Name: ABB PM864A Processor Unit, Part No. 3BSE018162R1 for AC800M / System 800xA DCS Controller - MASSIVE
Brand: ABB

Description

ABB PM864A Processor Unit, Part No. 3BSE018162R1 for AC800M / System 800xA DCS Controller

Product Description

The PM864A (3BSE018162R1) is a high-performance 32-bit processor unit for ABB AC800M controllers under System 800xA architecture. It executes real-time control logic, handles process data acquisition, closed-loop regulation, alarm management and system diagnostics. This CPU supports redundant controller configuration for high-availability applications with switchover time less than 10 ms. It integrates dual Ethernet ports for control network communication, two RS232 serial ports, ModuleBus for S800 I/O and CEX-Bus for expansion communication modules. Application programs, firmware and parameters are stored in onboard flash memory, backed up by a lithium battery to retain real-time clock and data during power loss. Widely deployed in power, pulp & paper, chemical and metal industries for spare replacement, maintenance and retrofit of AC800M distributed control systems.

PM864A 3BSE018162R1

Technical Specifications

Model: PM864A
ABB Part Number: 3BSE018162R1
Product Family: ABB AC800M, System 800xA
Type: Processor Unit (CPU)
Processor Clock: 96 MHz
Memory: 32 MB RAM, onboard Flash memory
Communication Interfaces:
- Dual 10/100 Mbps Ethernet
- 2 × RS232C serial ports
- ModuleBus for S800 I/O
- CEX-Bus for communication expansion modules
Redundancy: Supports dual redundant CPU hot standby
Power Supply: 24 V DC (19.2–30 V DC), typical consumption 6 W
Operating Temperature: 0 °C ~ +55 °C
Storage Temperature: -40 °C ~ +85 °C
Relative Humidity: 5%–95% non-condensing
Protection Class: IP20 (cabinet mounting)
Mounting: DIN rail mount with TP830 baseplate
Weight: Approx. 1.2 kg (CPU + baseplate)
Battery: Lithium backup battery for RTC and memory retention
Software: Configured via Control Builder M

Compatibility & Installation Pitfalls

Compatibility

Baseplate: TP830 base unit
I/O System: S800 I/O modules via ModuleBus
Expansion Modules: CI854, CI858, CI867, CI853 and other CEX-bus communication modules
Software: Control Builder M, System 800xA engineering and operation software
Terminator: TB850 CEX-bus terminator, TB807 ModuleBus terminator

Installation Pitfalls

Firmware Version Matching: New PM864A firmware must match the existing AC800M system and redundant partner CPU. Mismatched firmware leads to failed synchronization, communication faults or controller trip.
Battery Maintenance: The lithium backup battery has limited service life. A depleted battery causes loss of real-time clock and retention data after power outage.
Redundancy Synchronization: After CPU replacement, verify redundant sync status. Improper synchronization will fail hot standby switchover during a fault.
ESD Protection: The CPU PCB is ESD sensitive. ESD wrist strap is mandatory when handling outside the baseplate.
Terminator Installation: ModuleBus and CEX-Bus require correct terminators at bus endpoints. Missing or misplaced terminators cause unstable I/O communication.
Hot Swap Risk: Although the unit supports hot-swap in some rack configurations, avoid online replacement during critical process interlock operation.
IP Address & Configuration: After replacement, verify Ethernet IP settings, control network configuration and download the matching application program.

PM864A 3BSE018162R1

Standard Operating Procedure (SOP)

Pre-Installation

Verify part number PM864A / 3BSE018162R1. Inspect CPU, baseplate and connectors for physical damage.
Back up AC800M application project, controller configuration, firmware version and all I/O parameters via Control Builder M.
Record network IP addresses, redundancy settings and bus terminator layout.
Isolate and lock out rack power if the controller controls critical process trips. Prepare ESD protection tools.

CPU Replacement & Installation

Wear ESD wrist strap before handling the processor unit.
Unlock DIN rail latch and extract the old PM864A from TP830 baseplate.
Insert new into the TP830 baseplate, lock the slide mechanism.
Confirm ModuleBus and CEX-Bus terminators are correctly fitted.
Restore 24V DC rack power supply.

Post-Installation Verification

Check CPU LED indicators, confirm no hardware faults during self-test.
Download matching application and firmware if required.
Validate Ethernet communication to 800xA server and HMI stations.
Test redundant switchover function if installed in dual CPU configuration.
Check S800 I/O data exchange via ModuleBus and all CEX-bus communication modules.
Force test selected I/O points to verify control logic execution.
Save updated project backup, record serial number, firmware version and commissioning date in equipment log.