It adopts a dual-CPU redundant architecture with automatic switching between primary and backup processors (with extremely short switching time) to ensure continuous system operation in the event of a single CPU failure; it supports full system redundancy (CEX-Bus bus, Ethernet/serial communication, S800 I/O module) and dual power input to improve system reliability. It is widely used in industries such as chemical, petroleum, natural gas, power, manufacturing, and water treatment for critical scenarios such as production line control, process automation, robot control, generator monitoring, and power grid dispatching to ensure production continuity.

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　　Other names for PM864AK02 3BSE018164R1:

　　Redundant Controller Unit PM864AK02 3BSE018164R1

　　Redundant Communication Unit PM864AK02 3BSE018164R1

　　Analog Unit PM864AK02 3BSE018164R1

　　Product Positioning and Core Functions

　　Redundant Design: Adopts a dual-CPU redundant architecture with automatic switching between primary and backup processors (extremely short switching time), ensuring continuous system operation in the event of a single CPU failure; supports full system redundancy (CEX-Bus bus, Ethernet/serial communication, S800 I/O modules) and dual power inputs, improving system reliability.

　　Power Supply and Protection: 24V DC power supply, power consumption approximately 10-20W; IP20 protection rating, adaptable to a wide temperature range of 0°C to +60°C, and a humidity range of 5-95% with no condensation.

　　Application Scenarios: Widely used in chemical, petroleum, natural gas, power, manufacturing, and water treatment industries for critical scenarios such as production line control, process automation, robot control, generator monitoring, and power grid dispatching, ensuring production continuity.

　　Technical Specifications and Performance

　　Processor and Memory: Equipped with a high-performance industrial-grade CPU (such as MPC866, 67MHz clock frequency), 32MB RAM (application storage) and 4MB flash PROM (firmware storage), supporting 1000 Boolean operations in just 0.18 milliseconds for rapid processing of complex control logic.

　　Communication Interfaces:

　　Two RJ45 Ethernet ports (10 Mbit/s), supporting redundant communication.

　　Two RJ45 serial ports (COM3 is RS-232C, COM4 is an isolated port), compatible with industrial bus protocols such as Modbus, PROFIBUS, and Ethernet.

　　Expansion Capabilities:

　　Supports up to 12 CEX bus modules, compatible with communication modules such as CI854 (PROFIBUS DP-V1) and CI861, and can be expanded with remote I/O and third-party devices (such as the FOUNDATION Fieldbus system).

　　Supports dual power supply redundancy and isolation protection; built-in battery backup ensures data retention during power outages.

　　Supports up to 12 CEX bus modules, compatible with communication modules such as CI854 (PROFIBUS DP-V1) and CI861, and can be expanded with remote I/O and third-party devices (such as the FOUNDATION Fieldbus system).

　　Supports dual power supply redundancy and isolation protection; built-in battery backup ensures data retention during power outages.

　　Physical Characteristics:

　　Operating Temperature: -25℃ to +70℃; Storage Temperature: -40℃ to +70℃; IP20 protection rating; EMC certified; suitable for harsh industrial environments.

　　Dimensions: 119mm (W) × 186mm (H) × 135mm (D); Weight: approx. 2900g (including base); supports 35mm DIN rail mounting (slide rail & locking mechanism design).

　　Software and Compatibility:

　　Programming Tools: Programmed via ABB Compact Control Builder or 800xA Control Builder; compatible with System 800xA 6.0.2, Compact Control Builder 6.0.0-1 and above.

　　Diagnostics and Maintenance: Built-in LED indicators display real-time status; supports remote monitoring and diagnostics (e.g., via Compact Control Builder), simplifying troubleshooting; modular design allows for gradual expansion, reducing initial costs.

　　Supporting System Models

　　Core Components

　　CPU Module: PM864AK02 3BSE018164R1 redundant controller, built-in 32M RAM, supports dual CPU hot standby redundancy.

　　Base and Connectors: TP830 base (115mm width), CEX bus extension cable (TK850), module bus terminator (TB807), RCU-Link cable (TK851).

　　Power Supply and Battery: SD821/SD822/SD823 power modules (supports redundant power supply), spare battery (4943013-6, 3.6V/900mAh lithium battery).

　　Expansion Modules

　　Communication Modules: CI854 (PROFIBUS DP-V1), CI861 (fiber optic communication), CI630K02 (serial communication), AO810V2 (S800 communication card).

　　I/O Modules: S800 series remote I/O (e.g., AI801, AO801), intrinsically safe signal modules.

　　Safety Modules: PM865K02 (SIL3 certified redundant controller), SM810K01 (safe CPU module).

　　System Platform: AC 800M controller (integrated Control Builder M programming software), compatible with 800xA and Advant Controller systems.

　　Certifications and Quality

　　Certified by international standards such as CCC (China Compulsory Certification), ensuring compliance with safety and quality specifications; employs a high-reliability design, undergoes rigorous testing, and is suitable for high-intensity industrial applications.

　　Application Value

　　High Reliability: Redundant architecture reduces downtime risk, ensuring uninterrupted operation of critical processes.

　　High-Efficiency Control: Rapid data processing, supports real-time feedback and dynamic control, improving production efficiency and product quality.

　　Flexible Integration: Compatible with multiple communication protocols and devices, easy to integrate with DCS, MES, and other systems, adapting to distributed control and smart factory needs.

　　Maintenance Guidelines

　　Routine Maintenance

　　Hardware Checks: Monthly checks include power supply voltage stability (24V DC ±5%), CPU load rate (<70%), and communication link packet loss rate (<0.1%). Backup power supplies (e.g., diesel generators) require monthly no-load start-up tests, and backup CPUs require simultaneous winding insulation testing (≥0.5MΩ).

　　Connector Maintenance: Check CEX bus cables and fiber optic connectors for oxidation or looseness. Regularly clean module heatsinks to prevent dust accumulation.

　　Redundant System Special Maintenance

　　Switchover Testing: Quarterly simulations of primary CPU failure (e.g., power outage) verify the automatic takeover capability of the backup CPU, recording switchover time and data consistency.

　　Program and Data Backup: Monthly export of control programs and configuration files, storing them on a dedicated server or CF card to prevent data loss.

　　Troubleshooting

　　Synchronization Failure: Check fiber optic connection status and CPU firmware version consistency (must be the same). Verify synchronization cycle (1-5ms) and communication monitoring time (100ms) settings.

　　Power Failure: Use a multimeter to check the input voltage and troubleshoot issues such as aging capacitors or loose terminals in the power module.

　　I/O Anomalies: Check the module status using diagnostic tools. Power must be disconnected and hot-swappable procedures followed when replacing a faulty module.

　　Preventative Measures:

　　Configure a UPS power supply to ensure system power supply and prevent equipment damage caused by voltage fluctuations.

　　Regularly update firmware to the latest official ABB version to fix known vulnerabilities and improve performance.

　　Train operators to familiarize themselves with the redundant system logic to avoid misoperation leading to switching failures.

　　The PM864AK02 3BSE018164R1 redundant processor unit is a core component of the ABB AC 800M system, renowned for its high reliability, redundant design, and broad compatibility. It is suitable for industrial automation, process control, and safety-critical systems. Its triple redundancy architecture and SIL3 certification ensure stable operation in harsh environments, making it an ideal choice for industries such as petrochemicals, power, and manufacturing. Maintenance should follow the principle of "treating primary and backup equally," regularly checking hardware status, testing redundancy switching functionality, and backing up critical data to ensure long-term stable system operation.

　　Please note that all products on this website are specialty items, and market prices are constantly fluctuating.

　　Please refer to customer service for a specific quote, as the price may not be accurate for new products.

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