Product Overview
The ABB PM857K01 is a high-performance AC 800M controller designed for demanding industrial automation applications. With its powerful MPC866 processor running at 96 MHz, this module delivers fast and reliable control for process and discrete manufacturing. The PM857K01 supports up to 128 I/O signals and is certified for SIL 3, making it suitable for safety-critical operations.
This controller features a CPU board with microprocessor, RAM, real-time clock, LED indicators, INIT push button, and CompactFlash interface. The base plate includes two RJ45 Ethernet ports (CN1, CN2) for Control Network connectivity, plus two serial ports (COM3, COM4) for configuration and modem communication. Built-in CPU redundancy ensures high availability for critical processes.
Key Specifications
| Parameter |
Value |
| Processor |
MPC866 |
| Clock Frequency |
96 MHz |
| Memory |
32 MB |
| RAM for Application |
22.184 MB |
| Power Supply |
24 V DC (19.2–30 V DC) |
| Power Consumption |
210 / 360 mA (typ/max) at +24 V |
| Power Dissipation |
5.1 W (8.6 W max) |
| Ethernet Channels |
2 |
| Ethernet Interface |
IEEE 802.3, 10 Mbit/s, RJ-45 |
| Control Network Protocol |
MMS, IAC |
| Max I/O Signals |
128 |
| Certifications |
TÜV SIL 2/3, ISA Secure, CE, cULus |
| Operating Temperature |
+5 to +55 °C |
| Protection Class |
IP20 |
These specifications demonstrate the PM857K01's capability to handle complex control tasks with precision and speed.
Performance and Reliability
The PM857K01 executes 1000 boolean operations in just 0.17 ms, ensuring rapid logic processing. It supports up to 32 applications per controller, 64 programs per application, and 128 diagrams per application, offering extensive flexibility for large-scale automation projects. The controller also features a redundant power supply status input and a built-in backup battery (Lithium, 3.6 V) to maintain real-time clock accuracy.
With a switchover time of max 10 ms in redundant configurations, the PM857K01 maintains seamless operation even during component failures. Its event queue can store up to 3000 events per OPC client, facilitating comprehensive data logging and analysis.
Installation and Setup
Install the ABB PM857K01 on a standard DIN rail in a control cabinet that meets IP20 protection requirements. Ensure adequate ventilation to keep the ambient temperature within the +5 to +55 °C operating range. Connect the Ethernet ports (CN1, CN2) to the Control Network using shielded cables with RJ45 connectors. Use COM3 (RS-232C, non-isolated) for modem communication or COM4 (isolated) for configuration tool connection. The INIT push button allows for easy initialization, and the LED indicators provide status feedback during setup. Configure the controller using the 800xA Control Builder software, and for high-integrity applications, install the SM812 module and apply the appropriate SIL-certified software configuration.
Applications
The PM857K01 is ideal for industries requiring high availability and safety integrity, such as oil and gas, chemical processing, power generation, and water treatment. Its SIL 3 certification makes it suitable for emergency shutdown systems, fire and gas detection, and burner management. The controller supports S800 I/O High Integrity, enabling seamless integration with field devices. For example, in a chemical plant, the PM857K01 can manage critical process control loops while simultaneously handling safety interlocks, reducing the need for separate safety PLCs.
Compatibility and Integration
The PM857K01 works seamlessly with ABB's 800xA control system and supports the S800 I/O family. It communicates via MMS and IAC protocols over a 100 Mbit/s switched Ethernet backbone. The controller can be configured with the 800xA Control Builder, and its built-in redundant Ethernet ports ensure reliable communication. For high-integrity applications, combine it with the SM812 module to achieve SIL 3 certification. The PM857K01 also supports up to 12 communication modules on the CEX bus, providing extensive expansion capabilities.
Maintenance and Reliability
Regularly inspect the PM857K01 for dust accumulation and ensure cooling fans (if any) are operational. The unit's corrosion protection (G3 compliant to ISA 71.04) and wide operating temperature range ensure long-term reliability in harsh industrial environments. The built-in backup battery should be checked periodically and replaced every few years to maintain real-time clock accuracy. With proper maintenance, the PM857K01 offers extended service life, reducing downtime and total cost of ownership.
Purchasing Advice
When purchasing the ABB PM857K01, verify the article number 3BSE088385R1 to ensure you receive the correct model. Confirm that your system supports the required firmware version and that you have the necessary software licenses for 800xA Control Builder. For high-integrity applications, order the SM812 module separately. PLC Source PRO offers genuine ABB PM857K01 modules with fast shipping and expert support, ensuring you get the right part for your automation needs.