+86 18030182217
+86 18030182217
sandydcsplc@gmail.com
Description
Product Overview
The ABB KP2500 is a high-performance industrial controller module designed for mission-critical automation systems, serving as a core component of ABB’s AC800M distributed control system (DCS). Engineered for reliability and scalability, the KP2500 enables seamless integration of process control, data acquisition, and communication in industries such as power generation, oil & gas, and manufacturing. With dual redundant CPUs and advanced diagnostic capabilities, this module ensures continuous operation even in harsh industrial environments, making it ideal for applications requiring 24/7 uptime.
The ABB KP2500 is a high-performance industrial controller module designed for mission-critical automation systems, serving as a core component of ABB’s AC800M distributed control system (DCS). Engineered for reliability and scalability, the KP2500 enables seamless integration of process control, data acquisition, and communication in industries such as power generation, oil & gas, and manufacturing. With dual redundant CPUs and advanced diagnostic capabilities, this module ensures continuous operation even in harsh industrial environments, making it ideal for applications requiring 24/7 uptime.
As part of ABB’s modular AC800M platform, the KP2500 supports flexible I/O expansion through both electrical and fiber-optic ModuleBus connections, accommodating up to 12 S800 I/O modules or 7 remote I/O clusters . Its built-in Ethernet and RS232 ports facilitate direct connectivity to HMIs, PLCs, and supervisory systems, while Profibus-DP compatibility allows integration with third-party devices. The module’s compact design (100 mm × 150 mm × 200 mm) and DIN rail mounting simplify installation in control cabinets, reducing space requirements by 30% compared to legacy systems.
Key features include real-time data processing, configurable redundancy for fail-safe operation, and a wide operating temperature range (-20°C to +60°C), ensuring resilience in extreme conditions. The KP2500 also incorporates advanced cybersecurity measures, such as encrypted communication protocols, to protect against unauthorized access. By combining high computational power with industry-standard interfaces, the ABB KP2500 delivers unparalleled control precision and system integration, empowering engineers to optimize process efficiency and reduce downtime.
Technical Specifications
| Parameter Name | Parameter Value |
|---|---|
| Product Model | KP2500 |
| Manufacturer | ABB |
| Product Type | Industrial Controller Module (AC800M DCS System) |
| Processor | Dual-core 600 MHz CPU with 1 GB RAM |
| Communication Interfaces | 2x IEEE802.3 Ethernet, 2x RS232, 1x Profibus-DP |
| I/O Expansion | Up to 12 S800 I/O modules (electrical) or 7 remote clusters (fiber-optic) |
| Redundancy | Hot-swappable dual CPU configuration |
| Power Supply | 24V DC ±10% (20W typical consumption) |
| Physical Dimensions | 100 mm (H) × 150 mm (W) × 200 mm (D) |
| Weight | 0.8 kg |
| Operating Temperature | -20°C to +60°C |
| Storage Temperature | -40°C to +85°C |
| Protection Rating | IP20 (防尘) with conformal coating for moisture resistance |
| Certifications | CE, UL, cUL, IEC 61131-2, ISA 88/95 compliance |
Key Features and Advantages
High Availability Architecture: The ABB KP2500 supports dual redundant CPUs with automatic failover, ensuring zero downtime during maintenance or component failure. Its modular design allows individual module replacement without disrupting system operations.
High Availability Architecture: The ABB KP2500 supports dual redundant CPUs with automatic failover, ensuring zero downtime during maintenance or component failure. Its modular design allows individual module replacement without disrupting system operations.
Scalable I/O Configuration: With both electrical and fiber-optic expansion options, the KP2500 adapts to diverse control requirements, from small-scale PLC systems to large distributed control networks. It can manage up to 1,920 I/O points via ModuleBus and thousands more through Profibus-DP .
Advanced Communication Capabilities: Built-in Ethernet and RS232 ports enable seamless integration with ABB’s Control Builder M software and third-party SCADA systems. Profibus-DP compatibility allows connection to legacy devices, ensuring backward compatibility.
Robust Cybersecurity: The module incorporates AES-128 encryption for data transmission and role-based access control, safeguarding critical infrastructure against cyber threats.
Real-Time Performance: The dual-core CPU processes control loops at sub-millisecond speeds, making it suitable for high-speed applications like motor control and batch processing.
Efficient Maintenance: LED indicators for power, communication, and diagnostics simplify troubleshooting, while remote firmware updates reduce downtime. ABB’s global support network provides 24/7 technical assistance.
Application Areas
Power Generation: The ABB KP2500 controls steam turbines, generators, and boiler systems in thermal and nuclear power plants, ensuring stable energy production and grid synchronization. Its redundancy features meet the strict reliability requirements of utility-scale operations.
Power Generation: The ABB KP2500 controls steam turbines, generators, and boiler systems in thermal and nuclear power plants, ensuring stable energy production and grid synchronization. Its redundancy features meet the strict reliability requirements of utility-scale operations.
Oil & Gas: Deployed in offshore platforms and refineries, the module manages critical processes such as pipeline monitoring, compressor control, and emergency shutdown systems. Its rugged design withstands corrosive environments and extreme temperatures.
Manufacturing: In automotive and food processing plants, the KP2500 coordinates production lines, robotics, and quality control systems. Its real-time data processing ensures precise synchronization and minimizes waste.
Water/Wastewater Treatment: The module optimizes pump stations, filtration systems, and chemical dosing in municipal water plants. Its scalability supports both centralized control and decentralized monitoring.
Mining & Metals: Used in ore processing and smelting operations, the KP2500 controls conveyor belts, crushers, and ventilation systems. Its Profibus-DP compatibility integrates with legacy mining equipment for cost-effective upgrades.
Related Products
- ABB S800 I/O Modules: Complementary I/O modules for analog/digital signal processing, directly connectable to the KP2500 via ModuleBus .
- ABB AC800M CP602: High-performance CPU module for advanced control applications requiring higher computational power.
- ABB PCD232A: Profibus-DP communication module for expanding connectivity with third-party devices.
- ABB DO810: Digital output module for controlling actuators and relays in industrial processes.
- ABB CAI04: Current input module for monitoring high-power equipment in energy-intensive industries.
Installation and Maintenance
Pre-Installation Preparation:
Ensure the control cabinet is grounded and properly ventilated. Verify power supply compatibility (24V DC) and check for physical damage to the ABB KP2500. Use ABB’s Control Builder M software to configure network settings and download the latest firmware. Mount the module on a 35 mm DIN rail and secure connections using M4 screws.
Pre-Installation Preparation:
Ensure the control cabinet is grounded and properly ventilated. Verify power supply compatibility (24V DC) and check for physical damage to the ABB KP2500. Use ABB’s Control Builder M software to configure network settings and download the latest firmware. Mount the module on a 35 mm DIN rail and secure connections using M4 screws.
Maintenance Recommendations:
Regularly inspect LED indicators for 异常状态 and clean dust from the module’s vents. Replace the backup battery every 3 years to maintain data integrity. Perform firmware updates quarterly to access new features and security patches. ABB’s predictive maintenance tools can monitor module health and alert operators to potential issues. For hardware replacements, follow ABB’s hot-swap procedure to avoid system downtime.
Regularly inspect LED indicators for 异常状态 and clean dust from the module’s vents. Replace the backup battery every 3 years to maintain data integrity. Perform firmware updates quarterly to access new features and security patches. ABB’s predictive maintenance tools can monitor module health and alert operators to potential issues. For hardware replacements, follow ABB’s hot-swap procedure to avoid system downtime.
Product Warranty
The ABB KP2500 is backed by a 1-year warranty covering manufacturing defects and material flaws. ABB offers global technical support, including 24/7 emergency assistance for critical installations, and maintains spot inventory for rapid replacement. Customers benefit from 3-day delivery after payment and comprehensive post-sales services, including system integration consulting and operator training. ABB’s commitment to quality ensures the KP2500 meets rigorous industrial standards, providing long-term reliability for mission-critical automation projects.
The ABB KP2500 is backed by a 1-year warranty covering manufacturing defects and material flaws. ABB offers global technical support, including 24/7 emergency assistance for critical installations, and maintains spot inventory for rapid replacement. Customers benefit from 3-day delivery after payment and comprehensive post-sales services, including system integration consulting and operator training. ABB’s commitment to quality ensures the KP2500 meets rigorous industrial standards, providing long-term reliability for mission-critical automation projects.
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Contact info
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- Email: sandydcsplc@gmail.com
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