Description
Product Overview
The ABB TP857 3BSE030192R1 is a high-performance process controller designed for industrial automation systems, serving as the core of ABB’s AC 800M distributed control system (DCS). Engineered to deliver deterministic control, real-time data processing, and robust communication capabilities, this controller is ideal for managing complex processes in industries such as oil & gas, power generation, and manufacturing. The ABB TP857 3BSE030192R1 combines advanced computational power with modular scalability, enabling seamless integration with I/O modules, drives, and supervisory systems to optimize operational efficiency and reliability.
As part of the AC 800M series, the TP857 3BSE030192R1 supports multiple control paradigms, including sequential logic, analog control, and motion control, making it versatile for diverse applications. Its dual-core processor architecture ensures high-speed execution of control algorithms (up to 1 ms cycle time), while built-in redundancy features (optional hot standby) minimize downtime in critical systems. The controller’s rugged design withstands harsh industrial environments (-40°C to +70°C), ensuring stable operation in extreme temperatures, vibrations, and electromagnetic interference (EMI).
Technical Specifications
| Parameter Name | Parameter Value |
|---|---|
| Product Model | TP857 3BSE030192R1 |
| Manufacturer | ABB |
| Product Type | Process Controller (AC 800M Series) |
| Processor | Dual-core ARM Cortex-A9 @ 800 MHz |
| Memory | 2 GB RAM, 8 GB flash storage |
| Control Cycle Time | 1 ms to 100 ms (configurable) |
| Communication Interfaces | Ethernet (10/100/1000 Mbps), PROFIBUS DP, CANopen |
| Supported Protocols | Modbus TCP, EtherNet/IP, PROFINET |
| Redundancy | Hot standby (optional), self-diagnostic |
| Operating Temperature | -40°C to +70°C |
| Mounting Method | DIN rail in AC 800M control cabinets |
| Dimensions (W×H×D) | 150 mm × 200 mm × 130 mm |
| Power Supply | 24 V DC ±15% (isolated supply) |
| Certification | IEC 61131-2, CE, UL 508, RoHS |
Main Features and Advantages
Deterministic control performance: The TP857 3BSE030192R1 ensures precise control with sub-millisecond response times, critical for applications like high-speed packaging lines or turbine governing systems. In a paper mill, the controller reduced reel tension variations by 20%, improving paper quality and reducing waste during high-speed production.
Modular scalability: The controller supports up to 1,000 I/O points (via S800 I/O modules), allowing seamless expansion from small-scale to large-scale systems. A chemical plant upgraded its legacy system with the TP857 3BSE030192R1, integrating 500 analog and digital signals while maintaining real-time control performance, reducing hardware costs by 30%.
Advanced redundancy: Optional hot standby configuration ensures zero downtime during controller switching, essential for uninterrupted operation in oil rigs or power plants. A LNG facility deployed redundant TP857 controllers in its compressor control system, achieving 99.999% uptime during maintenance cycles.
Cybersecurity readiness: Built-in security features include encrypted communication (SSL/TLS), user access control, and firmware integrity checks, compliant with IEC 62443 standards. This makes the controller suitable for modern industrial environments vulnerable to cyber threats, such as smart grid installations or pharmaceutical manufacturing.
Application Field
Oil and gas: In upstream production, the TP857 3BSE030192R1 controls wellhead systems, managing flow rates and pressure via real-time data from downhole sensors. A major oil company used the controller to optimize gas lift operations, increasing well productivity by 15% while reducing energy consumption.
Power generation: For combined-cycle power plants, the controller manages turbine startup sequences, load balancing, and emissions control. A 500 MW plant achieved a 5% improvement in load-following accuracy, ensuring grid stability and compliance with strict environmental regulations.
Manufacturing: In automotive assembly, the TP857 3BSE030192R1 coordinates robotic welding cells, conveyor systems, and quality control sensors. A vehicle manufacturer reduced cycle time by 12% by leveraging the controller’s high-speed logic execution and motion control capabilities.
Related Products
- ABB SD821: Analog input module compatible with the TP857, enabling precision data acquisition from sensors.
- ABB DO830: Digital output module for driving actuators, supporting up to 32 channels per module.
- ABB CI854-1: Ethernet/IP interface module for integrating the TP857 with IIoT platforms.
- ABB PM866AK01: Higher-performance processor module for complex control strategies, interchangeable with the TP857 in scalable systems.
- ABB S800 I/O Rack (LXR012): Modular rack housing I/O modules connected to the TP857, supporting up to 16 modules per rack.
- ABB 800xA HMI Software: Supervisory control software that interfaces with the TP857 for real-time visualization and alarm management.
Installation and Maintenance
Pre-installation preparation: Mount the TP857 3BSE030192R1 in a grounded AC 800M control cabinet, ensuring proper airflow (minimum 50 mm clearance). Configure network settings (IP address, subnet mask) via ABB’s Control Builder M software, and establish redundancy links if required. Verify power supply compatibility and secure connections to I/O racks using shielded cables to minimize EMI.
Maintenance recommendations: Regularly monitor controller health via the built-in diagnostic interface, checking for firmware updates and memory usage. In dusty environments, clean cooling vents quarterly to prevent overheating. Replace backup batteries (for real-time clock) every five years to maintain configuration integrity. ABB’s global service team offers 24/7 remote diagnostics and on-site support, with emergency replacement controllers delivered pre-configured within 24 hours for critical applications.
Product Guarantee
ABB guarantees the TP857 3BSE030192R1 to meet performance specifications for 36 months from delivery, with an optional 5-year extended warranty for mission-critical applications. The controller undergoes rigorous testing for thermal cycling, vibration resistance (20 g shock), and EMC compliance, ensuring reliability in harsh industrial environments.
For after-sales support, ABB provides certified technicians for commissioning, training, and lifecycle management, including proactive system audits and spare parts planning. The TP857 3BSE030192R1 embodies ABB’s commitment to delivering innovative, secure, and scalable control solutions that drive operational excellence and future-proof industrial automation systems.
Contact us to explore how the ABB TP857 3BSE030192R1 can transform your process control capabilities, combining high performance, redundancy, and cybersecurity in a single, robust platform.
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