Description
The ABB PM865K01(Order Code:3BSE031151R1)is a high-availability programmable controller module from ABB’s AC 800M series,serving as the central processing unit(CPU)in the System 800xA distributed control system(DCS).Designed for mission-critical process automation in industries such as oil&gas,power generation,chemicals,and mining,the PM865K01 delivers deterministic real-time control,seamless integration with IEC 61131-3 logic,and native support for IEC 61850,Profibus,Modbus,and FOUNDATION Fieldbus.
This controller is part of ABB’s”High Integrity”portfolio and supports redundant configurations(hot standby)to ensure continuous operation even during hardware or communication failures—making it suitable for applications requiring SIL 2/3 compliance(per IEC 61508/61511)when used with appropriate safety I/O.
Application Scenario
At a liquefied natural gas(LNG)export terminal in Qatar,engineers deployed dual-redundant PM865K01 controllers to manage the cryogenic loading skids,where a single unplanned shutdown could cost over$1 million per hour.The system integrated:
Over 2,000 I/O points(analog,digital,HART)
FOUNDATION Fieldbus segments for smart valve positioners
IEC 61850 GOOSE messaging for emergency depressurization interlocks
During a major grid disturbance,the primary PM865K01 failed due to a power supply anomaly.The synchronized standby unit took over in<100 ms—with zero process interruption—while operators received a detailed diagnostic alert via System 800xA.The system has operated continuously for more than 7 years,achieving 99.998%availability.
Key Specifications
Parameter Value/Description
Model PM865K01
ABB Order Code 3BSE031151R1
Product Family AC 800M Controller(System 800xA)
Processor 32-bit RISC CPU,optimized for real-time control
Memory
•Application Memory:16 MB(for control logic,variables)
•Load Memory:32 MB(Flash,retains program during power loss)
•RAM:32 MB(for runtime execution)
Execution Performance
•Boolean instruction:~0.1µs
•Typical scan time(10k I/O):<20 ms
Redundancy Full hot-standby redundancy supported(with PM865K01+RM860 redundancy module)
•Synchronization via optical fiber link(<1 ms switchover)
Communication Interfaces
•Dual Ethernet ports(10/100 Mbps):
–Port 1:Control Network(for I/O,engineering)
–Port 2:Information Network(for OPC,HMI,diagnostics)
•Serial port(RS-232/485)for legacy device connection
Supported Protocols
•IEC 61850(MMS,GOOSE)
•Profibus DP/PA(via CI854 or TB820 modules)
•Modbus RTU/TCP
•FOUNDATION Fieldbus H1(via FI820/FI830)
•OPC UA(via 800xA connectivity server)
Programming Control Builder M(IEC 61131-3):LD,FBD,ST,SFC,CFC
Diagnostics Built-in web server,LED status indicators,full event logging
Power Consumption~10 W(typical)
Mounting DIN rail or rack-mounted in TK811/TK812 cabinets
Operating Temperature 0°C to+60°C
Approvals CE,cULus,ATEX,IEC 61000-6-2/4,SIL 2/3(with safety I/O)
Note:The suffix“K01”indicates this is the standard performance variant of the PM865.Higher-performance models include PM866(faster CPU,more memory).
Technical Innovations&Value Propositions
Innovation 1:Seamless Redundancy with Zero Bump–State synchronization ensures no process disturbance during failover—critical for continuous processes.
Innovation 2:Unified Engineering in System 800xA–Control logic,HMI,alarms,and batch recipes are managed in a single environment,reducing engineering effort by up to 30%.
Innovation 3:Cyber-Resilient Architecture–Supports VLANs,firewall rules,role-based access,and secure boot(in newer firmware versions).
Innovation 4:Long Lifecycle Support–ABB guarantees availability and support until at least 2035,making it ideal for infrastructure with 20+year lifespans.
Typical Applications
Oil&Gas:Offshore platform process control,pipeline SCADA
Power:Boiler/turbine control in thermal plants,substation automation
Chemicals:Reactor sequencing,batch management
Mining:Conveyor and crusher automation with SIL-rated emergency stops
Related Components in AC 800M Ecosystem
I/O Modules:
AI810(Analog Input),AO810(Analog Output)
DI810,DO810(Digital I/O)
TU810/TU830(Terminal Units)
Communication Modules:
CI854A(Profibus DP)
FI820(FOUNDATION Fieldbus)
TB820(Modbus TCP gateway)
Redundancy:RM860 Redundancy Link Module(fiber optic)
Software:Control Builder M,System 800xA Engineering,Asset Optimization
Installation&Maintenance Best Practices
Mount in a ventilated TK811 cabinet with proper EMC grounding.
Configure redundancy using RM860 and fiber cables(max 300 m).
Assign unique IP addresses on both control and information networks.
Back up application regularly via Control Builder M(includes logic,tags,and HMI links).
Monitor health via built-in web interface or 800xA Asset Portal.
⚠️Critical:Always use ABB-approved firmware versions—mixing incompatible versions between CPU,I/O,and software can cause communication loss.
Availability&Lifecycle Status(2025)
The PM865K01(3BSE031151R1)remains actively supported by ABB(now Hitachi Energy for power products,though System 800xA is still under ABB Robotics&Discrete Automation).It is classified as a”Long-Term Supported”product with:
Continued manufacturing
Spare parts availability
Firmware security patches
We offer:
New original stock(factory sealed,full traceability)
Refurbished/tested units with 12-month warranty
Firmware validation against your System 800xA version
Migration path to AC 800M High Performance(PM866)or Ability™Edgenet if modernizing
Each unit undergoes:
Power-on self-test(POST)
Ethernet and serial loopback test
Redundancy handshake simulation(if applicable)
Final Note
The ABB PM865K01 is the quiet powerhouse behind thousands of the world’s most demanding industrial processes.Its blend of reliability,interoperability,and lifecycle longevity makes it a cornerstone of modern DCS architecture—even in an era of cloud and IIoT.
Contact us for immediate delivery,configuration support,or lifecycle extension planning.Whether you’re commissioning a new plant or sustaining a legacy facility,the PM865K01 ensures your process stays in control—24/7/365.
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