ABB PM856K01 3BSE018104R1 is a core processor unit kit in the AC 800M series, part of the ABB 800xA automation system, featuring high reliability, flexibility and efficiency. As the “brain” of the distributed control system (DCS), this kit integrates all essential core components including the processor, baseplate, bus terminators and backup battery, allowing quick commissioning without additional parts. It is widely used in power, chemical, manufacturing, infrastructure and other industrial fields, performing complex logic control, sequential control, data acquisition and feedback tasks. It provides core support for stable and efficient industrial production, supports flexible expansion to adapt to different scale control requirements, and serves as a key hardware device in ABB’s industrial automation solutions.
Kit Components
The kit includes complete core components for basic deployment without extra procurement. All parts are genuine original ABB accessories as follows:
- Main Processor (CPU): PM 856 Processor (3BSE018128R1), the core computing unit responsible for executing all control logic, data processing and command output.
- Baseplate: TP 830 Baseplate (3BSE018114R1), with a width of 115 mm, used to mount the processor and various accessories, and to realize electrical connection and fixation between modules.
- Bus Terminators: Including TB 850 CEX Bus Terminator (3BSC950193R1) and TB 807 Module Bus Terminator (3BSE008538R1), used to stabilize bus communication, reduce signal interference and ensure reliable data transmission.
- Backup Battery: Lithium backup battery (model 4943013-6), used to protect programs and data in RAM during power failure to avoid data loss. The battery weighs approximately 9 g and uses lithium chemistry.
Auxiliary Parts: 4-pin power plug (3BSC840088R4), fuses (2 A, 3BSC770001R47 or 3.15 A, 3BSC770001R49), ensuring safe and stable power supply and overall electrical protection for the kit.
Core Technical Specifications
According to official ABB documentation and product specifications, the core technical parameters of the PM856K01 3BSE018104R1 kit are as follows, combining industrial-grade stability and efficient computing capabilities.
The unit uses a 32-bit RISC microprocessor (some versions can be equipped with Motorola 68040 processor at 25 MHz), supporting real-time multitasking with high-speed data computing and logic execution. Its processing speed can reach 550 μs, efficiently meeting the computing demands of medium-scale control scenarios.
It is equipped with 8 MB dynamic RAM (expandable to 16 MB in some versions) for storing operating firmware, hardware configuration information and application programs. The program capacity can reach 300 and data capacity up to 200. Battery-backed RAM ensures data and program security during power outages.
The kit supports multiple industrial communication interfaces, including 2 RS232C ports for local commissioning and third-party device connection, and 1 10/100 Mbps Ethernet port. It also supports CEX bus and ModuleBus (electrical and optical fiber) expansion interfaces, connecting up to 12 fieldbus modules and being compatible with protocols such as RS-485 and PROFIBUS. This facilitates data exchange with other controllers, automation systems and field devices, and supports redundant communication configurations for improved reliability.
The operating voltage is 24 VDC ±10% (some scenarios support 220 V). It supports redundant power supply with a soft-start function to reduce inrush current and eliminate power disturbances, ensuring stable power supply in complex industrial power environments.
The unit has a net height of 200 mm and net width of 130 mm, with dimensions adaptable to different installation scenarios. Its net weight is 1.1 kg (2.5 kg including packaging), making it suitable for DIN rail mounting and easy maintenance.
It operates within a temperature range of -20°C to +60°C, adapting to high and low temperature industrial environments. With low power consumption and fanless design, it can be installed in sealed, fan-free cabinets to reduce failure risks and improve operational reliability. It meets IP20 protection class, effectively resisting dust and foreign objects in harsh industrial environments.
The kit supports local and remote I/O expansion. Up to 8 local I/O stations can be connected via ModuleBus (7 in redundant configuration), and up to 98 remote stations via PROFIBUS DP, supporting a maximum of 1024 I/O points including 16 digital inputs, 8 digital outputs, 4 analog inputs and 2 analog outputs. This allows flexible connection to field sensors and actuators to meet different scale control requirements.
The unit supports up to 16 tasks with a minimum task cycle of 1 ms and SOE (Sequence of Events) resolution below 1 ms. It features a built-in watchdog and temperature monitoring for real-time status detection and timely fault feedback. It also supports error detection and correction to enhance system stability. New original products come with a one-year warranty and reliable after-sales support.
Key Functional Features
High-Performance Computing and Control
Equipped with a high-performance 32-bit RISC processor, the kit delivers fast data processing and logic execution, handling large volumes of on-site industrial data and performing complex logic control, sequential control and analog regulation tasks efficiently, whether for simple on-off control or medium-scale process control. It supports parallel multitasking with a minimum task cycle of 1 ms and SOE resolution below 1 ms, enabling precise capture of field device status changes, ensuring real-time execution of control commands, improving the controllability and stability of production processes, and meeting strict real-time requirements in industrial automation.
Modular Design and Flexible Expansion
Adopting the classic modular design of the ABB AC 800M series, the kit integrates core components and supports flexible expansion. Through the CEX bus slot, it can connect up to 12 fieldbus modules compatible with PROFIBUS DP, FF, Modbus and other communication protocols. I/O and communication modules can be expanded flexibly according to actual needs, covering applications from a small number of I/O points to thousands of points, with flexible deployment from local to remote installation. This adapts to automation scenarios in different industries and scales, reduces system upgrade and modification costs, and improves system adaptability and scalability.
High Reliability and Redundancy Support
Designed for industrial stability, the product provides multiple reliability guarantees. It supports full-range redundancy configuration including CPU, CEX bus, communication interfaces and S800 I/O. Two kits can form an active-standby system, synchronizing data and program status in real time through dedicated optical fiber or Ethernet links. When the primary controller fails, the backup takes over control seamlessly within milliseconds to ensure uninterrupted critical production processes for high-availability applications.
A backup battery effectively preserves programs and data during power failure to prevent data loss. The low-power design reduces heat dissipation requirements, and sealed installation eliminates potential failures caused by dust and foreign objects, further enhancing operational reliability and service life. Overcurrent protection and other safety features effectively protect the unit from damage and ensure stable system operation.
Easy Configuration, Programming and Maintenance
The kit supports configuration, programming, downloading and online debugging through ABB’s dedicated Compact Control Builder M (Control Builder M) engineering software, which complies with the five programming languages defined in the IEC 61131-3 standard: Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST), Sequential Function Chart (SFC) and Instruction List (IL). Users can select appropriate programming methods as needed, and reusable code and libraries simplify program configuration and development, improving programming efficiency.
In addition, the kit supports remote diagnosis and maintenance. The controller is equipped with LED indicators for power, operation, faults, battery status and communication data transmission, enabling quick and intuitive troubleshooting. Application programs can be stored and downloaded via CF flash cards, serial ports or Ethernet, suitable for batch repeated deployment and large program optimization, reducing maintenance costs and improving equipment operation efficiency.
Open Communication and Multi-System Integration
The unit features powerful communication capabilities and supports mainstream industrial protocols including Modbus TCP/RTU, OPC UA/DA, PROFIBUS DP/PA, Foundation Fieldbus, IEC 61850 and others. It can be deeply integrated with ABB 800xA operation systems, SCADA, MES and ERP systems, and communicate seamlessly with third-party controllers, field instruments and drive devices such as ABB inverters, adapting to complex multi-vendor automation environments.
Dual Ethernet ports can be configured as redundant with built-in redundancy switching logic to further improve communication reliability. RS232C ports can connect to terminals, printers and other external devices to meet diverse communication needs, enabling comprehensive monitoring and data exchange of production processes and supporting digital and intelligent transformation in industry.
Configuration, Programming and Commissioning
Configuration and programming of the PM856K01 3BSE018104R1 kit rely entirely on ABB Control Builder M, a Windows-based engineering tool dedicated to the AC 800M series. It features an intuitive interface and powerful functions, supporting the entire workflow from hardware configuration, program development and downloading to commissioning and real-time monitoring.
During programming, users can choose any of the IEC 61131-3 standard languages according to control requirements. The software includes abundant built-in function blocks such as PID control blocks, counters and flip-flops, and supports user-defined function blocks. Reusable code and libraries greatly improve programming efficiency and reduce difficulty. For batch applications, programs can be downloaded in bulk via CF flash cards to save commissioning time. For large programs, online debugging can be performed via serial port or Ethernet to monitor running status and optimize programs in real time.
During commissioning, the software allows real-time viewing of controller status, I/O status and communication status. LED indicators on the controller support quick fault identification such as low battery, abnormal communication and program errors, ensuring efficient system commissioning and rapid operation. Furthermore, the software supports online program and parameter modification without system shutdown, minimizing production downtime and improving commissioning and maintenance efficiency.
Typical Applications
As a medium-sized controller kit in the AC 800M series, PM856K01 3BSE018104R1 is widely used in various industrial fields thanks to its reliable performance, flexible expansion and convenient maintenance, especially for medium-scale automation control systems.
- Power Industry: Used in thermal power, hydropower and distribution automation to control generator sets and power distribution equipment, realizing real-time monitoring and control of power production and transmission to ensure stable and safe operation of the power system.
- Manufacturing: Applied in automated production lines, robot control and process control to achieve precise control of production equipment and optimized production flows, improving productivity and product quality while reducing labor costs.
- Chemical and Metallurgical Industry: Deployed in chemical plants and metallurgical equipment to withstand harsh environments with high temperature, dust and strong interference, delivering precise control of chemical reactions and metallurgical processes to ensure production safety and product qualification rates.
- Infrastructure: Used in water treatment, wastewater treatment and building automation to monitor and control various infrastructure equipment, achieving efficient resource utilization and environmental optimization.
- Transportation: Applied in rail transit and port automation to control traffic and port handling equipment, improving transportation and logistics efficiency and ensuring operational safety.
- Other Industries: Also used in food processing, pharmaceutical manufacturing and other industries requiring high precision and reliability, adapting to diverse automation scenarios and supporting the automation and intelligent transformation of various sectors.
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