Description

ABB PM864AK02 3BSE018164R1

I. Basic Information

Model: PM864AK02

Part No.: 3BSE018164R1

Brand: ABB

System: ABB AC800M Controller, compatible with 800xA DCS platform

Product Type: Redundant processor kit including 2 PM864A CPU units, 2 TP830 baseplates, CEX-bus synchronization cable, terminators and backup lithium batteries.

Product Positioning

PM864AK02 is a high-performance medium-end process controller designed for high-availability continuous process industries. It supports hardware CPU hot redundancy, deterministic real-time control, mass PID loop operation and large-scale I/O management, widely used in power auxiliary control, petrochemical, metallurgy and environmental protection automation projects. PM864AK01 is single CPU version, while PM864AK02 is factory integrated dual redundant CPU set for bumpless failover.

Hardware Architecture

Industrial reinforced flame-retardant PCB with multi-stage EMC filtering and electrical isolation, consisting of six core units: high-speed RISC real-time operation core, large-capacity memory, dual redundant Ethernet, CEX-bus redundancy synchronization unit, local debugging & diagnosis interface, backplane bus & multi-protection power unit. Equipped with backup battery for RTC clock and process data power-off retention.

Mounting & Standard Accessories

DIN rail mounting with TP830 baseplate; dimension: 119×186×135mm, total weight 2.9kg. Standard accessories: 2×PM864A CPU, 2×TP830 base, 1×TK850 redundancy cable, bus terminators, 2×backup batteries.

Compatible System

Hardware: AC800M rack, SD822 24VDC redundant power, S800 I/O modules, CI series communication modules
Software: Compact Control Builder M, supports IEC61131-3 standard programming languages
Upper System: 800xA, SCADA, MES, SIS, SOE event server
Typical Industries: Thermal power auxiliary control, petrochemical refining, metallurgy, municipal wastewater treatment, waste incineration power generation.

Key Product Advantages

Hardware dual CPU hot redundancy with typical switchover time ＜50ms, no process disturbance or data loss.
Dual independent Ethernet with RNRP redundant protocol to avoid single-point network failure offline.
32MB large RAM supports thousands of I/O points and complex batch process control algorithms.
Comprehensive hardware self-diagnosis + millisecond-level SOE event recording for accident traceability.
Industrial-grade EMC design adapts to harsh electromagnetic, vibration and dusty workshop environments.
Full backward compatibility with legacy AC800M controllers, convenient for single to redundant system technical renovation.

II. Technical Specifications

2.1 Electrical Parameters

Rated Power Supply: 24VDC ±10%, supports redundant power system
Typical Power Consumption per CPU: ≤12W
Protection: Overvoltage, undervoltage, overcurrent, reverse polarity lockout
Isolation Withstand Voltage: 500VAC; EMC immunity: ±4kV ESD, ±2kV EFT.

2.2 Performance Parameters

32-bit RISC real-time processor, 32MB RAM + onboard Flash memory
Configurable deterministic scan cycle: 1~100ms
Supports large-scale local & remote S800 I/O station expansion
Compliant with IEC 61131-3 international programming standard
Redundancy switch time: ＜50ms typical.

2.3 Communication Interfaces

2×10/100Mbps RJ45 Ethernet (RNRP, TCP/IP, Modbus TCP, OPC)
1×isolated RS232 for local download & firmware upgrade
1×CEX-Bus dedicated redundancy synchronization port
Backplane ModuleBus for local I/O & communication extension modules
Expandable via CI modules: Profibus DP, Profinet, IEC61850, Modbus RTU.

2.4 Environmental & Certification

Operating Temp: 0℃ ~ +55℃; Storage Temp: -40℃ ~ +70℃
Humidity: 5%~95%RH non-condensing
MTBF ≥220000h; Protection Class: IP20.

2.5 Mechanical Parameters

DIN 35mm standard rail mounting; Gold-plated anti-oxidation interface, multi-channel LED status indicators for power, run, fault, redundancy and network status.

III. Core Functions

Deterministic closed-loop PID process control, sequence interlock and batch production control.
Dual CPU hot standby redundant fault-tolerant control to eliminate single-point shutdown risk.
Dual Ethernet link redundancy ensures uninterrupted upper monitoring communication.
Full-link hardware fault diagnosis + high-precision SOE timestamp event storage for safety audit and accident analysis.
Multi-protocol open communication realizes seamless interconnection with third-party industrial equipment and intelligent remote operation & maintenance.

IV. Working Principle

After power-on self-test of two CPUs, the master and standby negotiate identity and complete full program & variable synchronization via CEX-bus. The primary CPU executes control logic and outputs commands, while the standby keeps hot synchronous listening. Once the master fails, seamless switchover within 50ms is triggered, and the faulty unit will trigger alarm and fault latch. After maintenance and re-powering, the repaired CPU automatically synchronizes data and rejoins the redundant system.

V. Application Scenarios

Thermal power plant auxiliary DCS control (water treatment, flue gas desulfurization, coal conveying).
Petrochemical refining, storage and pipeline pressure flow interlock control.
Metallurgical production line, cement kiln temperature control and fan pump interlock.
Municipal sewage treatment, waste incineration power generation environmental protection automation.
Legacy AC800M single CPU system upgrade to redundant high-availability architecture.