ABB PM861AK01 PM861AK02 High-Performance Redundant Controller AC 800M Series

Product Item : PM861AK01/02 3BSE018157R1 3BSE018160R1
Product Brand : ABB
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Product Description
Other Models

ABB PM861AK01 and PM861AK02 are high-performance processor units within the ABB AC 800M series, designed for advanced industrial automation and process control systems. As core components of the ABB Ability™ System 800xA, these controllers deliver powerful processing capabilities, extensive communication options, and support for CPU redundancy to ensure maximum system availability in critical applications.

The key distinction between the two models is that PM861AK01 is a single processor unit (non-redundant configuration), while PM861AK02 is a complete redundant processor unit kit containing two CPUs for high-availability applications requiring seamless failover .

These controllers are ideal for industries requiring high reliability, including oil & gas, petrochemical, power generation, pharmaceuticals, water treatment, and manufacturing automation. Their robust design, comprehensive certifications, and flexible configuration options make them a preferred choice for demanding distributed control systems (DCS).

Key Features

CPU Redundancy Support (PM861AK02): The redundant kit configuration provides seamless switchover with maximum 10 ms failover time, ensuring continuous operation in critical processes

High Processing Performance: Powered by MPC860 processor with 16 MB RAM, capable of handling complex control tasks and multiple communication protocols simultaneously

Extensive Communication Interfaces: Equipped with 2 Ethernet ports (CN1, CN2) for control network connectivity, plus 2 RS-232C serial ports (COM3 with modem control signals, COM4 isolated for configuration tools)

Protocol Support: Supports PROFIBUS DP-V1, Modbus RTU, Ethernet/IP, and other industrial communication protocols for seamless integration with third-party devices

Industrial Grade: Operates in temperatures from +5 °C to +55 °C, IP20 protection class, features battery-backed real-time clock, LED status indicators, and INIT push button for diagnostics

Modular Design: DIN rail mounting on TP830 baseplate, supports up to 12 communication modules on the CEX bus, with Modulebus supporting up to 96 I/O modules

CompactFlash Interface: Allows application loading without engineering tools, supporting OEM and remote solutions

Technical Specifications

Parameter PM861AK01 PM861AK02

Product Type Single Processor Unit Redundant Processor Unit Kit

Order Code 3BSE018157R1 3BSE018160R1

Processor MPC860 MPC860

Clock Frequency 33 MHz 33 MHz

Memory (RAM) 16 MB 16 MB

Flash Memory 4 MB (for firmware) 4 MB (for firmware)

Ethernet Ports 2x RJ45 (10 Mbit/s) 2x RJ45 (10 Mbit/s)

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

CEX Bus Support Up to 12 communication modules Up to 12 communication modules

Modulebus I/O Capacity Up to 96 I/O modules (non-redundant) Up to 96 I/O modules (non-redundant), up to 84 I/O modules (redundant)

Redundancy Support No (single CPU) Yes (dual CPU, max 10 ms switchover)

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

Typical Power Consumption 6.0 W (10.3 W max) 6.0 W (10.3 W max)

Operating Temperature +5 °C to +55 °C +5 °C to +55 °C

Storage Temperature -40 °C to +70 °C -40 °C to +70 °C

Protection Class IP20 IP20

Dimensions (H x W x D) 119 mm x 135 mm x 189 mm 119 mm x 135 mm x 189 mm

Net Weight Approx. 1.15 kg Approx. 2.9 kg (complete kit)

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Product List & Ordering Information

Below are the primary product codes for the PM861AK01 and PM861AK02 controllers:

Order Code ABB Part Number Description Included Components

PM861AK01 3BSE018157R1 Single Processor Unit (Non-redundant) 1x PM861A CPU, 1x TP830 Baseplate (115mm), 1x TB850 CEX-bus terminator, 1x TB807 ModuleBus terminator, 1x TB852 RCU-Link terminator, 1x Memory backup battery (4943013-6), 1x 4-position power plug

PM861AK02 3BSE018160R1 Redundant Processor Unit Kit (High Availability) 2x PM861A CPUs, 2x TP830 Baseplates (115mm), 1x TK850 CEX-bus expansion cable, 2x TB807 ModuleBus terminators, 1x TK851 RCU-Link cable, 2x Memory backup batteries (4943013-6)

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Required Accessories & Related Modules

To build a complete control solution, the following components are commonly ordered alongside PM861AK01/02:

Category Model / Order Code Description

Baseplate TP830 Required baseplate for mounting the PM861A CPU, provides backplane connectivity

CEX-Bus Terminator TB850 Required to terminate the CEX-Bus expansion bus

ModuleBus Terminator TB807 Required for ModuleBus termination

RCU-Link Terminator TB852 Required for RCU-Link termination (single CPU config)

Redundancy Cable TK851 RCU-Link cable for connecting two CPUs in redundant configuration (PM861AK02)

CEX-Bus Expansion Cable TK850 CEX-bus cable for expansion (PM861AK02)

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

Communication Modules CI853, CI854, CI857, CI858, CI867, CI871, FI830 (Profibus DP-V1), etc. PROFIBUS, Modbus, Ethernet/IP, and other protocol interfaces

Power Supply SD831, SD832, SD833, SD853, SD854 24 V DC power supply units for the controller and I/O system

Applications

The ABB PM861AK01/02 controllers are 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 (PM861AK02) ensures continuous operation in emergency shutdown systems (ESD), burner management, and critical utilities where downtime is not tolerated

Manufacturing Automation: Control of production lines, assembly systems, and material handling in automotive, electronics, and general manufacturing industries

Power Generation: Turbine control, substation automation, and smart grid applications requiring reliable performance in harsh electrical environments

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

Why Choose ABB PM861AK01/02?

The PM861A series controllers strike an optimal balance between performance and reliability. Key advantages include:

Proven Track Record: Widely deployed in mission-critical applications across multiple industries with documented 99.95% availability

Communication Versatility: Native support for both PROFINET (for real-time control) and Modbus (for data acquisition) allows seamless integration of new and legacy equipment

Investment Protection: Hot-swappable modules and backward compatibility with existing AC 800M infrastructure protect your automation investment

Global Support: Backed by ABB's worldwide service network and extensive technical documentation

Certifications: Full EMC compliance, TÜV functional safety capability (with appropriate configuration), and IEC 61508-SIL3 ready

Programming & Engineering

Engineering Tool: Compact Control Builder / Control Builder M (800xA) supports IEC 61131-3 programming languages including FBD, ST, and SFC

Firmware Compatibility: Compatible with System 800xA versions from 4.0 and AC 800M Control Software 4.0

ABB PM861AK01

ABB PM861AK02

3BSE018157R1

3BSE018160R1

ABB AC 800M controller

Redundant processor unit kit