Description
The ABB PM864AK01 (3BSE018161R1) is a 24 V DC powered, rack-mounted controller processor unit designed for the ABB System 800xA and Compact Product Suite platforms. Utilizing a 96 MHz Motorola ColdFire processor and equipped with 32 MB of volatile RAM, this unit executes control logic, manages local and remote I/O sub-systems, and handles peer-to-peer network communications via the AC 800M controller framework. It serves as the central processing core for medium-to-high complexity process loops in industrial automation environments.
Technical Specifications
| Parameter | Specification / Value |
| Brand | ABB |
| Model Number | PM864AK01 |
| Part Number (Ordering Code) | 3BSE018161R1 |
| Processor Type | 96 MHz Motorola ColdFire |
| On-Board Memory | 32 MB RAM (volatile, battery-backed), 8 MB Flash ROM |
| Input Power Voltage | 24 V DC (typical range: 19.2 to 30 V DC) |
| Power Consumption | 160 mA at 24 V DC (base unit configuration) |
| Built-in Communications | 2 x RJ45 Ethernet ports (Control Network), 2 x RS-232C serial ports |
| Supported Protocols | MMS (Manufacturing Message Specification), Modbus RTU, Profibus DP-V1 (via CI854A), MasterBus 300 (via CI855) |
| Redundancy Support | Dual-unit CPU redundancy supported via dedicated interconnect cable |
| Programming Environment | Control Builder M (compliant with IEC 61131-3) |
| Operating Temperature | +5 to +55 °C (+41 to +131 °F) |
| Storage Temperature | −40 to +70 °C (−40 to +158 °F) |
| Relative Humidity | 5% to 95%, non-condensing |
| Protection Rating | IP20 |
Field Application and System Integration Notes
Firmware and Software Compatibility
The PM864AK01 requires specific firmware versions depending on the active System 800xA or Compact Product Suite version deployed at your facility.
- Version Control: Ensure that the loaded firmware matched the Control Builder M engineering software version (e.g., version 5.1, 6.0, or 6.1). Mismatched major firmware versions will prevent successful application downloads and stall system initialization.
- Redundancy Pairing: When implementing CPU redundancy, both the primary and backup PM864AK01 modules must run identical firmware versions and hardware revisions. Check the revision stickers on the side of the housing before attempting hot-configuration syncs.
Application Capacity Constraints
With 32 MB of on-board RAM, this processor typically manages up to 1,000 I/O points depending on memory allocation for trends, alarms, and complex IEC 61131-3 logic programs.
- Execution of high-frequency tasks (e.g., 10 ms loops) should be restricted to critical interlocks to avoid CPU overloading.
- Monitor task execution times within Control Builder M to maintain cyclic load margins below 70% during normal operational steady-states.
Real-World Field Upgrades
In field deployments upgrading older PM861 or PM864 units to the PM864AK01, check the backplane physical tolerances and terminal base configurations (such as TP830). The “K01” kit includes the processor unit and the base plate, but you must manually transfer or replace the backup battery unit (SB821 or SB822) to prevent application loss during power cycles.
Commercial and Procurement Data
- Product Condition: New Original (New Surplus) in original factory-sealed packaging, or Refurbished (fully tested under load profiles). Specify requirements when requesting a quote.
- Standard Warranty: 12-month comprehensive warranty covering component failure and hardware defects.
- Estimated Lead Time: Departs warehouse within 1 to 3 business days from order confirmation. Global shipping available via DHL, FedEx, or UPS.
- Pricing Notice: The listed price is indicative and fluctuates based on global supply constraints and component availability. Contact our engineering sales division for a firm, itemized commercial proposal.
Frequently Asked Questions (FAQ)
What is the exact difference between the PM864A and the PM864AK01?
The PM864A refers specifically to the individual processor module. The PM864AK01 is the official designation for the complete controller kit, which typically includes the PM864A processor module, TP830 baseplate, and the necessary basic accessories for mounting. Verify exact line-item contents with the sales team prior to dispatch.
Can I hot-swap the PM864AK01 processor module during operation?
Yes, but only if the system is explicitly configured for CPU redundancy with a dual-baseplate assembly. In a redundant setup, you can remove the faulted secondary processor without interrupting the active control application. In a single-CPU configuration, pulling the module instantly cuts power to the controller logic, forcing all connected I/O loops into their configured fail-safe states.
How do I handle battery replacement without clearing the running application?
The processor retains the compiled application in its volatile RAM using the external backup battery (SB821/SB822) when 24 V DC system power is lost. To replace a degraded battery without losing data, perform the maintenance action while the controller receives primary 24 V DC input power. Do not power down the rack during battery extraction. Verify battery health status indicators via the hardware status flags in System 800xA before and after replacement.
