Employing a PowerPC processor with a 1GHz clock speed, equipped with 32MB RAM and Flash storage, it supports multi-task parallel processing to meet high-speed real-time control requirements. It supports CPU hot standby redundancy and achieves real-time data synchronization between dual CPUs (synchronization period 1-5ms) via a dedicated fiber optic synchronization module, with a switching time of <50ms, ensuring seamless switching in case of failure and uninterrupted system operation. It features built-in dual redundant Ethernet ports (supporting TCP/IP, Modbus TCP, OPC UA) and RS232/RS485 serial ports, and can be optionally equipped with Profibus DP, CAN, Ethernet/IP, and other fieldbus modules. Compatible with various industrial protocols, it is widely used in high-availability scenarios such as power (e.g., power plant DCS), petrochemical (process control), water treatment, and large-scale manufacturing (e.g., steel plants, automotive production lines), especially excelling in systems with strong redundancy requirements.

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　　Other names for PM861K02 3BSE018160R1:

　　PM861K02 3BSE018160R1 Redundant Controller Unit

　　Redundant Input/Output Unit PM861K02 3BSE018160R1

　　PM861K02 3BSE018160R1 Redundant Signal Processor Unit

　　System Architecture Role:

　　Belongs to the AC 800M modular controller family. Mounted via DIN rail, it can be integrated into the ABB 800xA or Compact Control Builder platform. It supports interconnection with third-party systems (such as HMI and SCADA) via OPC UA/Modbus TCP protocol. It is compatible with S800 I/O, Profibus DP, Foundation Fieldbus, and other fieldbuses, enabling local/remote I/O expansion (supports up to 98 remote stations, 500m cable/2km fiber optic).

　　Technical Parameters and Architecture:

　　Processor and Performance: Employs a PowerPC processor with a 1GHz clock speed, equipped with 32MB RAM and Flash storage, supporting multi-task parallel processing to meet high-speed real-time control requirements.

　　Redundancy Design: Supports CPU hot standby redundancy, achieving real-time data synchronization between dual CPUs via a dedicated fiber optic synchronization module (synchronization cycle 1-5ms), with a switching time of <50ms, ensuring seamless switching and uninterrupted system operation in case of failure.

　　Communication Interfaces:

　　Ethernet: Supports redundant TCP/IP, Modbus TCP, and other protocols.

　　Fieldbus: Optional Profibus DP, FF, CAN, and other modules (expansion required).

　　High-Performance Processing: Employs a 32-bit/64-bit processor, standard 32MB RAM and 64MB Flash storage, supporting complex logic control, data processing, and multi-task parallelism (minimum task cycle 1ms, SOE event resolution <1ms).

　　Communication Capabilities: Built-in dual redundant Ethernet ports (supporting TCP/IP, Modbus TCP, OPC UA), RS232/RS485 serial ports, with optional Profibus DP, CAN, Ethernet/IP, and other fieldbus modules, compatible with multiple industrial protocols.

　　Safety and Reliability: Compliant with IEC 61508 SIL3 safety certification, MTBF > 200,000 hours; built-in firewall and security encryption to prevent unauthorized access; supports power/communication redundancy, adaptable to a wide temperature range of 0-60℃, IP20 protection rating.

　　Expandability: Supports up to 12 communication modules, compatible with S800/S900 I/O modules (such as PM802F). Can connect to local I/O stations (up to 8 stations) via Modulebus (electrical/fiber) or expand remote I/O (up to 98 stations) via Profibus DP.

　　Environmental Adaptability: Industrial-grade design, operating temperature 0-60℃, IP20 protection rating (requires installation in a control cabinet), humidity tolerance 5-95% without condensation, power requirement 24V DC, power consumption approximately 10-20W.

　　Application Scenarios

　　Critical Industrial Control: Widely used in high-availability scenarios such as power (e.g., power plant DCS), petrochemicals (process control), water treatment, and large-scale manufacturing (e.g., steel mills, automotive production lines), especially excelling in systems with strong redundancy requirements.

　　Distributed Control Systems: As the core controller of the AC 800M series, it connects to remote I/O stations or third-party devices to achieve distributed control and centralized monitoring, such as in smart city public transportation systems and factory energy management systems.

　　Smart City Public Transportation: In subway and airport systems, redundant architecture ensures uninterrupted operation of signal control and energy management.

　　Factory Energy Management: For example, in Vishay factories, it integrates monitoring of multiple systems such as air compressors, air conditioning, and power, achieving centralized control through the PM864K02, reducing electricity consumption by 15-30% and saving nearly one million yuan in electricity costs annually.

　　Hazardous Environment Control: Supports intrinsically safe signal processing, suitable for explosion-proof scenarios such as petrochemicals and natural gas.

　　Safety Standards: Complies with IEC 61508 SIL3 certification, suitable for high-safety scenarios such as safety-critical process control.

　　Installation and Configuration

　　Hardware Installation: Requires redundant modules (e.g., TK851V010 EXC3BSC950262R1 redundant connection cable, TB852 3BSE018157R2 redundant terminal), following rack-mount specifications, ensuring proper heat dissipation and grounding.

　　Software Configuration: Programmed via ABB 800xA Control Builder or Compact Control Builder, supporting firmware serial upgrades (e.g., TK212 cable connection) and IP address configuration (IPConfig tool).

　　Maintenance and Diagnostics: Built-in hardware self-test and fault log, supports modular expansion (e.g., I/O modules, communication modules), and provides fault diagnosis functions.

　　Environment and Certification

　　Environmental Adaptability: Operating temperature 0°C~60°C, protection rating IP20 (must be installed in a control cabinet), humidity 5%~95% (non-condensing).

　　Power Requirements: 24V DC power supply, power consumption approximately 10~20W (depending on load).

　　Certifications: CE, UL, TÜV SIL 2/3 certified, meeting global industry standards.

　　Features

　　High Availability and Reliability: MTBF (Mean Time Between Failures) > 200,000 hours, compliant with IEC 61508 SIL3 safety certification, suitable for critical sectors such as power and petrochemical industries; built-in hardware self-test, fault log, and remote diagnostic functions support real-time monitoring and fault early warning.

　　Flexible Expansion Capabilities: Remote I/O can be expanded via communication modules such as CI854 3BSE025961R1 and CI861 3BSE058590R1, supporting up to 12 communication modules; compatible with ABB 800xA or Compact Control Builder programming software, supporting modular programming and plug-and-play functionality.

　　Security and Compatibility: Integrated firewall and security encryption functions prevent unauthorized access; supports data interaction with third-party systems (such as HMI and SCADA) via OPC Server, adapting to multi-system integration needs.

　　Matching Models and Systems

　　Communication Modules: CI853 33BSE018124R1 (Dual RS232), CI854 3BSE030220R1 (Profibus DP), CI855 3BSE018106R1 This (MB300), CI856 3BSE026055R1 (S100 I/O), CI857 3BSE018144R1 (INSUM), CI858 3BSE018135R1 (DriveBus), CI862 3BUA000037R1 (TRIO), etc., supporting multi-protocol conversion and fieldbus expansion.

　　Power Supply and Connectivity: SS823 3BSE038226R1 (power switching unit), SB821 3BSE018109R1 (external backup battery), TK851V010 EXC3BSC950262R1 (redundant controller connection cable), TB852 3BSE018157R2 (redundant connection terminal) ensure power supply stability and signal transmission reliability.

　　I/O Modules: S800/S900 series digital/analog I/O modules support intrinsically safe signal acquisition and control.

　　Software System: Compact Control Builder programming configuration software, 800xA monitoring platform, OPC Server (supporting AC800M data interaction) enable system configuration, monitoring, and remote diagnostics.

　　High Integrity Expansion: Upgrade to SIL3 safety level via SM812 module and SIL-certified software, suitable for high-safety-requirement scenarios such as nuclear power and rail transportation.

　　Software tools: Compact Control Builder (configuration programming), OPC Server for AC800M (data interaction), Control Builder M (logic development).

　　Compatible Processor Models:

　　PM851K01 3BSE018168R1, PM856K01 3BSE018104R1, PM860K01 3BSE018100R1, PM861K01 3BSE018105R1, PM861K02 3BSE018160R1, PM865K01 3BSE031151R1, PM865K02 3BSE031150R6, PM891K01 3BSE053241R1, PM891K02 3BSE053242R1, PM891 3BSE053240R1 (High Integrity Redundancy Version), etc., supporting the construction of dual-redundancy or multi-redundancy systems in conjunction with PM864K02.

　　Typical Configuration Example

　　In large-scale petrochemical plants, the PM864K02 is often combined with CI854 (Profibus DP) and CI857 (INSUM) modules to connect to S800 I/O stations and third-party devices (such as Siemens PLCs). It accesses the 800xA monitoring platform via redundant Ethernet, achieving integrated process control, safety interlocking, and data acquisition. The accompanying SB821 battery module ensures continuous program and data preservation after power failure, while the SS823 power supply unit ensures stable power supply.

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