ABB PM802F – Integrated Controller with 24VDC Supply, Ethernet & RS-485 for Industrial IoT Edge

Description

The ABB PM802F (Order Code: 3BSE013214R1) is a compact, integrated controller in the AC 800M family, designed for small to medium automation tasks where space, cost, and simplicity are critical—but without compromising on ABB’s industrial-grade reliability. Unlike larger rack-based CPUs (e.g., PM864A or PPC380AE01), the PM802F combines the CPU, power supply, and communication interfaces into a single DIN-rail-mounted unit, making it ideal for skid-mounted systems, auxiliary control panels, pump stations, and remote I/O applications.

It supports full IEC 61131-3 programming via Control Builder M, integrates seamlessly with System 800xA, and can communicate over Modbus RTU/TCP, PROFIBUS DP, and Ethernet/IP (with optional modules). While not supporting full hardware redundancy like high-end models, the PM802F offers robust diagnostics, wide voltage tolerance, and optional battery-backed real-time clock—ensuring dependable operation in harsh environments.

Application Scenarios

At a municipal water treatment facility in Sweden, aging relay logic panels controlled sludge dewatering centrifuges. During a digital upgrade, engineers replaced them with ABB PM802F 3BSE013214R1 units mounted directly inside local motor control centers (MCCs). Each PM802F:

Powered itself from the plant’s 24VDC bus (no external PSU needed)

Read analog signals from torque sensors and level transmitters

Controlled VFDs via Modbus RTU over RS-485

Reported alarms to the central SCADA via Ethernet

The compact footprint allowed installation in existing enclosures, avoiding costly panel rebuilds. Over three years, zero failures were recorded—even during winter temperatures down to -25°C.

Key Parameters

Technical Principles and Innovative Values

Innovation Point 1: True All-in-One Design – By integrating the power supply, CPU, and communications into one module, the PM802F eliminates external PSUs, terminal blocks, and interconnect wiring—reducing panel space by up to 60% and improving MTBF.

Innovation Point 2: Wide Ambient Temperature Operation – Rated for -25°C to +70°C, it operates reliably in unheated outdoor cabinets or near heat-generating equipment—unlike many compact PLCs limited to 0–55°C.

Innovation Point 3: Seamless AC 800M Ecosystem Integration – Despite its size, it uses the same programming environment, libraries, and I/O modules as larger AC 800M controllers—enabling standardized engineering across plant-wide systems.

Typical Industry Applications

Water/Wastewater: Pump station control, chemical dosing, UV disinfection skids

Power Generation: Cooling tower fans, lube oil systems, battery room monitoring

Oil & Gas: Wellhead control panels, flare gas monitoring, separator units

Industrial Manufacturing: Packaging lines, conveyor logic, HVAC control

Renewables: Solar tracker control, battery energy storage (BESS) auxiliary systems

Related Product Combination Solutions

TB510 / TB520: Terminal blocks for direct field wiring to PM802F I/O (if used with local modules)

CI854A 3BSE013246R1: Communication interface for expanding to remote I/O racks

AI810 / DI810: Standard I/O modules for analog/digital expansion

3BSE013215R1: Battery module for real-time clock backup (retains time during power loss)

Control Builder M: Programming software for logic development and download

System 800xA: For integration into larger DCS environments with HMI and historian

PMTL01: Mounting rail adapter for panel installation

PM801 / PM802: Legacy predecessors—PM802F is the recommended upgrade path

Installation, Maintenance & Lifecycle Support

Installation is straightforward: mount on DIN rail, connect 24VDC power, and wire field devices to local I/O or remote stations. The built-in Ethernet port allows direct connection to engineering laptops for commissioning.

Maintenance advantages include:

No external power supply to fail

Status LEDs for RUN, ERROR, COMM, and POWER

Removable terminal blocks for safe servicing

Firmware updates via Ethernet without disassembly

We supply genuine ABB PM802F 3BSE013214R1 units that are:

✅ Factory tested for power-up sequence and communication stability

✅ Verified for compatibility with Control Builder M v5.x–v6.x

✅ Available with or without battery backup module

Our support includes:

Migration guidance from PM801/PM802

Sample application code for pump sequencing or temperature control

Global shipping with technical documentation

Final Note

The PM802F proves that “compact” doesn’t mean “compromised.” It delivers the full power of ABB’s AC 800M architecture in a rugged, self-contained package—perfect for distributed intelligence at the edge of your automation network. Whether you’re building a new skid or modernizing legacy panels, the PM802F offers the optimal balance of performance, reliability, and total cost of ownership.