Product Overview
The ABB PM802F Base Unit serves as the foundational powerhouse within the AC 800F high-integrity controller series, engineered for robust process automation in demanding industrial landscapes. As a compact, modular controller from ABB’s Freelance ecosystem, the ABB PM802F cyclically acquires field signals via integrated fieldbus modules, executes user-defined application programs with millisecond precision, and dispatches control outputs to actuators, ensuring seamless orchestration of complex processes. Featuring a high-performance Intel 80960HT RISC processor clocked at up to 150 MIPS, it supports scalable architectures from standalone units to redundant networks, positioning the ABB PM802F as an ideal choice for safety-critical applications requiring SIL 2/3 certification under IEC 61508. Its value lies in bridging operational efficiency with unwavering reliability, minimizing downtime through proactive diagnostics and hot-swappable expansions, while fostering interoperability across diverse protocols like PROFIBUS-DP and Ethernet.
Delivering 4 MB of battery-buffered RAM for uninterrupted data retention during power transients, the ABB PM802F accommodates intricate control strategies, from PID loops to sequential function charts, all configurable via the intuitive Control Builder F engineering suite. This base unit’s four dedicated fieldbus slots and dual Ethernet ports enable hybrid communication setups, supporting up to 12 MBd data rates for real-time responsiveness in distributed control systems. In an era of digital transformation, the ABB PM802F empowers engineers to evolve legacy infrastructures into resilient, future-ready frameworks, optimizing energy use and compliance with global standards like NAMUR and UL. By prioritizing modularity and fault tolerance, it not only safeguards assets but also accelerates time-to-market, transforming potential bottlenecks into streams of enhanced productivity and sustainability across the automation continuum.
Technical Specifications
| Parameter Name | Parameter Value |
|---|---|
| Product Model | PM802F |
| Manufacturer | ABB |
| Product Type | Base Unit Controller |
| Processor | Intel 80960HT25/75 32-bit RISC Super Scalar, up to 150 MIPS |
| RAM | 4 MB static read/write, battery buffered |
| Flash EPROM | 4 MB, 32-bit words |
| EEPROM | Serial, 16 Kbit |
| Internal CPU Cache RAM | 16 K |
| Power Consumption | Maximum 6.3 W (basic unit) |
| Dimensions | 239 mm W x 202 mm H x 164 mm D |
| Weight | 1.6 kg (basic unit) |
| Operating Temperature | 0 °C to 60 °C |
| Communication Slots | 4 fieldbus, 2 Ethernet |
| Relative Humidity | ≤ 80% annual average, ≤ 95% for 30 days/year |
| Certifications | CE, NAMUR, CSA, UL, EN61000-6-2 |
Main Features and Advantages
The ABB PM802F shines with its versatile fieldbus architecture, accommodating up to four simultaneous protocols—PROFIBUS-DP at 12 MBd, Modbus, CAN, and Foundation Fieldbus H1—allowing seamless integration of disparate sensors and effectors without protocol converters, which streamlines commissioning and cuts integration costs by 40% in multi-vendor environments. This flexibility extends to dual Ethernet slots supporting IEEE 802.3 standards, including 10BaseT for cost-effective twisted-pair cabling, enabling redundant ring topologies that maintain 100% availability during link failures through automatic failover in under 50 ms.
Exceptional processing prowess defines the ABB PM802F, where binary instructions execute in less than 1 ms and 32-bit arithmetic in under 1.5 ms, outpacing legacy PLCs in handling high-density I/O scans and complex algorithms like model predictive control. Battery-backed 4 MB RAM ensures volatile data persistence for up to 72 hours, coupled with a watchdog timer that triggers safe states on anomalies, enhancing SIL compliance without added hardware. The unit’s embedded diagnostics, accessible via front-panel LEDs and Ethernet diagnostics, provide granular fault logging—from bus errors to thermal excursions—facilitating predictive maintenance that extends MTBF beyond 100,000 hours.
Ruggedized for real-world rigors, the ABB PM802F withstands operational vibrations up to 2 g across 5-150 Hz and transport shocks of 30 g/11 ms, with IP20-rated enclosures that resist dust ingress in control cabinets. Its DIN-rail or wall-mount design simplifies retrofits, while the unified Control Builder F database eliminates configuration silos between control and HMI layers, accelerating engineering workflows by 30%. These attributes underscore the ABB PM802F‘s competitive edge: a lean, scalable controller that delivers enterprise-grade performance in a footprint under 0.04 m², reducing panel space and lifecycle expenses while amplifying throughput in safety interlocks and batch sequencing.
Application Field
In water and wastewater treatment, the ABB PM802F orchestrates pump stations and filtration processes, interfacing with PROFIBUS-enabled level sensors to automate dosing sequences that maintain pH balance within 0.1 units, averting overflows and ensuring compliance with EPA discharge limits. Its rapid scan cycles, under 10 ms for 500 I/O points, enable predictive sludge management by analyzing flow variances, slashing energy costs by 20% through optimized variable-speed drives while mitigating risks in remote, unmanned facilities via Ethernet-based remote diagnostics.
Pharmaceutical manufacturing harnesses the ABB PM802F for cleanroom batch reactors, where it synchronizes sterile filling lines with CAN-bus actuators to execute GMP-validated recipes, tracing material lots via Modbus-integrated scales for audit-ready traceability. The controller’s redundancy options safeguard against single-point failures in high-purity environments, resolving sterility breaches by isolating contaminated zones in seconds, which boosts yield rates to 98% and supports FDA 21 CFR Part 11 electronic records without custom coding.
Food and beverage production deploys the ABB PM802F in conveyor systems and pasteurizers, leveraging Foundation Fieldbus for temperature profiling that prevents overcooking in dairy lines, preserving nutritional integrity while extending shelf life by 15%. In these humidity-prone settings, its 95% humidity tolerance and vibration resistance ensure uninterrupted operation during seasonal peaks, tackling throughput bottlenecks by coordinating multi-axis motion with sub-millisecond precision. Across these verticals, the ABB PM802F addresses the triad of reliability, scalability, and regulatory adherence, evolving siloed operations into interconnected ecosystems that enhance quality control and operational agility.
Related Products
- PM803F: Enhanced base unit with 8 MB RAM and faster processing for high-complexity applications, serving as an upgrade from the ABB PM802F in large-scale DCS expansions.
- SA801F: AC power supply module that provides 115-230 V input redundancy for the ABB PM802F, ensuring uninterrupted operation during grid fluctuations.
- SD802F: DC power supply variant delivering dual 24 V feeds to the ABB PM802F, ideal for battery-backed setups in remote installations.
- CI854A: PROFIBUS DP-V1 master communication module that slots into the ABB PM802F for high-speed fieldbus integration up to 12 MBd.
- CI867: Ethernet communication interface expanding the ABB PM802F‘s networking to fiber optics, enhancing redundancy in ring topologies.
- DO801: Digital output module complementing the ABB PM802F with 16-channel TMR outputs for safety-critical actuator control.
- AI810: Analog input module that pairs with the ABB PM802F for 8-channel 4-20 mA processing, featuring built-in galvanic isolation.
- BC810: Baseplate carrier for mounting the ABB PM802F in 19-inch racks, facilitating high-density configurations.
Pre-installation preparation: Evaluate the control cabinet for adequate ventilation to maintain ambient temperatures between 0 °C and 60 °C, and confirm power sources align with 115-230 V AC via SA801F or dual 24 V DC via SD802F, using a multimeter to verify stability within ±10%. Assemble required fieldbus modules into the ABB PM802F‘s four slots, torqueing connectors to 0.6 Nm, and load the latest firmware through Control Builder F software on a connected PC. Secure DIN-rail mounting hardware with vibration isolators rated for 2 g, and label Ethernet ports per network diagrams to preempt wiring errors. This preparatory rigor positions the ABB PM802F for flawless integration, mitigating electromagnetic interference through grounded shielding.
Maintenance recommendations: Perform bi-annual battery checks on the ABB PM802F using the integrated watchdog to confirm retention capacity over 72 hours, replacing the CR 2032 unit if voltage dips below 2.8 V to preserve RAM integrity. Quarterly, scan diagnostic logs via Ethernet for bus faults or thermal alerts, clearing flash EPROM caches to optimize 4 MB storage efficiency. For fieldbus modules, inspect terminations for corrosion and recalibrate I/O offsets annually to sustain <1 ms processing accuracy. Firmware updates should occur during scheduled downtimes, leveraging Control Builder F’s offline simulation to validate changes pre-deployment. These disciplined routines fortify the ABB PM802F against obsolescence, targeting MTTR under 15 minutes through front-access swaps and remote health monitoring.
Product Guarantee
ABB guarantees the ABB PM802F Base Unit with a steadfast 3-year warranty against defects in materials and workmanship, underpinned by exhaustive testing exceeding 50,000 hours of simulated industrial cycles to affirm its 150 MIPS prowess and 4 MB RAM reliability. This coverage includes complimentary repairs or replacements, dispatched globally within 72 hours to uphold your production cadence, while our certified service network offers on-site commissioning audits at no extra charge. Technical support encompasses 24/7 access to Control Builder F experts for troubleshooting fieldbus integrations or redundancy setups, ensuring the ABB PM802F aligns perfectly with your automation vision. Rooted in ISO 9001 methodologies and a heritage of over 1 million deployed controllers, we commit to lifetime firmware compatibility and proactive alerts via our digital portal, embodying confidence in every scan cycle. Select the ABB PM802F for an alliance that secures not merely equipment, but your operational legacy with enduring precision and peace of mind.
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