Description

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　　PM866K02 3BSE050199R1 Other Names:

Redundant Processing Unit PM866K02 3BSE050199R1

PM866K02 3BSE050199R1 Redundant Analog Unit

Redundant Input/Output Unit PM866K02 3BSE050199R1

Product Positioning and Core Features

Series Affiliation: ABB AC 800M series high-performance redundant controllers, belonging to the core control unit of industrial automation, suitable for scenarios with high reliability requirements (such as power, manufacturing, oil and gas, process control, etc.).

Redundant Design: Supports dual-machine hot standby redundancy, with extremely short switching time (e.g., 0.15ms level), ensuring uninterrupted system operation and meeting the continuity requirements of critical infrastructure.

Modular Architecture: Employs a modular design, supporting DIN rail/modular rack mounting, and expandable local/remote I/O (supporting up to 12 local I/O stations or 98 remote I/O stations), facilitating gradual system upgrades and maintenance.

　　Technical Specifications and Performance

　　Hardware Configuration:

Processor: MPC862, 96MHz clock frequency, 32MB RAM (application-available) + 23.522MB Flash storage.

Communication Interfaces: Dual redundant Ethernet ports, PROFIBUS DP, Modbus TCP/IP, Ethernet IP, etc., supporting multiple industrial protocols.

Physical Characteristics: IP20 protection rating (indoor installation), dimensions 16cm × 16cm × 12cm, weight approximately 1.2kg, 24V DC power supply, power consumption meets ABB energy efficiency standards.

Environmental adaptability: Operating temperature range -25℃ to 60℃, relative humidity 20% to 90% (non-condensing), vibration/shock resistance meets industrial environment requirements (e.g., 1.25g@10~100Hz vibration).

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　　PM866K02 3BSE050199R1 redundant controller matching models and functions:

PM861AK01 3BSE018157R1/PM861AK02 3BSE018160R1, PM864AK02 3BSE018164R1, PM866K01 EXC3BSE050198R1

Function:

Dual-machine hot standby redundancy: Supports full redundancy design of CPU, CEX bus, communication interface and I/O modules, switching time ≤10ms, ensuring uninterrupted system operation.

Performance Expansion: The PM864AK02 offers a 32MB RAM version, while the PM866K02 supports higher I/O capacities (such as 96 local/84 redundant I/O modules) to meet large-scale control requirements.

High Integrity Certification: Some models (such as the PM867K02) integrate IEC 61508/TÜV certification, are compatible with the 800xA 6.0.2+ system, and achieve integrated safety and process control.

Communication Module

Model Examples: CI853K01 3BSE018103R1 (Dual RS232-C), CI854AK01 3BSE030220R1 (PROFIBUS DP-V1), CI855K01 3BSE018106R1 (MB300), CI868K01 3BSE048845R1 (IEC 61850), CI867K01 3BSE043660R1 (Modbus TCP)

Function:

Protocol Compatibility: Supports industrial protocols such as Ethernet, PROFIBUS DP, Modbus TCP/IP, Ethernet IP, and FF HSE, enabling seamless integration with PLCs, HMIs, and third-party systems (such as S7-1200 and MCGS).

Remote Expansion: Supports remote I/O stations (up to 98) and long-distance communication (e.g., 500m PROFIBUS DP cable, 20km fiber optic cable) via fiber optic/cable.

Diagnosis and Maintenance: Built-in LED indicators and serial port configuration interface support real-time status monitoring and remote debugging.

Power Supply and Backup Module

Model Examples: SD821/SD822/SD823 (Switching Power Supply), SB821/SB822 (External Battery)

Function:

Stable Power Supply: Converts AC 155/230V to 24V DC, supports redundant/non-redundant configurations, input voltage range 19.2-30V, power consumption ≤8.6W, ensuring stable system operation.

Data Protection: Built-in lithium battery backs up memory data (e.g., RAM/Flash), supports program retention after power failure, and works with the BC810 module to achieve segmented maintenance of the CEX bus.

Environmental Adaptability: Meets IP20 protection standards, operating temperature -25℃~60℃, vibration/shock resistant (1.25g@10-100Hz), meeting the requirements of harsh industrial environments.

I/O and Expansion Modules

Model Examples: S800 I/O series (e.g., DI803, AI modules), ModuleBus expansion cards (CI860K01 FF HSE, CI857K01 INSUM)

Functions:

Signal Acquisition and Control: Supports digital/analog I/O, intrinsically safe signals, and remote I/O expansion. Connects up to 12 local I/O clusters or 7 remote clusters via the ModuleBus electrical/fiber optic interface.

Bus Expansion: Connects to Profibus DP, FF HSE, and other fieldbus modules via the CEX bus to achieve a distributed control architecture.

Hot-Swapping and Maintenance: Modular design supports hot-swapping, simplifying fault isolation and system upgrades.

Diagnostic and Auxiliary Modules

Model Examples: TB850 (CEX Bus Terminal), TB807 (ModuleBus Terminal), RCU Link Terminal

Functions:

Bus Management: Optimizes bus signal integrity, reduces electromagnetic interference, and improves communication stability through the terminal module.

System Diagnostics: Built-in Error Detection and Correction (ECC) function, combined with LED indicators for rapid fault location.

Clock Synchronization: Supports CNCP protocol to achieve 1ms-level clock synchronization between controllers, ensuring SOE (Event Sequence Record) resolution ≤1ms.

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　　Application Scenarios and Compatibility

Typical Applications: Industrial automation, robot control (such as ABB robot systems), power energy management, process control, factory automation, etc.

System Compatibility: Compatible with ABB 800xA control systems, supports the Control Builder software development environment, and can be integrated into the AC 800M hardware platform (such as AC 800M versions 4.0/5.0/5.1).

Certifications and Standards: EMC certified (EN 61000-6-4/6-2), CE certified, UL 508, IEC 61131-2, etc., compliant with RoHS/WEEE environmental requirements. Some models have marine certifications (e.g., ABS, DNV-GL).

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　　Installation and Maintenance

Installation Method: Supports DIN rail or modular rack mounting, equipped with a CEX-Bus expansion interface, allowing for bus segmentation via the BC810 module for easy system expansion and fault isolation.

Maintenance Features: Built-in backup battery (maintains memory data), supports hot-swappable modules, diagnostic functions simplify troubleshooting, and provides a 12-month warranty.

Summary: The PM866K02 3BSE050199R1 is a highly reliable redundant controller for ABB’s industrial automation field. With its modular design, strong redundancy capabilities, broad protocol support, and adaptability to harsh environments, it has become the preferred control solution for industries such as power, manufacturing, and oil and gas.

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