ABB PPE100A Modules | 3BHE037824R0101

Technical Dossier

Product Details And Specifications

ABB PPE100A Series: Comprehensive Module Range and Technical Overview

The ABB PPE100A series is a processor and control board platform deployed within ABB's AC800M and Symphony Plus DCS architecture. It is installed across high-criticality continuous-process industries including petrochemical refineries, nuclear power auxiliary systems, offshore oil and gas platforms, and large-scale chemical manufacturing facilities. The PPE100A designation identifies the primary processor execution board responsible for real-time control task scheduling, inter-module communication arbitration, and redundancy switchover logic within the controller chassis. Its global installed base spans facilities in Europe, the Middle East, and Asia-Pacific, where long equipment lifecycles of 15–25 years make spare part availability a persistent operational requirement.

The Evolution of PPE100A Architecture

The PPE100A board was introduced as part of ABB's transition from the earlier Advant OCS and MOD 300 control platforms toward the unified AC800M controller family in the early 2000s. Early revisions of the PPE100A operated under ABB's Control Builder M engineering environment and communicated via the ModuleBus backplane protocol at fixed cycle rates. Subsequent hardware revisions introduced expanded SDRAM capacity, improved watchdog timer resolution, and enhanced EMC shielding to meet IEC 61000-4 industrial immunity standards.

Compatibility constraints are a critical consideration for maintenance engineers. PPE100A boards are chassis-slot-specific and must match the firmware baseline of the PM856, PM860, or PM861 controller modules they support. Cross-revision substitution without firmware alignment will result in a non-recoverable boot fault. As the AC800M platform has matured into a stable/late-lifecycle phase, ABB has shifted primary development resources to the AC800PEC and System 800xA next-generation platforms. PPE100A boards are no longer manufactured in volume; procurement now relies on certified refurbished stock and authorized spare parts distributors.

PPE100A Full Catalog & Functionalities (SKU List)

The following SKUs represent verified components within or directly associated with the ABB PPE100A and AC800M ecosystem. Each entry reflects a distinct hardware function within the controller or I/O subsystem.

3BHE037824R0101 (PPE100A): Primary processor execution board for AC800M controller chassis.
3BHE024577R0101 (PPE100B): Successor processor board with extended memory addressing.
3BSE018877R1 (PM856AK01): AC800M controller module, single CPU, 32 MB RAM.
3BSE018878R1 (PM856AK02): AC800M controller module with redundancy support.
3BSE020520R1 (PM860AK01): High-performance AC800M CPU module, 64 MB RAM.
3BSE020521R1 (PM860AK02): Redundant-capable high-performance CPU module.
3BSE056631R65 (PM861AK01): AC800M controller, extended I/O scan rate, 128 MB RAM.
3BSE013208R1 (CI854AK01): PROFIBUS DP communication interface module.
3BSE022366R1 (CI855AK01): PROFIBUS DP/V1 master communication module.
3BSE025255R1 (CI856AK01): Foundation Fieldbus HSE linking device interface.
3BSE030220R1 (CI857K01): HART multiplexer communication interface module.
3BSE018105R1 (CI860K01): IEC 61850 Ethernet communication interface module.
3BSE013232R1 (SD821): 24 VDC power supply module for AC800M rack.
3BSE013233R1 (SD822): Redundant 24 VDC power supply module.
3BSE013234R1 (SD823): 48 VDC power supply module for extended rack configurations.
3BSE008516R1 (TB820V2): ModuleBus optical port expansion module.
3BSE002616R1 (AI810): 8-channel analog input module, 4–20 mA / 0–10 V.
3BSE008544R1 (AO810V2): 8-channel analog output module, 4–20 mA.
3BSE008510R1 (DI810): 24-channel 24 VDC digital input module.
3BSE014751R1 (DO810): 24-channel 24 VDC digital output module, 0.5 A per channel.

Sourcing Hard-to-Find & Obsolete PPE100A Parts

DriveKNMS maintains a dedicated inventory program for ABB AC800M and PPE100A series components that have been discontinued or placed on extended lead time by ABB's official supply chain. Our sourcing protocol covers three categories of stock: factory-surplus new-in-box units acquired through authorized liquidation channels, professionally refurbished boards that have undergone full functional restoration, and tested-pulls removed from decommissioned systems under documented chain-of-custody procedures.

For the PPE100A 3BHE037824R0101 specifically, DriveKNMS provides cross-reference verification against the installed firmware version and chassis revision before shipment. Customers operating under IEC 61511 functional safety requirements can request batch traceability documentation. Emergency same-day dispatch is available for critical process shutdown scenarios.

Quality Control for the PPE100A Range

PPE100A processor boards present specific test challenges due to their integrated ModuleBus backplane arbitration logic and dual-port RAM architecture used for inter-processor communication in redundant configurations. DriveKNMS applies the following test sequence to all PPE100A units prior to dispatch:

1. Visual inspection under 10× magnification for BGA solder joint integrity, capacitor ESR degradation, and conformal coating delamination.
2. Power-on self-test (POST) verification using an ABB-compatible AC800M test chassis with known-good PM856 or PM860 controller module.
3. ModuleBus communication loopback test at rated 5 Mbit/s transfer rate.
4. Redundancy switchover simulation: forced primary fault with measured switchover time logged against ABB specification (<100 ms).
5. 48-hour burn-in at 55°C ambient with continuous I/O polling to screen for latent thermal failures.
6. Final firmware version verification and label reconciliation against the board's hardware revision marking.