The ABB PM866AK01 is a high-performance, redundant-capable controller module belonging to the ABB Ability™ System 800xA family. Specifically part of the AC 800M controller series, the PM866 is designed to handle demanding industrial processes that require high processing speed, large memory capacity, and extreme reliability.
The “AK01” suffix typically denotes a complete kit that includes the CPU (PM866), the baseplate (TP830), and the necessary terminators or accessories required for standard installation. As the centerpiece of the AC 800M architecture, the PM866 serves as the primary intelligence unit for managing complex control loops, functional safety (when integrated with safety modules), and extensive communication networks.
Product Introduction
The AC 800M series is renowned for its modularity and flexibility. The PM866 is positioned at the higher end of this series, offering significantly more computational power than its predecessors like the PM861 or PM864. It is designed to execute control logic, regulate processes, and manage data exchange across the industrial environment.
A key feature of the PM866AK01 is its support for Controller Redundancy. By installing two PM866 modules in a redundant pair, the system ensures that if the primary unit fails, the secondary unit takes over control bumplessly (without interrupting the process). This is critical for industries where a single second of downtime can lead to massive financial loss or safety hazards.
Product Parameters (Datasheet)
The following parameters define the technical capabilities of the PM866 module:
| Parameter | Specification |
| Model Number | PM866AK01 (Kit) / PM866 (Module) |
| Processor Type | High-speed 32-bit RISC Processor (450 MHz) |
| Memory (RAM) | 64 MB (ECC protected) |
| Flash Memory | 16 MB for application and firmware storage |
| Redundancy Support | Yes, full CPU redundancy supported |
| Onboard Interfaces | 2x Ethernet (RNRP), 2x Serial (RS-232), 1x CEX-Bus |
| Max. I/O Points | Up to several thousand (depending on cycle time) |
| Module Termination Unit | TP830 |
| Power Supply | 24 VDC (Typical 19.2V to 30V DC) |
| Current Consumption | Max 1.2 A |
| Clock Synchronization | Support for SNTP and High-Precision Clock |
| Operating Temp | +5°C to +55°C |
| Dimensions (W x H x D) | 119 mm x 186 mm x 135 mm |
Country of Origin
- Origin: Sweden (ABB AB, Control Technologies)
Application Areas
The PM866AK01 is deployed in environments where process complexity is high and the cost of failure is astronomical. Major application sectors include:
- Oil and Gas: Management of offshore platforms, refineries, and pipeline systems where thousands of digital and analog I/O points must be monitored in real-time.
- Chemical Processing: Precise control of reactors, distillation columns, and blending units that require high-speed PID loops and complex logic.
- Power Generation: Control of turbine systems, boiler logic, and grid synchronization in thermal, hydro, and nuclear plants.
- Pharmaceuticals: Batch processing control that adheres to strict regulatory requirements, utilizing the large memory capacity for audit trails and recipe management.
- Pulp and Paper: Controlling massive paper machines and pulping processes where high-speed communication between the controller and drive systems is essential.
Product Technical Description
The PM866 is built on a “Processor and Baseplate” concept. The processor contains the CPU, memory, and communication ports, while the baseplate (TP830) provides the physical mounting on a DIN rail and the electrical connections for power and I/O expansion.
- Redundancy Link: When used in a redundant pair, the two CPUs are linked via a dedicated synchronization cable. The secondary CPU remains in “hot standby” mode, mirroring the memory and state of the primary unit at every clock cycle.
- CEX-Bus: The Communication Expansion Bus (CEX-Bus) allows for the addition of specialized communication modules, such as those for Profibus DP, Foundation Fieldbus, or Modbus TCP, without overloading the main CPU.
- ModuleBus: For local I/O, the ModuleBus interface allows the controller to talk directly to S800 I/O modules mounted on the same or adjacent rails.
Instructions for Use
1. Pre-Installation Check
Before installing the PM866AK01, verify that the environment is free from corrosive gases and excessive moisture. Ensure that the 24V DC power supply is stable and within the specified voltage range.
2. Mounting and Grounding
- Snap the TP830 baseplate onto a standard 35mm DIN rail.
- Ensure the DIN rail is properly grounded to the cabinet’s common earth point.
- Insert the PM866 module into the baseplate until you hear a click. Secure it with the locking mechanism.
3. Wiring
- Power: Connect the dual 24V inputs (for power redundancy) to the terminals on the baseplate.
- Network: Connect the Ethernet cables to the ports labeled CN1 and CN2. These are typically used for the Redundant Network Routing Protocol (RNRP) to communicate with the 800xA HMI or other controllers.
- Serial: Use the RS-232 ports for local maintenance or for connecting to legacy serial devices.
4. Firmware and Programming
- Use ABB Control Builder M software to configure the controller.
- Perform a firmware upgrade if the module is being integrated into an existing system with a different version of 800xA.
- Download the hardware configuration first, followed by the application logic (Ladder, Function Block, or Structured Text).
5. Battery Maintenance
The PM866 uses a lithium battery to retain the RAM contents during power outages. Check the battery status LED on the front panel. If the LED is red, replace the battery immediately while the system is powered on to prevent data loss.
Product Related News
The PM866 series has recently been highlighted in ABB’s “Digital Transformation” initiatives. As industries move toward “Industry 4.0,” the PM866’s ability to act as an edge device—collecting vast amounts of data and performing pre-analysis before sending it to the cloud—has become a significant selling point.
ABB has also introduced enhanced cybersecurity firmware for the PM866, protecting the controller against unauthorized access and network-based threats. This makes the PM866AK01 one of the most secure controllers on the market for critical infrastructure protection.
Product Q&A (Common Questions)
Q: Can the PM866 handle Functional Safety (SIL 2/3)? A: The PM866 itself is a standard controller. For safety applications, it is typically paired with the SM810 or SM811 Safety Module and integrated into the AC 800M High Integrity (HI) system. This creates a SIL-certified environment for safety-critical tasks.
Q: What is the maximum number of CEX-Bus modules I can add? A: Typically, up to 12 communication expansion modules can be added to a single PM866 controller, depending on the power budget and the specific communication protocols used.
Q: Can I replace a PM864 with a PM866? A: Yes, the PM866 is generally backward compatible with the AC 800M architecture. However, you must update the hardware configuration in the Control Builder M software and ensure the firmware versions are compatible.
Q: What does a flashing yellow “Run” LED mean? A: A flashing yellow LED usually indicates that the controller is in a “Ready” state but is not currently executing the application program (e.g., after a reset or before a download).
Q: How do I perform a “Cold Start”? A: A Cold Start can be triggered via the software or by holding the “Init” button on the front panel while cycling the power. This clears the RAM and restarts the controller from its stored Flash image.
Summary Table of Components in PM866AK01 Kit
| Part Number | Component Name | Description |
| 3BSE050198R1 | PM866 | Processor Unit |
| 3BSE018100R1 | TP830 | Baseplate / Termination Unit |
| 3BSE008545R1 | TB807 | ModuleBus Terminator |
| – | Battery | Lithium 3.6V Battery for RAM |
