The ABB PM861AK02 (Part Number: 3BSE018160R1) is a high-performance central processing unit (CPU) designed for the ABB Ability™ System 800xA. As a cornerstone of the AC 800M controller family, this module is engineered to provide reliable, deterministic control for a wide range of industrial automation and process control applications.
Product Introduction
The PM861AK02 is a modular, rack-mounted processor that functions as the intelligence hub of the AC 800M system. It is designed to execute complex control logic, manage communication with I/O modules, and interface with higher-level supervisory systems. The “AK” designation typically indicates a kit that includes the processor base unit and essential mounting components.
The module is built on a robust architecture that supports multitasking, allowing it to handle time-critical protection loops alongside slower process optimization algorithms simultaneously. Its integration within the System 800xA environment ensures seamless data flow from the field level to the operator desk, facilitating improved decision-making and operational efficiency.
Product Parameters (Datasheet)
The following technical specifications define the capabilities and operational limits of the PM861AK02:
| Feature | Specification |
| Product ID | 3BSE018160R1 |
| Model Designation | PM861AK02 |
| Processor Type | 32-bit RISC Processor (96 MHz) |
| Onboard RAM | 16 MB |
| Flash Memory | 4 MB (Firmware storage) |
| Power Supply | 24 V DC (19.2 to 30 V DC range) |
| Power Consumption | Max 150 mA at 24 V |
| Redundancy Support | Yes (CPU Redundancy supported) |
| Communication Ports | 2x Ethernet (Built-in), 2x RS-232, 1x ModuleBus |
| Clock Frequency | 96 MHz |
| Operating Temperature | +5°C to +55°C (Standard industrial range) |
| Humidity | 5% to 95% (Non-condensing) |
| Protection Rating | IP20 (According to IEC 60529) |
Country of Origin
- Origin: Sweden / Estonia
ABB maintains primary manufacturing and assembly lines for the AC 800M series in Sweden, with specialized component production often handled in Estonia. All units undergo rigorous testing in European facilities to meet global CE, UL, and maritime certifications.
Application Areas
The versatility of the PM861AK02 makes it suitable for various demanding sectors:
- Oil and Gas: Used in both upstream and downstream operations for wellhead control, pipeline monitoring, and refinery process automation.
- Power Generation: Managing turbine controls, boiler logic, and substation automation where high-speed synchronization is required.
- Chemical Processing: Executing precise batch control logic, managing safety interlocks, and monitoring reactor temperatures.
- Pulp and Paper: Controlling large-scale paper machines and energy management systems within the mill.
- Marine and Offshore: Providing propulsion control and vessel management systems on ships and drilling rigs, often utilizing its high vibration resistance.
Product Technical Description
The PM861AK02 utilizes a sophisticated operating system optimized for real-time control. Key technical features include:
- Memory Management: With 16 MB of RAM, the processor can store significant amounts of user application code and live data. The memory is protected by parity checks to ensure data integrity.
- Redundancy Logic: When paired with a second PM861A module, the system operates in a “Hot Standby” mode. If the primary processor detects a hardware fault or internal error, control is transferred to the backup unit in less than 10 milliseconds, preventing process interruption.
- Built-in Ethernet: The two integrated Ethernet ports support the RNRP (Redundant Network Routing Protocol), ensuring that communication between the controller and the HMI or other controllers remains active even if one network path fails.
- ModuleBus Integration: This port allows for the direct connection of S800 I/O modules via a dedicated electrical or optical bus, ensuring high-speed I/O scanning cycles.
Product Usage Instructions
1. Hardware Installation
- Mounting: The module should be snapped onto a standard DIN rail. It must be placed on a compatible baseplate (e.g., TP830) which provides the electrical connections to the backplane.
- Grounding: Ensure the DIN rail is properly grounded to the cabinet’s earth bar to prevent electromagnetic interference.
- Battery: Install the lithium backup battery to the front of the module. This battery preserves the RAM content and the real-time clock during power outages.
2. Wiring and Power-Up
- Connect the redundant 24 V DC power feeds to the baseplate terminals.
- Observe the front panel LEDs during the boot sequence. The “Power” LED should be green, and the “Run” LED should eventually turn green once a valid application is loaded.
3. Configuration and Programming
- Use the ABB Compact Control Builder or 800xA Engineering software to configure the hardware tree.
- Define the IP addresses for the Ethernet ports to establish communication with the engineering station.
- Download the firmware to the module if the version is not compatible with the software release being used.
4. Maintenance
- Battery Replacement: The “Batt” LED will turn yellow when the battery is low. Replace the battery while the system is powered up to avoid memory loss.
- Firmware Updates: Periodically check for firmware patches from ABB to ensure the processor is protected against security vulnerabilities and software bugs.
Product Related News
Recent developments surrounding the AC 800M and the PM861 series focus on Cyber Security and Lifecycle Sustainability.
- Cyber Security Enhancements: ABB has recently released updated firmware for the PM861 series that includes signed firmware and enhanced encryption protocols for communication, meeting the latest IEC 62443 standards. This is in response to increasing threats against critical infrastructure.
- Extended Support Lifecycle: ABB has reaffirmed its commitment to the AC 800M platform. While newer processors like the PM891 offer higher speeds, the PM861 remains a core “Active” product, with guaranteed support and spare parts availability for the next decade, ensuring that existing plants do not face premature obsolescence.
- Sustainability in Manufacturing: ABB’s factories in Sweden have transitioned to 100% renewable energy for the production of these modules, aligning with corporate ESG (Environmental, Social, and Governance) goals.
Common Problems Q&A
Q: What does a red “Fault” LED indicate on the PM861AK02? A: A solid red Fault LED usually indicates a critical hardware failure or a fatal software error. If a power cycle does not clear it, the module may need replacement. A flashing red LED often indicates a firmware mismatch or a configuration error that prevents the CPU from starting.
Q: Can I use the PM861AK02 in a SIL-rated safety application? A: No, the PM861A is a standard process controller. For safety-critical applications (SIS), you must use the “High Integrity” versions, such as the PM865 or PM867, which include the necessary internal diagnostics and hardware for SIL 2 or SIL 3 certification.
Q: How do I perform a factory reset on the module? A: There is a “Stop” button on the front panel. By holding this button during power-up (following a specific sequence described in the technical manual), you can clear the application memory and reset the Ethernet settings to factory defaults.
Q: Is the PM861AK02 compatible with older S100 I/O? A: Yes, through the use of a CI856 communication interface module, the PM861AK02 can communicate with legacy S100 I/O racks, allowing for phased system upgrades.
Q: Why is my redundant CPU not syncing? A: Check the “BC” (Bus Cable) connecting the two processors. Ensure both CPUs have identical firmware versions and that the redundancy link is enabled in the Control Builder software. Also, verify that the “Upper” and “Lower” positions on the baseplate are correctly identified.
Recommended Similar/Associated Models
- ABB PM864AK01: A higher-capacity processor for larger applications.
- ABB PM866AK01: Offers faster processing speeds and more RAM for intensive control tasks.
- ABB CI854A: A communication interface for Profibus DP integration.
- ABB TP830: The standard baseplate required for mounting the PM861A.
- ABB S800 I/O Series: Compatible I/O modules for field device interface.
