Description
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Other names of PM891K02 3BSE053242R1:
Redundant unit PM891K02 3BSE053242R1
PM891K02 3BSE053242R1 redundant controller
Control unit PM891K02 3BSE053242R1
Editable controller PM891K02 3BSE053242R1
AC800M PM891K02 3BSE053242R1 is one of the core components in the System 800xA distributed control system, designed to meet the complex control needs in the field of industrial automation. It has powerful processing power and a high degree of redundancy to ensure the stability and reliability of the system. It belongs to ABB’s high-end process control product line, mainly used in the fields of industrial automation and process control.
The PM891K02 3BSE053242R1 processor is a single-chip unit equipped with a power supply, CPU board and unit terminal. The unit contains a microprocessor and RAM memory, a real-time clock, LED indicators, an INIT button and a secure digital interface. The PM891K02 3BSE053242R1 does not contain any internal battery. The PM891K02 3BSE053242R1 has two RJ45 Ethernet ports (CN1, CN2) for connecting to the control network and one RJ45 serial port (COM4). The COM4 port is isolated and is used for configuration tools. The PM891K02 3BSE053242R1 supports CPU redundancy for higher availability (CPU, CEX bus, communication interface and S800 I/O).
The communication expansion bus (CEX-Bus) is installed on the device. The CEX-Bus is used to expand the onboard communication ports via a communication interface unit. Redundant communication interfaces can be used on the CEX-Bus. The CEX-Bus interconnect unit BC810 is used to increase the availability of the CEX-Bus by dividing it into separate segments. The optical Modulebus of the device can be used to connect seven clusters of S800 I/O units (each cluster contains up to 12 units). Each PM891K02 3BSE053242R1 has a unique Ethernet address that provides hardware identification for the unit.
Product Features
High performance: The control module is equipped with a powerful processor and sufficient memory to quickly process large amounts of data and control tasks, ensuring the real-time and responsiveness of the system.
High availability: Supports CPU redundancy design. When the main controller fails, it can seamlessly switch to the backup controller to ensure continuous operation and stability of the system.
Communication capabilities: Supports multiple communication protocols and interfaces, such as Ethernet, serial communication, etc., and can be seamlessly integrated and exchanged with other devices, modules and systems.
Scalability and flexibility: Provides high scalability and flexibility, and can be customized and expanded according to specific application requirements.
Fault diagnosis and troubleshooting: With powerful diagnostic and troubleshooting functions, it can help users quickly locate and solve problems through event logging and remote access.
Hardware configuration
Core components: single-chip unit, equipped with power supply, CPU board and unit terminal.
Included components: microprocessor, RAM memory, real-time clock, LED indicator, INIT button and secure digital interface.
Communication ports: Two RJ45 Ethernet ports (CN1, CN2) and one RJ45 serial port (COM4), where the COM4 port is isolated and used for configuration tools.
Communication expansion bus: CEX-Bus, used to increase the availability of the CEX bus by dividing the CEX bus into separate segments.
Communication interface:
Two RJ45 Ethernet ports (CN1, CN2) for connecting to the control network
One RJ45 serial port (COM4) for configuration tools
Equipped with communication expansion bus (CEX-Bus), the CEX bus is divided into separate segments through the BC810 unit to improve availability
Control function: It can realize advanced control such as cascade, feedforward, decoupling, adaptive and predictive control, integrating continuous control, sequential control and batch control
System compatibility: Supports open DCS (distributed control system) design, adopts open, standardized, modular and serialized design, and facilitates computers in the system to communicate and transmit information through the local area network
Application field
AC800M PM891K02 3BSE053242R1 redundant system control module has a wide range of applications in many industries, including but not limited to:
Oil and gas extraction and processing: used to monitor and control the extraction, processing and transportation of oil and gas.
Power generation and energy management: used for automation control of power plants and integration of energy management systems.
Chemical and pharmaceutical industry: used for automated control and monitoring in chemical and pharmaceutical processes.
Water and wastewater treatment: used for automated control and monitoring of water and wastewater treatment plants.
Manufacturing automation: used for control and management of automated production lines and equipment in manufacturing.
In summary, the ABB AC800M PM891K02 3BSE053242R1 redundant system control module is a powerful, flexible and reliable product that can meet various complex control needs in the field of industrial automation.
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admin –
AC800M PM891K02 3BSE053242R1 is one of the core components in the System 800xA distributed control system, designed to meet the complex control needs in the field of industrial automation. It has powerful processing power and a high degree of redundancy to ensure the stability and reliability of the system. It belongs to ABB’s high-end process control product line, mainly used in the fields of industrial automation and process control.
The PM891K02 3BSE053242R1 processor is a single-chip unit equipped with a power supply, CPU board and unit terminal. The unit contains a microprocessor and RAM memory, a real-time clock, LED indicators, an INIT button and a secure digital interface. The PM891K02 3BSE053242R1 does not contain any internal battery. The PM891K02 3BSE053242R1 has two RJ45 Ethernet ports (CN1, CN2) for connecting to the control network and one RJ45 serial port (COM4). The COM4 port is isolated and is used for configuration tools. The PM891K02 3BSE053242R1 supports CPU redundancy for higher availability (CPU, CEX bus, communication interface and S800 I/O).
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admin –
Hardware configuration
Core components: single-chip unit, equipped with power supply, CPU board and unit terminal.
Included components: microprocessor, RAM memory, real-time clock, LED indicator, INIT button and secure digital interface.
Communication ports: Two RJ45 Ethernet ports (CN1, CN2) and one RJ45 serial port (COM4), where the COM4 port is isolated and used for configuration tools.
Communication expansion bus: CEX-Bus, used to increase the availability of the CEX bus by dividing the CEX bus into separate segments.
Communication interface:
Two RJ45 Ethernet ports (CN1, CN2) for connecting to the control network
One RJ45 serial port (COM4) for configuration tools
Equipped with communication expansion bus (CEX-Bus), the CEX bus is divided into separate segments through the BC810 unit to improve availability
https://www.axcontroler.com/ABB/abb—pm891—ac-800m-controllers—pm891
admin –
ABB 3BSE053242R1 is a core control module in the AC 800M controller series and a key component of ABB’s industrial automation system. The module is widely used in power, metallurgy, chemical, oil and gas and other industries, supporting complex logic control, process regulation and distributed control system (DCS) integration. Its core functions include:
High-performance control: Based on a multi-task processor, it supports fast logic operations and real-time process control.
Flexible expansion: Modular design, compatible with a variety of I/O modules and communication protocols.
High reliability: Industrial-grade design, adaptable to harsh environments (such as high temperature, high humidity, vibration).
Technical specifications and functions
Core parameters
Model and series: 3BSE053242R1, belongs to the AC 800M controller series.
Processor architecture: Adopts a high-performance multi-task processor to support complex control algorithms.
I/O configuration:
Digital input/output: supports a variety of DI/DO channels (the specific number depends on the configuration).
Analog input/output: supports AI/AO channels with 16-bit accuracy.
Expansion capability: supports up to 1024 I/O points through expansion modules.
Communication protocols:
Supports industrial protocols such as Profibus DP, Modbus TCP/IP, Ethernet/IP, etc.
Integrated serial communication interface (such as RS-232/RS-485).
Programming environment:
Supports IEC 61131-3 standard programming languages (LD, FBD, ST, IL, SFC).
Compatible with ABB Control Builder tool for program development and debugging.
Key functions
Logic control: realizes sequential control, timing control and interlocking protection functions.
Process regulation: supports advanced algorithms such as PID control and fuzzy control, suitable for parameter regulation such as temperature, pressure, flow, etc.
Data acquisition and monitoring: collect field data in real time through the integrated communication interface, and interact with the host computer (such as SCADA system).
Redundant design: supports controller redundant configuration to ensure high system availability.
Application scenarios
Industrial automation
Power industry:
Power plant control: used for logic control and process regulation of boilers, steam turbines, and generators.
Substation automation: integrated in the DCS system to achieve remote monitoring and protection.
Metallurgical industry:
Rolling mill control: accurately adjust rolling force and speed to improve steel quality.
Blast furnace control: optimize blast furnace temperature and air flow distribution to reduce energy consumption.
Chemical and oil and gas:
Reactor control: adjust temperature, pressure and other parameters to ensure safe and efficient chemical reactions.
Pipeline monitoring: real-time monitoring of pipeline pressure and flow to prevent leakage accidents.
Machine automation
Robot control: used for motion control and path planning of industrial robots.
CNC machine tools: integrated in the CNC system to achieve high-precision processing control.
Troubleshooting and maintenance suggestions
1. Common problems and solutions
Possible causes of faults and solution steps
Controller does not respond Power failure, firmware error or communication interruption 1. Check the stability of power input (24V DC ±10%).
2. Verify whether the communication line connection is normal.
3. Update the firmware to the latest version or reset the parameters to the default values.
I/O signal abnormal Channel damage or ground interference 1. Use a multimeter to detect the channel voltage/current and confirm whether the input signal range is within the module range.
2. Check the grounding system to ensure signal transmission stability.
Overheat protection triggers Poor heat dissipation or load exceeds the limit 1. Clean the dust in the controller heat sink and check the fan operation status.
2. Reduce the complexity of the control task or upgrade to a higher performance module.
2. Key troubleshooting steps
Power supply and connection check:
Confirm that the input voltage is stable (24V DC ±10%), without phase loss or fluctuation.
Check if the communication cable (such as Profibus DP) is firmly connected, without oxidation or looseness.
Firmware and parameter update:
Update the firmware through the ABB Control Builder tool and reset the parameters to the default values.
I/O module test:
Test the I/O channels one by one, troubleshoot the faulty modules and replace them.
Compatibility and alternative solutions
1. System compatibility
Recommended system: ABB AC 800M control system, working with master control modules such as PM856 and PM860.
Extended compatibility: supports integration with ABB 800xA DCS system to achieve enterprise-level automation management.
2. Alternative models
If the module is discontinued, it is recommended to contact ABB for alternative solutions, which may include upgrading to a higher performance version (such as PM864AK01).
Maintenance recommendations
1. Environmental requirements
Install in a dry, dust-free environment, with a temperature range of -25℃ to 70℃ and humidity ≤ 95% (non-condensing).
Avoid exposure to corrosive gases or liquids to ensure long-term stable operation of the module.
2. Regular inspections
Clean dust from the controller heat sink every 6 months and check the oxidation of the connector.
Perform a comprehensive self-diagnosis test once a year to ensure that all functions of the module are normal.
admin –
Technical specifications and functions
Core parameters
Model and series: 3BSE053242R1, belongs to the AC 800M controller series.
Processor architecture: Adopts a high-performance multi-task processor to support complex control algorithms.
I/O configuration:
Digital input/output: supports a variety of DI/DO channels (the specific number depends on the configuration).
Analog input/output: supports AI/AO channels with 16-bit accuracy.
Expansion capability: supports up to 1024 I/O points through expansion modules.
Communication protocols:
Supports industrial protocols such as Profibus DP, Modbus TCP/IP, Ethernet/IP, etc.
Integrated serial communication interface (such as RS-232/RS-485).
Programming environment:
Supports IEC 61131-3 standard programming languages (LD, FBD, ST, IL, SFC).
Compatible with ABB Control Builder tool for program development and debugging.
Key functions
Logic control: realizes sequential control, timing control and interlocking protection functions.
Process regulation: supports advanced algorithms such as PID control and fuzzy control, suitable for parameter regulation such as temperature, pressure, flow, etc.
Data acquisition and monitoring: collect field data in real time through the integrated communication interface, and interact with the host computer (such as SCADA system).
Redundant design: supports controller redundant configuration to ensure high system availability.
Application scenarios
Industrial automation
Power industry:
Power plant control: used for logic control and process regulation of boilers, steam turbines, and generators.
Substation automation: integrated in the DCS system to achieve remote monitoring and protection.
Metallurgical industry:
Rolling mill control: accurately adjust rolling force and speed to improve steel quality.
Blast furnace control: optimize blast furnace temperature and air flow distribution to reduce energy consumption.
Chemical and oil and gas:
Reactor control: adjust temperature, pressure and other parameters to ensure safe and efficient chemical reactions.
Pipeline monitoring: real-time monitoring of pipeline pressure and flow to prevent leakage accidents.
Machine automation
Robot control: used for motion control and path planning of industrial robots.
CNC machine tools: integrated in the CNC system to achieve high-precision processing control.
Troubleshooting and maintenance suggestions
1. Common problems and solutions
Possible causes of faults and solution steps
Controller does not respond Power failure, firmware error or communication interruption 1. Check the stability of power input (24V DC ±10%).
2. Verify whether the communication line connection is normal.
3. Update the firmware to the latest version or reset the parameters to the default values.
https://www.weikunfadacai1.com/product/abb-ac800m-3bse053240r1-pm891/
admin –
ABB PM891 (Order No.: 3BSE053240R1) is a high-performance redundant central processing unit (CPU module) in the AC 800M controller series and is a core component of the ABB System 800xA distributed control system. This module is designed for complex industrial process control and has high reliability, high performance and strong expansion capabilities. It is suitable for automation control needs in industries such as power, petrochemicals, metallurgy, and water treatment. Its core functions include:
Redundant control: Supports CPU, power supply, and network redundancy to ensure disturbance-free system switching in the event of a single point failure.
High-performance processing: Based on the industrial-grade PowerPC architecture, it can quickly process complex control algorithms and logic.
Flexible expansion: Modular design supports the expansion of multiple I/O modules, communication modules, and functional modules.
Technical specifications and functions
1. Core parameters
Processor architecture: Industrial-grade PowerPC architecture with high-performance processing capabilities.
Memory and storage: Standard 128 MB RAM, 32 MB Flash, support for external memory card expansion.
Redundancy design:
CPU redundancy: The master and standby controllers achieve millisecond-level switching through dedicated redundant links (such as CEX bus).
Power redundancy: Supports dual power input to ensure power supply stability.
Network redundancy: Built-in two Ethernet ports (CN1, CN2), supporting redundant network protocols.
I/O configuration: Connect S800 I/O units through CEX bus, and each CEX bus segment supports up to 12 units.
Communication protocol: Supports Profibus, Modbus, EtherNet/IP, OPC UA and other protocols to achieve seamless integration with third-party devices.
Programming environment: Use ABB Control Builder M tool, support IEC 61131-3 standard programming language (LD, FBD, ST, etc.).
2. Key functions
Redundancy switching: The master and standby controllers synchronize data in real time, and automatically switch when a fault occurs to ensure uninterrupted control.
Real-time performance: Equipped with a real-time operating system (RTOS), it meets the strict requirements of industrial control for real-time performance.
Diagnosis and synchronization: built-in watchdog timer, SNTP/NTP clock synchronization function, hot-swap support (with redundant system).
Safety function: complies with IEC 61508/61511 standards, can be used for SIL 2/3 level safety control systems.
Application scenarios
1. Power industry
Power plant control: used for logic control and process regulation of generators and transformers to ensure stable operation of the power grid.
Substation automation: integrated in 800xA DCS system to achieve remote monitoring and protection.
2. Petrochemical and chemical industry
Complex process control: suitable for closed-loop control of parameters such as temperature, pressure, flow, and emergency shutdown system (ESD).
Safety-critical applications: complies with functional safety standards and provides SIL 2/3 level safety protection.
https://www.axcontroler.com/ABB/abb—pm891—3bse053240r1—ac-800m-controllers—pm891
https://www.weikunfadacai1.com/product/s-073n-abb-high-voltage-inverter-phase-module-3bhb009884r0021-s-073n/
admin –
ABB PM891 (Order No.: 3BSE053240R1) is a high-performance redundant central processing unit (CPU module) in the AC 800M controller series and is a core component of the ABB System 800xA distributed control system. This module is designed for complex industrial process control and has high reliability, high performance and strong expansion capabilities. It is suitable for automation control needs in industries such as power, petrochemicals, metallurgy, and water treatment. Its core functions include:
Redundant control: Supports CPU, power supply, and network redundancy to ensure disturbance-free system switching in the event of a single point failure.
High-performance processing: Based on the industrial-grade PowerPC architecture, it can quickly process complex control algorithms and logic.
Flexible expansion: Modular design supports the expansion of multiple I/O modules, communication modules, and functional modules.
Technical specifications and functions
1. Core parameters
Processor architecture: Industrial-grade PowerPC architecture with high-performance processing capabilities.
Memory and storage: Standard 128 MB RAM, 32 MB Flash, support for external memory card expansion.
Redundancy design:
CPU redundancy: The master and standby controllers achieve millisecond-level switching through dedicated redundant links (such as CEX bus).
Power redundancy: Supports dual power input to ensure power supply stability.
Network redundancy: Built-in two Ethernet ports (CN1, CN2), supporting redundant network protocols.
I/O configuration: Connect S800 I/O units through CEX bus, and each CEX bus segment supports up to 12 units.
Communication protocol: Supports Profibus, Modbus, EtherNet/IP, OPC UA and other protocols to achieve seamless integration with third-party devices.
Programming environment: Use ABB Control Builder M tool, support IEC 61131-3 standard programming language (LD, FBD, ST, etc.).
2. Key functions
Redundancy switching: The master and standby controllers synchronize data in real time, and automatically switch when a fault occurs to ensure uninterrupted control.
Real-time performance: Equipped with a real-time operating system (RTOS), it meets the strict requirements of industrial control for real-time performance.
Diagnosis and synchronization: built-in watchdog timer, SNTP/NTP clock synchronization function, hot-swap support (with redundant system).
Safety function: complies with IEC 61508/61511 standards, can be used for SIL 2/3 level safety control systems.
Application scenarios
1. Power industry
Power plant control: used for logic control and process regulation of generators and transformers to ensure stable operation of the power grid.
Substation automation: integrated in 800xA DCS system to achieve remote monitoring and protection.
2. Petrochemical and chemical industry
Complex process control: suitable for closed-loop control of parameters such as temperature, pressure, flow, and emergency shutdown system (ESD).
Safety-critical applications: complies with functional safety standards and provides SIL 2/3 level safety protection.
3. Metallurgy and water treatment industry
Production line control: used for logic control and motion control of equipment such as rolling mills and crushers.
Water treatment system: realizes automated management of equipment such as pumps and valves, and optimizes the processing process.
Troubleshooting and maintenance suggestions
1. Common problems and solutions
Fault phenomenonPossible causesSolution steps
Controller does not respondPower failure, communication interruption or firmware error1. Check the stability of the power input (24V DC ±10%).
2. Verify whether the communication line connection is normal.
3. Update the firmware to the latest version or reset the parameters to the default value.
Redundancy switching failedRedundancy link failure or inconsistent firmware version1. Check the CEX bus connection to confirm that the firmware version of the main and standby controllers is consistent.
2. Check the synchronization status indicator to ensure real-time data synchronization.
I/O signal abnormalChannel damage or ground interference1. Use a multimeter to detect the channel voltage/current and confirm whether the input signal range is within the module range.
2. Check the grounding system to ensure signal transmission stability.
Key troubleshooting steps
Power supply and connection check:
Confirm that the input voltage is stable (24V DC ±10%), without phase loss or fluctuation.
Check that the communication cables (such as Profibus DP, Ethernet) are firmly connected, without oxidation or looseness.
Firmware and parameter update:
Update the firmware through the ABB Control Builder M tool to ensure that the versions of the main and standby controllers are consistent.
Reset parameters to default values, or restore configurations from backup files.
Redundant link test:
Use ABB diagnostic tools to check the CEX bus status and confirm that the redundant link is fault-free.
Simulate the failure of the main controller to verify whether the standby controller can take over seamlessly.
Compatibility and alternative solutions
1. System compatibility
Recommended system: ABB AC 800M control system, compatible with S800 I/O modules, CI854 communication modules, etc.
Extended compatibility: Supports integration with ABB 800xA DCS system to achieve unified engineering management and human-machine interface (HMI) development.
admin –
The PM891 processor is a monolithic unit equipped with power supply, CPU-boards and unit termination. The unit contains microprocessor and RAM memory, a real-time clock, LED indicators, INIT push button and a Secure Digital interface. The PM891 does not contain any internal battery The PM891 has two RJ45 Ethernet ports (CN1, CN2) for connection to the Control Network, and one RJ45 serial port (COM4). The COM4 port is isolated and used for a configuration tool. The PM891 supports CPU redundancy for higher availability (CPU, CEX-Bus, communication interfaces and S800 I/O).
The communication expansion bus (CEX-Bus) is mounted on the unit. The CEX-Bus is used for extending the on-board communication ports with communication interface units. It is possible to use redundant communication interfaces on the CEX-Bus. The CEX-Bus Interconnection unit BC810 is used to increase the availability on the CEX-Bus by dividing it into separate segments. The optical Modulebus of the unit can be used for connecting seven clusters of S800 I/O units (each comprising up to 12 units). Each PM891 is provided with a unique Ethernet address which provides hardware identity to the unit.
Package including:
2 pcs PM891K01 Processor Unit
1 pcs TK850V007 CEX-bus Extension Cable
1 pcs TK855 RCU Data Link Cable
1 pcs TK856 RCU Control Link Cable
Please note: The BC810K02 is not included in the PM891K02 Redundant Processor Unit kit. In order to make hot replacement of PM891 Processor Unit possible, the BC810K02 is required and has to be ordered separately.
Features and benefits
Reliability and simple fault diagnosis procedures
Modularity, allowing for step-by-step expansion
IP20 Class protection without the requirement for enclosures
The controller has full EMC certification
High performance and large application memory
Sectioned CEX-Bus using a pair of BC810
Built-in redundant Ethernet Communication ports