Description
Product Core Brief
- Model: PM864AK01
- Order code: 3BSE018161R1
- Brand: ABB
- Series: ABB AC 800M / System 800xA control system family
- Core Function: Central processor module for AC 800M controllers, executing continuous and batch control logic, managing S800 I/O via ModuleBus, and providing Ethernet connectivity for engineering, operator stations, and plant networks.
- Product Type: Processor module / CPU controller
- Key Specs: 32 MB RAM | 96 MHz MPC860 processor | 2× 10/100 Mbit/s Ethernet ports | 2× RS-232C serial ports | CompactFlash card slot | CEX-bus expansion for up to 12 communication modules | supports CPU redundancy | connects to S800 I/O via TP830 baseplate
- Condition: New Original / New Surplus
Key Technical Specifications
- Order code: 3BSE018161R1
- Product designation: PM864AK01 processor unit
- System family: ABB AC 800M / System 800xA
- Processor: MPC860, 96 MHz clock frequency
- Memory: 32 MB RAM, approximately 23.522 MB available for application
- Power supply: 24 VDC nominal (19.2–30 VDC), supplied via AC 800M base unit
- Communication interfaces: 2× RJ45 Ethernet ports (CN1, CN2) for control network; 2× RS-232C serial ports (COM3 with modem control signals, COM4 isolated for configuration tool)
- Fieldbus expansion: Supports PROFIBUS DP, FOUNDATION Fieldbus HSE, Modbus TCP, MasterBus 300, and other protocols via CEX-bus communication interface modules (CI8xx series), up to 12 modules
- I/O architecture: No onboard I/O; connects to S800 I/O through ModuleBus on TP830 baseplate; non-redundant configuration supports up to 12 S800 I/O modules (192 points) per cluster
- Redundancy: Supports CPU redundancy configurations (hot-standby with automatic failover in under 10 ms), including redundant CPU, CEX-bus, communication interfaces, and S800 I/O
- Storage: CompactFlash card slot for application and firmware storage
- Operating temperature: 0 to +55 °C (typical)
- Mounting: DIN-rail mounting via TP830 baseplate
- Typical applications: Process control, power generation, oil and gas, water treatment, chemical processing, metallurgy, pulp and paper, and distributed industrial automation systems
- Note: Exact firmware version, communication module configuration, and system compatibility should be confirmed from the ABB product documentation or the unit nameplate
Product Introduction
The ABB PM864AK01 3BSE018161R1 is a high-performance central processing unit designed for the ABB AC 800M control system architecture. It serves as the core controller in distributed automation applications, executing deterministic control programs, coordinating I/O data exchange through the TP830 baseplate and S800 I/O modules, and providing Ethernet-based connectivity for plant networks and engineering access.
The PM864AK01 features an MPC860 processor running at 96 MHz with 32 MB of RAM, of which approximately 23.522 MB is available for application use—roughly double the memory of the PM861K01. The module includes two 10/100 Mbit/s Ethernet ports for control network communication and two RS-232C serial ports, with COM4 isolated for configuration tool connection. A CompactFlash card slot provides non-volatile storage for applications and firmware, enabling controller recovery after power interruptions without requiring a full download from the engineering station.
The module supports CPU redundancy configurations, allowing two PM864AK01 units to operate in a hot-standby arrangement for higher system availability. Redundancy extends to CEX-bus communication modules and S800 I/O, providing comprehensive fault tolerance with automatic failover in under 10 ms. The “A” variant (PM864AK01) adds support for additional redundant communication modules (CI85A, CI860, BC810) compared to the standard PM864K01. Fieldbus connectivity such as PROFIBUS DP, FOUNDATION Fieldbus HSE, and Modbus TCP can be added through ABB CI8xx communication interface modules on the CEX-bus, with support for up to 12 modules.
This module is not a standalone PLC and must be installed as part of a compatible AC 800M / System 800xA system with a TP830 baseplate. Before replacement, always confirm the existing system configuration, firmware version, communication interface modules, and connected S800 I/O arrangement.
QA & Testing SOP
- Order code verification: Confirm PM864AK01 and 3BSE018161R1 on the nameplate.
- Visual inspection: Check the module housing, Ethernet ports, serial ports, CompactFlash slot, and mounting hardware for damage or corrosion.
- Power-up test: Install the module into the correct TP830 baseplate position, apply 24 VDC supply, and verify normal start-up without fault indicators.
- Communication check: Verify Ethernet connectivity on both ports and serial port communication via COM3/COM4.
- System test: Confirm program download/upload capability, S800 I/O communication, redundancy status if applicable, and stable controller operation within the AC 800M / System 800xA environment.
Installation Pitfalls & Guide
❗ Confirm system compatibility. PM864AK01 is designed for the ABB AC 800M / System 800xA architecture with TP830 baseplate. It cannot be directly substituted into AC 800F / Freelance or other ABB controller families.
❗ Record existing configuration. Before removal, save the controller program, firmware version, communication module configuration, and baseplate slot assignment.
❗ Verify CompactFlash card. Ensure the CompactFlash card is present and contains the correct application. The card is essential for controller recovery after power loss.
❗ Check redundancy configuration. If the system uses CPU redundancy, confirm that both primary and secondary units are properly configured and synchronized before replacing either module.
❗ Follow proper grounding practices. Ensure correct grounding and shielding to minimize electromagnetic interference in industrial environments.
Replacement steps:
- Pre-install: Back up the existing controller program, note the firmware version, communication configuration, and slot position.
- Removal: Follow safe shutdown procedures, disconnect power if required, then remove the processor module.
- Install: Insert the PM864AK01 into the correct TP830 baseplate position, verify all connectors, and confirm proper seating.
- Commissioning: Power up the system, confirm normal startup, verify Ethernet and fieldbus communication, check S800 I/O status, validate redundancy if applicable, and confirm process control operation before returning to production.
Technical FAQ
Is 3BSE018161R1 the correct order code for PM864AK01? Yes, 3BSE018161R1 is listed as the order code for the ABB PM864AK01 processor module. Always confirm the full designation on the existing nameplate.
What does the “A” in PM864AK01 mean? The “A” variant (PM864AK01) supports additional redundant communication modules (CI85A, CI860, BC810) compared to the standard PM864K01. Both share the same processor and memory specifications.
What system is PM864AK01 used in? It is designed for the ABB AC 800M control system and integrates with System 800xA environments, using S800 I/O and CEX-bus communication interface modules.
Is PM864AK01 the same as PM864K01? Both belong to the PM864 family with 32 MB RAM and 96 MHz processor. The “A” variant adds support for additional redundant communication modules (CI85A, CI860, BC810).
Does PM864AK01 have onboard I/O? No. PM864AK01 has no onboard discrete or analog I/O by design. Field I/O is handled through S800 I/O modules connected via the TP830 baseplate ModuleBus.
Can PM864AK01 be configured for redundancy? Yes. PM864AK01 supports CPU redundancy configurations for higher availability in critical process applications, with automatic failover in under 10 ms.
Do you offer price flexibility? Yes. Pricing depends on condition, firmware visibility, quantity, and urgency. New original stock and tested surplus units are quoted separately.
What warranty is included? Typical coverage is 12 months from delivery for functional defects, excluding incorrect installation, firmware mismatch, communication configuration errors, or damage from improper handling. Final terms are confirmed on the quotation.
