ABB PM825 Modules | 3BSE010796R1

Technical Dossier

Product Details And Specifications

ABB PM825 Series: Comprehensive Module Range and Technical Overview

The ABB PM825 is a processor module belonging to the AC800M controller family, ABB's flagship DCS/PLC platform deployed across global heavy industry. AC800M controllers — with PM825 as a core CPU variant — are installed in chemical processing plants, oil refineries, nuclear power facilities, pulp and paper mills, and offshore platforms. The PM825 executes control applications compiled in ABB's Control Builder M engineering environment and communicates with I/O clusters via the S800 I/O bus. Its deterministic real-time execution, redundancy support, and long-term ABB lifecycle commitment have made it a standard specification in greenfield and brownfield automation projects since the early 2000s.

The Evolution of PM825 Architecture

The AC800M platform was introduced by ABB in the late 1990s as a successor to the Advant OCS and MOD 300 controller families. The PM825 processor module entered production as a mid-range CPU within this platform, positioned between the entry-level PM856 and the high-performance PM864/PM866 variants. Early hardware revisions (R1) operated at lower clock speeds with limited onboard memory, targeting small-to-medium control loops. Subsequent revisions (R2, R3) introduced expanded SDRAM, faster flash storage, and improved Ethernet port handling, enabling larger application programs and faster scan cycles without requiring a hardware platform change.

Compatibility across revisions is maintained at the backplane level: PM825 modules of different revisions can replace one another in the same S800 I/O station without reconfiguration of the I/O bus, provided the Control Builder M project is compiled against the correct firmware baseline. Firmware upgrades are delivered via ABB's software update mechanism and do not require physical hardware changes in most cases. The PM825 is compatible with CI858, CI854, CI801, and CI840 communication interface modules, enabling PROFIBUS DP, FOUNDATION Fieldbus H1, and Modbus TCP connectivity within the same controller chassis.

As of 2024, the PM825 has entered the mature/limited phase of ABB's product lifecycle. ABB continues to supply spare units and firmware support, but new engineering projects are directed toward the AC800M High Integrity (HI) platform and the System 800xA next-generation controllers. For installed base maintenance, PM825 remains fully supported with documented migration paths to PM864 and PM866 for sites requiring expanded capacity.

PM825 Full Catalog & Functionalities (SKU List)

The following SKUs represent verified part numbers within the ABB AC800M PM825 processor module family and associated S800 I/O modules commonly deployed alongside PM825 controllers. Each entry reflects a distinct hardware configuration or revision.

3BSE010796R1: PM825 processor module, AC800M, revision 1, standard memory configuration, single Ethernet port.
3BSE010796R2: PM825 processor module, revision 2, expanded SDRAM, improved boot firmware.
3BSE010796R3: PM825 processor module, revision 3, latest production release, enhanced flash storage.
3BSE008584R1: PM856 processor module, AC800M entry-level CPU, single CEX-Bus interface.
3BSE018100R1: PM860 processor module, AC800M, dual redundant CPU configuration support.
3BSE018168R1: PM861 processor module, AC800M, standard performance, dual Ethernet.
3BSE018100R2: PM860 processor module, revision 2, updated firmware baseline.
3BSE020520R1: PM864 processor module, AC800M high-performance CPU, 32 MB application memory.
3BSE050198R1: PM866 processor module, AC800M, highest performance tier, dual redundant Ethernet.
3BSE013065R1: CI854 communication interface, PROFIBUS DP master, for use with PM825 chassis.
3BSE030220R1: CI858 communication interface, FOUNDATION Fieldbus H1, compatible with AC800M.
3BSE020512R1: CI801 communication interface, Modbus TCP/PROFINET, AC800M compatible.
3BSE040662R1: CI840 communication interface, PROFIBUS DP slave interface module.
3BSE013599R1: TB820 Termination Unit, S800 I/O, 8-channel AI/DI base for use with PM825 I/O clusters.
3BSE008516R1: AI810 analog input module, 8-channel, 4–20 mA, S800 I/O series.
3BSE008534R1: AO810 analog output module, 8-channel, 4–20 mA, S800 I/O series.
3BSE008536R1: DI810 digital input module, 24 VDC, 16-channel, S800 I/O series.
3BSE008538R1: DO810 digital output module, 24 VDC, 16-channel, S800 I/O series.
3BSE013258R1: SA811 power supply module, S800 I/O station, 24 VDC input.

Sourcing Hard-to-Find & Obsolete PM825 Parts

DriveKNMS maintains a dedicated inventory program for ABB AC800M components, with particular focus on PM825 revision R1 and R2 units that are no longer available through standard ABB distribution channels. For facilities operating legacy AC800M installations where a full platform migration is not economically viable, DriveKNMS provides lifecycle extension support through three supply channels: new-old-stock (NOS) units sourced from decommissioned plant inventories, factory-refurbished modules tested against ABB's original acceptance criteria, and exchange programs where a defective unit is returned in exchange for a tested replacement.

All PM825 units sourced by DriveKNMS are accompanied by test reports documenting firmware version, memory integrity check results, and Ethernet port validation. Customers requiring specific firmware revisions for compatibility with existing Control Builder M projects can specify the required version at the time of order. DriveKNMS also maintains stock of associated CI8xx communication interface modules and S800 I/O modules to support complete station-level replacements.

Quality Control for the PM825 Range

PM825 processor modules present specific test challenges due to their integrated CEX-Bus backplane interface and dual-port Ethernet architecture. DriveKNMS applies a structured test protocol to each PM825 unit prior to shipment. The protocol includes: power-on self-test (POST) verification with logged output, CEX-Bus communication integrity test using a reference S800 I/O station, Ethernet port throughput and packet-loss measurement at 100 Mbps, onboard flash read/write cycle verification, and firmware version confirmation against the customer's specified baseline. Modules that fail any stage of this protocol are quarantined and not returned to inventory. Test reports are issued in PDF format and shipped with each unit.