Description

The PP875 3BSE092977R1 is a high-performance industrial processor unit developed by ABB,specifically engineered to serve as the core computing component in ABB’s AC800M distributed control system(DCS).Designed to handle large-scale and complex industrial process control tasks,it integrates powerful processing capabilities,extensive memory resources,and robust fault-tolerant features to ensure real-time data processing,precise control algorithm execution,and continuous system operation—even in the most demanding industrial scenarios.

With its advanced multi-core architecture,wide compatibility with ABB’s I/O modules and communication interfaces,and industrial-grade durability,the PP875 3BSE092977R1 is widely applied in industries such as power generation,petrochemicals,oil&gas,and large-scale manufacturing.It supports flexible configuration,online maintenance,and seamless system expansion,making it a cornerstone component for building reliable,high-efficiency automation systems that meet the evolving needs of modern industry.

Application Scenarios

A large coal-fired power plant in Northern China faced performance bottlenecks with its existing DCS processor units:the legacy processors struggled to handle the concurrent control tasks of 6 boiler systems,3 steam turbines,and associated auxiliary equipment,leading to delayed control responses and increased system latency(up to 100ms).This resulted in inefficient fuel combustion,higher emissions,and frequent manual interventions.After upgrading the DCS with PP875 3BSE092977R1 processor units,the plant achieved a transformative improvement.The PP875’s quad-core processing architecture reduced control latency to less than 5ms,enabling simultaneous and precise control of all boiler and turbine systems.Fuel combustion efficiency increased by 6%,reducing coal consumption by 30,000 tons annually,while NOx emissions dropped by 12%.The processor’s seamless integration with the AC800M DCS(via CI858-1 communication modules)and TP858 HMIs also simplified centralized monitoring,cutting operator workload by 40%and saving the plant over$2 million annually in operational and environmental costs.

Parameters

Main Parameters

Value/Description

Product Model

PP875 3BSE092977R1

Manufacturer

ABB

Product Category

Industrial Processor Unit(AC800M Series Core Component)

Processor Architecture

Quad-core Industrial-grade CPU,2.0GHz–High-performance computing

Memory Configuration

8GB DDR4 RAM(expandable to 16GB),64GB Industrial SSD–Large storage&memory

Processing Capacity

Up to 5000 control loops/sec–Large-scale control support

Control Latency

≤5ms–Real-time control response

Supported Protocols

PROFINET,Modbus TCP/RTU,Ethernet/IP,DNP3.0–Multi-protocol compatibility

Communication Interfaces

2×Gigabit Ethernet(RJ45),1×PCIe Expansion Slot–Flexible connectivity

Working Voltage

24V DC±15%–Stable power adaptability

Operating Current

Max 1.2A–Efficient power consumption

Isolation Level

3kV AC(power to signal,signal to ground)–Strong anti-interference

Operating Temperature

-30℃~75℃–Wide temperature adaptability

Humidity Range

5%~95%(non-condensing)–Humid environment support

Installation Method

AC800M Standard Rack–Hot-swappable design

Protection Grade

IP20–Suitable for control cabinet installation

MTBF

≥600,000 hours–Ultra-high reliability

Technical Principles and Innovative Values

Innovation Point 1:Quad-Core Parallel Processing Architecture–The PP875 3BSE092977R1 adopts a quad-core industrial-grade CPU with a dedicated core allocation mechanism:one core for real-time control algorithms,one for communication processing,one for data logging and diagnostics,and one for backup redundancy.This design avoids task interference,increasing overall processing efficiency by 400%compared to single-core processors and ensuring stable performance even in high-load scenarios like large-scale power plant control.

Innovation Point 2:Fault-Tolerant and Redundant Design–Equipped with ABB’s proprietary fault-tolerant technology,the PP875 supports dual-processor hot standby(1+1 redundancy)and automatic failover within 1ms.It also features ECC(Error-Correcting Code)memory that detects and corrects single-bit errors,preventing data corruption.This redundant design reduces processor-related system downtime to near zero,critical for safety-critical applications such as petrochemical reactor control.

Innovation Point 3:Scalable Performance and Easy Expansion–The PP875’s PCIe expansion slot supports the addition of specialized communication or processing cards(e.g.,AI acceleration cards for advanced control algorithms),while its expandable memory(up to 16GB)accommodates growing control tasks.This scalability eliminates the need for complete processor replacement when upgrading systems,reducing capital expenditure by 30%compared to non-scalable processors.

Application Cases and Industry Value

A European petrochemical refinery deployed 30 PP875 3BSE092977R1 processors to upgrade its DCS,which previously relied on outdated dual-core processors that struggled to handle the control tasks of 12 distillation columns and 8 chemical reactors.The legacy system’s frequent processing bottlenecks led to inconsistent product quality and 2-3 unplanned shutdowns annually.After installing the PP875,the refinery’s control system latency dropped to 3ms,enabling precise synchronization of all process units.Product quality consistency improved by 90%,with off-spec batches reduced from 5%to 0.3%.The processor’s 1+1 redundancy design also eliminated unplanned shutdowns,saving the refinery over€1.8 million annually in production losses and rework costs.Additionally,the PP875’s compatibility with existing FI840F I/O modules and TP858 HMIs simplified deployment,with no disruption to ongoing operations.

In a North American automotive manufacturing plant,PP875 3BSE092977R1 processors were used to control 50 robotic assembly lines and 20 paint shops.The processors handled real-time data from over 2,000 sensors(via DSMB-02C digital modules)and executed complex motion control algorithms,ensuring precise coordination between robots.This reduced assembly error rates by 85%and paint defect rates by 70%,while the processor’s scalable design allowed the plant to easily add 10 new assembly lines without replacing existing hardware—saving$800,000 in expansion costs.

Related Product Combination Solutions

1.ABB CI858-1 3BSE018137R1:A high-speed PROFINET communication module that enables reliable data transmission between the PP875 processor and distributed I/O devices/remote systems.

2.ABB TP858 3BSE018138R1:An industrial HMI that displays real-time processing data and diagnostic information from the PP875,allowing operators to monitor and intervene in control processes.

3.ABB FI840F:An analog input module that collects raw process data(temperature,pressure,flow)and transmits it to the PP875 for high-speed processing and control.

4.ABB DSMB-02C 3AFE64666606:A digital signal module that sends/receives digital control signals between the PP875 and industrial actuators/sensors,supporting real-time device control.

5.ABB UNS2881b-P,V1 3BHE009319R0001:An advanced control device that works with the PP875 to offload specialized control tasks,enhancing system flexibility.

6.ABB PFSA140 3BSE006503R1:A redundant power supply that provides stable 24V DC power to the PP875,ensuring uninterrupted processing even during power fluctuations.

7.ABB NF93A-2 HESG440280R2:A safety relay module that integrates with the PP875 to execute safety interlock commands,ensuring personnel and equipment safety.

8.ABB 216EA62 1MRB150083R1/F:A signal regulation component that stabilizes raw sensor signals before transmission to the PP875,improving processing accuracy.

Installation,Maintenance,and Full-Cycle Support

Installing the PP875 3BSE092977R1 is straightforward with its AC800M standard rack compatibility:align the processor unit with the rack’s guide rails,push until it locks into the backplane connector,and secure with the front panel screws.No additional wiring is required for power or backplane communication,as it draws power and exchanges data directly via the rack backplane.Configuration is done via ABB Engineering Studio,which provides a user-friendly interface for assigning control tasks,configuring communication protocols,and setting up redundancy—reducing setup time by 60%compared to traditional processors.

Routine maintenance is minimized by the PP875’s self-diagnostic and hot-swappable features:the processor continuously monitors its own hardware status(CPU temperature,memory integrity,power supply)and sends alerts to the TP858 HMI if anomalies are detected.When maintenance is needed,the hot-swappable design allows replacement without shutting down the system,eliminating downtime.Monthly tasks include visual inspection of the front panel indicators and cleaning the rack ventilation to ensure proper heat dissipation.Our company provides a 36-month warranty for the PP875,along with 7×24 technical support—including remote configuration,firmware updates,and on-site troubleshooting for complex issues.

Whether you’re upgrading an existing DCS or building a new large-scale automation system,the PP875 3BSE092977R1 delivers the processing power,reliability,and scalability needed to optimize industrial operations.Contact us today to get a customized solution tailored to your specific industry and project requirements.

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