Description
Product Core Brief
- Model: PM864AK01
- Order Code: 3BSE018161R1
- Brand: ABB
- Series: AC800M / Industrial IT 800xA
- Core Function: High-performance redundant processor unit (CPU) for ABB AC800M distributed control systems
- Product Type: DCS CPU Module / Redundant Controller
- Key Specs: 32-bit RISC CPU (MPC862), 96 MHz | 32 MB RAM (27 MB application-available) with ECC | CPU / power / network redundancy | Control Builder M engineering | PROFIBUS DP, Modbus, Foundation Fieldbus communication
- Condition: New Original / New Surplus (verify per listing)
Key Technical Specifications
| Parameter | Specification |
|---|---|
| Product Model | |
| Order Code | 3BSE018161R1 |
| Product Type | AC800M High-Performance Redundant Processor Unit |
| Platform | ABB AC800M / Industrial IT 800xA |
| CPU | 32-bit RISC microprocessor, MPC862, 96 MHz |
| Program Memory | 32 MB SDRAM (27 MB available for application, 5 MB for firmware) |
| Firmware Storage | 2 MB Flash PROM |
| Redundancy | CPU redundancy, power redundancy, network redundancy; switchover < 10 ms |
| Communication Interfaces | 2× Ethernet (RJ45, 10 Mbit/s) |
| Fieldbus Support | PROFIBUS DP, Modbus, Foundation Fieldbus via CEX bus modules |
| CEX Bus Capacity | Up to 12 communication modules |
| ModuleBus I/O | Up to 96 I/O modules (single CPU) or 84 modules (redundant) |
| Task Processing | Up to 16 tasks, minimum cycle 1 ms |
| Power Supply | 24 V DC (19.2–30 V DC) |
| Power Consumption | Typical 6.9 W (11.9 W incl. ModuleBus/CEX-bus supply) |
| Battery Backup | 3.6 V lithium battery for RAM retention (internal backup ~36 h; external SB821/SB822 up to 24 weeks) |
| Operating Temperature | 0 °C to +60 °C (standard); some aftermarket sources cite -40 °C to +70 °C — confirm nameplate |
| Dimensions | 189 × 135 × 119 mm (with TP830 baseplate) |
| Weight | Approximately 1.15–1.2 kg |
Note: PM864AK01 is the “A” version of PM864, supporting redundant communication modules such as CI85A, CI860 and BC810. The non-“A” PM864K01 does not support these redundant CEX modules. PM864AK01 has 32 MB RAM and a 96 MHz processor, compared with PM861AK01’s 16 MB RAM and 48 MHz processor. Always confirm the exact order code 3BSE018161R1 against the nameplate.
Product Introduction
The ABB PM864AK01 (3BSE018161R1) is a high-performance redundant processor unit for the ABB AC800M controller platform, widely used in Industrial IT 800xA distributed control systems. It serves as the central processing unit for AC800M stations, executing control logic, managing fieldbus communication, and coordinating local and remote I/O for continuous, batch, and hybrid process applications.
The module is built around a 32-bit MPC862 RISC processor running at 96 MHz, with 32 MB of SDRAM featuring error detection and correction (ECC). It supports full hardware redundancy — including CPU, power supply, and control network — with automatic switchover in less than 10 ms, making it suitable for critical applications in power generation, oil and gas, chemical processing, metallurgy, and water treatment.
The PM864AK01 baseplate includes two Ethernet ports (CN1, CN2) for control network communication and two RS-232C serial ports (COM3, COM4). COM3 supports modem control signals, while COM4 is isolated for configuration tools. Through the CEX bus, it can accommodate up to 12 communication modules for PROFIBUS DP, Modbus, Foundation Fieldbus, and other protocols. The ModuleBus supports up to 96 I/O modules in single-CPU mode or 84 modules in redundant mode.
For MRO buyers and system integrators maintaining legacy AC800M / 800xA installations, PM864AK01 is typically replaced during controller upgrades, panel rebuilds, spare-part replenishment, or when an existing station experiences CPU faults, communication loss, or redundancy errors. Because the “A” suffix indicates support for redundant communication modules, it must be matched carefully against the existing system configuration. The order code 3BSE018161R1 should be confirmed exactly before replacement.
QA & Testing SOP
- Nameplate verification — Confirm PM864AK01 and full order code 3BSE018161R1.
- Visual inspection — Check the module housing, TP830 baseplate connectors, Ethernet/serial ports, CompactFlash slot, and status LEDs.
- Battery check — Verify the 3.6 V lithium backup battery is installed and within voltage range.
- Power-on test — Install into a compatible AC800M rack with the correct power module and verify normal LED status.
- Communication check — Confirm communication with the Control Builder M engineering station via Ethernet.
- Redundancy verification — If configured for redundancy, verify RCU link synchronization and switchover behavior.
- Application verification — Verify existing program download, online monitoring, and fault-free operation.
All units ship in anti-static packaging. A test log can be provided on request when rack testing is available.
Installation Pitfalls & Guide
Confirm it is AC800M, not AC800F or Advant OCS. PM864AK01 belongs to the AC800M / 800xA platform. It is not interchangeable with AC800F PM802F, Advant OCS PM665/PM825, or AC500 PLCs.
Verify the “A” suffix. PM864AK01 (3BSE018161R1) is the “A” version, supporting redundant communication modules (CI85A, CI860, BC810). The non-“A” PM864K01 does not support these redundant CEX modules. Do not substitute without verifying the system configuration.
K01 vs K02 variants. PM864AK01 and PM864AK02 are both AC800M processor units, but firmware, hardware revision, or redundancy features may differ. Always confirm the exact order code.
Verify power and baseplate compatibility. PM864AK01 mounts on a TP830 baseplate and pairs with SD821/SD822/SD823 power modules.
Back up before replacement. Save the existing control application, configuration, and parameter set via Control Builder M before removing the faulty module.
Handle as ESD-sensitive equipment. Use anti-static packaging and avoid touching connectors or PCB components.
Replacement steps:
- Back up the control application and record current alarms.
- Power down the rack if required by site procedure.
- Remove the faulty PM864AK01 and label all connections.
- Install the replacement module and verify seating on the TP830 baseplate.
- Power up and check status LEDs.
- Verify communication via Control Builder M, load the application, and confirm stable operation.
- If redundant, verify RCU synchronization and perform a controlled switchover test.
Technical FAQ
What is the order code for PM864AK01? The factory order code is 3BSE018161R1.
How is PM864AK01 different from PM861AK01? PM864AK01 has a 96 MHz processor and 32 MB RAM, while PM861AK01 has a 48 MHz processor and 16 MB RAM. PM864AK01 delivers approximately 50% higher execution performance.
How is PM864AK01 different from PM864K01? PM864AK01 is the “A” version, supporting redundant communication modules (CI85A, CI860, BC810). PM864K01 does not support these redundant CEX modules.
Does it support CPU redundancy? Yes. PM864AK01 supports CPU redundancy with automatic switchover in less than 10 ms.
Which software is used for programming? ABB Control Builder M (CBM), supporting IEC 61131-3 languages including FBD, LD, IL, ST, and SFC.
What communication protocols does it support? It supports PROFIBUS DP, Modbus, Foundation Fieldbus, and other protocols via CEX bus communication modules.
Is this product still in production? AC800M is a mature platform. Availability is typically through surplus, refurbished, or remaining OEM stock. Confirm condition and warranty before purchase.
Do you stock single units? Yes. Single units are available for MRO replacement; multi-unit spares and project support can be quoted on request.
