The PM665 is a high-performance processor module within the ABB Advant Controller 160 series, designed based on the Power PC microprocessor architecture and specifically engineered for complex industrial automation control tasks. This module represents a significant upgrade in control performance, processing capability, and system scalability for the Advant Controller 160 series. Compared to its predecessor, the PM645, the PM665 delivers approximately six times better performance, enabling it to meet the demands of more rigorous logic and regulatory control applications.
The PM665 processor module supports multiprocessing and redundancy configurations. Up to six processor modules can be plugged into a single basic station, enabling distributed control and high-availability system architectures. The module is compatible with the Advant OCS system software platform and the Control Builder A engineering toolchain, allowing seamless integration into ABB Advant automation systems.
As part of the Advant Controller 160 series, the PM665 supports S600 I/O and S800 I/O systems and features communication capabilities via various fieldbuses, including Advant Fieldbus 100, PROFIBUS-DP, MODBUS, and SERCOS. Its flexible communication architecture and powerful data processing capabilities make it widely applicable in continuous and batch process control for industries such as power generation, chemical, metallurgy, water treatment, and oil & gas.
2. Core Features
2.1 High-Performance Power PC Processor
The PM665 uses a Power PC microprocessor, significantly enhancing instruction execution speed and data processing capacity. In typical applications, the PM665 achieves approximately a sixfold performance increase over the PM645 module. The processor features an instruction cache that further optimizes code execution efficiency, making it well-suited for large-scale control logic and complex algorithm computations.
2.2 Large Data Storage and Handling Capacity
The PM665 supports up to 500 MDAT datasets, greatly expanding data exchange capabilities. The module incorporates built-in Flash PROM for storing the system software, communication software, and option software. The system software supports online upgrades and option loading, facilitating on-site maintenance and functional expansion.
2.3 Powerful Redundancy and Multiprocessing Capabilities
The PM665 can operate cooperatively with other processor modules within the same station, supporting up to six modules running in parallel to achieve a true multiprocessing control architecture. The module supports both CPU redundancy and station redundancy modes, ensuring continuous system operation under high-availability demands. In redundancy configurations, the master and slave modules automatically synchronize the application program and support hot replacement and bumpless switchover.
2.4 Rich Communication Interfaces and Protocol Support
The PM665 provides multiple communication interfaces, including:
Com A interface: Used for system software download and engineering station connection.
Com B interface: Supports DCF77 time synchronization, MODBUS protocol, and minute pulse synchronization.
Advant Fieldbus 100 interface (via CI630/CI631 communication modules): Used for high-speed process data exchange.
PROFIBUS-DP interface: For connecting S800 I/O or third-party slave devices.
MODBUS master/slave protocol support.
SERCOS digital drive interface support.
2.5 Broadly Compatible I/O System Support
The PM665 is compatible with both S600 I/O and S800 I/O systems, supporting a wide range of module types including analog input/output, digital input/output, sequence of events (SOE) modules, and safety-related I/O modules. The module supports redundant I/O communication interfaces and redundant fieldbus architectures, ensuring high reliability in data transmission.
2.6 Precise Time Synchronization
The PM665 supports multiple time synchronization methods, including:
DCF77 radio clock synchronization.
External minute pulse synchronization.
System time broadcast via Advant Fieldbus 100.
Support for the T_DIFF 100 µs option, enabling time compensation with 100-microsecond precision.
These functions provide a high-precision time base for SOE event recording and process diagnostics.
2.7 Complete Engineering and Diagnostic Tool Support
The PM665 is fully compatible with the Control Builder A engineering environment and supports:
Application Builder 4.1 and later revisions.
Function Chart Builder 6.2/1 and later revisions.
PROFIBUS Library Editor.
AMPL configuration language and DB element libraries.
Online monitoring, diagnostics, and error reporting functions.
Module status display and debugging interfaces.
3. Technical Advantages
3.1 Significantly Enhanced Processing Performance
Benefiting from the Power PC architecture and an optimized instruction cache mechanism, the PM665 excels when handling large-scale control tasks. According to internal ABB tests, the PM665's execution speed is approximately six times that of the PM645 in typical application scenarios, making it especially suitable for high-density logic control, complex PID regulation, and multi-loop control tasks.
3.2 Higher System Integration
The PM665 supports running multiple processor modules in the same station, each independently undertaking different control tasks to realize a true distributed control architecture. Modules can exchange data via the high-speed backplane bus (BIOB), supporting data-sharing mechanisms such as MDAT and DSP.
3.3 Flexible Redundancy and Fault Tolerance Mechanisms
The PM665 supports two redundancy modes:
CPU Redundancy: Two modules within the same station provide mutual backup; if the master module fails, the slave takes over without disturbance.
Station Redundancy: Redundancy between modules located in separate stations, suitable for distributed control scenarios.
Redundant modules automatically synchronize the application program and support the "Update Slave" function, facilitating online maintenance and fault recovery.
3.4 Extensive Option Expansion Capability
The PM665 supports numerous optional software function modules (OPTs), including:
Extended PC Element Set (OPT1).
MVI Multi-Vendor Interface handling (OPT2).
Event handling (OPT3).
MODBUS protocol support (OPT4).
Station redundancy and rotational speed measurement (OPT6).
S800 via PROFIBUS connection (OPT7).
Warm Start function (OPT8).
T_DIFF 100 µs time difference compensation.
DI65x for ProtSyst, dedicated safety system option.
Options can be loaded or disabled online via the engineering station's serial interface, facilitating functional configuration and system upgrades.
3.5 Enhanced Diagnostics and Maintenance Capabilities
The PM665 is equipped with a 7-segment digital display that shows the module's operating status and fault codes in real time. It supports online error reporting, module status querying, communication interface diagnostics, and other functions. The module supports hot swapping and a PASSIVE mode, facilitating replacement and maintenance without downtime.
4. Application Scenarios
The PM665 is suitable for a wide range of industrial automation control scenarios, including but not limited to:
Boiler control and protection systems in large-scale thermal power plants.
Process control and water quality monitoring in water treatment plants.
Continuous process control in petrochemical installations.
Blast furnace and converter control systems in iron and steel metallurgy.
Natural gas compression and transportation control.
Rotational speed monitoring and protection for large rotating machinery (in conjunction with the RSM option).
Safety Instrumented Systems (SIS) and Emergency Shutdown Systems (ESD).
5. Upgrade and Maintenance Considerations
5.1 Upgrading from PM645 to PM665
The power consumption of the PM665 is about 3 W higher than the PM645; verify that the station power supply capacity is adequate.
The CS software download interface has changed: for the PM665, the CS software is loaded via Com A instead of Com B.
The physical Com B interface is changed from a female connector to a male connector, with pins 2 and 3 crossed, making it compatible with standard PC serial cables.
The application program structure must consider 64-bit alignment requirements. Some PC elements use a larger local data area, which may require splitting overly large control structures.
5.2 Software Version Matching
It is essential to ensure that the Communication Section (CS) software version matches the Processing Section (PS) system software version; otherwise, the module may not start properly.
It is recommended to load the CS software first, then load the system software.
If power is interrupted during the loading process, the module will enter the "PL" state and the system software must be reloaded.
5.3 Redundant Module Maintenance
When replacing a redundant module, set the mode selector to "PASSIVE" (position 3) to avoid impacting the running master module.
After replacement, a Voter Test must be performed to verify correct module functionality.
Application program synchronization can be completed via the ACK button or an engineering station command.
