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ABB Control Board | UFC789AE101 | 3BHE014023R0101 | AC 800PEC High-Performance Control Unit

ABB UFC789AE101 (order no. 3BHE014023R0101) high-performance control board/control unit for ABB AC 800PEC high-performance motion controller and UNITROL 6000 excitation system, high-speed FPGA + CPU hybrid architecture, 24V DC supply (redundancy supported), made in Sweden, operating temperature -20 to +60°C, core control module for high-precision motion control and excitation regulation in industrial automation. Order available.
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Product Details

1. Product Overview

The ABB UFC789AE101 (order number 3BHE014023R0101) is a high-performance control board/control unit manufactured by ABB Group, belonging to the ABB AC 800PEC high-performance motion controller series and UNITROL 6000 excitation system series. It is the core control module for high-precision motion control and excitation regulation systems in industrial automation, widely used in rolling mills, paper machinery, printing machinery, textile machinery, test stands, machine tools, cranes, marine propulsion, power excitation, and other industrial applications requiring high-precision speed and position control.

The AC 800PEC is ABB's high-end programmable motion controller, specifically designed for applications requiring multi-axis coordination, high-precision synchronization, fast response, and complex motion trajectory control. It is widely used in high-end industrial equipment such as metallurgical rolling mills, paper machines, printing machines, and test stands. As the core control board of the AC 800PEC system, the UFC789AE101 undertakes key functions including motion control algorithm computation, real-time task scheduling, I/O signal processing, communication protocol conversion, and system status monitoring, serving as the "brain" of the entire control system.

Meanwhile, the UFC789AE101 is also applied in the ABB UNITROL 6000 excitation system series. UNITROL 6000 is ABB's high-end digital excitation regulation system for synchronous generators and synchronous motors, widely used in power generation applications such as thermal power, hydro power, nuclear power, gas turbines, and combined cycle power plants, as well as industrial applications with large synchronous motor drives (such as rolling mill main drives, compressors, fans, etc.). In the excitation system, the UFC789AE101 undertakes core functions including excitation regulation algorithm computation, voltage/current/power factor closed-loop control, limiter and protection function logic processing, communication, and human-machine interface.

This control board adopts a high-speed FPGA + CPU hybrid architecture design. The FPGA (Field-Programmable Gate Array) handles high-speed real-time tasks (such as pulse acquisition, PWM generation, high-speed logic control, encoder signal processing, etc.), while the CPU handles motion control algorithms, communication protocols, system management, and human-machine interaction. The two work collaboratively, ensuring both microsecond-level real-time response capability and powerful complex algorithm computation capability, meeting the stringent requirements of high-end motion control and excitation regulation for real-time performance and computing power.

In terms of power supply design, the UFC789AE101 adopts 24V DC industrial standard power supply (voltage range 24V DC ±10%), supporting dual power supply redundancy configuration. When one power supply fails, it automatically switches to the other, ensuring continuous and stable operation of the control system, meeting industrial field requirements for power supply reliability. The power input features reverse polarity protection and overvoltage protection, adapting to complex power supply environments in industrial sites. Low power consumption design with minimal heat generation, suitable for long-term continuous operation.

This control board features a plug-in board structure design, installed in an ABB dedicated control rack or backplane, performing high-speed data exchange with other modules (such as I/O modules, communication modules, power modules, etc.) via the backplane bus to form a complete control system. The modular design makes system expansion and maintenance very convenient, allowing flexible configuration of I/O points and communication interface quantities according to application requirements. Onboard status indicators can display power status, operating status, fault status, and communication status in real time, facilitating field maintenance personnel to quickly assess device operating status and locate faults.

In terms of environmental adaptability, the UFC789AE101 has an operating temperature range of -20°C to +60°C (referencing multi-source public information, specific subject to ABB official data sheet), with a wider storage temperature range (Contact via email for confirmation), relative humidity 5% to 95% (non-condensing, Contact via email for confirmation), adapting to temperature and humidity conditions of most industrial sites. It features industrial-grade electromagnetic compatibility (EMC), passing strict industrial standard tests, and can operate stably in strong electromagnetic interference environments (near VFDs, motors, welding machines). Vibration and shock resistance meet industrial standard requirements, suitable for use on industrial equipment with significant vibration (such as rolling mills, crushers, construction machinery). Made in Sweden, manufactured by ABB's Swedish factory with reliable quality.

Note: This product UFC789AE101 (3BHE014023R0101) is the core control board of ABB's high-end control system. In public information, various suppliers have different descriptions of some technical parameters (such as I/O channel count, communication interface type and quantity, specific dimensions, memory capacity, etc.). Some parameters above reference consistent information from multi-source public materials. Specific technical specifications are subject to ABB official data sheet and product manual; Contact via email for confirmation. Installation and replacement must be performed by professional engineers trained by ABB, strictly following electrical safety operation procedures and ABB system installation and maintenance manuals. After replacing the control board, it may be necessary to re-download the application program and configuration parameters.

2. Specifications

表格

Parameter Value
Brand ABB (Asea Brown Boveri, Swiss/Swedish multinational group)
Model UFC789AE101 (also written as UF C789 AE101)
Order No./Part No. 3BHE014023R0101
Product Type High-Performance Control Board / Control Unit
Product Series AC 800PEC High-Performance Motion Controller / UNITROL 6000 Excitation System
Application Field High-precision motion control, excitation regulation, industrial automation core control
Processor Architecture High-speed FPGA + CPU hybrid architecture
FPGA Functions High-speed real-time task processing (pulse acquisition, PWM generation, high-speed logic, encoder signal processing, etc.)
CPU Functions Motion control algorithms, communication protocols, system management, human-machine interaction
Supply Voltage 24V DC (±10%)
Power Redundancy Dual power redundancy supported (Contact via email for specific configuration)
Reverse Polarity Protection Yes (reference same-series ABB control boards)
Overvoltage Protection Yes (reference same-series ABB control boards)
Power Consumption Contact via email (reference low power design)
Mounting Plug-in board, installed in ABB dedicated control rack/backplane
Backplane Bus ABB dedicated high-speed backplane bus (Contact via email for protocol and speed)
I/O Expansion I/O modules expandable via backplane bus (Contact via email for max I/O points)
Communication Interface Contact via email (reference supports Ethernet, Modbus, etc., specific interface type and quantity subject to official)
Digital I/O Channels Contact via email (public information descriptions inconsistent, subject to ABB official data sheet)
Analog I/O Channels Contact via email
Encoder Interface Contact via email (reference supports incremental/absolute encoders, specific type subject to official)
Memory Capacity Contact via email (program memory, data memory, Flash, etc.)
Real-Time OS Contact via email (ABB dedicated real-time operating system)
Programming Method Contact via email (ABB dedicated programming tools, such as Automation Builder / Control Builder, etc.)
Status Indicators Power LED, Run LED, Fault LED, Comm LED (Contact via email for specific indicator configuration)
Reset Button Contact via email for confirmation
Operating Temperature -20°C ~ +60°C (reference multi-source public information, specific subject to ABB official data sheet)
Storage Temperature Contact via email (reference -40°C ~ +85°C)
Relative Humidity Contact via email (reference 5% ~ 95% non-condensing)
EMC Industrial grade (Contact via email for specific standards and levels)
Vibration Resistance Industrial grade (Contact via email for specific standards)
Shock Resistance Industrial grade (Contact via email for specific standards)
Protection Degree Contact via email (reference IP20, plug-in module installed inside control cabinet)
Certifications/Standards Contact via email (CE, UL, cUL, etc.)
Origin Sweden
Dimensions Contact via email (public information descriptions inconsistent, subject to ABB official data sheet)
Weight Contact via email
Matching Rack/Backplane Requires ABB dedicated control rack/backplane (Contact via email for model confirmation)
Matching Power Module Requires ABB dedicated power module (Contact via email for model confirmation)
Replacement Model No direct replacement model (reference public information)
Minimum Order Quantity 1 unit
HS Code Contact via email (reference 8537 electrical control board or 8542 integrated circuits)
Stock Status Order available
Warranty 12 months

5. Model Explanation

Model: UFC789AE101

Order No./Part No.: 3BHE014023R0101

Product Description: ABB AC 800PEC high-performance motion controller / UNITROL 6000 excitation system core control board, high-speed FPGA + CPU hybrid architecture, 24V DC supply, made in Sweden

UFC789AE101 Model Overview:

  • UFC789AE101 is the core control board model of ABB's high-end control system
  • Applicable to ABB AC 800PEC high-performance motion controller series
  • Also applicable to ABB UNITROL 6000 digital excitation regulation system series
  • High-speed FPGA + CPU hybrid architecture, balancing real-time performance and computing power
  • 24V DC industrial standard power supply, redundancy supported
  • Plug-in board structure, installed in ABB dedicated control rack/backplane
  • Made in Sweden, industrial-grade quality

Order No. 3BHE014023R0101 Explanation:

  • 3BHE prefix is the part number prefix for ABB industrial automation/drive system products
  • 3BHE014023R0101 is the globally unified part number/order number for the UFC789AE101 control board
  • When purchasing, please provide both the model (UFC789AE101) and order number (3BHE014023R0101) to ensure accurate supply
  • No direct replacement model; when replacing, must use a product with the same model and order number

Applicable System Series:

表格

System Series Description
AC 800PEC ABB high-performance programmable motion controller for high-precision multi-axis motion control in rolling mills, paper machines, printing machines, test stands, etc.
UNITROL 6000 ABB high-end digital excitation regulation system for synchronous generator/motor excitation control, widely used in power and industrial applications

Related Products (ordered separately, Contact via email):

  • ABB AC 800PEC system rack/backplane
  • ABB system power module (24V DC input)
  • ABB digital I/O modules (DI/DO)
  • ABB analog I/O modules (AI/AO)
  • ABB communication modules (Profinet, EtherNet/IP, Modbus TCP, Profibus DP, etc.)
  • ABB encoder interface modules
  • ABB programming cables and configuration software
  • ABB system termination resistors and termination modules

Official Documentation Reference:

  • ABB AC 800PEC Hardware Manual
  • ABB AC 800PEC System Overview and Technical Data Sheet
  • ABB UNITROL 6000 Technical Specification and Hardware Manual
  • ABB UFC789AE101 Control Board Product Data Sheet
  • ABB Control System Installation and Maintenance Manual

6. Why Choose Us

  1. Professional Procurement, Genuine ABB Quality Guaranteed — All ABB control boards and system modules obtained through professional procurement channels, ensuring genuine ABB original products, with product identification, factory inspection certificates, and technical documentation, 12-month quality warranty. Pre-shipment appearance inspection, model confirmation, order number verification, board component integrity check, connector check, and packaging check performed.
  2. Worldwide Delivery, Professional Industrial Electronics Logistics — DHL/FedEx/UPS international courier, global delivery available. Control boards and other precision industrial electronic devices use shock-proof moisture-proof anti-static professional packaging (anti-static bag + foam cushioning + rigid carton), ensuring safe transport. Expedited logistics and customs clearance available, delivery to 200+ countries, meeting urgent project and equipment maintenance needs.
  3. Professional Technical Support, ABB Control System Full-process Service — Control board selection consultation (confirming applicable system series, firmware version, hardware configuration, I/O requirements, communication protocol requirements), installation guidance (rack mounting specifications, power wiring, backplane insertion, terminal wiring, grounding guidance), system configuration (hardware configuration, I/O mapping, communication parameter setting, motion control parameter commissioning, excitation regulation parameter tuning), fault analysis (alarm code troubleshooting, indicator status diagnosis, communication fault detection, power fault analysis, program loss recovery, spare parts replacement guidance, firmware upgrade guidance), and system spare parts list review, helping users correctly select, install and maintain ABB control systems.
  4. Flexible Procurement, Project Bulk and Spare Parts Framework Agreements — Single unit and bulk project orders, tiered discounts. Complete ABB control system package solutions available (control board + power module + I/O module + communication module + rack + programming cable + configuration software combination) and annual spare parts framework agreements, helping users optimize procurement cost, ensure spare parts supply, minimize system downtime risk. Customized quotations and long-term cooperation solutions available for metallurgy, power, paper, printing, test stand, marine, and other industry users.
  5. Pre-shipment Verification, Test Report Available — Appearance, packaging, model, order number checks before shipment; control board test report available if necessary (appearance inspection, component integrity check, connector check, solder joint quality check, silkscreen identification verification, packaging check, accessory inventory), ensuring delivered product in good condition. For urgent project needs (control system fault repair, production line emergency repair, project commissioning, equipment modification and upgrade), priority inventory coordination and expedited shipping available.

7. Frequently Asked Questions (FAQ)

Q1: What is ABB UFC789AE101 3BHE014023R0101? What are the main parameters?

A: ABB UFC789AE101 (order no. 3BHE014023R0101) is a high-performance control board/control unit manufactured by ABB, belonging to the ABB AC 800PEC high-performance motion controller series and UNITROL 6000 excitation system series, serving as the core control module for high-precision motion control and excitation regulation systems in industrial automation.

Core parameters: Brand ABB, model UFC789AE101 (also written as UF C789 AE101), order no./part no. 3BHE014023R0101, product type High-Performance Control Board / Control Unit, product series AC 800PEC High-Performance Motion Controller / UNITROL 6000 Excitation System, processor architecture High-speed FPGA + CPU hybrid architecture, supply voltage 24V DC (±10%) with dual power redundancy supported, mounting plug-in board in ABB dedicated control rack/backplane, operating temperature -20°C~+60°C (reference multi-source public information, subject to official), origin Sweden, replacement model no direct replacement.

Main applications:

  • AC 800PEC motion control applications: Metallurgical rolling mills (hot rolling/cold rolling/continuous casting), paper machinery (paper machine drive/coater/winder), printing machinery (multi-color offset/gravure/flexo), textile machinery, test stands (engine/motor/gearbox test), machine tools (CNC lathe/machining center), cranes, marine electric propulsion, and other applications requiring high-precision multi-axis coordinated motion control.
  • UNITROL 6000 excitation applications: Thermal power plant synchronous generator excitation, hydro power plant synchronous generator excitation, nuclear power plant excitation system, gas turbine and combined cycle power plant excitation, large synchronous motor drives (rolling mill main drives, compressors, fans, pumps, etc.) excitation control.

Note: This product is the core control board of ABB's high-end control system. In public information, some technical parameters (I/O channel count, communication interface, memory capacity, dimensions, etc.) have inconsistent descriptions among suppliers. Specific specifications are subject to ABB official data sheet; Contact via email for confirmation. Replacement of the control board must be performed by professional engineers trained by ABB, and after replacement it may be necessary to re-download the application program and configuration parameters.

Q2: Which ABB systems is UFC789AE101 applicable to? What are AC 800PEC and UNITROL 6000?

A: UFC789AE101 is mainly applicable to the following two ABB high-end control system series:

1. AC 800PEC High-Performance Motion Controller Series

The AC 800PEC is ABB's high-end programmable motion controller, specifically designed for applications requiring multi-axis coordination, high-precision synchronization, fast response, and complex motion trajectory control.

Key features of AC 800PEC:

  • High-performance processor architecture with powerful motion control algorithm computation capability
  • Supports multi-axis coordinated control (can control synchronous motion of dozens or even hundreds of axes)
  • Microsecond-level task cycle time, meeting real-time requirements of high-precision motion control
  • Supports electronic gear, electronic cam, flying shear, follow-up shear, winding tension control, and other complex motion functions
  • Rich communication interfaces, supporting Profinet, EtherNet/IP, Modbus TCP, Profibus DP, and other industrial fieldbuses
  • Modular design, flexible expansion of I/O and communication interfaces
  • High reliability, suitable for long-term continuous operation in industrial sites

Typical applications of AC 800PEC:

  • Metallurgical rolling mills: hot rolling mill, cold rolling mill, continuous casting machine, temper mill, tension leveler, etc.
  • Paper machinery: paper machine drive system, coater, calender, winder, rewinder, etc.
  • Printing machinery: multi-color offset press, gravure press, flexographic press, corrugated paper printer, etc.
  • Test stands: engine test stand, motor test stand, gearbox test stand, chassis dynamometer, etc.
  • Machine tools: high-precision CNC lathes, machining centers, grinding machines, etc.
  • Others: textile machinery, packaging machinery, cranes, marine electric propulsion, etc.

2. UNITROL 6000 Digital Excitation Regulation System Series

UNITROL 6000 is ABB's high-end digital excitation regulation system for synchronous generators and synchronous motors, the latest generation of ABB's UNITROL series excitation systems.

Key features of UNITROL 6000:

  • High-performance digital regulator with high-speed processor and real-time operating system
  • Supports multiple regulation modes: constant voltage regulation (AVR), constant current regulation (FCR), constant power factor regulation (PF), constant reactive power regulation (VAr), etc.
  • Built-in multiple limiters and protection functions (over-excitation limiter, under-excitation limiter, V/Hz limiter, stator current limiter, inverse-time protection, etc.)
  • Supports dual-channel redundant configuration, improving system reliability
  • Rich communication interfaces, supporting communication with plant DCS/SCADA systems
  • Built-in event recording and fault recording functions for fault analysis
  • Modular design, convenient maintenance

Typical applications of UNITROL 6000:

  • Thermal power plants: steam turbine generator excitation system
  • Hydro power plants: hydro generator excitation system
  • Nuclear power plants: steam turbine generator excitation system
  • Gas turbines and combined cycle power plants: generator excitation system
  • Industrial applications: large synchronous motor drives (rolling mill main drives, compressors, fans, pumps, etc.) excitation control
  • Others: pumped storage power plants, diesel generator excitation, etc.

Role of UFC789AE101 in both systems:

  • In AC 800PEC: As the core control board, undertaking motion control algorithm computation, real-time task scheduling, I/O signal processing, communication protocol conversion, etc.
  • In UNITROL 6000: As the core regulation board, undertaking excitation regulation algorithm computation, voltage/current/power factor closed-loop control, limiter and protection logic processing, communication and human-machine interface, etc.

To confirm whether UFC789AE101 is applicable to your specific system configuration, please provide system model, firmware version, hardware configuration list, etc.; Contact via email for confirmation.

Q3: How to replace a faulty UFC789AE101 control board? What should be noted?

A: The UFC789AE101 is the core control board of ABB's high-end control system. Replacement must be performed by professional engineers trained by ABB, strictly following the steps and precautions below:

Pre-replacement preparation:

  1. Confirm model and order number: Verify the model (UFC789AE101) and order number (3BHE014023R0101) of the faulty control board, ensuring the new spare part is completely identical. This product has no direct replacement model and cannot be replaced by other models.
  2. Backup system configuration: Before replacement, back up all application programs, hardware configurations, parameter settings, etc. of the control system to a computer or storage medium via ABB programming software to prevent configuration loss after replacement.
  3. Record wiring and jumpers: Take photos of all wiring, jumpers, DIP switch settings on the control board to ensure complete restoration when installing the new board.
  4. Prepare tools: Prepare anti-static wrist strap, Phillips screwdriver, tweezers, multimeter, etc.
  5. Safety confirmation: Ensure the system is shut down, relevant power supplies are disconnected, and lockout/tagout (LOTO) measures are taken to prevent accidental power-up.

Replacement steps (reference):

  1. Power off: Disconnect all power supplies of the control system (including 24V DC control power and possible backup power), wait at least 5 minutes for capacitor discharge.
  2. Anti-static: Wear an anti-static wrist strap and ground it reliably to prevent electrostatic damage to electronic components on the control board.
  3. Remove faulty board:
    • Disconnect all wiring and connectors on the control board (note marking each cable position)
    • Loosen the fixing screws or release the latches of the control board
    • Pull out the faulty control board smoothly along the rail/slot direction
    • Place the faulty board in an anti-static bag for storage
  4. Install new board:
    • Check the new control board for no appearance damage, no component 脱落，no connector deformation
    • Verify the new board model and order number match the faulty board
    • Insert the new control board smoothly along the rail/slot direction, ensuring fully inserted
    • Tighten fixing screws or engage latches
    • Restore all wiring and connectors according to previously recorded photos
    • Check jumper and DIP switch settings match the faulty board
  5. Pre-power-on check:
    • Check all wiring is correct and no looseness
    • Check no tools, screws, or other foreign objects around the control board
    • Confirm power supply voltage is within normal range (24V DC ±10%)
  6. Power-on test:
    • Turn on control power, observe status indicators on the control board
    • Power indicator should be steady on (green)
    • Run indicator should blink or be steady on normally
    • Fault indicator should not be steady on
    • If abnormal, immediately power off and check
  7. Restore configuration:
    • Connect to the control system via ABB programming software
    • Download previously backed up application program and configuration parameters
    • Check hardware configuration matches actual configuration
    • Perform I/O test and communication test
  8. System commissioning:
    • Gradually test each function in manual mode
    • Confirm motion control/excitation regulation parameters are correct
    • Perform no-load test and load test
    • Put into automatic operation after confirming normal system operation

Replacement precautions:

  1. Electrostatic protection: The control board has many CMOS devices sensitive to static electricity. Always wear an anti-static wrist strap during operation, hold only the board edges, do not touch components and solder joints on the circuit board with hands.
  2. Power safety: Before replacement, must completely power off, including main power and backup power (such as UPS, redundant power), wait for capacitors to fully discharge. The control system may have multiple power circuits, be sure to disconnect all.
  3. Model consistency: Must use exactly the same model (UFC789AE101) and order number (3BHE014023R0101), cannot be replaced by other models. Different versions of control boards may have firmware and hardware differences, mixed use may cause system failure.
  4. Configuration backup: Must backup application program and configuration parameters before replacement. The new control board may not have user application program from factory and needs to be re-downloaded.
  5. Firmware version: Note whether the firmware version of the new control board is compatible with the system, may need to upgrade or downgrade firmware if necessary. Contact via email for firmware compatibility confirmation.
  6. Parameter restoration: After replacement, need to re-set hardware configurations such as jumpers, DIP switches, termination resistors on the control board, ensuring consistency with the original board.
  7. Professional operation: Replacement must be performed by professional engineers trained by ABB. Personnel without relevant qualifications and experience should not attempt replacement to avoid equipment damage or personal injury.
  8. Waste disposal: The replaced faulty control board is electronic waste, should be properly disposed of according to local environmental regulations, do not discard casually.

For replacement guidance or technical support, please Contact via email; we can provide remote technical guidance or arrange on-site engineer services.

Q4: In stock? Lead time? Price?

A: Currently Order Available. Specific stock of ABB high-end control board products fluctuates with market.

  • Lead time: Standard 4-8 weeks (ABB high-end control boards are industrial-grade customized products, some common configurations may be in stock, specific subject to formal quotation).
  • Price: Subject to formal quotation, depends on specific model configuration, quantity, supply channel, whether includes technical service and on-site commissioning support, etc. Bulk procurement enjoys tiered discounts.
  • Package solutions: Complete ABB control system package solutions available (control board + power module + I/O module + communication module + rack + programming cable + configuration software combination), combined procurement price more favorable. If the system requires other spare parts, it is recommended to purchase at the same time.
  • Expedited service: For urgent needs (control system fault repair, production line emergency repair, project commissioning, equipment modification and upgrade), we can try to coordinate stock or expedited ordering, please contact sales team.
  • Please indicate: required quantity, desired delivery time and destination, specific model and order number, applicable system series (AC 800PEC or UNITROL 6000), whether matching other modules needed, whether installation commissioning and technical support services needed when inquiring; we will coordinate fastest delivery and optimal price.
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