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Detailed Parameter Table
| Parameter Name | Parameter Value |
|---|---|
| Product Model | 3BHE039724R0C3D PPD513 A0C-100440 AC800PEC |
| Manufacturer | ABB |
| Product Category | Industrial Controller (PLC/DCS Module) |
| Application | Process Automation, Distributed Control Systems, Industrial Machinery |
| Platform Series | ABB AC800PEC (Industrial IT Platform) |
| Processor | Dual-core ARM Cortex-A9 @ 1 GHz |
| Memory | 2 GB RAM, 8 GB Flash (user-accessible) |
| Communication Interfaces | Ethernet (10/100/1000 Mbps), PROFIBUS DP, CANopen |
| I/O Capacity | Up to 256 digital/analog channels (expandable via racks) |
| Real-Time Operating System | ABB Control Builder M, IEC 61131-3 compliant |
| Operating Temperature | -40°C to +70°C |
| Dimensions (W×H×D) | 150 mm × 220 mm × 80 mm |
| Mounting Method | DIN rail or rack mount (19-inch standard) |
| Certification | IEC 61508 (SIL 2), IEC 61131-2, CE, UL, RoHS |
Product Introduction
The ABB 3BHE039724R0C3D PPD513 A0C-100440 AC800PEC is a high-performance industrial controller designed as the core of ABB’s AC800PEC distributed control system (DCS). Engineered for mission-critical applications in process industries, this controller combines advanced processing power with rugged industrial design, delivering deterministic control, real-time data processing, and seamless integration with field devices and supervisory systems. As part of the Industrial IT Platform, the AC800PEC controller ensures reliable automation for complex workflows, from batch processing in pharmaceuticals to high-speed manufacturing in automotive plants.
Featuring a dual-core ARM Cortex-A9 processor and 2 GB of RAM, the AC800PEC handles up to 1,000 control loops with sub-millisecond cycle times, making it suitable for applications requiring precise coordination of motors, valves, and sensors. Its expandable architecture supports up to 256 I/O channels via modular racks, accommodating analog inputs/outputs (e.g., 4–20 mA, 0–10 V), digital signals, and specialized modules for temperature control or high-speed counting. The controller’s built-in Ethernet, PROFIBUS DP, and CANopen interfaces enable seamless communication with drives, HMIs, and third-party systems, while its compliance with IEC 61508 (SIL 2) ensures functional safety in critical processes.
The AC800PEC controller simplifies system integration through ABB’s Control Builder M software, which supports IEC 61131-3 programming languages (Ladder Logic, Structured Text) and offers advanced diagnostics for real-time monitoring of CPU load, network traffic, and I/O status. Its compact DIN rail-mountable design (150 mm width) optimizes space in control panels, while the -40°C to +70°C operating range ensures reliability in harsh environments, from offshore platforms to steel mills.
Core Advantages and Technical Highlights
Deterministic performance and scalability: The AC800PEC’s dual-core processor and real-time operating system guarantee predictable task execution, with cycle times as low as 1 ms for critical control loops. A chemical plant used the controller to manage a complex distillation column, achieving ±0.5°C temperature control accuracy and reducing product waste by 18%. Its modular design allows easy expansion—an automotive factory added 128 digital I/O channels to its existing AC800PEC system within hours, scaling production without downtime.
Advanced safety and cybersecurity: Certified for SIL 2, the controller incorporates hardware and software redundancy features, such as dual power supplies and hot-swappable modules, to minimize single points of failure. In a food processing facility, the AC800PEC’s built-in firewall and encrypted Ethernet communication (SSL/TLS) protected against cyber threats, ensuring compliance with FDA 21 CFR Part 11 for batch record integrity.
Energy efficiency and diagnostics: The controller’s low-power design (≤20 W) reduces energy consumption in large-scale systems, while its predictive diagnostics monitor component health (e.g., capacitor lifespan, fan performance). A paper mill used these features to schedule proactive maintenance, reducing unplanned downtime by 25% and extending the controller’s operational life by 30%.
Seamless integration with digital ecosystems: The AC800PEC supports ABB’s Ability™ digital platform, enabling remote monitoring via cloud-based dashboards. A renewable energy plant integrated the controller with predictive analytics software, optimizing turbine performance based on real-time data and increasing energy output by 12%.
Typical Application Scenarios
Process industries: In oil refineries and chemical plants, the AC800PEC manages complex process control, such as reactor temperature regulation and flow metering. A major LNG terminal used the controller to automate its cryogenic pump systems, achieving ±1% flow accuracy and reducing manual intervention by 40%.
Manufacturing automation: For automotive and electronics assembly lines, the AC800PEC coordinates robotics, vision systems, and quality control stations. A smartphone factory deployed the controller to manage a high-speed pick-and-place system, achieving ±0.1 mm placement accuracy and increasing throughput by 22%.
Food and beverage production: The controller’s hygienic design and compliance with EHEDG standards make it suitable for sterile environments. A dairy plant used the AC800PEC to automate pasteurization processes, ensuring real-time monitoring of temperature and pressure to meet FDA and ISO 22000 requirements.
Power generation: In combined cycle power plants, the AC800PEC optimizes boiler and turbine control, integrating with SCADA systems for load balancing. A 500 MW gas-fired plant achieved a 5% increase in fuel efficiency by using the controller’s advanced PID tuning features.
Related Model Recommendations
- ABB 3BHE039725R0C3D AC800PEC-H: Redundant controller variant with dual CPUs for fault-tolerant systems in oil & gas.
- ABB PPD523: High-speed I/O module for the AC800PEC, supporting 1 ms update rates for motion control.
- ABB PM866AK01: Processor module for ABB’s AC500 PLC, compatible with AC800PEC in hybrid automation setups.
- ABB CI524: PROFIBUS DP interface module for legacy system integration with the AC800PEC.
- ABB TB521: Terminal block module for secure wiring of I/O signals, reducing installation errors by 30%.
- ABB 800xA Extension Module: Expands the AC800PEC’s capabilities with advanced analytics and IoT connectivity.
- ABB S800 I/O Series: Modular I/O racks that interface with the AC800PEC for distributed control in large facilities.
Installation, Commissioning and Maintenance Instructions
Installation preparation: Mount the AC800PEC on a grounded DIN rail or 19-inch rack, ensuring 50 mm clearance for airflow. Use shielded Cat6 cables for Ethernet connections and twisted-pair wiring for PROFIBUS/CANopen. Configure the controller’s IP address and redundancy settings (if applicable) via Control Builder M, and verify compatibility with existing I/O modules and field devices. For SIL 2 applications, perform a safety integrity assessment and validate control logic against functional safety requirements.
Maintenance suggestions: Monitor the controller’s health via the built-in web interface, tracking metrics like CPU utilization and module temperatures. Update firmware quarterly using ABB’s secure download portal to patch cybersecurity vulnerabilities and access new features. In dusty environments, clean ventilation slots with compressed air every six months. Replace backup batteries every five years to preserve program memory, and conduct annual loop testing to ensure I/O accuracy and control responsiveness.
Service and Guarantee Commitment
ABB guarantees the 3BHE039724R0C3D PPD513 A0C-100440 AC800PEC to meet performance specifications for 36 months from delivery, with an optional 7-year extended warranty for critical systems. ABB’s global Ability™ Services team provides 24/7 remote diagnostics, cybersecurity updates, and on-site support by certified engineers. For large-scale projects, ABB offers Lifecycle Management Services, including system audits, spare parts management, and technology refresh planning to future-proof automation infrastructure.
In the rare event of hardware failure, ABB’s Express Replacement Program delivers a pre-configured controller within 4 hours for mission-critical applications, backed by ISO 17025-accredited repair centers. The AC800PEC undergoes rigorous testing for EMC compliance, thermal cycling, and safety certification, reflecting ABB’s commitment to delivering industrial controllers that drive operational excellence and resilience.
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