ABB PM861K01 3BSE018105R1 Processor Module

ABB PM861K01 3BSE018105R1 Processor Module

Product core positioning

The ABB PM861K01 3BSE018105R1 processor module is a high-order core computing unit in the AC 800M series PLC, designed specifically for ultra large and high complexity industrial automation control systems. Its core functions include handling massive data processing, executing multi-dimensional control algorithms, cross system collaborative scheduling, and high reliability redundant operation tasks. Compared with the PM825 module in the same series, its computing performance has been improved by more than 60%, the memory capacity has been doubled, and it supports high-speed communication and I/O expansion with more channels. It can adapt to super large I/O systems with more than 10000 points and is the "control center" for petrochemical plant control, power grid scheduling, metallurgical integrated production and other scenarios. It can seamlessly integrate with the TC820-1 temperature control module, TC512V1 bus module and 5SDF1045H0002 IGBT power module of the AC 800M series, and build a complete closed-loop system from control instruction issuance to power execution.

Key technical parameters

（1） Core operations and memory parameters

Advantages compared to PM825

Processor performance

Adopting a quad core 32-bit industrial grade processor with a processing speed of 220 MIPS and support for parallel multi-threaded processing

60% increase in computing speed and 2-fold increase in multi-threaded processing efficiency

Memory configuration

Standard 64 MB program memory+128 MB data memory, supports up to 256 MB external SD card expansion

Double the program memory and data memory, and increase the expansion capacity by 1 times

Control task cycle

Minimum task cycle of 0.05 ms, supporting over 2000 concurrent control tasks

Reduce task cycle by 50% and double the number of tasks that can be carried

Programming language support

Compatible with IEC 61131-3 standard language (ladder diagram, functional block diagram, etc.), supports C/C++custom algorithm library, MATLAB/Simulink model import

Add MATLAB model import to adapt to complex modeling and control requirements

（2） Hardware and power supply parameters

Power supply specifications

Input voltage 24 VDC (allowable fluctuation range ± 15%), power consumption ≤ 8 W, suitable for industrial wide voltage power supply environment

Size specifications

Width 40mm x height 100mm x depth 170mm, similar in size to PM825, with only a 5mm increase in depth, compatible with standard 35mm DIN rails

Environmental adaptability

Working temperature -40 ° C to+75 ° C (high temperature performance better than PM825+70 ° C), storage temperature -40 ° C to+85 ° C; relative humidity 5% to 95% (no condensation); Vibration resistance level IEC 60068-2-6 (10-500 Hz, 20 g acceleration), impact resistance level IEC 60068-2-27 (25 g, 11 ms)

Protection level

Module body IP20, wiring terminal IP40, dust-proof and splash proof design

（3） Communication and Extension Parameters

Advantages compared to PM825

Ethernet interface

4 10/100/1000 Mbps Gigabit Adaptive Ethernet ports (RJ45), supporting IEEE 1588 PTP v2 precise time synchronization (accuracy ± 100 ns)

Doubling the number of Ethernet ports and increasing time synchronization accuracy by 10 times

Serial communication interface

2 RS485 interfaces (supporting Modbus RTU, Profibus DP/PA), 1 RS232 interface, 1 fiber optic communication interface (single-mode/multi-mode optional)

Added fiber optic interface, supporting long-distance (20 km) relay free communication

Internal bus interface

Two internal bus interfaces of AC 800M system, with a data transmission rate of 400 Mbps (PM825 is 200 Mbps)

Double the internal bus speed and support dual bus parallel expansion

I/O expansion capability

Supports up to 256 I/O modules (digital, analog, functional modules), with a maximum of 16384 I/O points

Scalability is twice that of PM825, suitable for ultra large systems

（4） Redundancy and safety parameters

Redundant functions

Support processor redundancy (1:1/2:1 hot standby), power redundancy, communication redundancy, with a switching time of ≤ 5 ms

Security certification

Compliant with SIL 3 safety level certification (IEC 61508), supporting safety related control and emergency stop functions

Data Security

Built in hardware encryption chip, supporting data encryption transmission and storage, preventing unauthorized access and data tampering

Core performance advantages

Ultra high performance computing and multitasking scheduling: With a quad core processor and 220 MIPS computing speed, it can simultaneously handle over 2000 control tasks (such as multivariable PID, model predictive control, logic interlocking). Even in a super large system with 16384 I/O points, it can maintain a task response time of 0.05 ms (such as improving the synchronization control accuracy of thousands of valves in the petrochemical plant to ± 0.01 s).

Super scalability and cross system compatibility: With 256 I/O module expansion capabilities and 16384 I/O points, it can seamlessly integrate with the TC820-1 temperature control module and PM820-2 pulse counting module of the AC 800M series. It is also compatible with third-party high-end devices such as Siemens S7-400 PLC and Schneider Modicon M580, and can achieve distributed system interconnection within 20 km through fiber optic interfaces without the need for additional gateways.

High safety and high reliability redundancy: SIL 3 safety certification meets the requirements of safety critical scenarios such as nuclear power plants and large-scale chemical industries (such as emergency shutdown system response time ≤ 5 ms); 1: 1/2:1 processor redundancy with dual internal buses ensures uninterrupted system operation in the event of a single module or bus failure, with an average time between failures (MTBF) of over 150000 hours.

High precision time synchronization and big data interaction: IEEE 1588 PTP v2 protocol achieves ± 100 ns level time synchronization, which can meet the microsecond level collaboration of multiple devices in distributed systems (such as motor synchronization control of multi stand rolling mills in the metallurgical industry, with speed deviation ≤ 0.01 rpm); 4 Gigabit Ethernet ports support industrial IoT big data transmission (real-time upload of 100000 points/second of production data to MES system).

Complex Algorithm and Modeling Support: Supports direct import of MATLAB/Simulink models, allowing for quick conversion of complex control algorithms (such as neural network predictive control and fuzzy control) into control programs without the need for manual programming; C/C++custom algorithm library supports users to develop exclusive control logic (such as grid frequency regulation algorithm for new energy power plants), suitable for highly customized scenarios.

Typical application scenarios

Integrated control of the entire petrochemical plant:

In multi million ton refineries or ethylene plants, PM861K01 serves as the central main CPU, connecting 256 I/O modules (including TC820-1 temperature control module and PM820-2 flow counting module) through dual internal buses to collect real-time data from 16384 points such as reactor temperature, pipeline pressure, and medium flow rate; Using a quad core processor to execute a multivariable PID algorithm, coordinating the operation of thousands of valves, pumps, and compressors; By interconnecting with the tank area control system 20 km away through fiber optic interfaces, the integrated control of the entire process of "production equipment tank area public works" is achieved. At the same time, data is uploaded to the group level MES system through Gigabit Ethernet to meet the production scheduling needs of the entire plant.

Power system wide dispatch and control:

At the regional power grid dispatch center, PM861K01 connects remote I/O stations of multiple substations and collects data on transformer temperature (TC820-1 module), line current, voltage, etc. through Profibus PA protocol; Using the IEEE 1588 PTP v2 protocol to achieve ± 100 ns level time synchronization with each substation and accurately calculate the power grid flow distribution; Execute complex algorithms such as power grid frequency regulation and load distribution, control the SVG (Static Var Generator) composed of 5SDF1045H0002 IGBT modules through TC512V1 bus module, stabilize the power grid voltage, and ensure SIL 3 safety certification to ensure rapid power grid disconnection protection in emergency situations.

Full process production control in the metallurgical industry:

In large steel joint ventures, PM861K01 serves as the core controller, connecting I/O modules throughout the entire process of sintering, ironmaking, steelmaking, and rolling steel. TC820-1 module monitors blast furnace temperature and converter oxygen content, and PM820-2 module collects rolling mill speed; Using the rolling force prediction model imported from MATLAB, dynamically adjust the rolling mill reduction and speed; Four Gigabit Ethernet ports are connected to the MES system, equipment management system, and energy monitoring system, enabling parallel transmission of production data, equipment status, and energy consumption data. The 256 I/O module expansion capability meets the real-time control needs of thousands of control points throughout the entire process.

New energy power plant cluster control:

In the cluster of million kilowatt photovoltaic power stations, PM861K01 connects 10 photovoltaic sub stations located 20 km away through fiber optic interfaces to collect the inverter status (including 5SDF1045H0002 module operation data) and photovoltaic array power generation of each sub station; Execute cluster power prediction and grid scheduling algorithms, dynamically adjust the output power of each sub power station according to grid instructions; Support C/C++customized grid friendly control logic (such as low voltage ride through and reactive power compensation), upload cluster data to the grid dispatch center through Gigabit Ethernet, and meet the stability requirements of large-scale new energy grid connection.