password protection for upload/download & online change
  • Application Scenarios:
    • Boiler auxiliaries (fan start/stop sequencing, damper control, low‑level interlock)
    • Water treatment (pump lead‑lag, chemical dosing pump control, tank level interlock)
    • Package compressor / chiller skid control (communicates setpoints to onboard compressor controller via Modbus RTU)
    • Retrofit of obsolete PLC5 / S5 with modern ABB Compact 800
  • Material & Structure:
    • Housing: Gray polyamide (PA66) UL 94 V-0 with label pocket
    • Removable screw terminals (DI/DO/AI/AO/Power/RS-485)
    • DIN clip (top & bottom — lock levers)
    • Front: LEDs + RJ45 + D-sub 9 (RS-232)
  • Working Principle:

    Cyclic execution: Read onboard DI & AI → execute user logic (IEC 61131-3) → update DO & AO → exchange data via Ethernet/RS-485 (Modbus polls / IEC 61850 MMS) → repeat scan (typical 10–100 ms scan time settable). Retentive variables preserved across power cycles (battery-backed RAM + flash backup on download).

  • Installation Requirements:
    1. Mount on 35 mm DIN rail in panel — leave top/bottom space for wiring & ventilation
    2. Connect 24 V DC plant PSU (+ / –) to Power terminals — fuse 2 A slow-blow typical
    3. Wire field DI (dry contact between Ix & C) — for N.C. E-Stop wire accordingly & invert in logic
    4. Wire DO to load (e.g., contactor coil via interposing relay if >2 A AC3) — note relay contact rating (2 A resistive)
    5. Wire AI (4–20 mA Tx loop-powered: PSU+ → Tx+ → Tx– → AI+ → AI– → PSU–; for V: signal +/– to AI+/AI–)
    6. Connect Ethernet to plant switch / HMI; RS-485 to drives/HMI as needed
    7. In Control Builder M: create “Compact 800” project → select PCD235A101 → define I/O mapping → write logic → download
    8. After download: verify Run LED solid green; force DI/DO to test; monitor AI values with simulator signal (mA calibrator / pot)
    9. Replace battery every 3–5 yr (or per PM schedule) — with power ON (hot-swap) to preserve retentive vars; after new battery verify no “Battery Low” LED
  • Precautions:
    • Battery:​ If battery dies with power off → retentive vars lost → controller may start with default / force init values per your program design — best practice: on first power-up after battery change force re-init or download known-good values
    • Onboard DO Rating:​ Relay contacts 2 A — for contactor / solenoid >2 A AC3 use interposing relay (ABB K-series etc.) driven by PCD DO
    • AI Shunt:​ For 4–20 mA — ensure internal shunt jumper selected (if present — some PCD have fixed 250 Ω; some have software selectable — check manual)
    • Firmware Compatibility:​ Control Builder M version must support PCD235 FW — if mismatch prompt to update FW (requires online connection & may reset app — backup first)
    • Keep project (.acp) & parameter printout on file server

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