ABB PM860AK01 (Order No. 3BSE066495R1) is the core processor unit in the AC 800M control system, belonging to the ABB 800xA automation platform. It features a modular DIN‑rail mounting design and is equipped with an MPC860 processor, delivering high computing performance, abundant communication interfaces and flexible scalability. It achieves IP20 protection without an additional enclosure, adapting to the complex environments of industrial sites. Configuration can be completed via 800xA Control Builder, and it is widely used for logic operations, process control and other tasks in various industrial control fields.
The CPU board contains the microprocessor and RAM memory, a real-time clock, LED indicators, INIT push button, and a CompactFlash interface.
The base plate of the PM860A controller has two RJ45 Ethernet ports (CN1, CN2) for connection to the Control Network, and two RJ45 serial ports (COM3, COM4). One of the serial ports (COM3) is an RS-232C port with modem control signals, whereas the other port (COM4) is isolated and used for the connection of a configuration tool.
Hardware & Performance Specifications
Processor & Computing Performance
Equipped with an MPC860 processor with a clock frequency of 48 MHz. It executes 1000 Boolean operations in only 0.23 ms. Supports up to 32 controller tasks and 32 distinct cycle times, with an application cycle time as low as 1 ms, providing sufficient computing efficiency for industrial real-time control.
Memory Configuration
Starting from 800xA version 5.1 FP4, the unit comes standard with 16 MB RAM, of which 10.346 MB is available for application execution. It includes 2 MB Flash PROM for firmware storage and supports additional Flash memory. A built-in 3.6 V lithium battery provides RAM backup power to ensure data retention in case of power loss.
Real-Time Clock
Integrated high-precision real-time clock with a stability of 100 ppm (approximately 1 hour deviation per year). Supports 1 ms precision clock synchronization between AC 800M controllers via the CNCP protocol, ensuring time consistency for multi-device coordinated control.
Interfaces & Communication Capabilities
The unit is equipped with multiple standardized interfaces for industrial control networks, configuration tool connections, and I/O expansion. Hardware is designed based on Ethernet, PROFIBUS DP, and other standards, offering excellent communication compatibility.
Ethernet Interface
2 x RJ45 Ethernet channels (CN1, CN2), compliant with IEEE 802.3, transmission rate 10 Mbit/s. Supports MMS (Manufacturing Message Specification) and IAC (Inter-Application Communication) control network protocols. A 100 Mbit/s switched Ethernet is recommended as the control network backbone.Each backplane has a unique Ethernet address to provide a hardware identifier for the CPU.
Serial Interface
2 x RJ45 RS232C serial ports (COM3, COM4):
- COM3: Non‑galvanically isolated, supports 75–19200 baud rate with full RTS‑CTS flow control and modem control signals.
- COM4: Galvanically isolated, fixed 9600 baud rate without RTS‑CTS, dedicated for configuration tool connection.
Expansion Buses
- CEX Bus: Supports expansion of up to 12 single CEX bus communication modules, with a maximum supply current of 2.4 A.
- Modulebus: Supports 1 electrical + 7 optical I/O clusters, allowing up to 96 I/O modules with a scan rate of 0–100 ms (actual rate depends on the number of I/O modules).Maximum supply current for electrical Modulebus: 1.0 A at 24 V DC and 1.5 A at 5 V DC.
OPC Communication
Each OPC client supports an event queue capacity of up to 3000 events in the controller. Transmission rates to the OPC server are:
- 36–86 events/sec
- 113–143 data messages/secSatisfies communication requirements for industrial data acquisition and monitoring.
Power Supply & Power Consumption
Power Rating
Powered by 24 V DC, with an operating voltage range of 19.2–30 V DC. Supports redundant power status input to meet industrial power configuration requirements.
Power Consumption
At 24 V DC:
- Typical operating current: 180 mA
- Maximum operating current: 300 mA
- Typical power consumption: 4.32 W
- Maximum power consumption: 7.2 WIts low-power design allows dense mounting without additional cooling equipment.
Software & Configuration
Configuration Tool
Fully compatible with ABB 800xA Control Builder software, supporting IEC 61131-3 standard programming languages for fast control application development and configuration.
Program Management
A single controller supports up to 32 applications, each containing up to 64 programs and 128 charts. Programs can be downloaded via CompactFlash, serial port, or Ethernet to meet various on-site configuration needs.
Environmental Adaptability
Operating EnvironmentOperating temperature: +5 to +55 °CStorage temperature: -40 to +70 °CTemperature change rate: ≤ 3 °C/minMaximum operating altitude: ≤ 2000 mRelative humidity: 5–95% (non‑condensing)Pollution degree: Degree 2Corrosion protection: Compliant with ISA 71.04 G3Vibration resistance: Withstands vibration in the range of 10–500 Hz (with corresponding amplitudes/acceleration at different frequency ranges)Operating noise: < 55 dB(A)
Mechanical Characteristics
MountingFeatures a unique slide‑lock mechanism for fast DIN‑rail mounting and removal. Simple installation meets the standard requirements for industrial control cabinets.
DimensionsWidth: 119 mm (4.7 in)Height: 186 mm (7.3 in)Depth: 135 mm (5.3 in)Weight: 1100 g (2.4 lb)Compact size saves installation space in control cabinets.
Core Product Advantages
High ReliabilityComprehensive fault diagnostics, integrated lithium battery backup, full EMC certification, and suitability for harsh industrial environments. Fan‑less compact design reduces failure points and ensures long‑term stable operation.
Modular ExpansionSupports multiple expansion types via CEX bus and Modulebus. Allows gradual expansion of communication and I/O modules to match the upgrade of control scale.
Standardized DesignHardware and communication protocols are based on industrial standards. Compatible with mainstream industrial buses such as Ethernet and PROFIBUS DP, and seamlessly integrated with the 800xA platform, reducing system integration and maintenance costs.
User‑friendly OperationEquipped with LED indicators and an INIT reset button for easy status monitoring and fault reset. Unique Ethernet address simplifies device identification and network configuration.
Applications of ABB PM860AK01 3BSE066495R1
- Petrochemical industry
- Power and energy (power plant DCS / substation automation)
- Pharmaceutical industry
- Water treatment
- Automotive manufacturing
- Food and beverage
- Metallurgy
- Railway traction power supply
- Building automation
- Chemical interlock control
- Furnace safety supervision
- Emergency Shutdown System (ESD)
- Continuous casting process control
- Feeder protection and control
- Continuous production process automation
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