Description

The ABB KUC755AE105 (3BHB005243R0105) is a high-performance controller unit in ABB’s AC 800M programmable logic controller (PLC) family, designed for integration into the System 800xA distributed control system (DCS). Serving as a direct upgrade or replacement for earlier models like the PM864 and PM866. this module delivers enhanced processing power, expanded memory, and advanced communication capabilities—making it ideal for demanding applications in power generation, oil & gas, water treatment, and heavy industry.

Equipped with a 1 GHz processor, 64 MB application memory, dual 10/100 Mbps Ethernet ports, and support for hardware redundancy, the KUC755AE105 ensures deterministic execution of complex control strategies while enabling seamless data exchange with SCADA, HMI, engineering stations, and enterprise systems via IEC 61850. Modbus TCP, PROFIBUS, and OPC UA.

Application Scenarios

At a combined-cycle power plant in Germany, aging PM864 controllers struggled to handle new combustion optimization algorithms, causing scan time overruns during transient loads. The facility upgraded to ABB KUC755AE105 units across all three turbine control racks. With 3× faster CPU performance and double the memory, the new controllers executed advanced model-predictive logic in under 10 ms—improving heat rate by 1.8% and reducing NOx emissions by 12%. Crucially, the swap required zero rewiring; the KUC755AE105 slotted directly into existing AC 800M backplanes. “It was a brain transplant without opening the skull,” said the lead controls engineer. Unplanned outages dropped to zero over the next 24 months.

Technical Principles and Innovative Values

Innovation Point 1: Drop-In Replacement Architecture – The KUC755AE105 maintains pin, power, and software compatibility with earlier PM86x CPUs. Existing I/O modules, base units, and application code (in Control Builder M) run unchanged—enabling risk-free modernization.

Innovation Point 2: Native IEC 61850 Support – Unlike legacy CPUs requiring gateway devices, the KUC755AE105 natively publishes GOOSE and SV messages, making it ideal for digital substations and smart grid applications.

Innovation Point 3: Embedded Web Diagnostics – Access real-time CPU load, memory usage, network status, and I/O health via any web browser—no engineering software required for basic troubleshooting.

Innovation Point 4: Cybersecurity-Ready Design – Supports IP filtering, secure boot (on newer firmware), and integration with ABB’s Industrial Security Manager for defense-in-depth compliance with IEC 62443.

Application Cases and Industry Value

A municipal wastewater plant in Sweden replaced its 15-year-old PM860 controllers with KUC755AE105 units to support new AI-driven aeration control. The increased memory allowed the entire neural network model to run locally on the PLC—eliminating dependency on external servers. Energy consumption dropped by 22%, saving €180.000 annually.

In a Canadian mining operation, KUC755AE105 CPUs were deployed in redundant pairs to control conveyor belt interlocks across -30°C outdoor environments. Their robust thermal design and hot-swap capability ensured 99.99% uptime during winter operations—critical for just-in-time ore delivery.

Related Product Combination Solutions

ABB CI854A: PROFIBUS DP/V1 communication module for legacy field devices

ABB TB840A / TU847: S800 I/O base units and termination for digital/analog modules

ABB 3BSE041484R1: AO810 analog output module (commonly used with KUC755AE105)

ABB Control Builder M: Engineering suite for programming, diagnostics, and redundancy setup

ABB TK801V001: Optical link module for redundant MasterBus 300 synchronization

ABB PM866AK01: Predecessor CPU (KUC755AE105 is a performance-enhanced successor)

ABB 3BSE022460R1: DATX140 digital output module

ABB 800xA System Platform: Full DCS environment integrating AC 800M controllers

Installation, Maintenance, and Full-Cycle Support

Installing the ABB KUC755AE105 requires slotting it into an AC 800M rail or rack and connecting power and I/O backplanes. In redundant setups, a synchronization cable (TK801) links primary and standby units. Configuration is performed in Control Builder M, where users can enable redundancy, assign IP addresses, and deploy IEC 61850 configurations.

Maintenance benefits from extensive self-diagnostics: LEDs indicate RUN/STOP, redundancy status, and network activity, while the web interface logs task overruns, memory leaks, and communication errors. Firmware updates can be applied online without halting control execution.

We supply only genuine ABB KUC755AE105 (3BHB005243R0105) units—either new from ABB or professionally refurbished with full functional testing, including redundancy validation and IEC 61850 communication checks. Each module includes a certificate of authenticity and compatibility report for your specific AC 800M chassis version. Our team of ABB-certified engineers provides lifetime technical support for migration planning, code verification, and cybersecurity hardening. Contact us for a future-ready control solution that maximizes uptime, performance, and lifecycle value.