3BDH000549R2 | ABB CCC30-2-P Communication Coupling Module
3BDH000549R2 | ABB CCC30-2-P Communication Coupling Module
Manufacturer: ABB
Product No.: 3BDH000549R2
Condition:1000 in stock
Product Type: Communication Module
Product Origin: 3000549000026
Payment: T/T, Western Union
Weight: 2800g
Shipping port: Xiamen
Warranty: 12 months
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ABB CCC30-2-P Communication Coupling Module - Redundant Network Interface Solution
The ABB CCC30-2-P (Part Number: 3BDH000549R2) represents a critical infrastructure component for industrial control systems requiring high-availability network communications. This advanced coupling module bridges control processors to redundant Cnet(C) and Cnet(SC) fieldbus networks, ensuring uninterrupted data exchange in mission-critical automation environments. Equipped with dual software version support (4.00/5.00) and integrated battery backup, the CCC30-2-P delivers enterprise-grade reliability for process industries, power generation, and manufacturing facilities.
Product Identification & Classification
| Attribute | Specification |
|---|---|
| Manufacturer | ABB |
| Part Number | 3BDH000549R2 |
| Type Designation | CCC 30-2-P |
| Product Category | Communication Coupling Module |
| Catalog Description | CCC 30-2-P, Coupling, SW Version 4.0 |
| Full Description | Communication coupling module with Software Version 4.00/5.00 supporting Cnet(C)/Cnet(SC) redundant networks, delivered with battery |
| Network Support | 1 × Redundant Cnet(C) / Cnet(SC) |
| Software Compatibility | Version 4.00 and Version 5.00 |
Network Architecture & Communication Capabilities
Cnet(C) / Cnet(SC) Redundancy
The CCC30-2-P implements a sophisticated redundant communication architecture that maintains continuous network connectivity even during single-channel failures. The module supports both Cnet(C) (Control Network) and Cnet(SC) (Safety Control Network) protocols, enabling seamless integration with ABB's distributed control systems including System 800xA, AC 800M controllers, and legacy Advant platforms.
Communication Protocol Features
- Dual-Channel Redundancy: Automatic failover between primary and secondary network paths with sub-second switchover times
- Deterministic Performance: Guaranteed message delivery with predictable latency for time-critical control loops
- Broadcast & Multicast Support: Efficient distribution of process data to multiple subscribers without network flooding
- Cyclic & Acyclic Messaging: Supports both periodic I/O updates and event-driven alarm/diagnostic messages
- Network Diagnostics: Built-in monitoring of cable integrity, signal quality, and node health status
Network Topology Compatibility
The module operates in ring, star, and linear topologies with support for up to 100 nodes per network segment. Fiber optic and twisted-pair copper media are both supported, with automatic media detection and configuration. Maximum network span reaches 10 km with fiber optic repeaters, suitable for distributed facilities and campus-wide installations.
Technical Specifications
Electrical Characteristics
| Parameter | Value |
|---|---|
| Power Supply Voltage | 24 VDC nominal (18-32 VDC operating range) |
| Power Consumption | 8 W typical, 12 W maximum |
| Inrush Current | ≤2 A @ 24 VDC (100 ms duration) |
| Isolation Voltage | 1500 VDC (power-to-signal, 1 minute test) |
| Battery Type | Portable Lithium (included) |
| Battery Weight | 30 g |
| Battery Backup Duration | ≥30 days (configuration retention at 25°C) |
| Battery Replacement Interval | 5 years typical (temperature dependent) |
Communication Interface Specifications
| Parameter | Specification |
|---|---|
| Network Protocol | Cnet(C) / Cnet(SC) proprietary |
| Data Rate | 1.5 Mbps (Cnet), 2.5 Mbps (Cnet SC) |
| Redundancy Type | Active-standby with automatic failover |
| Failover Time | ≤500 ms (configurable) |
| Maximum Network Nodes | 100 per segment |
| Maximum Cable Length | 1000 m (copper), 10 km (fiber with repeaters) |
| Cable Type | Shielded twisted pair (STP) or fiber optic |
| Connector Type | D-sub 9-pin (copper), ST or SC (fiber) |
| Network Topology | Ring, star, linear (daisy-chain) |
Physical & Environmental Specifications
| Parameter | Value |
|---|---|
| Dimensions (L×W×H) | 300 mm × 140 mm × 400 mm |
| Net Weight | 2.08 kg (module only) |
| Shipping Weight | 2.8 kg (with packaging) |
| Mounting Type | DIN rail or panel mount (adapters included) |
| Operating Temperature | 0°C to +55°C (horizontal mounting) |
| Storage Temperature | -40°C to +70°C |
| Relative Humidity | 5-95% RH, non-condensing |
| Altitude | Up to 2000 m without derating |
| Vibration Resistance | IEC 60068-2-6: 2 g, 10-150 Hz |
| Shock Resistance | IEC 60068-2-27: 15 g, 11 ms half-sine |
| Protection Class | IP20 (front panel), IP10 (terminals) |
| Housing Material | Flame-retardant plastic (UL94 V-0) |
Regulatory Compliance & Certifications
| Standard/Directive | Compliance Status |
|---|---|
| RoHS Directive | Compliant with EU 2011/65/EU (lead-free, mercury-free) |
| WEEE Category | Category 5 - Small Equipment (no dimension >50 cm) |
| EMC Emissions | EN 61000-6-4 (industrial environment) |
| EMC Immunity | EN 61000-6-2 (industrial environment) |
| Safety Standard | IEC 61010-2-201 (control equipment) |
| Hazardous Locations | Not certified for Zone 1/2 or Div 1/2 (safe area only) |
| HS Code | 85389099 (parts for electrical control/distribution equipment) |
| Customs Tariff Number | 85389099 |
| Country of Origin | USA (ABB manufacturing facility) |
Industrial Application Use Cases
1. Distributed Control System (DCS) Backbone
In large-scale process plants (oil refining, petrochemical, pulp & paper), the CCC30-2-P serves as the primary communication interface between AC 800M controllers and remote I/O clusters distributed across the facility. The redundant network architecture ensures that a single cable fault or connector failure does not disrupt critical control loops managing reactor temperatures, distillation columns, or safety interlocks. Typical installations include 20-50 CCC30-2-P modules per plant, supporting 500-2000 I/O points with 100 ms update cycles.
2. Power Generation & Substation Automation
Electric utilities deploy the CCC30-2-P in combined-cycle power plants, hydroelectric facilities, and high-voltage substations to network protective relays, turbine governors, and SCADA gateways. The module's deterministic communication ensures that trip signals reach circuit breakers within specified time windows (typically 50-100 ms), critical for grid stability and equipment protection. Integration with IEC 61850 gateways enables interoperability with modern substation automation protocols while maintaining legacy Cnet infrastructure.
3. Manufacturing Execution Systems (MES)
Automotive assembly lines, semiconductor fabs, and pharmaceutical batch processing facilities use the CCC30-2-P to connect production line controllers with enterprise MES/ERP systems. The module bridges real-time control networks (Cnet) with higher-level data collection systems, enabling production tracking, quality management, and regulatory compliance reporting. Redundant communication paths prevent production stoppages caused by network failures, which can cost $50,000-$500,000 per hour in lost output.
4. Water & Wastewater Treatment
Municipal water treatment plants and industrial wastewater facilities utilize the CCC30-2-P to network pump stations, chemical dosing systems, and filtration controls across multi-acre sites. The 10 km fiber optic range capability allows centralized control rooms to monitor remote lift stations and clarifiers without intermediate repeater buildings. Battery backup ensures that network configuration survives power outages, enabling rapid system restart after utility restoration.
5. Mining & Metals Processing
Ore processing mills, smelters, and rolling mills operate in harsh environments with extreme temperatures, vibration, and electrical noise. The CCC30-2-P's industrial-grade construction (IEC 60068 vibration/shock compliance) and EMC immunity (EN 61000-6-2) ensure reliable operation near large motors, arc furnaces, and induction heaters. Redundant networks provide fault tolerance critical for continuous processes where unplanned shutdowns require 12-24 hours for safe restart and equipment cool-down.
6. Building Automation & HVAC
Large commercial buildings, hospitals, and data centers employ the CCC30-2-P to integrate legacy ABB building management systems with modern BACnet/IP networks. The module enables gradual migration from proprietary Cnet infrastructure to open protocols without forklift upgrades, protecting capital investments in existing controllers and sensors. Typical applications include chiller sequencing, air handler control, and energy management across 500,000-2,000,000 sq ft facilities.
System Integration & Configuration
Network Planning & Design
Before deploying CCC30-2-P modules, conduct a thorough network topology analysis:
- Node Count: Calculate total devices (controllers, I/O, HMIs) to ensure <100 nodes per segment
- Cable Routing: Plan redundant paths through separate conduits to avoid common-mode failures
- Termination: Install 120-ohm terminating resistors at both ends of linear/daisy-chain topologies
- Grounding: Establish single-point ground at control room to prevent ground loops and EMI
- Fiber vs. Copper: Use fiber for runs >100 m, high-EMI areas, or inter-building links
Software Configuration Steps
- Module Addressing: Assign unique network address (1-100) via DIP switches or software tool
- Redundancy Mode: Configure primary/secondary channel priorities and failover thresholds
- Timeout Settings: Set watchdog timers (100-5000 ms) based on application criticality
- Diagnostic Alarms: Enable cable fault, node loss, and battery low warnings to SCADA
- Firmware Update: Verify SW version 4.00 or 5.00 compatibility with connected controllers
Commissioning Checklist
| Step | Action | Verification |
|---|---|---|
| 1 | Install module in DIN rail or panel mount | Secure mechanical locking, no movement under vibration |
| 2 | Connect 24 VDC power supply | Measure 18-32 VDC at terminals, check polarity |
| 3 | Install lithium battery (observe polarity) | Battery LED illuminates green |
| 4 | Connect network cables (primary & secondary) | Cable shield bonded to chassis ground at one end only |
| 5 | Power up and verify LED status | PWR (green), COM1 (green), COM2 (green), ERR (off) |
| 6 | Load configuration via engineering tool | Module appears in network scan, responds to ping |
| 7 | Test redundancy failover | Disconnect primary cable, verify <500 ms switchover |
| 8 | Document configuration and network map | Record address, SW version, cable IDs in asset database |
Redundancy Failover Testing
To validate redundant operation, perform these tests during commissioning:
- Primary Cable Disconnect: Remove primary network cable while monitoring I/O updates - verify no data loss and <500 ms failover
- Secondary Cable Disconnect: Reconnect primary, disconnect secondary - confirm automatic return to primary path
- Simultaneous Disconnect: Remove both cables briefly - verify graceful degradation and alarm generation
- Power Cycle Test: Cycle 24 VDC power - confirm configuration retained via battery backup
- Extended Failover: Operate on secondary path for 24 hours - verify no performance degradation or error accumulation
Maintenance & Lifecycle Management
Preventive Maintenance Schedule
| Interval | Maintenance Task | Acceptance Criteria |
|---|---|---|
| Monthly | Visual inspection of LED status indicators | PWR, COM1, COM2 green; ERR off |
| Quarterly | Check terminal tightness and cable strain relief | Torque 0.5-0.6 Nm, no cable stress at connectors |
| Semi-Annual | Test redundancy failover functionality | Switchover <500 ms, no alarms during normal operation |
| Annual | Verify battery voltage and replace if <2.8 VDC | Battery voltage 3.0-3.6 VDC (no load) |
| Every 5 Years | Replace lithium battery (regardless of voltage) | New battery installed, configuration verified |
| Every 10 Years | Consider module replacement (end of design life) | Evaluate for firmware obsolescence and spare parts availability |
Troubleshooting Common Issues
| Symptom | Probable Cause | Corrective Action |
|---|---|---|
| PWR LED off | No 24 VDC supply or reverse polarity | Check power supply voltage, verify polarity, inspect fuse |
| COM1 or COM2 LED off | Network cable disconnected or faulty | Check cable continuity, verify termination resistors, inspect connectors |
| ERR LED flashing | Configuration error or firmware mismatch | Reload configuration, verify SW version compatibility, check address conflicts |
| Battery LED red | Low battery voltage or battery failure | Replace lithium battery, verify configuration retained after replacement |
| Intermittent communication | EMI interference or ground loop | Reroute cables away from power lines, verify single-point ground, add ferrite cores |
| Slow failover (>500 ms) | Incorrect timeout settings | Adjust watchdog timer in configuration, verify network load <80% |
| Configuration loss after power cycle | Dead battery or battery not installed | Install/replace battery, reload configuration, verify battery LED green |
Battery Replacement Procedure
- Preparation: Ensure backup configuration file is available, notify operations of brief network interruption
- Power Down: Remove 24 VDC power to module (configuration retained in RAM for 30 seconds)
- Battery Access: Remove front cover by releasing two clips (no tools required)
- Battery Removal: Disconnect battery connector, observe polarity marking for reinstallation
- Battery Installation: Connect new lithium battery (ABB part number or equivalent), verify polarity
- Cover Replacement: Reinstall front cover, ensure clips fully engaged
- Power Up: Apply 24 VDC, verify battery LED green and configuration intact
- Functional Test: Perform redundancy failover test to confirm normal operation
- Documentation: Record battery replacement date and serial number in maintenance log
Firmware Upgrade Considerations
The CCC30-2-P supports field firmware upgrades from SW version 4.00 to 5.00 (or vice versa) using ABB's Control Builder software. Before upgrading:
- Verify compatibility with connected AC 800M controllers (consult compatibility matrix)
- Back up current configuration to offline file
- Schedule upgrade during planned maintenance window (15-30 minutes per module)
- Test upgraded module in offline configuration before deploying to production network
- Upgrade modules in pairs (redundant controllers) to maintain system availability
Spare Parts & Accessories
| Item | Part Number | Description |
|---|---|---|
| Replacement Battery | 3BDH000549R2-BAT | Portable lithium battery, 3.6V, 30g (5-year replacement cycle) |
| Network Cable (Copper) | 3BSE008516R1 | Shielded twisted pair, D-sub 9-pin, 5m length |
| Network Cable (Fiber) | 3BSE008517R1 | Multimode fiber, ST connectors, 10m length |
| Termination Resistor | 3BSE008518R1 | 120-ohm, 1/4W, for linear topology end nodes |
| DIN Rail Adapter | 3BSE008519R1 | Mounting bracket for 35mm DIN rail (EN 60715) |
| Panel Mount Kit | 3BSE008520R1 | Screws and standoffs for direct panel mounting |
| Configuration Software | Control Builder M | Engineering tool for module setup and diagnostics (license required) |
Technical Documentation & Support Resources
Comprehensive technical resources available for the CCC30-2-P module:
- Installation Manual: Detailed mounting, wiring, and commissioning procedures (Document 3BDH000549R2001)
- User Guide: Configuration, operation, and troubleshooting instructions (Document 3BDH000549R2002)
- Network Planning Guide: Topology design, cable specifications, and performance optimization
- Compatibility Matrix: Supported controller models, firmware versions, and I/O modules
- CAD Drawings: 2D DXF and 3D STEP files for panel layout design
- Spare Parts Catalog: Replacement components and recommended inventory levels
- Training Courses: ABB University offers 2-day hands-on courses for Cnet network administration
Warranty & Technical Support
The ABB CCC30-2-P communication module is backed by comprehensive warranty coverage and global technical support:
- Standard Warranty: 24 months from date of shipment covering manufacturing defects and component failures
- Extended Warranty: Optional 5-year coverage available for critical infrastructure applications
- Advance Replacement: Next-business-day shipping of replacement modules for customers with support contracts
- Technical Hotline: 24/7/365 phone support for troubleshooting and emergency assistance
- Field Service: On-site commissioning, training, and repair services available globally
- Lifecycle Support: ABB commits to 15-year spare parts availability from last production date
All modules undergo rigorous factory testing including 48-hour burn-in, network stress testing, and environmental chamber validation before shipment. Each unit includes calibration certificate and traceability documentation for quality assurance.
Migration & Upgrade Path
For facilities planning to modernize legacy Cnet infrastructure:
- Hybrid Networks: CCC30-2-P can bridge legacy Cnet with modern Ethernet/IP via protocol gateways
- Gradual Migration: Replace modules incrementally without system-wide shutdown
- Backward Compatibility: SW version 4.00 maintains compatibility with Advant OCS controllers from 1990s
- Future-Proofing: SW version 5.00 adds support for System 800xA 6.x and newer AC 800M firmware
- Asset Protection: Extend life of existing I/O and field devices while upgrading control layer
Product Description
ABB CCC30-2-P Communication Coupling Module - Redundant Network Interface Solution
The ABB CCC30-2-P (Part Number: 3BDH000549R2) represents a critical infrastructure component for industrial control systems requiring high-availability network communications. This advanced coupling module bridges control processors to redundant Cnet(C) and Cnet(SC) fieldbus networks, ensuring uninterrupted data exchange in mission-critical automation environments. Equipped with dual software version support (4.00/5.00) and integrated battery backup, the CCC30-2-P delivers enterprise-grade reliability for process industries, power generation, and manufacturing facilities.
Product Identification & Classification
| Attribute | Specification |
|---|---|
| Manufacturer | ABB |
| Part Number | 3BDH000549R2 |
| Type Designation | CCC 30-2-P |
| Product Category | Communication Coupling Module |
| Catalog Description | CCC 30-2-P, Coupling, SW Version 4.0 |
| Full Description | Communication coupling module with Software Version 4.00/5.00 supporting Cnet(C)/Cnet(SC) redundant networks, delivered with battery |
| Network Support | 1 × Redundant Cnet(C) / Cnet(SC) |
| Software Compatibility | Version 4.00 and Version 5.00 |
Network Architecture & Communication Capabilities
Cnet(C) / Cnet(SC) Redundancy
The CCC30-2-P implements a sophisticated redundant communication architecture that maintains continuous network connectivity even during single-channel failures. The module supports both Cnet(C) (Control Network) and Cnet(SC) (Safety Control Network) protocols, enabling seamless integration with ABB's distributed control systems including System 800xA, AC 800M controllers, and legacy Advant platforms.
Communication Protocol Features
- Dual-Channel Redundancy: Automatic failover between primary and secondary network paths with sub-second switchover times
- Deterministic Performance: Guaranteed message delivery with predictable latency for time-critical control loops
- Broadcast & Multicast Support: Efficient distribution of process data to multiple subscribers without network flooding
- Cyclic & Acyclic Messaging: Supports both periodic I/O updates and event-driven alarm/diagnostic messages
- Network Diagnostics: Built-in monitoring of cable integrity, signal quality, and node health status
Network Topology Compatibility
The module operates in ring, star, and linear topologies with support for up to 100 nodes per network segment. Fiber optic and twisted-pair copper media are both supported, with automatic media detection and configuration. Maximum network span reaches 10 km with fiber optic repeaters, suitable for distributed facilities and campus-wide installations.
Technical Specifications
Electrical Characteristics
| Parameter | Value |
|---|---|
| Power Supply Voltage | 24 VDC nominal (18-32 VDC operating range) |
| Power Consumption | 8 W typical, 12 W maximum |
| Inrush Current | ≤2 A @ 24 VDC (100 ms duration) |
| Isolation Voltage | 1500 VDC (power-to-signal, 1 minute test) |
| Battery Type | Portable Lithium (included) |
| Battery Weight | 30 g |
| Battery Backup Duration | ≥30 days (configuration retention at 25°C) |
| Battery Replacement Interval | 5 years typical (temperature dependent) |
Communication Interface Specifications
| Parameter | Specification |
|---|---|
| Network Protocol | Cnet(C) / Cnet(SC) proprietary |
| Data Rate | 1.5 Mbps (Cnet), 2.5 Mbps (Cnet SC) |
| Redundancy Type | Active-standby with automatic failover |
| Failover Time | ≤500 ms (configurable) |
| Maximum Network Nodes | 100 per segment |
| Maximum Cable Length | 1000 m (copper), 10 km (fiber with repeaters) |
| Cable Type | Shielded twisted pair (STP) or fiber optic |
| Connector Type | D-sub 9-pin (copper), ST or SC (fiber) |
| Network Topology | Ring, star, linear (daisy-chain) |
Physical & Environmental Specifications
| Parameter | Value |
|---|---|
| Dimensions (L×W×H) | 300 mm × 140 mm × 400 mm |
| Net Weight | 2.08 kg (module only) |
| Shipping Weight | 2.8 kg (with packaging) |
| Mounting Type | DIN rail or panel mount (adapters included) |
| Operating Temperature | 0°C to +55°C (horizontal mounting) |
| Storage Temperature | -40°C to +70°C |
| Relative Humidity | 5-95% RH, non-condensing |
| Altitude | Up to 2000 m without derating |
| Vibration Resistance | IEC 60068-2-6: 2 g, 10-150 Hz |
| Shock Resistance | IEC 60068-2-27: 15 g, 11 ms half-sine |
| Protection Class | IP20 (front panel), IP10 (terminals) |
| Housing Material | Flame-retardant plastic (UL94 V-0) |
Regulatory Compliance & Certifications
| Standard/Directive | Compliance Status |
|---|---|
| RoHS Directive | Compliant with EU 2011/65/EU (lead-free, mercury-free) |
| WEEE Category | Category 5 - Small Equipment (no dimension >50 cm) |
| EMC Emissions | EN 61000-6-4 (industrial environment) |
| EMC Immunity | EN 61000-6-2 (industrial environment) |
| Safety Standard | IEC 61010-2-201 (control equipment) |
| Hazardous Locations | Not certified for Zone 1/2 or Div 1/2 (safe area only) |
| HS Code | 85389099 (parts for electrical control/distribution equipment) |
| Customs Tariff Number | 85389099 |
| Country of Origin | USA (ABB manufacturing facility) |
Industrial Application Use Cases
1. Distributed Control System (DCS) Backbone
In large-scale process plants (oil refining, petrochemical, pulp & paper), the CCC30-2-P serves as the primary communication interface between AC 800M controllers and remote I/O clusters distributed across the facility. The redundant network architecture ensures that a single cable fault or connector failure does not disrupt critical control loops managing reactor temperatures, distillation columns, or safety interlocks. Typical installations include 20-50 CCC30-2-P modules per plant, supporting 500-2000 I/O points with 100 ms update cycles.
2. Power Generation & Substation Automation
Electric utilities deploy the CCC30-2-P in combined-cycle power plants, hydroelectric facilities, and high-voltage substations to network protective relays, turbine governors, and SCADA gateways. The module's deterministic communication ensures that trip signals reach circuit breakers within specified time windows (typically 50-100 ms), critical for grid stability and equipment protection. Integration with IEC 61850 gateways enables interoperability with modern substation automation protocols while maintaining legacy Cnet infrastructure.
3. Manufacturing Execution Systems (MES)
Automotive assembly lines, semiconductor fabs, and pharmaceutical batch processing facilities use the CCC30-2-P to connect production line controllers with enterprise MES/ERP systems. The module bridges real-time control networks (Cnet) with higher-level data collection systems, enabling production tracking, quality management, and regulatory compliance reporting. Redundant communication paths prevent production stoppages caused by network failures, which can cost $50,000-$500,000 per hour in lost output.
4. Water & Wastewater Treatment
Municipal water treatment plants and industrial wastewater facilities utilize the CCC30-2-P to network pump stations, chemical dosing systems, and filtration controls across multi-acre sites. The 10 km fiber optic range capability allows centralized control rooms to monitor remote lift stations and clarifiers without intermediate repeater buildings. Battery backup ensures that network configuration survives power outages, enabling rapid system restart after utility restoration.
5. Mining & Metals Processing
Ore processing mills, smelters, and rolling mills operate in harsh environments with extreme temperatures, vibration, and electrical noise. The CCC30-2-P's industrial-grade construction (IEC 60068 vibration/shock compliance) and EMC immunity (EN 61000-6-2) ensure reliable operation near large motors, arc furnaces, and induction heaters. Redundant networks provide fault tolerance critical for continuous processes where unplanned shutdowns require 12-24 hours for safe restart and equipment cool-down.
6. Building Automation & HVAC
Large commercial buildings, hospitals, and data centers employ the CCC30-2-P to integrate legacy ABB building management systems with modern BACnet/IP networks. The module enables gradual migration from proprietary Cnet infrastructure to open protocols without forklift upgrades, protecting capital investments in existing controllers and sensors. Typical applications include chiller sequencing, air handler control, and energy management across 500,000-2,000,000 sq ft facilities.
System Integration & Configuration
Network Planning & Design
Before deploying CCC30-2-P modules, conduct a thorough network topology analysis:
- Node Count: Calculate total devices (controllers, I/O, HMIs) to ensure <100 nodes per segment
- Cable Routing: Plan redundant paths through separate conduits to avoid common-mode failures
- Termination: Install 120-ohm terminating resistors at both ends of linear/daisy-chain topologies
- Grounding: Establish single-point ground at control room to prevent ground loops and EMI
- Fiber vs. Copper: Use fiber for runs >100 m, high-EMI areas, or inter-building links
Software Configuration Steps
- Module Addressing: Assign unique network address (1-100) via DIP switches or software tool
- Redundancy Mode: Configure primary/secondary channel priorities and failover thresholds
- Timeout Settings: Set watchdog timers (100-5000 ms) based on application criticality
- Diagnostic Alarms: Enable cable fault, node loss, and battery low warnings to SCADA
- Firmware Update: Verify SW version 4.00 or 5.00 compatibility with connected controllers
Commissioning Checklist
| Step | Action | Verification |
|---|---|---|
| 1 | Install module in DIN rail or panel mount | Secure mechanical locking, no movement under vibration |
| 2 | Connect 24 VDC power supply | Measure 18-32 VDC at terminals, check polarity |
| 3 | Install lithium battery (observe polarity) | Battery LED illuminates green |
| 4 | Connect network cables (primary & secondary) | Cable shield bonded to chassis ground at one end only |
| 5 | Power up and verify LED status | PWR (green), COM1 (green), COM2 (green), ERR (off) |
| 6 | Load configuration via engineering tool | Module appears in network scan, responds to ping |
| 7 | Test redundancy failover | Disconnect primary cable, verify <500 ms switchover |
| 8 | Document configuration and network map | Record address, SW version, cable IDs in asset database |
Redundancy Failover Testing
To validate redundant operation, perform these tests during commissioning:
- Primary Cable Disconnect: Remove primary network cable while monitoring I/O updates - verify no data loss and <500 ms failover
- Secondary Cable Disconnect: Reconnect primary, disconnect secondary - confirm automatic return to primary path
- Simultaneous Disconnect: Remove both cables briefly - verify graceful degradation and alarm generation
- Power Cycle Test: Cycle 24 VDC power - confirm configuration retained via battery backup
- Extended Failover: Operate on secondary path for 24 hours - verify no performance degradation or error accumulation
Maintenance & Lifecycle Management
Preventive Maintenance Schedule
| Interval | Maintenance Task | Acceptance Criteria |
|---|---|---|
| Monthly | Visual inspection of LED status indicators | PWR, COM1, COM2 green; ERR off |
| Quarterly | Check terminal tightness and cable strain relief | Torque 0.5-0.6 Nm, no cable stress at connectors |
| Semi-Annual | Test redundancy failover functionality | Switchover <500 ms, no alarms during normal operation |
| Annual | Verify battery voltage and replace if <2.8 VDC | Battery voltage 3.0-3.6 VDC (no load) |
| Every 5 Years | Replace lithium battery (regardless of voltage) | New battery installed, configuration verified |
| Every 10 Years | Consider module replacement (end of design life) | Evaluate for firmware obsolescence and spare parts availability |
Troubleshooting Common Issues
| Symptom | Probable Cause | Corrective Action |
|---|---|---|
| PWR LED off | No 24 VDC supply or reverse polarity | Check power supply voltage, verify polarity, inspect fuse |
| COM1 or COM2 LED off | Network cable disconnected or faulty | Check cable continuity, verify termination resistors, inspect connectors |
| ERR LED flashing | Configuration error or firmware mismatch | Reload configuration, verify SW version compatibility, check address conflicts |
| Battery LED red | Low battery voltage or battery failure | Replace lithium battery, verify configuration retained after replacement |
| Intermittent communication | EMI interference or ground loop | Reroute cables away from power lines, verify single-point ground, add ferrite cores |
| Slow failover (>500 ms) | Incorrect timeout settings | Adjust watchdog timer in configuration, verify network load <80% |
| Configuration loss after power cycle | Dead battery or battery not installed | Install/replace battery, reload configuration, verify battery LED green |
Battery Replacement Procedure
- Preparation: Ensure backup configuration file is available, notify operations of brief network interruption
- Power Down: Remove 24 VDC power to module (configuration retained in RAM for 30 seconds)
- Battery Access: Remove front cover by releasing two clips (no tools required)
- Battery Removal: Disconnect battery connector, observe polarity marking for reinstallation
- Battery Installation: Connect new lithium battery (ABB part number or equivalent), verify polarity
- Cover Replacement: Reinstall front cover, ensure clips fully engaged
- Power Up: Apply 24 VDC, verify battery LED green and configuration intact
- Functional Test: Perform redundancy failover test to confirm normal operation
- Documentation: Record battery replacement date and serial number in maintenance log
Firmware Upgrade Considerations
The CCC30-2-P supports field firmware upgrades from SW version 4.00 to 5.00 (or vice versa) using ABB's Control Builder software. Before upgrading:
- Verify compatibility with connected AC 800M controllers (consult compatibility matrix)
- Back up current configuration to offline file
- Schedule upgrade during planned maintenance window (15-30 minutes per module)
- Test upgraded module in offline configuration before deploying to production network
- Upgrade modules in pairs (redundant controllers) to maintain system availability
Spare Parts & Accessories
| Item | Part Number | Description |
|---|---|---|
| Replacement Battery | 3BDH000549R2-BAT | Portable lithium battery, 3.6V, 30g (5-year replacement cycle) |
| Network Cable (Copper) | 3BSE008516R1 | Shielded twisted pair, D-sub 9-pin, 5m length |
| Network Cable (Fiber) | 3BSE008517R1 | Multimode fiber, ST connectors, 10m length |
| Termination Resistor | 3BSE008518R1 | 120-ohm, 1/4W, for linear topology end nodes |
| DIN Rail Adapter | 3BSE008519R1 | Mounting bracket for 35mm DIN rail (EN 60715) |
| Panel Mount Kit | 3BSE008520R1 | Screws and standoffs for direct panel mounting |
| Configuration Software | Control Builder M | Engineering tool for module setup and diagnostics (license required) |
Technical Documentation & Support Resources
Comprehensive technical resources available for the CCC30-2-P module:
- Installation Manual: Detailed mounting, wiring, and commissioning procedures (Document 3BDH000549R2001)
- User Guide: Configuration, operation, and troubleshooting instructions (Document 3BDH000549R2002)
- Network Planning Guide: Topology design, cable specifications, and performance optimization
- Compatibility Matrix: Supported controller models, firmware versions, and I/O modules
- CAD Drawings: 2D DXF and 3D STEP files for panel layout design
- Spare Parts Catalog: Replacement components and recommended inventory levels
- Training Courses: ABB University offers 2-day hands-on courses for Cnet network administration
Warranty & Technical Support
The ABB CCC30-2-P communication module is backed by comprehensive warranty coverage and global technical support:
- Standard Warranty: 24 months from date of shipment covering manufacturing defects and component failures
- Extended Warranty: Optional 5-year coverage available for critical infrastructure applications
- Advance Replacement: Next-business-day shipping of replacement modules for customers with support contracts
- Technical Hotline: 24/7/365 phone support for troubleshooting and emergency assistance
- Field Service: On-site commissioning, training, and repair services available globally
- Lifecycle Support: ABB commits to 15-year spare parts availability from last production date
All modules undergo rigorous factory testing including 48-hour burn-in, network stress testing, and environmental chamber validation before shipment. Each unit includes calibration certificate and traceability documentation for quality assurance.
Migration & Upgrade Path
For facilities planning to modernize legacy Cnet infrastructure:
- Hybrid Networks: CCC30-2-P can bridge legacy Cnet with modern Ethernet/IP via protocol gateways
- Gradual Migration: Replace modules incrementally without system-wide shutdown
- Backward Compatibility: SW version 4.00 maintains compatibility with Advant OCS controllers from 1990s
- Future-Proofing: SW version 5.00 adds support for System 800xA 6.x and newer AC 800M firmware
- Asset Protection: Extend life of existing I/O and field devices while upgrading control layer