Description

Product Overview

The ABB PPC380AE102 is an advanced redundant controller module designed for mission-critical industrial automation within ABB’s PPC (Process Control Controller) series. Building on the robust foundation of the ABB PPC380AE02, this enhanced model integrates dual-core processing with advanced redundancy features, making it ideal for applications requiring zero downtime and high reliability. Engineered for seamless integration with ABB’s AC 800M and 800xA systems, the ABB PPC380AE102 delivers real-time control, enhanced cybersecurity, and scalable connectivity for complex processes in sectors like power generation, oil & gas, and smart manufacturing.

Technical Specifications

Parameter Name	Parameter Value
Product Model	ABB PPC380AE102
Manufacturer	ABB
Product Type	Enhanced Redundant Controller Kit (PPC Series)
Processor	Dual-core ARM Cortex-A9 1.5 GHz (per module), with hardware-based error detection
Memory	4 GB DDR3 RAM per module, 16 GB eMMC storage per module
Communication Interfaces	4 × Gigabit Ethernet (10/100/1000 Mbit/s), 8 × USB 3.0, 4 × RS485/422 (dual-module)
Redundancy Support	Hot standby redundancy (switchover ≤3 ms), dual-path failover with automatic diagnostics
Power Supply	24 V DC (18–32 V DC), 28 W typical consumption (dual modules)
Operating Temperature	-25°C to +65°C (standard), -40°C to +80°C with extended environment kit
Safety Certification	CE, UL, cUL, ATEX Zone 2, SIL3 (IEC 61508), Cybersecurity-certified (ISA/IEC 62443)
Vibration Resistance	5–500 Hz, 3 g (IEC 60068-2-6)
Protection Class	IP20 (conformal coating standard for moisture resistance)
Dimensions	119 mm × 186 mm × 135 mm (per module), total kit size: 240 mm × 186 mm × 135 mm
Weight	3.4 kg (kit)
Protocol Support	Profinet RT, Ethernet/IP, Modbus TCP, OPC UA 1.04, ABB Ability™ integration, MQTT

Key Features and Advantages

Ultra-Fast Redundancy with SIL3 Compliance

The ABB PPC380AE102 sets a new standard with switchover times ≤3 ms, ensuring uninterrupted operation in safety-critical systems. Its SIL3 certification (IEC 61508) makes it suitable for emergency shutdown (ESD) systems and other applications where failure risks catastrophic consequences.

Enhanced Processing and Memory

Each module features a 1.5 GHz dual-core processor and 4 GB DDR3 RAM, enabling real-time control of up to 5,000 I/O points and 20,000 tags. The 16 GB eMMC storage supports advanced data logging and edge computing for predictive maintenance.

Advanced Cybersecurity Integration

With built-in cybersecurity features compliant with ISA/IEC 62443, the PPC380AE102 safeguards against unauthorized access and firmware tampering. Dual Ethernet ports support secure VLAN segmentation, while encrypted communication protocols protect data integrity.

Rugged Design for Extreme Environments

Rated for -25°C to +65°C operation and 3 g vibration resistance, this module thrives in harsh environments like offshore platforms, mining sites, and chemical plants. Standard conformal coating protects against dust, moisture, and corrosive gases.

Future-Ready Connectivity

Support for OPC UA 1.04 and MQTT enables seamless integration with cloud-based analytics and IoT platforms. The module’s open architecture allows easy adoption of Industry 4.0 technologies without disrupting existing infrastructure.

Application Areas

Nuclear and Renewable Energy

Deployed in nuclear power plants for reactor control and in renewable energy farms for grid integration, the ABB PPC380AE102 ensures compliance with strict safety standards. Its SIL3 certification and cybersecurity features make it ideal for critical energy infrastructure.

Offshore Oil & Gas

Manages subsea wellheads, FPSO systems, and pipeline networks in harsh marine environments. The module’s extended temperature range and corrosion-resistant coating ensure reliable operation in saltwater and high-humidity conditions.

Pharmaceutical and Biotechnology

Controls sterile manufacturing processes, bioreactors, and quality control systems in GMP-compliant facilities. The PPC380AE102’s redundant design minimizes batch failures and ensures regulatory compliance.

Smart Cities and Transportation

Orchestrates metro signaling systems, tunnel ventilation, and smart grid networks. Its low-latency processing and rugged design make it suitable for real-time control in urban infrastructure.

Related Products

Model	Relationship/Use Case
PPC380AE02	Previous-generation redundant kit, compatible for system expansion or legacy support.
PPC380AE01	Non-redundant base model, suitable for non-critical applications as a standalone controller.
PM891K01	Monolithic safety controller with SIL3 certification, integrates with PPC380AE102 in hybrid safety systems.
S800 I/O-eA Series	Extended-environment I/O modules (e.g., AI830-eA) for harsh industrial sites, compatible with PPC380AE102.
CI867-eA	Profinet communication module with cybersecurity features, enhances network reliability for PPC380AE102 setups.

Installation and Maintenance

Installation Preparation

Mount the ABB PPC380AE102 kit on adjacent TP830 baseplates with 50 mm spacing for optimal heat dissipation. Use shielded CAT6 cables for Gigabit Ethernet connections and terminate redundancy loops with TB852-eA modules. Configure failover parameters via ABB’s Control Builder M software, ensuring synchronization with external time servers (IEEE 1588) for precise event logging.

Maintenance Recommendations

Conduct bi-monthly health checks using ABB’s Remote Diagnostics Tool, monitoring CPU load, memory usage, and redundancy status. Replace backup batteries (model 4943013-6) every 18 months to preserve program data. For cybersecurity updates, apply firmware patches promptly via ABB’s secure update portal, maintaining an air-gapped environment for critical systems.

Product Assurance

ABB provides a 2-year warranty for the PPC380AE102 kit, covering both modules and redundancy components. Customers benefit from ABB’s Global Service Network, including 24/7 cybersecurity incident response, priority spare parts delivery, and annual system health audits. The kit undergoes rigorous testing for thermal cycling, vibration, and cybersecurity penetration to ensure compliance with industrial and safety standards.

HS:7326909000

Contact info

WhatsApp: +86 18030182217
Email: sandydcsplc@gmail.com
Phone: +86 18030182217
Wechat: +86 18030182217
Website: www.xiongbaparts.com