ABB PM861AK01 3BSE018157R1 Processor Unit

The PM861AK01 is a high-performance processor unit developed by ABB for the industrial automation control sector, belonging to the AC 800M controller series. This product is an integrated package solution combining the PM861A Processor Unit and the TP830 Operator Panel, specifically designed for control applications demanding high reliability, robust processing power, and flexible expandability. As a core component in industrial control systems, the PM861AK01 is widely used for monitoring and managing critical processes in industries such as power generation, chemicals, oil & gas, water treatment, and manufacturing, capable of meeting diverse requirements including complex logic control, sequential control, process regulation, and data acquisition.

The unit features a modular, compact design and supports both single and redundant configuration modes, making it particularly suitable for redundant application scenarios where system availability is paramount. The product complies with stringent industrial standards and excels in electromagnetic compatibility (EMC), electrical safety, and environmental adaptability, ensuring stable operation in harsh industrial environments. The PM861AK01 integrates seamlessly into ABB's 800xA Extended Automation System or Compact Product Suite, providing users with a powerful, reliable, and easy-to-maintain control platform.

This product introduction will detail the technical features, specifications, functional advantages, and application information of the PM861AK01.

2. Product Composition and Key Features

The standard PM861AK01 package includes the following components, offering an out-of-the-box solution:

• PM861A Processor Unit: The core computing and control component of the system.

• TP830 Operator Panel: Used for local status display, diagnostics, and basic operation.

• Baseplate: For mounting the processor unit on a DIN rail.

• CEX-Bus Terminator (TBB50): For proper termination of the CEX extension bus.

• ModuleBus Terminator (TBB07): For proper termination of the ModuleBus I/O bus.

• RCU-Link Terminator (TBB52): For proper termination of the link in redundant configurations.

• Memory Backup Battery (Model includes 4943013-6-4): For retaining RAM data during power loss.

• Power Plug (3BSC84008BRA): For connecting the power cable.

Core Feature Highlights:

1. Powerful Processing Capability:

• Utilizes a high-performance MPC860 microprocessor running at 48 MHz, ensuring fast task execution and response.

• Equipped with ample memory resources to meet the demands of complex control programs and data.

2. High-Reliability Redundancy Support:

• Designed specifically for redundant configuration, featuring a built-in Redundancy Control Unit (RCU) Link.

• Supports hot standby for dual CPUs, with a switchover time from Primary to Backup CPU of less than 10 milliseconds, minimizing downtime due to system faults.

• Provides redundant power supply status inputs (SA, SB) to enhance system power supply reliability.

3. Rich Communication and Expansion Capabilities:

• Integrates multiple standard communication ports for easy system integration and network connectivity.

• Can connect up to 12 S800 series I/O units via the electrical ModuleBus, enabling flexible I/O expansion.

• Features a Compact Flash card interface for convenient application loading and cold retain data storage.

4. Persistent Data Retention:

• Supports backup power for memory via an internal battery or external battery unit (SB821/SB822), ensuring critical data is not lost during power failures.

5. Compact and Robust Design:

• Conforms to IP20 protection rating, suitable for installation inside control cabinets.

• Standard DIN rail mounting saves space and simplifies installation.

3. Fault-Finding and Maintenance Guidelines

The PM861AK01 provides clear LED status indications and is accompanied by detailed fault-finding procedures for quick problem identification and resolution.

Common Fault-Finding:

1. Battery (B) LED is Flashing:

• Possible Cause: Internal or external battery voltage is below 3.1 V or non-existent; external battery cable disconnected.

• Corrective Action: Install a new battery; check and connect the external battery cable.

2. DUAL LED is OFF on Both CPUs:

• Possible Cause: CPUs are in the process of being restarted or configured; RCU Link cable disconnected; different control software in the two CPUs.

• Corrective Action: Allow time for startup/configuration to finalize; check and connect the RCU Link cable; upgrade both CPUs with the same control software version.

3. Fault LED is ON:

• Possible Cause: Controller has detected an internal error.

• Corrective Action: First, check the controller event log for detailed error codes and information, then troubleshoot based on the log guidance.

Maintenance Key Points:

• Battery Replacement: Regularly check and replace the internal or external battery based on the application's data retention time requirements. Replacement should be performed with the system powered on to ensure memory data is not lost.

• Software Management: Regularly back up control programs and data. When performing software upgrades, both CPUs in a redundant system must be upgraded synchronously.

• Cleaning and Inspection: With power disconnected, periodically clean the unit's ventilation slots with dry compressed air and check that all connectors are secure.

4. Application Areas and System Integration

As a member of the AC 800M controller family, the PM861AK01's application areas are closely tied to the entire system platform.

• Applicable Industries:

• Power Industry: Auxiliary system control, sequence control system (SCS) in power plants (thermal, hydro, renewable energy).

• Process Industries: Continuous and batch process control in oil & gas, petrochemicals, chemicals, pharmaceuticals, and metallurgy.

• Public Utilities/Infrastructure: Control and monitoring of water treatment, wastewater treatment plants, and district heating networks.

• Manufacturing: Production line automation in automotive, food & beverage, pulp & paper, and other sectors.

• System Integration:

• Integration with 800xA System: Serves as the underlying controller in the 800xA Extended Automation System. Through Aspect Object technology, it achieves deep integration with higher-level systems at information, operation, and engineering levels, forming a plant-wide integrated monitoring and management platform. The PM861AK01 is compatible with multiple AC 800M Hardware versions including 4.0, 4.1, 5.0, and 5.1.

• Integration with Compact Product Suite: In applications requiring a compact solution, it can serve as the control core of the Compact Product Suite, providing reliable and cost-effective control functionality.

• Communication Networks: Its Ethernet ports allow easy connection to plant information networks (e.g., OPC UA, Modbus TCP). Its serial ports can connect to legacy devices or modems for remote access.

5. Ordering and Environmental Information

• Ordering Code: 3BSE018157R1.

• Customs Tariff Number: 85371091 (Electrical control panels).

• Dangerous Goods Classification: Due to contained lithium battery, transport classification is UN Class 9 (Miscellaneous Dangerous Goods), UN Number UN3091.

• Environmental Compliance:

• RoHS: The current product version is Not RoHS Compliant.

• WEEE: Falls under Category 5: "Small Equipment (no external dimension more than 50 cm)". Should be recycled according to local Waste Electrical and Electronic Equipment regulations at end-of-life.

• Battery: Contains one portable lithium battery (lithium composition), weighing approximately 9 g.