ABB PM866K02 3BSE050199R1 Redundant Processor Unit for AC 800M 800xA

Product ID (Kit): PM866K02

Order Code (Kit): 3BSE050199R1

Brand: ABB

Product Family: AC 800M

Type: Redundant Processor Unit / CPU Kit for High Availability Systems

Single Unit Variant: PM866K01 (3BSE050198R1) – Single Processor Unit

Product Overview

The ABB PM866K02 (3BSE050199R1) is a pre-assembled redundant processor unit kit engineered for the ABB AC 800M control system and 800xA distributed control system (DCS). Designed for mission-critical applications where system uptime is non-negotiable, this kit provides a complete hot-standby redundancy solution.

The kit consists of two PM866K01 processor units, pre-configured to operate in a master-slave redundancy pair. In the event of a primary CPU failure, the system performs an automatic bumpless transfer to the standby unit in under 50 milliseconds, ensuring continuous operation without process interruption.

For non-redundant applications, the PM866K01 (3BSE050198R1) is available as a single-processor unit, offering identical performance for smaller or non-critical control systems.

Complete Redundant Kit Components (PM866K02)

The PM866K02 ships as a turnkey redundancy solution containing all necessary components for immediate deployment:

Component Quantity Description

PM866K01 Processor Units 2 Dual 133 MHz CPUs with 64 MB RAM each

TP830 Baseplates 2 Mounting base for each CPU (115 mm width)

TK850 CEX-bus Cable 1 Expansion bus cable for I/O communication

TK851 RCU-Link Cable 1 Redundancy link for CPU synchronization

TB850 CEX-bus Terminators 2 Bus termination modules

TB807 ModuleBus Terminators 2 ModuleBus termination modules

Lithium Batteries 2 Memory backup (4943013-6)

Note: 800xA software licenses (e.g., for PROFIBUS or IEC 61850) are not included and must be ordered separately.

Key Features & SEO Keywords

Hot-Standby Redundancy: Dual CPUs in master-standby configuration with automatic failover (<50ms) ensures continuous operation for critical processes.

High-Performance Processor: Powered by 133 MHz MPC866 (PowerPC architecture) or dual-core ARM Cortex-A9 (800MHz), depending on revision, providing robust processing for complex control logic.

Sufficient Memory: 64 MB SDRAM per CPU (128 MB total system) with 2-4 MB Flash for firmware storage.

Dual Ethernet Connectivity: Two integrated RJ45 Ethernet ports (CN1, CN2) for control network redundancy and communication with operator stations.

Comprehensive Diagnostics: Features real-time redundancy status monitoring, predictive fault detection, and an integrated web server for remote health checks.

Online Maintenance Capability: Hot-swappable design allows replacement of failed processors without shutting down the control system.

Wide Operating Temperature: Operates reliably from -20°C to +60°C, suitable for harsh industrial environments.

Technical Specifications (Datasheet)

Specification PM866K02 (Kit) / PM866K01 (Single)

Part Numbers Kit: 3BSE050199R1 / Single: 3BSE050198R1

Processor 133 MHz (MPC866) / Dual-core ARM Cortex-A9 800MHz (variant dependent)

RAM 64 MB per CPU (128 MB total for redundant pair)

Flash Memory 2-4 MB per CPU

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

Current Consumption Approx. 210 mA per CPU

Failover Time <50 ms (bumpless transfer)

Communication Ports 2 × Ethernet (CN1/CN2, 10 Mbit/s), 2 × RS-232C (COM3/COM4)

I/O Capacity Up to 96 I/O modules per single CPU; 84 per redundant CPU

Task Cycle Minimum 1 ms, supports multi-task scheduling

Operating Temperature -20°C to +60°C

Storage Temperature -40°C to +85°C

Dimensions (per CPU) 135 mm (D) × 186 mm (H) × 119 mm (W)

Kit Weight Approx. 2.7 – 2.9 kg

Certifications CE, UL, ATEX, IECEx, SIL2 capable

Important Note for Legacy Systems: The PM866K02 (3BSE050199R1) is not RoHS compliant and is intended for legacy systems installed before July 2017. For new installations, ABB recommends ordering the PM866AK02 instead.

Hot-Standby Redundancy Architecture

The PM866K02's redundancy architecture ensures maximum system availability through three key mechanisms:

Automatic State Synchronization: The dual processors continuously mirror process data, control logic execution, and I/O states through the high-speed RCU-Link (TK851 cable) . This real-time synchronization ensures the standby CPU maintains an identical operational state at all times.

Sub-50ms Failover Performance: Advanced redundancy algorithms detect processor faults, communication failures, or power supply issues within milliseconds. The automatic switchover to the standby CPU occurs so rapidly that control loops, communication links, and operator displays continue without visible disruption.

Online Maintenance Capability: The hot-swappable design allows replacement of failed processors, I/O modules, and communication interfaces without shutting down the control system. This capability is essential for 24/7 operations requiring scheduled maintenance during production runs.

Applications & Use Cases

The ABB PM866K02 is widely deployed across industries requiring continuous process availability:

Petrochemical Refineries: Controls distillation towers, catalytic crackers, and hydroprocessing units where unplanned shutdowns result in millions of dollars in lost production.

Power Generation Facilities: Manages turbine control, boiler automation, and emissions monitoring in combined-cycle plants and coal-fired stations.

Chemical Manufacturing: Coordinates batch reactors, continuous polymerization processes, and hazardous material handling systems requiring SIL-rated safety functions.

Pharmaceutical Production: Ensures FDA 21 CFR Part 11 compliance through validated control sequences and electronic batch records.

Water & Wastewater Treatment: Operates municipal treatment plants and desalination facilities where service interruptions impact public health.

Metallurgy & Mining: Controls critical processing equipment in continuous production environments.

System Integration & Compatibility

The PM866K02 integrates seamlessly with ABB's automation ecosystem:

Control Software: Programmed using ABB Control Builder M or 800xA engineering software, supporting all IEC 61131-3 programming languages (Ladder Diagram LD, Structured Text ST, Function Block Diagram FBD, etc.).

I/O Systems: Compatible with ABB S800 I/O, S900 I/O, and third-party I/O systems via PROFIBUS DP, Modbus TCP/RTU, and FOUNDATION Fieldbus protocols.

Communication Protocols: Supports MasterBus 300, COMLI, Modbus, Siemens 3964R, PROFIBUS DP, and OPC UA.

Network Topologies: Supports star, ring, and redundant Ethernet configurations with automatic failover switching.

Backward Compatibility: Compatible with legacy AC 800M installations, enabling phased upgrades without complete system replacement.

Why Choose the ABB PM866K02 / PM866K01?

Feature Benefit

Proven Reliability ABB's AC 800M platform is a market-leading DCS solution with decades of industrial deployment.

Complete Kit Solution The PM866K02 includes all cables, terminators, and baseplates – no additional component sourcing required.

Global Service Network Backed by ABB's worldwide support, including 24/7 technical assistance and spare parts availability.

Legacy System Support Specifically designed for existing ABB installations, ensuring continued operation of mature systems.

Ordering Information

Product Order Code Description

PM866K02 Kit 3BSE050199R1 Complete redundant kit: 2x PM866K01, 2x TP830, TK850, TK851, 2x TB850, 2x TB807, 2x batteries

PM866K01 Single 3BSE050198R1 Single processor unit (non-redundant, requires separate baseplate)

PM866AK02 3BSE081637R1 Advanced redundant processor (RoHS compliant, for new installations)

Required Accessories (sold separately):

Redundant power supplies (e.g., SD8xx series, PS501)

800xA software licenses

Additional I/O or communication modules (e.g., CI854AK01 for PROFIBUS DP)

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