Description
ABB PM864AK02 3BSE018164R1 — AC 800M Redundant Processor Unit
Key Technical Specifications
| Parameter | Specification |
|---|---|
| Model | PM864AK02 |
| Order number | 3BSE018164R1 |
| Manufacturer | ABB |
| Platform | AC 800M / System 800xA |
| Kit type | Redundant processor unit |
| CPU quantity | 2 × PM864A |
| Processor type | MPC862 |
| Clock frequency | 96 MHz per CPU |
| RAM | 32 MB per CPU |
| Application RAM | Approximately 23.522 MB per CPU, per ABB data sheet |
| Power input | 24 VDC per CPU |
| Allowable supply range | 19.2–30 VDC |
| Typical / maximum current | 287 / 487 mA per CPU at 24 VDC |
| Typical power dissipation | 6.9 W per CPU |
| Ethernet | Two Ethernet channels per CPU |
| CEX-bus | Supports communication modules; configuration limits apply |
| Redundancy switchover | Maximum 10 ms, per ABB family data sheet |
| Baseplate | 2 × TP830 |
| ModuleBus terminator | 2 × TB807 |
| CEX-bus cable | TK850 |
| RCU-Link cable | TK851 |
| Backup battery | 4943013-6, one per CPU |
| Kit dimensions | Approximately 119 × 186 × 135 mm, listed kit dimensions |
| Kit net weight | Approximately 2.9 kg |
| Protection class | IP20 for the controller family |
The processor specifications are based on ABB’s AC 800M technical data. Current consumption and memory figures are per processor, not combined kit values. The exact delivered kit contents should be checked against the order documentation.
PM864AK02 3BSE018164R1
Product Introduction
The ABB PM864AK02 3BSE018164R1 is a redundant processor unit kit for compatible ABB AC 800M control systems. It contains two PM864A processor units and the associated baseplates, termination components, redundancy cables, and memory-backup batteries specified for the kit. Its purpose is to support controller-level redundancy in process automation installations where continued control availability is an operational requirement.
For maintenance teams, the kit designation matters. Ordering a single PM864A or PM864AK01 does not establish that all components required for a redundant arrangement are included. Before replacement, verify the existing controller architecture, installed firmware, application compatibility, CEX-bus modules, ModuleBus configuration, and RCU-Link arrangement against the site’s approved drawings and ABB documentation.
Application Scenarios & Field Pitfalls — The Engineer’s Perspective
Engineering Pain Point
A redundant controller is only as useful as its complete configuration. Two compatible CPUs alone do not guarantee a functioning redundant pair: the interconnection cables, firmware compatibility, configuration data, communications modules, and controller synchronization all need to be correct. A replacement should be planned as a controller-system maintenance task rather than a simple board swap.
Typical Applications
- Continuous process control: Redundant controller arrangements in compatible System 800xA installations.
- Plant availability maintenance: Replacement of an existing PM864AK02 kit when the approved design specifies the same configuration.
- Planned DCS upgrades or outages: Restoration of controller redundancy after inspection or hardware replacement.
- Spare-parts planning: Maintaining a matched redundant kit to reduce the risk of missing interconnection hardware during a scheduled repair.
Technical Pitfalls to Avoid
- Confirm kit completeness. Verify both PM864A CPUs, both TP830 baseplates, TK850, TK851, both TB807 terminators, and both memory-backup batteries against the supplied-parts list. Do not assume a loose CPU module constitutes the complete PM864AK02 kit.
- Do not confuse K01 and K02. PM864AK01 is the single-processor package; is the redundant kit. Check the order number and actual contents on the quotation.
- Verify controller firmware and software compatibility. Confirm that the target AC 800M and System 800xA software versions support the replacement processors and the existing application.
- Inspect redundancy interconnections. Confirm that the correct TK850 CEX-bus expansion cable and TK851 RCU-Link cable are installed and correctly seated. Do not infer cable compatibility from appearance alone.
- Check the 24 VDC supply under load. Verify the voltage at each processor and inspect the power distribution and grounding arrangements before diagnosing CPU faults.
- Review application capacity. The published memory and performance figures are per CPU. Check the running application and communication workload against the target controller’s limits rather than adding the two CPUs’ resources together.
- Confirm communications and I/O architecture. Review the installed CEX-bus modules, ModuleBus arrangement, remote I/O configuration, and network settings before commissioning.
- Protect the running process during changeover. Follow the site’s approved redundancy test and changeover procedure. Confirm synchronization, controller status, diagnostics, and process behavior before returning the system to normal operation.
Related Products
These components are relevant to the AC 800M controller family. They are not all direct substitutes for .
- PM864AK01 — 3BSE018161R1: Single-processor package based on PM864A; not the same kit configuration.
- PM864A: Individual processor used in the PM864AK01 and packages.
- TP830: AC 800M processor baseplate used in the kit.
- TK850: CEX-bus expansion cable included in the redundant kit.
- TK851: RCU-Link cable included in the redundant kit.
- TB807: ModuleBus terminator included in the kit.
- PM861AK02 — 3BSE018160R1: Redundant processor kit from the AC 800M family with a different CPU model.
- PM866AK02 — 3BSE081637R1: Redundant processor kit based on PM866A; verify application and hardware compatibility before considering an upgrade.
- PM891K02 — 3BSE053242R1: Higher-tier AC 800M redundant processor package; not a drop-in substitute without engineering review.
Confirm exact order numbers, hardware revisions, firmware requirements, and approved system compatibility before selecting a related component. (ABB AC 800M product catalog)
Procurement Note
When purchasing , specify that the requirement is for the redundant processor kit, not an individual CPU. Request a detailed contents list and photographs of the supplied modules, labels, cables, baseplates, terminators, and batteries.
Before installation, verify the target system’s controller configuration, firmware, application backup, redundancy cabling, and power distribution. Confirm the condition of the batteries and the test evidence available for the actual unit supplied. Do not infer that the kit is new, unused, refurbished, or tested solely from the part number.
