ABB PM866AK02 AC 800M Redundant CPU Kit 3BSE081637R1 Processor

Overview

The ABB PM866AK02 (3BSE081637R1) delivers high-performance processing power for the AC 800M controller family. Designed for critical industrial automation, this redundant CPU package ensures continuous process uptime with seamless max 10 ms switchover capability. The system features a 133 MHz MPC866 processor, 64 MB onboard memory, and native support for up to 32 concurrent control applications.

Technical Specifications

Installation Guide

• Mount unit onto standard 35 mm DIN rails using the slide & lock mechanism.
• Ensure physical separation between power lines and high-frequency communication cabling.
• Connect dual 24 V DC feeds to power inputs to enable redundant power monitoring.
• Verify Ethernet MAC addresses printed directly on the TP830 baseplate labels.
• Install TB807 bus terminators on both ends of the ModuleBus chain.
• Link redundant CPU pairs using the provided TK851 RCU-Link cable.

Commissioning & Maintenance Convenience

• Configure automation code using ABB System 800xA Control Builder software tool.
• Access active diagnostics via front-panel LED indicators and dedicated serial COM4 ports.
• Hot-swap primary processor modules during live plant operations without interrupting logic.
• Replace memory backup lithium batteries while system maintains primary power.

System Compatibility

• Fully compatible with ABB S800 I/O clusters via optical and electrical ModuleBus.
• Supports up to 12 CEX-Bus communication interface modules using TK850 expansion cables.
• Communicates on Control Network via MMS and Inter Application Communication protocols.
• Integrates natively with third-party OPC servers at 36-86 events per second transmission rates.

Certifications & Compliance

• ISASecure Certified: Ensures robust cybersecurity defenses for critical infrastructure.
• Electrical Safety: Complies with EN 50178, IEC 61131-2, and UL 61010-2-201.
• Hazardous Location: Certified for UL 60079-15, cULus Class 1 Zone 2 (Ex nA IIC T4 Gc X).
• Marine Approvals: DNV-GL, ABS, BV, and LR classification society approvals.
• Environmental Directives: Fully compliant with EU RoHS, UAE RoHS, CN RoHS, and WEEE.

Package List, Warranty & Delivery

• Package Includes:
• 2 pcs PM866A CPU units
• 2 pcs TP830 Baseplates (115 mm width)
• 2 pcs TB807 ModuleBus Terminators
• 1 pc TK850 CEX-Bus Expansion Cable
• 1 pc TK851 RCU-Link Cable
• 2 pcs Backup Batteries for memory protection (Part 4943013-6)
• Warranty: Includes a comprehensive 12-month factory-grade warranty.
• Shipping Express: Fast dispatch within 24-48 hours via FedEx, UPS, or DHL.

Typical Application Scenarios

• Continuous oil and gas refining processes requiring zero-downtime CPU redundancy.
• Large-scale power generation units utilizing high-speed CNCP clock synchronization protocols.
• Chemical batch manufacturing requiring G3 corrosion protection in harsh atmospheric environments.

Diagnostics & System Visibility

• Onboard event queue buffers up to 3000 events per connected OPC client.
• Front-panel status LEDs indicate CPU activity, fault conditions, and network channel integrity.
• Self-diagnostic firmware detects memory corruption, power voltage dips, and communication timeouts automatically.

Global PLC Spare HUB Insight

In high-availability power plant upgrades, engineering teams often encounter communication trips caused by improper bus termination. During a recent field deployment involving the PM866AK02 unit, field engineers noted that using non-isolated serial tools on COM3 caused grounding loops. Connecting the specialized configuration tool strictly to the opto-isolated COM4 port eliminated communication dropouts instantly. Always maintain proper optical isolation when running diagnostic tools in high-noise electrical substations.

Frequently Asked Questions & Selection Guide

Question: What is the main operational difference between PM866K01 and the PM866AK02 kit?

Answer: The PM866AK02 (3BSE081637R1) is a complete dual-redundant kit containing two PM866A CPUs, two baseplates, interconnecting cables, and terminators. The single-CPU version lacks redundant synchronization cables and second-channel hardware, making the PM866AK02 ideal for mission-critical processes.

Question: How do I select between electrical and optical ModuleBus for my I/O clusters?

Answer: When deploying a redundant PM866AK02 controller, electrical ModuleBus expansion is restricted to 0 clusters. You must use optical ModuleBus expansion interfaces, supporting up to 7 optical I/O clusters and 84 total I/O modules.

Question: How long does the back-up battery maintain application memory during a full power outage?

Answer: The onboard 3.6 V lithium battery preserves user code and retention variables in RAM during power down. Under normal ambient operating conditions, the battery provides several months of memory backup power.

Question: Can I replace a single faulty CPU module while the control system remains live?

Answer: Yes, the PM866AK02 supports hot-swapping. Unclipping the standby processor does not interrupt control logic execution on the primary CPU, which maintains active process execution continuously.

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