PM858K02 3BSE082896R1 ABB AC 800M Redundant Controller Kit Fast Dispatch

PM858K02 ABB AC 800M Redundant Controller Kit Overview

The ABB PM858K02 (Article Number 3BSE082896R1) is a high-availability redundant controller kit engineered for the AC 800M series automation platform. Driven by a 33 MHz MPC866 processor with 16 MB onboard memory (7.147 MB application RAM), this assembly ensures continuous process execution with seamless hardware switchover times under 10 ms. The dual-controller setup eliminates single points of failure across critical control loops and complex automation architectures.

Each PM858K02 package provides a complete dual redundant hardware foundation, including two PM858 CPUs, two TP830 baseplates with unique physical hardware Ethernet addresses, ModuleBus terminators, expansion interlinks, and lithium backup batteries. Built with ISA Secure certification and robust G3 conformal coating, this unit delivers high immunity against harsh industrial environments, high-level RFI/EMI interference, and corrosive atmospheres.

Package Bill of Materials

• 2 pcs PM858 CPU Modules
• 2 pcs TP830 Baseplates (Includes unique hardware MAC addresses)
• 2 pcs TB807 ModuleBus Terminators
• 1 pcs TK850 CEX-Bus Expansion Cable
• 1 pcs TK851 RCU-Link Cable
• 2 pcs Lithium Backup Batteries for Memory Retention (P/N: 4943013-6)

Technical Specifications

System Architecture & Mounting Integration

• Mounts to standard DIN rails utilizing the integrated baseplate slide-and-lock snap mechanism.
• Exposes front CompactFlash slots for easy cold-start firmware updates and project loading.
• Uses the TK851 RCU-Link cable to synchronize real-time application memory states between redundant CPUs.
• Connects to CEX-Bus expansion racks via the TK850 cable or sectioned BC810/BC820 bus optical isolators.
• Interfaces with optical ModuleBus clusters using TB807 terminators to execute high-speed S800 I/O scans.

Target Equipment & Industrial Application Scenarios

• Continuous Petrochemical Processing: High-availability DCS supervision over catalytic reactors and distillation columns.
• Power Generation Turbomachinery: Redundant speed, trip, and sequence control loops for utility-scale gas and steam turbines.
• Offshore Production Platforms: Emergency Shutdown Systems (ESD) requiring certified ISA Secure G3 ruggedized computing hardware.
• Pharmaceutical Batch Synthesizers: Real-time recipe execution across complex multi-tasking batch control structures.
• Water Treatment Distribution Grids: Wide-area SCADA telemetry via dual redundant Ethernet networks running MMS protocols.

Diagnostic & Signal Integrity Capabilities

• Executes hardware-driven sub-10ms CPU switchovers with zero disturbance to active field output states.
• Monitors onboard power supply rails, backup battery voltage drops, and internal ambient temperature thresholds.
• Front-panel LED indicators report system RUN, FAULT, MAINT, and network activity states in real time.
• Stores up to 3,000 system events per OPC client connection with precise 1 ms CNCP time synchronization across controllers.
• Isolated COM4 port allows field technicians to debug runtime tasks locally without breaking plant network traffic.

Global PLC Spare HUB's Insight

When engineering redundant process systems around the ABB PM858K02, network layout dictates system stability. In redundant CPU configurations, the TK851 RCU-Link cable must be connected before applying 24 VDC auxiliary power to the TP830 baseplates. Powering up redundant PM858 units without the dedicated sync cable plugged in forces both processors into standalone Primary mode, resulting in IP address conflicts on the Control Network.

During an upgrade at an oil refinery, an engineering team reported intermittent communications on a newly installed PM858K02 redundant rack. Our diagnostic inspection revealed that the optical ModuleBus fiber rings were routed next to heavy variable frequency drive cabling without proper separation. Moving the fiber links away from high-noise power conduits and re-securing the TK850 CEX-Bus extension cable shield restored full 10 ms synchronization speeds, enabling uninterrupted 24/7 uptime across all connected S800 I/O clusters.

Selection & Compatibility Guide

• Verify System Version: The PM858K02 kit strictly requires System 800xA version 6.0.2 or Compact Control Builder 6.0.0-1 (or higher).
• ModuleBus I/O Capacity: Redundant PM858 controllers support up to 7 optical ModuleBus clusters (no direct electrical cluster on redundant CPU baseplates). Plan your S800 I/O layout accordingly.
• Power Supply Redundancy: Connect separate, galvanically isolated 24 VDC power feeds to both inputs on each TP830 baseplate to maintain true dual-path power reliability.

Packaging, Logistics & Warranty Terms

• Package Condition: Ships as a brand-new, factory-sealed ABB PM858K02 complete hardware kit with factory documentation.
• Warranty Policy: Fully backed by a 12-month factory-grade replacement warranty starting from dispatch date.
• Warehouse Processing: Order fulfillment and package dispatch within 24 to 48 hours following order confirmation.
• Express Global Shipping: Rapid door-to-door transit worldwide via priority air courier with FedEx, UPS, and DHL Express.

Frequently Asked Questions

Q: What is the main structural difference between the single PM858K01 and the redundant PM858K02 kit?

A: The PM858K02 includes two complete PM858 CPUs, two TP830 baseplates, and sync interlinks (TK850/TK851) for hardware redundancy. The K01 set contains only a single CPU and baseplate without redundant tracking cables.

Q: Can the serial COM3 port be used for modem communication in a redundant PM858K02 system?

A: No. The COM3 port with full RTS-CTS modem support is strictly restricted to non-redundant controller setups. In a redundant PM858K02 setup, serial communications are restricted to the isolated diagnostic interface.

Q: How does memory backup operate on the PM858 CPU during main power loss?

A: Every PM858 CPU contains a replaceable 3.6V lithium battery (Part Number 4943013-6) plugged into the front housing. It retains application RAM and real-time clock parameters during complete power outages.

Q: What happens if an active primary CPU in a PM858K02 pair encounters a hardware fault?

A: The backup CPU detects the fault over the dedicated TK851 RCU-Link cable and assumes control in under 10 ms. The field outputs hold their last valid states without interruption during the transfer.

Q: How do field technicians verify the factory hardware MAC address of a TP830 baseplate?

A: Each TP830 baseplate features a physical hardware label on its side frame printing its unique Ethernet MAC address. This hardware identity persists regardless of CPU swaps or firmware re-flashing.

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