ABB PM860AK01 3BSE066495R1 AC 800M High-Performance Processor Unit

ABB PM860AK01 (Order Code: 3BSE066495R1) is a high-performance processor unit kit within the ABB AC 800M series, designed for advanced industrial automation and process control systems. As a core hardware component of the ABB Ability™ System 800xA, the PM860AK01 delivers balanced processing power, extensive communication capabilities, and support for CPU redundancy to ensure maximum system availability in demanding applications.

This controller is ideal for industries requiring reliable, deterministic control, including oil & gas, power generation, chemical processing, pharmaceuticals, water treatment, and manufacturing. Its modular design, comprehensive certifications, and flexible configuration options make it a preferred choice for distributed control systems (DCS) and high-availability PLC environments.

Key Features

CPU Redundancy Support: Fully supports high-availability redundant CPU configurations to eliminate downtime and ensure process continuity during hardware maintenance or failure

Optimized Processing Performance: Powered by a 48 MHz 32-bit RISC processor with 16 MB RAM and 4 MB Flash memory, capable of handling medium-scale process control with both discrete and regulatory control strategies

Integrated Communication Interfaces: Equipped with 2x RJ45 Ethernet ports (10/100 Mbit/s) for plant and control networks, 2x RS-232C serial ports (COM3 for general use, COM4 isolated for configuration tools)

Dedicated ModuleBus: High-speed electrical path for direct communication with local S800 I/O clusters, ensuring low-latency I/O processing

Scalable Communication: Compatible with a wide range of CEX-bus communication modules supporting protocols such as Modbus TCP, PROFIBUS DP, PROFINET, and CANopen

Industrial Grade Design: DIN rail mounting on TP830 baseplate, battery-backed real-time clock, LED status indicators, and CompactFlash interface for firmware and application storage

No Onboard I/O: By design, centralizes control while flexibly connecting to S800 I/O, S900 I/O, or field networks via communication modules

Technical Specifications

Parameter Details

Product Type Processor Unit Kit (CPU + Baseplate + Accessories)

Order Number 3BSE066495R1

Series ABB AC 800M / System 800xA

Processor 48 MHz, 32-bit RISC 

RAM Memory 16 MB 

Flash Memory 4 MB (for firmware and application storage) 

Ethernet Ports 2x RJ45 (10/100 Mbit/s, IEEE 802.3) 

Serial Ports 2x RJ45 (COM3: RS-232C, COM4: Isolated RS-232C) 

ModuleBus 1x dedicated port for local S800 I/O connection 

CEX-Bus Support Supports up to 12 communication modules 

Redundancy Support Yes (CPU, CEX-Bus, Communication interfaces) 

Power Supply 24 V DC (19.2 – 30 V DC) 

Operating Temperature 0 °C to +55 °C (+32 °F to +131 °F) 

Storage Temperature -40 °C to +70 °C (-40 °F to +158 °F)

Protection Class IP20 

Dimensions (H x W x D) 186 mm x 119 mm x 135 mm 

Product Net Weight 1.1 kg 

Gross Weight (packaged) 2.1 kg 

Battery Lithium, 9 g (for real-time clock and memory backup) 

Certifications CE, RoHS compliant 

HS Code 85371091 

What's Included in the Kit (PM860AK01)

Component Description Quantity

PM860A CPU module with processor and memory 1

TP830 Baseplate with Ethernet address label (DIN rail mounting) 1

TB850 CEX-bus terminator 1

TB807 ModuleBus terminator 1

Battery Lithium battery for memory backup (4943013-6) 1

Note: No software license is included with the kit .

Product List & Ordering Information

The PM860AK01 is the standard processor unit kit for the AC 800M platform. Below are the primary product codes and related items:

Order Code ABB Part Number Description Typical Application

PM860AK01 3BSE066495R1 Standard Processor Unit Kit (Non-redundant) Single controller configuration

PM860AK02 (Contact ABB) Redundant Processor Unit Kit (High Availability) Redundant CPU configuration

Compatible Accessories & Related Modules

Category Model / Order Code Description

Baseplate TP830 Required baseplate for PM860A CPU (included in kit)

CEX-Bus Terminator TB850 Required to terminate the CEX-Bus expansion bus (included in kit)

ModuleBus Terminator TB807 Required for ModuleBus termination (included in kit)

Redundancy Cable TK851V010 RCU-Link cable for connecting two CPUs in redundant configuration

Redundancy Cable TK853V020 Extended RCU-Link cable for redundant configurations

External Battery Unit SB822 Optional external battery for extended RAM backup time

Communication Modules CI853, CI854, CI857, CI858, CI867, CI868, etc. PROFIBUS, Modbus, Ethernet/IP, and other protocol interfaces

Power Supply Units SD831, SD832, SD833, SD853, SD854 24 V DC power supplies for controller and I/O systems

Related AC 800M CPU Models

Model Memory Redundancy Order Code

PM851AK01 8 MB RAM No 3BSE066485R1

PM856AK01 8 MB RAM No 3BSE066495R1

PM860AK01 16 MB RAM Yes 3BSE066495R1

PM861AK01 16 MB RAM No 3BSE018157R1

PM861AK02 16 MB RAM Yes 3BSE018160R1

PM864AK01 32 MB RAM No 3BSE018161R1

PM864AK02 32 MB RAM Yes 3BSE018164R1

PM866K01 – No 3BSE050198R1

PM866K02 – Yes 3BSE050199R1

Source: 

Applications

The ABB PM860AK01 controller is widely used in:

Process Control Systems (DCS): For precise and stable control of reactors, distillation columns, boilers, and turbines in oil & gas, chemical, and power plants

High Availability & Critical Processes: Redundant configuration ensures continuous operation in emergency shutdown systems (ESD), burner management, and critical utilities

Manufacturing Automation: Control of machinery in mining, metals, cement, and pulp & paper industries, including mills, crushers, kilns, and conveyors

Infrastructure: Water and wastewater treatment plants, HVAC systems, and building automation where reliability and remote monitoring are essential

Why Choose ABB PM860AK01?

The PM860AK01 strikes an optimal balance between performance and cost for medium-scale process control applications. It offers:

Mid-range Processing Power: 48 MHz processor with 16 MB RAM—positioned between PM856 (8 MB) and PM861 (16 MB but newer architecture)

Full Redundancy Support: Unlike lower-end PM851/PM856 models, the PM860 supports CPU redundancy for high-availability applications

Proven Reliability: Based on the field-proven AC 800M platform with extensive global installations

Long Lifecycle Support: Backed by ABB's commitment to long-term spare part availability for System 800xA

Comprehensive Compatibility: Fully compatible with S800 I/O, existing engineering tools (Compact Control Builder), and standard fieldbuses

Installation & Maintenance

Cabinet Environment: Mount on DIN rail in a clean, ventilated enclosure (IP20 minimum). Keep ambient temperature 0–55 °C, non-condensing

Power & Grounding: Stable 24 V DC supply with proper protective earth; segregate power and signal cable routing

Networking: Use industrial Ethernet switches; separate control and plant networks when possible. Label ETH ports clearly for maintenance

I/O and Buses: Connect S800 I/O and fieldbus modules via the CEX-bus; follow ABB guidelines for segment lengths and termination

Safety & ESD: De-energize before insertion/removal; use ESD protection when handling the CPU and memory media

Routine Maintenance: Schedule backups of the controller image, keep firmware at approved revisions, inspect connectors, and replace the real-time clock battery as recommended

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