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Product Description

Brand:​ABB

Model:​LD 800HSE

Part Number:​3BDH000320R02

Series:​AC800M High Integrity Controller Communication Module

Function:​Ethernet/IP Communication Interface Module

Protocol:​Ethernet/IP Adapter(and optional Scanner)

ABB LD 800HSE 3BDH000320R02​is a high-performance Ethernet/IP communication interface module​designed for the ABB AC800M High Integrity(HI)​controller family.It provides seamless integration of safety and standard control applications into Rockwell Automation’s EtherNet/IP​network architecture.This module enables the AC800M HI controller to act as an Adapter(slave)​on an EtherNet/IP network,exchanging data with scanners(masters)like ControlLogix or CompactLogix PLCs.It is a critical component for building hybrid control systems that combine ABB’s high-integrity process control with Rockwell’s discrete manufacturing ecosystems.Genuine ABB component,fully tested and certified.

Application Scenarios

In a large pharmaceutical plant,the core batch reactor process is controlled by an ABB AC800M HI​controller for its superior safety and batch management capabilities,certified for SIL 2/3​applications.However,the surrounding material handling system—conveyors,robotic palletizers,and packaging machines—is built on a Rockwell ControlLogix​platform using EtherNet/IP​as the backbone.The critical challenge is seamless,deterministic data exchange between these two worlds:the process controller must signal”batch complete”to the packaging line,and the packaging line must report”station ready”and any faults back to the process controller.Hardwiring hundreds of I/O points is impractical and unreliable.The ABB LD 800HSE 3BDH000320R02​module is the engineered solution.Installed directly into the AC800M HI rack,it gives the safety controller a native presence on the plant-wide EtherNet/IP network.The Rockwell PLCs can now directly”talk”to the AC800M as if it were another EtherNet/IP device.Process parameters and batch status are mapped into pre-defined Produced​and Consumed Tags​that flow across the network with millisecond precision.This eliminates custom gateways,reduces wiring by over 70%,and creates a unified data layer.For the system integrator,the LD 800HSE​is not just a communication card;it’s a strategic enabler that breaks down automation silos,allowing them to select the best-in-class controller for each domain while maintaining a cohesive,manageable,and future-proof architecture.

Key Parameters

Parameter

Value/Description

Product Model​

LD 800HSE​

Manufacturer Part Number​

3BDH000320R02​

Manufacturer​

ABB

Product Type​

Ethernet/IP Communication Interface Module

Compatible Controller​

ABB AC800M High Integrity(HI)Controllers(e.g.,PM861,PM864,PM866)

Network Protocol​

EtherNet/IP​(CIP)–Primarily functions as an Adapter(Slave).May support limited Scanner(Master)functionality depending on firmware.

Physical Interface​

2 x 10/100/1000 Mbps RJ-45 Ethernet ports(copper).

Network Topology​

Supports linear,star,and ring topologies.Ports can be used for device-level connection and/or system network separation.

CIP Connection Support​

Multiple explicit messaging(Class 3)and implicit I/O(Class 1)connections.

Data Exchange Capacity​

Supports configurable Assembly Instances​for cyclic and acyclic data transfer.

Configuration​

Configured using ABB Control Builder Plus​engineering software with the module’s specific add-in.

Status Indication​

Multiple LEDs for module status,network activity,link status,and diagnostic information.

Power Supply​

Powered from the AC800M controller backplane.

Certifications​

Relevant industrial and network communication certifications(often tested for interoperability with major vendors).

Key Application​

Bridging ABB’s high-integrity/process control systems with Rockwell Automation’s EtherNet/IP based control and I/O systems.

Technical Principles and Innovative Values

The ABB LD 800HSE 3BDH000320R02​is a masterclass in industrial interoperability,transforming a high-integrity controller into a first-class citizen on the world’s most prevalent industrial Ethernet network.Its innovation lies in its deep,native implementation of the protocol stack and its seamless integration into the safety controller’s architecture.

Innovation Point 1:Native EtherNet/IP Adapter Implementation with High Performance

Unlike a generic protocol gateway that translates between two separate networks,the LD 800HSE​implements the CIP(Common Industrial Protocol)​stack natively within the AC800M HI’s communication subsystem.This means it communicates directly using standard EtherNet/IP UDP/IP​and TCP/IP​packets.It supports both Explicit Messaging​for parameter access and configuration,and,most importantly,Implicit I/O Messaging(Class 1 Connections)​for high-speed,deterministic cyclic data exchange.This allows it to establish Produced/Consumed Tag​relationships with Rockwell scanners,enabling sub-10ms update times for critical process data.The dual Gigabit ports support Device Level Ring(DLR)​topologies for network redundancy,ensuring communication paths remain available even during a single cable fault,which is critical for high-availability processes.

Innovation Point 2:Seamless Integration with AC800M HI Safety and Standard Applications

The module is not an external black box;it is a fully integrated part of the AC800M HI system.In Control Builder Plus,it appears as a configurable hardware module.Data exchange is configured through intuitive”Assembly Instance”​mapping.Engineers simply define which controller variables(from both standard and Safe Application​logic)should be published(Produced)to the network or subscribed to(Consumed)from the network.The module handles all the underlying network specifics.This deep integration ensures that data from safety-related applications can be communicated with the proper context and integrity,although the safety integrity itself is not extended over the open network—a crucial architectural principle.The module’s diagnostics are fully integrated into the controller’s fault reporting system.

Innovation Point 3:Advanced Diagnostics and Cybersecurity Features

The LD 800HSE​provides rich diagnostic capabilities visible both from the Rockwell scanner(via the network)and from the ABB engineering station.It can report detailed connection status,packet statistics,and error counts.From a cybersecurity perspective,it supports features like IP address filtering​and explicit connection configuration,preventing unauthorized devices from establishing data connections.Its design acknowledges the modern threat landscape of connected industrial control systems.The dual ports can also be used to separate traffic,for example,dedicating one port to the machine-level EtherNet/IP network and the other to a separate plant network for higher-level data collection,enhancing network segmentation and security.

Innovation Point 4:Unlocking Hybrid System Architectures and Legacy Integration

This module’s greatest value is strategic:it enables”best-of-breed”system design.Process engineers are no longer forced to choose a single vendor for an entire plant.They can deploy the AC800M HI​for its superior batch processing,safety,and regulatory compliance in the process area,while using Rockwell PLCs and the extensive ecosystem of EtherNet/IP​remote I/O,drives,and HMIs for material handling.It also serves as a powerful tool for brownfield modernization,allowing a new AC800M-based system to be seamlessly grafted onto an existing Allen-Bradley dominated network without a costly and risky”rip-and-replace”strategy.

Application Cases and Industry Value

Case Study:Food&Beverage Hybrid Processing and Packaging Line

A global food manufacturer built a new flagship line for high-margin,aseptically packaged products.The process side—involving precise thermal treatment,sterile holding,and recipe management—required a controller with robust batch functionality and traceability.The packaging side,with high-speed fillers,cappers,and case packers,demanded the fast sequencing and extensive machine vendor support found in the Rockwell ecosystem.

The solution was a hybrid system.An ABB AC800M HI​controller,equipped with an LD 800HSE 3BDH000320R02​module,managed the process skid.A Rockwell ControlLogix​PLC managed the packaging machines.Both were connected to a managed EtherNet/IP​network.The LD 800HSE​module was configured to produce a data structure containing batch ID,product code,target fill volume,and process”Ready”signal.The ControlLogix consumed this data to configure its packaging machines.Conversely,the ControlLogix produced status packets for filler readiness,cap supply low,and line faults,which the AC800M consumed to manage its process sequence and generate operator alerts.

During commissioning,the value was immediate.The line’s Overall Equipment Effectiveness(OEE)dashboard,built on a Rockwell FactoryTalk system,could pull data directly from both controllers without middleware.When a packaging machine fault stopped the line,the process controller automatically entered a safe”hold”state,preserving product quality.The plant’s IT/OT convergence project used the same network infrastructure for data collection.

The quantified benefits were clear:​1.Reduced Integration Cost:​Eliminated the need for a separate OPC server and custom driver development,saving an estimated 200 engineering hours.2.Increased Line Flexibility:​Recipe changes in the AC800M automatically propagate to the packaging line via the network,reducing changeover time.3.Enhanced Diagnostics:​A single network troubleshooting tool could trace issues across both control systems.The project manager stated,”The LD 800HSE​module was the linchpin.It turned a potential integration nightmare into a plug-and-play success,allowing us to leverage the strengths of both ABB and Rockwell without compromise.It future-proofed our investment.”

Related Product Combination Solutions

The LD 800HSE​operates within a multi-vendor ecosystem.Key related components and systems include:

ABB AC800M High Integrity Controller​(e.g.,PM864F):The host safety controller that the LD 800HSE​module physically and logically integrates with.

Rockwell Automation ControlLogix/CompactLogix PLC:The typical”scanner”or master controller that initiates data exchange with the LD 800HSE-equipped AC800M.

ABB Control Builder Plus Engineering Software:The essential tool for configuring the LD 800HSE​module,mapping data,and programming the AC800M controller.

Rockwell Studio 5000/RSLogix 5000:The engineering environment for the Rockwell PLC,where the LD 800HSE​is configured as an EtherNet/IP Adapter device using its EDS(Electronic Data Sheet)file.

Stratix Managed Industrial Ethernet Switches:Provide the robust,managed network infrastructure recommended for performance and security in a hybrid system.

ABB S800 I/O with PROFIBUS/Profisafe:The native I/O system for the AC800M,handling local process instrumentation,while the LD 800HSE​handles controller-to-controller communication.

Rockwell Point/Distributed I/O(PointIO,FlexIO):The remote I/O that the Rockwell PLC can communicate with over the same EtherNet/IP network.

Third-party EtherNet/IP Devices:Any other device on the network(vision systems,weigh scales,RFID readers)can share data indirectly with the AC800M through the Rockwell PLC or,in some cases,directly if the LD 800HSE​supports scanner functionality.

Installation,Maintenance,and Full-Cycle Support

Installation&Hardware Integration:​The LD 800HSE​module is installed directly into a free slot in the AC800M HI​controller rack.Ensure the controller is powered down.Align the module with the guide rails and press firmly until it clicks into place and the locking levers engage.Connect standard Cat5e or Cat6 Ethernet cables from the module’s RJ-45 ports to the plant’s industrial Ethernet switch.The dual ports can be used for a redundant ring connection or for separating networks.Proper network planning is essential:assign a static IP address​to the module that is within the correct subnet and does not conflict with other devices.This is configured in Control Builder Plus.

Software Configuration&Commissioning:​Configuration is a two-step process:

In Control Builder Plus:​Add the LD 800HSE​module to the controller’s hardware configuration.Set its parameters(IP address,subnet mask).In the module’s configuration,define the Assembly Instances.Map controller variables(e.g.,%MW,%QW)to specific bytes within the produced and consumed assembly data structures.This defines the”language”the module will speak on the network.

In Rockwell Studio 5000:​Add a new EtherNet/IP module to the I/O configuration of the Rockwell controller.Select the generic”EtherNet/IP Adapter”module or import the specific EDS file​for the LD 800HSE.Enter the IP address of the ABB module.Configure the data connection,specifying the exact size and format of the produced/consumed tags that match the assembly instances defined in Control Builder Plus.Map these tags to the Rockwell PLC’s data tables.

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