Description
The ABB PM802F 3BDH000002R1 is a high-performance process controller designed as the core computing engine for ABB’s AC 800M distributed control system (DCS). Engineered to manage complex industrial processes with precision, this controller belongs to ABB’s premium PM800 series, renowned for its reliability, scalability, and advanced automation capabilities. The PM802F 3BDH000002R1 serves as the central hub for real-time control, data processing, and communication in applications ranging from manufacturing to energy and infrastructure, ensuring seamless coordination between field devices, human-machine interfaces (HMIs), and supervisory systems.
Featuring a 32-bit RISC processor and dual-core architecture, the ABB PM802F 3BDH000002R1 delivers deterministic performance with cycle times as low as 10 ms, making it ideal for high-speed control loops and sequential logic applications. Its core functions include advanced PID control, motor management, and compliance with IEC 61131-3 programming standards (Ladder Logic, Function Block Diagram), enabling flexible configuration for diverse automation needs. Positioned as a cornerstone of smart industrial systems, the controller enhances operational efficiency by minimizing latency, supporting predictive maintenance, and facilitating integration with IIoT platforms via its built-in Ethernet/IP and Profibus DP interfaces.
| Parameter Name |
Parameter Value |
| Product Model |
PM802F 3BDH000002R1 |
| Manufacturer |
ABB |
| Product Type |
Process Controller (AC 800M Series) |
| Processor |
32-bit RISC, 400 MHz |
| Memory |
256 MB RAM, 256 MB Flash |
| Communication Interfaces |
Ethernet/IP (10/100 Mbps), Profibus DP, CANopen |
| I/O Capacity |
Up to 2048 I/O points (via S800 I/O modules) |
| Power Supply |
24 V DC (redundant supply supported) |
| Operating Temperature |
-20°C to +60°C |
| Dimensions (W×H×D) |
140 mm × 200 mm × 150 mm |
| Mounting Method |
DIN rail or rack mounting |
| Certification |
CE, UL, CSA, IEC 61131-2, ATEX (optional) |
The ABB PM802F 3BDH000002R1 stands out for its combination of computational power and industrial ruggedness. Its dual-core processor supports parallel execution of control logic and communication tasks, ensuring high throughput even in complex multi-loop systems. The controller’s built-in redundancy features—including hot-swappable modules and dual power supplies—enhance system availability by enabling failover without interrupting operations, a critical feature for mission-critical applications like oil refineries or power plants.
A key advantage is the PM802F 3BDH000002R1’s compatibility with ABB’s Control Builder M software, which simplifies programming, diagnostics, and firmware updates. The software’s drag-and-drop interface reduces engineering time by up to 50%, while real-time monitoring tools provide insights into processor load, memory usage, and I/O status. The controller’s open architecture also supports integration with third-party systems via OPC UA, making it suitable for hybrid automation environments.
The controller’s compact design optimizes space in control panels, while its wide temperature range and resistance to vibration and electromagnetic interference ensure reliability in harsh industrial environments. The PM802F 3BDH000002R1 also incorporates advanced cybersecurity measures, such as secure boot and encrypted communication, compliant with IEC 62443 standards to protect against evolving cyber threats.
The ABB PM802F 3BDH000002R1 is widely deployed across industries requiring precise process control and high system availability. In manufacturing, it orchestrates assembly lines, robotics, and quality control systems, ensuring consistent product quality and throughput. For the energy sector, the controller manages power generation units, steam turbines, and renewable energy systems (e.g., solar/wind farms), balancing production with grid demand while adhering to safety standards.
In the chemical and pharmaceutical industries, the PM802F 3BDH000002R1 controls batch processes, reactor conditions, and sterilization cycles, ensuring regulatory compliance and product consistency. It also excels in water and wastewater treatment, where it optimizes pump operations, filtration systems, and chemical dosing to meet environmental standards.
By addressing challenges like process variability, maintenance complexity, and cybersecurity, the controller helps customers achieve higher OEE (Overall Equipment Effectiveness), reduce energy consumption, and accelerate digital transformation. Its scalability makes it suitable for both small-scale PLC replacements and large-scale DCS deployments.
- ABB PM866AK01 3BSE066503R1: An upgraded variant with faster processing and additional memory, ideal for high-performance applications.
- ABB CI858-1 3BSE018137R1: An Ethernet communication module that pairs with the PM802F to enable PROFINET and Modbus TCP connectivity.
- ABB S800 I/O Modules (e.g., DI810, AO810): Distributed I/O modules that expand the controller’s input/output capabilities.
- ABB TB820 V2: A terminal block unit for field wiring, compatible with the S800 I/O system used by the PM802F.
- ABB 800XA Extended Automation System: A software platform that integrates with the PM802F for advanced analytics and cloud-based monitoring.
- ABB PM801F 3BDH000001R1: A predecessor model with basic control capabilities, suitable for simpler automation tasks.
Pre-installation preparation: Mount the ABB PM802F 3BDH000002R1 on a DIN rail in a grounded control panel, ensuring proper ventilation and separation from high-power components. Connect the 24 V DC power supply using shielded cables and attach Ethernet/Profibus cables to the controller’s communication ports. Use Control Builder M to configure the controller’s IP address, I/O modules, and control logic, verifying compatibility with field devices and supervisory systems.
Maintenance recommendations: Regularly monitor the controller’s status LEDs and Control Builder M diagnostics for alerts on processor overload, communication errors, or memory issues. Update firmware quarterly to leverage new features and security patches, and backup project files to prevent data loss. Clean the controller’s ventilation slots with compressed air to maintain thermal performance, and inspect connections for signs of wear or corrosion. In redundant systems, test failover functionality during scheduled outages to ensure reliability. For hardware failures, replace the controller with a pre-configured spare to minimize downtime, ensuring the new unit is calibrated and tested before deployment.
ABB stands behind the PM802F 3BDH000002R1 with a comprehensive quality assurance program, including rigorous testing for EMC compliance, thermal stability, and functional safety. The controller is backed by a standard [X-year] warranty, covering defects in materials and workmanship. ABB’s global technical support team provides 24/7 assistance for troubleshooting, remote diagnostics, and on-site maintenance, ensuring rapid resolution of issues. Customers can access training modules, software tools, and documentation via ABB’s online platforms, reinforcing the company’s commitment to delivering reliable, future-proof automation solutions. With a focus on performance and service, ABB ensures the PM802F 3BDH000002R1 remains a trusted foundation for industrial control systems worldwide.
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