Description

ABB PM864AK01 3BSE018161R1 is a high-performance processor unit and a core component in the ABB AC 800M control system.AC 800M is a part of ABB System 800xA Distributed Control System(DCS),widely used in various complex industrial automation and process control fields.PM864AK01 serves as the brain of the AC 800M controller,responsible for executing control logic,processing real-time data,managing communication between I/O modules and upper computer systems,and ensuring the precise and efficient operation of the entire industrial process.

This processor unit has powerful processing capabilities and is equipped with the MPC862 processor(according to some sources,another source shows it as a Dual core ARM Cortex-A9 1.5 GHz processor,which may vary between different versions or sub models),as well as ample memory.It supports CPU redundancy,significantly improving system availability and reliability,ensuring the continuous operation of critical industrial processes,and minimizing downtime caused by single point failures.The motherboard(TP830)of PM864AK01 provides multiple communication ports,including two RJ45 Ethernet ports(for connecting control networks)and two RJ45 serial ports(for general communication and configuration tool connections),which provide great flexibility for system integration and expansion.

PM864AK01 is suitable for control applications of various scales,especially playing a key role in industries that require high system performance,reliability,and scalability,such as process control,power generation,and manufacturing.

PM864AK01 3BSE018161R1 ABB

technical specifications

Product model:PM864AK01 3BSE018161R1

Manufacturer:ABB

Product type:Processor Unit/CPU module

Compatible system:ABB AC 800M control system(belonging to ABB System 800xA DCS)

Processor type:MPC862(based on some information)/Dual core ARM Cortex-A9(based on some information,may be different versions)

Clock frequency:96 MHz(for MPC862 version)/1.5 GHz(for ARM Cortex-A9 version)

Memory:32 MB(of which approximately 23.522 MB can be used for applications)

Flash memory:2 MB(for firmware storage);Supports CompactFlash interface for storing applications and data

Ethernet interface:2 RJ45 ports(10/100/1000Base-T,may vary depending on the specific version)for connecting to the control network(CN1,CN2)

Serial interface:2 RJ45 ports(COM3:RS-232C with modem control signal,COM4:isolated,used for configuration tools)

Redundancy support:Supports CPU redundancy(CPU,CEX Bus,communication interface,and S800 I/O)

Performance(1000 Boolean operations):0.15 ms

Switching time(under redundant configuration):maximum 10 ms

Number of applications per controller:32

Number of programs per application:64

Number of charts per application:128

Number of tasks per controller:32

Different cycle times:32

Application cycle time:as low as 1 ms

CEX Bus communication module supports:up to 12

Modulabus I/O cluster:non redundant CPU:1 electrical+7 fiber optic;Redundant CPU:0 electrical+7 optical fibers

Modulabus I/O capacity:up to 96 I/O modules per CPU;Redundant CPU with a maximum of 84 I/O modules

Power supply:24 VDC(19.2-30 VDC)

Typical power consumption:6.9 W(maximum 11.4 W)

Built in backup battery:lithium battery,3.6 V(for memory backup)

Clock synchronization:1 ms synchronization between AC 800M controllers achieved through CNCP protocol

Working temperature:+5°C to+55°C

Storage temperature:-40°C to+70°C

Relative humidity:5%to 95%(non condensing)

Protection level:IP20(according to EN 60529,IEC 529)

Corrosion protection:Complies with ISA 71.04 G3 level

Certification:CE mark,UL 508,UL 60079-15(hazardous locations),compliant with RoHS,WEEE,etc.(some materials mention Marine certificates:ABS,BV,DNV-GL,LR)

Physical dimensions(width x height x depth):119 mm x 196 mm x 135 mm(CPU board)/16 cm x 16 cm x 12 cm(packaging dimensions)

Weight(including base):Approximately 1.2 kg(2.6 lbs)

Main features and advantages

The ABB PM864AK01 3BSE018161R1 processor unit provides significant advantages for industrial automation systems with its high performance,reliability,and flexibility

High performance processing capability:Equipped with a powerful processor,PM864AK01 can execute complex control logic at high speed and efficiency,achieving real-time and precise control of processes.Its fast Boolean operation performance and flexible loop time configuration make it suitable for various high demand industrial applications.

Excellent redundancy support:This module supports CPU redundancy,as well as redundant configurations for CEX Bus,communication interfaces,and S800 I/O.This means that even if the main CPU or communication path fails,the system can automatically and seamlessly switch to the backup unit,greatly improving the availability and reliability of the system and ensuring the continuity of the production process.

Flexible communication options:The motherboard integrates two Ethernet ports for connecting to ABB’s control network(such as a 100 Mbit/s switched Ethernet backbone network),supporting protocols such as MMS and IAC.Meanwhile,the two serial ports provide connectivity to various devices,including configuration tools.This diverse communication interface ensures high interconnectivity of the system.

Powerful Scalability:PM864AK01 supports connecting up to 12 CEX Bus communication modules and can manage a large number of S800 I/O modules(up to 96 in a single CPU configuration and up to 84 in a redundant CPU configuration).This enables the system to flexibly expand to adapt to industrial applications of different scales and complexities.

Durable industrial design:PM864AK01 is designed for harsh industrial environments,capable of stable operation over a wide temperature range of+5°C to+55°C,and meets IP20 protection level and G3 corrosion protection standards.Its modular and DIN rail installation design also simplifies installation and maintenance.

Easy to maintain and diagnose:The CPU board includes LED indicator lights(PWR,STA,RUN),an Initiat button,and a CompactFlash interface.These features,along with the System 800xA control builder and diagnostic tools,help simplify troubleshooting and daily maintenance operations.

PM864AK01 3BSE018161R1 ABB

application area

The ABB PM864AK01 3BSE018161R1 processor unit is widely used in various large-scale industrial automation and process control fields.As the core component of ABB System 800xA DCS:

Oil and gas industry:used in refineries,natural gas processing plants,offshore platforms,and pipeline systems to control complex production processes such as distillation,catalytic cracking,compression,pumping,and storage to ensure production efficiency,safety,and compliance.

Chemical and petrochemical industries:used in chemical plants,fertilizer plants,etc.to precisely control key parameters such as chemical reactions,separation processes,temperature,pressure,and flow rate,ensuring product quality and production safety.

Electricity generation industry:used in thermal power plants,nuclear power plants,hydroelectric power plants,and renewable energy generation facilities to control boilers,turbines,generator sets,auxiliary systems,and grid connections,ensuring stable,efficient,and reliable electricity production.

Metallurgical industry:used in the production process of metals such as steel and aluminum to control key equipment such as blast furnaces,rolling mills,and continuous casting machines,optimize production processes,and improve product quality and efficiency.

Mining:Used in mining and mineral processing to control processes such as crushing,grinding,flotation,and refining,improving mineral recovery rates and operational efficiency.

Pulp and paper industry:used in pulp production and papermaking processes to control various links from wood processing to finished paper rolls,optimizing production efficiency and product quality.

Water treatment and sewage treatment:Used in municipal and industrial water treatment plants to automate processes such as water pumps,valves,filtration,and disinfection,ensuring water supply safety and meeting sewage discharge standards.

Related products

The products related to ABB PM864AK01 3BSE018161R1 mainly include ABB AC 800M control system and other components of System 800xA:

ABB TP830 base plate:PM864AK01 is installed on it,providing electrical and communication connections.

ABB TB850 CEX Bus Terminator/TB807 Modulus Bus Terminator/TB852 RCU Link Terminator:Terminal devices used for bus connections.

ABB CI8xx series communication interface modules,such as CI854(PROFIBUS DP master station),CI858(DriveBus interface),CI860(FOUNDATION Fieldbus HSE interface),are connected to PM864AK01 via CEX Bus to expand their fieldbus connectivity capabilities.

ABB S800 I/O module:ABB’s remote I/O system,including various digital input/output and analog input/output modules,connected to PM864AK01 through ModulaBus or CEX Bus.

ABB SA8xx series power module:provides power for AC 800M controllers and I/O modules.

ABB System 800xA software:including Control Builder,Operator Workplace,Engineering Workplace,etc.,used for configuring,programming,operating,monitoring,and diagnosing PM864AK01.

CompactFlash card:used for storing applications and data.

Battery:Used for RAM memory backup.

Installation and maintenance

Preparation before installation:

Before installing the ABB PM864AK01 3BSE018161R1 processor unit,it is essential to carefully read the detailed installation manual,technical specifications,and safety guidelines for the ABB System 800xA and AC 800M controller systems.Ensure that the installation environment meets the temperature,humidity,vibration,and EMC(electromagnetic compatibility)requirements of the module.Before performing any electrical connection operation,be sure to disconnect all power sources and take appropriate locking/tagging procedures to prevent accidental power on.

Insert the PM864AK01 processor unit correctly into its matching TP830 motherboard,ensuring that the module is fully inserted and securely fixed.According to the system design,connect the Ethernet cable to the CN1 and CN2 ports,and connect the serial cable to the COM3 and COM4 ports as needed.Ensure proper power connection and proper grounding.

Maintenance suggestion:

To ensure the long-term stable operation of the ABB PM864AK01 3BSE018161R1 processor unit and the highest availability of the System 800xA system,it is recommended to perform regular maintenance:

Regular inspection:Regularly check whether the physical connections of the module are secure,including its insertion status in the base plate,the connection of power cords and all communication cables.

Environmental cleanliness:Keep the interior of the control cabinet clean and regularly remove dust and pollutants from the surface of the PM864AK01 module to ensure good heat dissipation and avoid overheating.

Status monitoring:Continuously monitor the running status of the CPU and system health through the LED indicator lights(PWR,STA,RUN)on the module and the diagnostic function in the System 800xA software.Once any abnormalities or alarms are detected,the cause should be immediately identified and corrective measures taken.

Software update:According to ABB’s recommendations,regularly check and update the firmware of the controller and the System 800xA system software.This helps to obtain the latest features,performance improvements,security patches,and support for new hardware.

Battery maintenance:Regularly check the status of the built-in lithium battery(used for memory backup)and replace it in a timely manner when the battery is low or the lifespan expires to prevent application data from being lost during power outages.

System backup:Regularly backup the application programs and configuration data of the controller to CompactFlash cards or other storage media,in order to quickly restore the system in the event of a failure.

Troubleshooting:Utilize the engineering tools and diagnostic functions of System 800xA to conduct system level health checks,performance analysis,and troubleshooting.All complex repair or replacement operations should be carried out by qualified personnel who have received professional training from ABB.

PM864AK01 3BSE018161R1 ABB

Product Guarantee

ABB provides strict product assurance for the PM864AK01(3BSE018161R1)processor unit.