PM802F ABB

Description

ABB PM802F Base Unit Controller

1. Product Description

• High-Speed Processing: Equipped with a 150 MIPS super scalar RISC processor, the PM802F efficiently executes complex control algorithms and manages real-time data from sensors, actuators, and higher-level systems.
• Multi-Protocol Communication: Supports industrial standards like PROFIBUS DP, MODBUS RTU/TCP, and Ethernet, enabling seamless connectivity with I/O modules, HMIs, and third-party devices.
• Modular Expansion: Features 4 slots for fieldbus modules and 2 slots for Ethernet communication modules, allowing users to customize the system with additional I/O or safety functionalities as needed.
• Redundancy for Reliability: Offers dual-port Ethernet redundancy and battery-backed RAM to retain data during power outages, ensuring continuous operation in critical applications.
• Environmental Resilience: Operates reliably in temperatures ranging from -20°C to +60°C and withstands vibrations (up to 5g) and electromagnetic interference (EMI), making it suitable for offshore, chemical, and power plant environments.

2. Technical Parameters

Parameter	Specification
Brand	ABB
Model	PM802F
Controller Type	Base Unit Controller (CPU for AC 800F)
Processor	150 MIPS RISC processor with EDC (Error Detection and Correction)
Memory	4 MB static RAM (EDC), 4 MB Flash-EPROM, 16 kbit EEPROM
Communication Interfaces	2x Ethernet (10/100 Mbps), PROFIBUS DP, MODBUS RTU/TCP
I/O Slots	4 slots for fieldbus modules, 2 slots for Ethernet modules
Power Supply	24V DC ±10% (non-isolated, loop-powered)
Power Consumption	≤10 W (active), ≤5 W (standby)
Operating Temperature	-20°C to +60°C (non-condensing humidity: 5%–95%)
Storage Temperature	-40°C to +85°C
Dimensions (W×H×D)	28 mm × 155 mm × 125 mm (DIN rail mountable)
Weight	0.8 kg
Certifications	CE, RoHS, IEC 61131-2 (safety), IEC 61000-6-2 (EMC compliance)
Compatibility	ABB AC 800F system, S800 I/O modules, third-party PROFIBUS/MODBUS devices

PM802F

3. Advantages and Features

• Rugged Reliability: The PM802F is built for long-term stability, with a mean time between failures (MTBF) exceeding 150,000 hours and built-in self-diagnostics that detect hardware faults and communication errors in real time.
• Scalable Performance: Supports up to 125 slave devices on a single PROFIBUS DP network and integrates seamlessly with ABB’s S800 I/O modules, allowing users to scale systems from basic control loops to complex industrial networks.
• Flexible Programming: Compatible with ABB’s Control Builder F software, which supports IEC 61131-3 programming languages (Ladder Logic, Function Block Diagram, Structured Text), enabling efficient configuration and debugging.
• Energy Efficiency: Low power consumption and advanced power management reduce operational costs, while the hot-swappable design minimizes downtime during module replacement.
• Redundancy for Critical Systems: Dual-port Ethernet and optional PROFIBUS DP redundancy ensure uninterrupted operation, a feature that reduces unplanned downtime by up to 40% in mission-critical applications.

4. Application Areas and Case Study

Application Areas:

• Energy Production: Manages turbine control, generator protection, and boiler systems in thermal power plants and renewable energy facilities.
• Chemical Processing: Optimizes reactor controls, distillation columns, and safety interlocks in petrochemical and pharmaceutical plants.
• Water Treatment: Automates pump control, filtration processes, and quality monitoring in wastewater treatment and desalination plants.
• Manufacturing: Controls conveyor systems, robotic arms, and quality control sensors in automotive and food & beverage production lines.

Case Study:

5. Competitive Comparison

• Tight Ecosystem Integration: Native compatibility with ABB’s AC 800F software and S800 I/O modules reduces engineering time by 25% compared to non-integrated solutions.
• Extreme Environment Adaptability: Operates at a wider temperature range (-20°C to +60°C) and offers higher vibration resistance (5g) than many alternatives, making it suitable for harsh industrial sites.
• Cost-Effective Redundancy: Built-in redundancy features eliminate the need for additional hardware, providing high availability at a lower total cost of ownership.
  

  PM802F

6. Selection Recommendations

• System Compatibility: Ensure the PM802F aligns with your existing ABB AC 800F system or planned modular control architecture to leverage full functionality.
• Environmental Needs: Choose this controller for applications with challenging conditions (e.g., high temperature, vibration) to benefit from its rugged design.
• Scalability Requirements: Evaluate the number of I/O slots and communication protocols needed for current and future expansions, especially for systems requiring PROFIBUS or MODBUS integration.
• Budget Considerations: Balance performance with cost by prioritizing the PM802F for critical applications where reliability and redundancy are non-negotiable.

7. Precautions

• Installation:
  • Power down the entire control system before installing the PM802F to prevent electrostatic discharge (ESD) damage. Use anti-static wrist straps during handling.
  • Ensure proper grounding and shielded cables for communication interfaces to minimize EMI interference.
• Configuration:
  • Use ABB’s Control Builder F software to configure network parameters (e.g., IP addresses, PROFIBUS baud rates) and validate connectivity with field devices before full deployment.
• Maintenance:
  • Regularly update firmware via the control system to access the latest security patches and performance optimizations.
  • Inspect terminal connections quarterly for loose wires or corrosion, particularly in humid environments.
• Storage:
  • Store unused units in anti-static packaging within the specified temperature range (-40°C to +85°C) to preserve component integrity.