Description

ABB PM862K02 3BSE081636R1

The ABB PM862K02 3BSE081636R1 is a redundant processor unit designed for the ABB AC 800M control system. It delivers high reliability, real-time performance, and scalability through its dual-CPU redundant architecture, multi-protocol communication capabilities, real-time control logic execution, and comprehensive fault tolerance mechanisms. Its working principle encompasses the entire process of data acquisition, arithmetic processing, communication interaction, and system management, making it a core component for "stable, efficient, and intelligent" control in modern industrial automation.

Hardware Components

CPU:
Dual PM862 CPUs provide redundancy and failover capabilities, ensuring continuous operation of the control system even if a processor unit fails. Each CPU operates at 67MHz with 32MB of memory, capable of handling complex control tasks.
Communication Interfaces:

Two RJ45 Ethernet ports (CN1, CN2) for connecting to the control network.
Two RJ45 serial ports (COM3, COM4): COM3 is an RS-232C port with modem control signals; COM4 is isolated for configuration tools.
CAN bus support for flexible device connectivity.

Other Components:
Microprocessor, Random Access Memory (RAM), Real-Time Clock (RTC), LED indicators, initialization button, and Compact Flash interface.

Features & Advantages

High Reliability:
Robust design with simple fault diagnosis, full EMC certification, IP20 protection, and stable operation in industrial environments.
Scalability:
Modular design allows step-by-step system expansion.
Excellent Communication:
Multi-protocol support (Ethernet, PROFIBUS DP, etc.) with redundant Ethernet ports for reliable data transmission.
Flexible Configuration:
Configurable via 800xA Control Builder for customized settings.

Technical Specifications

Processor:

CPU: MPC866 microprocessor, 67MHz clock frequency.
Performance: 0.18ms for 1000 Boolean operations.

Memory:

RAM: 32MB (battery-backed for applications).
Flash: 4MB Flash PROM (firmware storage), Compact Flash card (application and cold-start data).

Communication Interfaces:

Ethernet: Two RJ45 ports (CN1, CN2), IEEE 802.3 compliant, 10Mbit, supporting MMS and IAC. Recommended backbone: 100Mbit switched Ethernet.
RS-232C: Two RJ45 serial ports (COM3, COM4): COM3 (75-19200 baud with modem control); COM4 (isolated, 9600 baud for configuration).

Power Supply:

Voltage: 24V DC (19.2-30V DC input range).
Current: 210mA typical, 360mA max (excluding module bus and CEX-bus power).
Power: 5.1W typical, 8.6W max (including all buses).
Redundant Power: Supports redundant power status inputs (SA, SB), 30V max input voltage.

I/O Characteristics:

I/O Clusters: 1 electrical + 7 optical on non-redundant module bus; 7 optical on redundant bus.
I/O Capacity: Up to 96 I/Os (single PM862) or 84 I/Os (redundant PM862).
Bus Scan Rate: 0-100ms (depends on I/O module count).

Physical Dimensions:

Width: 119mm
Height: 186mm
Depth: 135mm
Weight: 2800g

Environmental Parameters:

Operating Temperature: +5°C to +55°C
Storage Temperature: -40°C to +70°C
Humidity: 5-95% (non-condensing)
Altitude: 2000m max
Protection Class: IP20

Other Features:

Clock Synchronization: 1ms precision via CNCP protocol.
OPC Client: Up to 3000 events in the event queue.
OPC Server Speed: 36-86 events/sec, 113-143 data messages/sec.
CEX Bus: 12 modules supported, 2.4A max power current.

Working Principle

The PM862K02 executes control logic, data processing, communication coordination, and system management through the following mechanisms:

1. Hardware Architecture & Component Coordination

Dual-CPU Redundancy:
Active/Standby CPUs with real-time synchronization via high-speed internal bus.
Communication Interfaces:
Ethernet (redundant paths), serial ports (isolated COM4), and CAN bus for I/O modules.
Storage & Clock:
Compact Flash for firmware/programs; RTC for precise time stamping.

2. Control Logic Execution Flow

Data Acquisition:
Scans I/O modules, preprocesses analog/digital signals (filtering, linearization).
Logic Processing:
Executes PID control, safety interlocks, and data analysis based on IEC 61131-3 programming.
Output Control:
Converts results to analog/digital signals with output validation and fault protection.

3. Communication Mechanisms

Industrial Ethernet:
Modbus TCP, PROFIBUS DP, and ABB proprietary protocols with redundant links.
Serial Communication:
RS-232/RS-485 with isolation for legacy devices.
CAN Bus:
CANopen protocol for high-speed I/O data transfer.

4. Redundancy & Fault Handling

Hot Standby Switching:
Automatic failover in <50ms upon detection of faults (e.g., watchdog timeout).
Self-Diagnosis:
Continuous monitoring of CPU, memory, and I/O connections with LED/alarm indicators.
EMC Protection:
Isolated power, shielded enclosure, and filtering for industrial environments.

5. System Management

Firmware Updates:
Remote upgrade via Ethernet (FTP/HTTP).
Time Synchronization:
NTP or hardware clock for event logging consistency.
Event Logging:
Stores critical operations (program downloads, faults) for auditing.

Typical Applications

Process Industry:
Closed-loop temperature/pressure control for reactors; safety interlock systems for refineries.
Power Systems:
Turbine speed control; substation automation.
Manufacturing:
Robot coordination; precision motion control.
Energy Management:
Microgrid control; HVAC optimization in smart buildings.

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