ABB PM864AK02

ABB PM864AK02

Product Overview:
The ABB PM864AK02 (Order Code: 3BSE018164R1) is a high-performance, redundant controller module belonging to the ABB AC 800M series. It is designed to serve as the central processing brain in complex Distributed Control Systems (DCS) and programmable logic controllers (PLC). Operating on a 32MB RAM architecture, it supports seamless CPU redundancy, ensuring continuous, uninterrupted operation and high availability for critical industrial processes.

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Description

ABB PM864AK02

Technical Specifications:

  • Processor: High-performance PowerPC microprocessor operating at a frequency of up to 1 GHz.
  • Memory Capacity: 32MB SDRAM (with approximately 23.5MB available for user application code and data) and 4MB Flash PROM for firmware storage.
  • Communication Interfaces: Integrated dual Ethernet ports (CN1, CN2 – 10BaseT RJ45) and dual RS-232C serial ports (COM3, COM4).
  • Power Supply: Standard 24V DC input with a wide operating range of 19.2V to 30V DC.
  • Power Consumption: Typical power consumption of 6.9W, with a maximum of 11.4W when fully loaded with ModuleBus and CEX-Bus supplies.
  • Protection Rating: IP20 enclosure rating, suitable for standard industrial control cabinet environments.

Functional Features:

  • Comprehensive Redundancy: Supports full CPU redundancy, CEX-Bus redundancy, communication link redundancy, and S800 I/O module redundancy. In the event of a primary failure, the system achieves a seamless switchover to the backup unit in less than 10ms.
  • High-Speed Multitasking: Capable of handling up to 16 concurrent tasks with a minimum task cycle time of 1ms and a Sequence of Events (SOE) resolution of less than 1ms.
  • Extensive Protocol Support: Natively supports Modbus, PROFIBUS DP, and EtherNet/IP, facilitating seamless integration with SCADA, MES, and third-party field devices.
  • Safety Integrity: Fully compliant with IEC 61508 SIL3 safety standards, making it suitable for safety-critical applications when paired with certified software and I/O modules.
  • Advanced Diagnostics: Features built-in self-diagnostics, integrated firewall, and security encryption to protect against unauthorized access and cyber threats.

Application Scenarios:

  • Process Industries: Complex continuous and batch control in petrochemical, oil refining, and pharmaceutical manufacturing.
  • Power Generation: Substation automation, turbine control, and smart grid management requiring high reliability.
  • Heavy Manufacturing: High-speed, high-precision automation in steel rolling, paper mills, and automotive assembly lines.
  • Marine and Offshore: Harsh-environment control systems for LNG terminals, offshore drilling platforms, and ship automation.

Performance Parameters:

  • Processing Speed: Non-redundant configuration delivers double the theoretical performance of the PM860 model, with optimized real-time execution.
  • I/O Expansion: Supports direct connection to up to 12 local S800 I/O units via the ModuleBus and up to 98 remote I/O stations via PROFIBUS DP.
  • Data Retention: Internal battery backup provides a minimum of 36 hours of memory retention during power loss, expandable to several weeks using external battery modules (SB821/SB822).
  • Environmental Tolerance: Rated for continuous operation in ambient temperatures ranging from +5°C to +55°C and relative humidity from 5% to 95% (non-condensing).

Material Composition & Structural Characteristics:

  • Enclosure: Ruggedized black aluminum-reinforced casing designed for superior electromagnetic interference (EMI) shielding and thermal dissipation.
  • Mounting Mechanism: Features a unique slide-and-lock mechanism for secure and effortless installation on standard 35mm DIN rails.
  • Kit Components: The redundant kit typically includes two PM864A CPUs, two TP830 base plates, CEX-bus extension cables (TK850), RCU-Link cables (TK851), and battery backup modules.
  • Physical Dimensions: Compact footprint measuring 119mm (W) x 186mm (H) x 135mm (D), weighing approximately 1.2kg per unit.

Working Principle:
The PM864AK02 operates by continuously scanning field inputs, executing complex control algorithms stored in its 32MB RAM, and refreshing digital/analog outputs. In a redundant setup, the primary and secondary CPUs operate synchronously via the RCU-Link and CEX-Bus. Both processors process identical logic simultaneously. If the primary processor detects an internal fault or loses power, the secondary processor instantly assumes control without disrupting the I/O state or communication network.

Installation Requirements:

  • Software Configuration: System parameters, redundancy settings, and control logic must be configured using ABB’s Control Builder M software prior to deployment.
  • Wiring and Grounding: Shielded communication cables must be used for Ethernet and serial connections, with proper grounding to prevent signal interference.
  • Power Stability: A stable, regulated 24V DC power supply is required. The use of an Uninterruptible Power Supply (UPS) is highly recommended to ensure clean power delivery.
  • Cooling Clearance: Adequate vertical clearance must be maintained above and below the module to allow for natural convection cooling.

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