ABB PM856K01

Description

ABB PM856K01

Product introduction

The PM856K01 is a high – performance central processing unit (CPU) module from ABB, designed as a core component for industrial control systems. As part of ABB’s AC 800M series, it serves as the “brain” of the control system, responsible for executing control programs, processing data, and managing communication between various components in an industrial automation setup.

This module combines powerful processing capabilities with extensive communication and I/O interface options. It can receive real – time data from sensors, analyze it according to pre – programmed control algorithms, and then send out control signals to actuators. For example, in a large – scale manufacturing plant, the PM856K01 can manage the operation of an entire production line, coordinating the movement of conveyor belts, the activation of robotic arms, and the control of temperature and pressure in processing equipment. Its Ethernet and PROFIBUS DP interfaces enable seamless integration with other devices on the factory floor, such as human – machine interfaces (HMIs), other PLCs, and intelligent sensors.

Core advantages and technical highlights

High – speed processing: With a Motorola 68040 processor running at 25 MHz or a 32 – bit RISC processor, the PM856K01 can execute control programs rapidly. In a high – speed packaging line, it can process thousands of input signals per second and make real – time decisions to adjust the packaging speed, product placement, and sealing operations. This ensures smooth and efficient production, reducing downtime and product waste.

Flexible and extensive communication: The multiple communication interfaces make the PM856K01 highly adaptable. The Ethernet interface allows for fast data transfer over local area networks, enabling remote monitoring and control of the industrial process. In a power generation plant, operators can use this interface to access real – time data from the PM856K01 – controlled systems, such as turbine speed, generator voltage, and fuel flow, from a central control room located miles away. The PROFIBUS DP slave interface simplifies integration with PROFIBUS – based devices, which are commonly used in industrial automation. This allows for easy connection to a wide range of sensors, actuators, and other PROFIBUS – compatible modules, expanding the functionality of the control system.

Scalable I/O configuration: The modular bus capacity that supports up to 96 I/O modules provides exceptional flexibility. In a large – scale water treatment plant, the PM856K01 can be connected to numerous analog and digital I/O modules. These modules can monitor and control various parameters such as water level, pH value, and the operation of pumps and valves. As the water treatment plant expands or its processes change, additional I/O modules can be easily added to the system, without the need for a complete overhaul of the control system.

Reliable operation in industrial environments: Designed to operate within a temperature range of +5 °C to +55 °C and withstand a relative humidity of 5 to 95% (non – condensing), the PM856K01 can function reliably in harsh industrial settings. In a steel mill, where the environment is hot, dusty, and electrically noisy, the module can continue to operate without interruption. Its IP20 protection class and compliance with strict electromagnetic compatibility (EMC) standards, such as EN 61000 – 6 – 4 and EN 61000 – 6 – 2, ensure that it can resist external interference and prevent its own emissions from affecting other sensitive equipment in the vicinity.

Typical application scenarios

Manufacturing industry: In an automotive assembly plant, the PM856K01 can control the movement of robotic arms used for welding, painting, and component assembly. The module receives input signals from sensors that detect the position and orientation of car parts, and then sends control signals to the motors of the robotic arms. The Ethernet interface allows for communication with the plant’s manufacturing execution system (MES), which can schedule production tasks, monitor production progress, and manage inventory in real – time.

Energy sector: In a power distribution substation, the PM856K01 can be used to control and monitor the operation of transformers, circuit breakers, and other electrical equipment. The analog inputs can measure parameters such as voltage, current, and power factor, while the digital outputs can control the opening and closing of circuit breakers. The PROFIBUS DP interface can connect to intelligent electronic devices (IEDs) that are used for protection and control functions in the substation, ensuring safe and efficient power distribution.

Water and wastewater treatment: A large – scale water treatment facility can use the PM856K01 to manage the entire water treatment process. The module can control the operation of pumps, filters, and chemical dosing systems based on real – time data from sensors that measure water quality parameters such as turbidity, chlorine levels, and dissolved oxygen. The expandable I/O capabilities allow for the addition of more sensors and actuators as the treatment plant upgrades or expands its operations.

Related model recommendations

PM850: A lower – cost alternative in ABB’s AC 800M series, suitable for smaller – scale industrial applications where the processing power and I/O requirements are not as extensive as those for PM856K01. It still offers reliable control capabilities and basic communication interfaces, making it a good choice for simple automation tasks.

PM852: This model has enhanced memory capabilities compared to PM850, which can be beneficial for applications that require more data storage for historical trends or complex control algorithms. It also has similar communication and I/O expansion capabilities as the PM856K01, but at a slightly lower processing speed, making it suitable for mid – sized industrial projects.

CI856K01: A communication module that pairs well with PM856K01. It supports multiple communication protocols such as PROFIBUS DP, MODBUS RTU, IEC 60870 – 5 – 101/104, and DNP3. In a complex industrial network where different devices use various communication protocols, the CI856K01 can be used in conjunction with PM856K01 to ensure seamless communication between all components.

AI810: An analog input module that can be connected to PM856K01. It has a high resolution and can accurately measure various analog signals such as voltage, current, and temperature. In applications where precise analog data acquisition is crucial, such as in a pharmaceutical manufacturing process where temperature and pressure need to be tightly controlled, the AI810 module can work together with PM856K01 to provide accurate data for control decisions.

DO810: A digital output module that can be used to drive discrete devices such as relays, solenoids, and motors. When paired with PM856K01, it can be used to control the on – off operation of equipment in industrial processes. For example, in a packaging machine, the DO810 can be used to control the operation of the sealing mechanism based on the control signals from PM856K01.

HMI – 800xa: A human – machine interface specifically designed to work with ABB’s 800xa control system, which includes the PM856K01. It provides an intuitive graphical interface for operators to monitor and control the industrial process. Through the HMI – 800xa, operators can view real – time data, adjust control parameters, and receive alarms, improving the overall usability and efficiency of the control system.

ABB PM856K01

Installation, commissioning and maintenance instructions

Installation preparation: Mount the PM856K01 module on a suitable DIN rail using the provided mounting brackets. Ensure that the mounting location is clean, dry, and well – ventilated. Connect the power supply wires (24 V DC) to the designated terminals on the module, making sure to observe the correct polarity. Use shielded cables for connecting communication interfaces and I/O signals to minimize electromagnetic interference. For Ethernet connections, use standard Ethernet cables with RJ – 45 connectors. For PROFIBUS DP connections, use PROFIBUS – compliant cables and connectors.

Commissioning: Before powering on the module, verify all physical connections. Power on the module and check the status LEDs on the module. The LEDs will indicate the power status, communication status, and any error conditions. Use ABB’s 800xa Control Builder software to load the control program onto the module. Configure the communication settings for Ethernet, PROFIBUS DP, and other communication interfaces as required. Set the IP address, subnet mask, and other network parameters for Ethernet communication. For PROFIBUS DP, configure the slave address and other relevant parameters. Test the I/O functionality by connecting some sample sensors and actuators to the I/O modules connected to the PM856K01 and monitoring the data flow.

Maintenance suggestions: Regularly inspect the module for any signs of physical damage, such as loose connections, burnt components, or discoloration. Clean the module periodically to remove dust and debris, as these can affect the performance of the module. Check the status LEDs regularly to identify any potential issues. If an error LED is lit, refer to the module’s manual or use the 800xa Control Builder software to diagnose the problem. Update the firmware of the module periodically to ensure that it has the latest features and bug fixes. ABB provides firmware update packages on their official website. Replace any faulty components promptly. ABB offers a range of replacement parts, including memory modules, communication modules, and power supply units, which can be easily installed to restore the functionality of the module.

Service and guarantee commitment

ABB offers a 1 – year warranty on the PM856K01 module, covering defects in materials and workmanship. During this period, if the module fails due to a manufacturing defect, ABB will provide free repair or replacement. ABB also offers 24/7 technical support to assist customers with any issues related to the module. Their team of experts can provide guidance on installation, commissioning, and troubleshooting. Additionally, ABB provides access to software updates, application notes, and user manuals through their online support portal. This ensures that customers can keep their modules up – to – date and operating at peak performance. For customers who require on – site support, ABB can arrange for trained technicians to visit the location and provide assistance.