ABB PM864AK02 AC 800M Redundant Processor Unit Kit

Description

Technical Specifications

• Manufacturer: ABB
• Model: PM864AK02 (3BSE018164R1)
• Product Type: AC 800M Redundant Processor Unit Kit
• Processor: 32‑bit PowerPC architecture, high‑speed clock frequency
• Memory:
  • RAM: 16 MB for application and data processing
  • Flash Memory: 64 MB non‑volatile flash for firmware, program, and data storage
  • Backup Battery: 3.6 V lithium battery (4943013‑6) for real‑time clock and data retention
• System Compatibility: ABB AC 800M Controller, ABB 800xA Distributed Control System
• Power Supply: 24 V DC nominal (19.2–30 V DC)
• Power Consumption: Typical 6.0 W, maximum 10.3 W per CPU module
• Communication Interfaces:
  • 2 × 10 Mbps Ethernet ports (RJ‑45) per CPU for control network connectivity
  • 2 × Serial ports (RS‑232C) per CPU: 1 general‑purpose port, 1 isolated port for configuration tools
  • Supports MMS, IAC, Modbus RTU/TCP, OPC DA/UA, Profibus DP (via expansion modules)
  • CEX‑bus and ModuleBus for internal system communication
• Control Performance:
  • Minimum application program scan cycle: 1 ms
  • Supports up to 64 PID control loops
  • Deterministic execution of complex control algorithms
• Redundancy Support: Full CPU redundancy (CPU, CEX‑bus, communication interfaces, S800 I/O); maximum switch‑over time of 10 ms
• I/O Capacity:
  • Max 96 I/O modules (single configuration) or 84 I/O modules (redundant configuration) on ModuleBus
  • Supports up to 12 single or 6 redundant CEX‑bus modules
• Environmental Ratings:
  • Operating temperature: -25°C to +70°C
  • Storage temperature: -40°C to +85°C
  • Relative humidity: 5%–95% (non‑condensing)
  • Protection rating: IP20
• Physical Characteristics:
  • Baseplate width: 115 mm
  • Weight: 2.3 kg (complete redundant kit)
  • DIN‑rail mountable design for industrial control cabinets
• Certifications: CE, UL, CSA compliant; full EMC certification; meets industrial safety standards

Functional Features

• Ultra‑High Performance: Delivers powerful processing capabilities for executing large, complex control programs and multi‑tasking operations in large‑scale systems.
• Deterministic Real‑Time Control: Maintains a minimum scan cycle of 1 ms, ensuring precise and responsive regulation of critical industrial processes.
• Full Redundancy Capability: Supports hot‑standby CPU redundancy with a maximum 10 ms switch‑over time, eliminating single points of failure and ensuring 99.999% system availability.
• Dual Ethernet Connectivity: Two 10 Mbps Ethernet ports per CPU enable seamless data exchange with other controllers, HMIs, SCADA systems, and third‑party devices.
• Isolated Serial Communication: One isolated RS‑232C port per CPU dedicated to configuration tools, ensuring secure and reliable setup and maintenance.
• Non‑Volatile Data Retention: Backup batteries preserve critical control programs, process data, and real‑time clock settings during power outages.
• Modular & Scalable Design: Easily integrates with AC 800M I/O modules and communication expansion cards, supporting flexible system scaling to meet evolving large‑scale application needs.
• Online Configuration & Maintenance: Supports online program editing, parameter adjustment, and firmware updates without system shutdown, minimizing production downtime.
• Comprehensive Diagnostics: Built‑in self‑monitoring, status indicators, and event logging enable proactive fault detection and efficient troubleshooting.
• Industrial‑Grade Durability: Constructed to withstand extreme temperatures, vibration, and electrical interference, ensuring reliable operation in harsh industrial environments.
• User‑Friendly Programming: Configurable via ABB Control Builder M using IEC 61131‑3 standard languages (LD, FBD, ST, IL, SFC), enabling efficient development of custom control logic.
• Synchronized Operation: Supports high‑precision clock synchronization between AC 800M controllers, ensuring coordinated system performance.

Application Scenarios

• Process Industries: Large‑scale chemical, petrochemical, and pharmaceutical plants for reactor control, distillation, batch processing, and GMP‑compliant automation.
• Power Generation: Large fossil fuel, combined‑cycle, and renewable power plants for boiler control, turbine governing, generator synchronization, and balance‑of‑plant automation.
• Oil & Gas: Large refineries, offshore platforms, and long‑distance pipeline networks for process control, safety shutdown systems, compressor control, and asset management.
• Water & Wastewater: Large municipal treatment plants, desalination facilities, and regional water distribution networks for pump control, filtration, and process automation.
• Manufacturing: Large food & beverage, pulp & paper, and metal processing facilities for production line control, material handling, and quality assurance.
• Mining & Minerals: Large‑scale ore processing, smelting, and material handling systems for reliable operation in harsh mining environments.
• Cement & Building Materials: Large cement manufacturing facilities for kiln control, raw material handling, and finished product packaging.
• Machine Automation: Large‑scale packaging machinery, conveyor systems, and industrial robot fleets for precise motion control and production line optimization.
• Building Automation: Large commercial and industrial buildings for HVAC systems, energy management, and facility control.