Product Overview

The ABB 086406-002 is a high-performance PROFIBUS DP Master Communication Module designed for seamless integration into the AC 800M controller platform,which forms the backbone of ABB’s System 800xA Distributed Control System(DCS).This module enables the AC 800M to act as a central PROFIBUS master on industrial field networks,connecting directly to a wide array of PROFIBUS-compliant slaves—including remote I/O stations(such as ABB’s own S800 or S900 I/O),variable frequency drives(VFDs),motor protection relays,valve positioners,and intelligent field devices—thereby consolidating control architecture and reducing wiring complexity.The ABB 086406-002 supports both standard and redundant configurations,making it suitable for critical applications in power,oil&gas,and heavy process industries where uptime and data integrity are paramount.

Engineered for robust industrial operation,the ABB 086406-002 features galvanic isolation,built-in diagnostic LEDs,and compliance with PROFIBUS FDL(Fieldbus Data Link)standards up to 12 Mbps.It integrates natively with Control Builder M,ABB’s engineering toolset,allowing automatic device import via GSD files,real-time network monitoring,and detailed fault logging—including slave drop detection,bus short-circuit alerts,and communication timeout diagnostics.In redundant AC 800M setups,two 086406-002 modules can operate in synchronized hot-standby mode,ensuring uninterrupted field communication even during hardware failure.As a key enabler of hybrid DCS/PLC architectures,the ABB 086406-002 bridges enterprise-level process control with device-level automation,delivering deterministic,low-latency data exchange essential for modern industrial operations.

Technical Specifications

Parameter Name Parameter Value

Product Model 086406-002

Manufacturer ABB Ltd.

Product Type PROFIBUS DP Master Communication Module

Compatible Controller AC 800M(PM86x series)

Bus Protocol PROFIBUS DP(Class 1&2),compliant with IEC 61158/EN 50170

Communication Speed 9.6 kbps to 12 Mbps(auto-negotiable)

Max.Slave Devices Up to 126 per segment(with repeaters)

Isolation 500 Vrms between backplane and fieldbus

Redundancy Support Yes(hot-standby with dual modules in redundant CPU system)

Physical Interface 9-pin D-SUB(RS-485),isolated,with PG/FG grounding terminal

Operating Temperature 0°C to+60°C

Certifications CE,cULus,ATEX(for hazardous area use with proper enclosure),IEC 61000-6-2/4

Main Features and Advantages

Seamless Integration with System 800xA:The 086406-002 is fully recognized within ABB’s Control Builder M engineering environment.Engineers can import slave device descriptions using standard GSD files,configure cyclic I/O data exchange,and monitor bus health through intuitive graphical diagnostics—all without third-party tools.This native integration drastically reduces engineering time and eliminates configuration errors common with generic communication gateways.

Robust Redundancy and Diagnostics:In safety-critical or continuous-process applications,the 086406-002 supports synchronized redundant operation.If the primary module fails,the standby unit takes over within milliseconds,maintaining communication continuity.Onboard LEDs indicate module status,bus activity,and fault conditions,while detailed diagnostic buffers log events such as slave loss,parity errors,or cable faults—enabling rapid troubleshooting during plant operation.

High-Speed,Deterministic Field Communication:With support for PROFIBUS speeds up to 12 Mbps,the 086406-002 ensures fast update cycles for time-sensitive applications like coordinated drive control or emergency shutdown systems.Its deterministic polling mechanism guarantees predictable data latency,essential for closed-loop control over distributed devices.Moreover,the module supports PROFIBUS DP-V1,enabling acyclic parameter access for advanced device configuration and asset management.

Flexible Field Connectivity:The 086406-002 connects directly to standard PROFIBUS cables using shielded twisted-pair(e.g.,Belden 3079A),with proper termination and grounding handled via its dedicated terminals.It interoperates seamlessly with major vendors’PROFIBUS devices—Siemens,Schneider,Danfoss,Yaskawa—making it ideal for brownfield retrofits or multi-vendor plants.For extended networks,it works reliably with PROFIBUS repeaters and fiber-optic converters.

Application Field

The 086406-002 is widely deployed in thermal and hydroelectric power plants,where it links AC 800M controllers to motor control centers(MCCs),boiler feed pumps,condenser vacuum systems,and turbine auxiliary drives via PROFIBUS.In oil&gas upstream and midstream facilities,it integrates wellhead control panels,compressor station VFDs,and pipeline valve actuators into a unified System 800xA architecture.Chemical and petrochemical plants leverage the 086406-002 to connect reactor temperature controllers,agitator drives,and safety shutdown valves across large process units,benefiting from reduced cabling costs and centralized diagnostics.

Additionally,the module plays a vital role in mining and metals processing,where it communicates with hoist drives,conveyor systems,and mill lubrication units over long distances.In water and wastewater treatment,the 086400-002(note:correct model is 086406-002)enables centralized control of aeration blowers,sludge pumps,and chemical dosing skids via PROFIBUS networks spanning entire sites.Wherever legacy 4–20 mA hardwiring is being replaced by digital fieldbuses—or where hybrid analog/digital systems require reliable master-slave coordination—the 086406-002 delivers proven,scalable connectivity that enhances both operational efficiency and system resilience.

Related Products

086406-001:Earlier revision of the same PROFIBUS module;086406-002 includes firmware and compatibility enhancements

086407-001:PROFINET IO communication module for AC 800M,offering Ethernet-based alternative to 086406-002

086405-001:MODBUS RTU/ASCII serial communication module for legacy device integration

CI854:Redundant PROFIBUS module for AC 800M with enhanced diagnostics(part of newer I/O generations)

TB854:Terminal base for 086406-002,providing fieldbus connector and mounting

PM864/PM865:AC 800M CPU modules that host the 086406-002 in controller racks

S800 I/O with PROFIBUS Adapter:Remote I/O solution that can be controlled by 086406-002 as a PROFIBUS slave

Installation and Maintenance

Pre-installation preparation:Before installing the 086406-002,verify that the target AC 800M CPU(e.g.,PM864)has available I/O slots and sufficient memory for PROFIBUS configuration.Ensure the terminal base(TB854)is correctly mounted and grounded.Use certified PROFIBUS cable(e.g.,Type A)with proper shielding,and install 220Ωtermination resistors at both ends of the bus segment.Confirm that all slave devices have unique PROFIBUS addresses and matching GSD files loaded in Control Builder M.

Maintenance recommendations:The 086406-002 requires minimal routine maintenance but benefits from periodic network health checks.Monitor diagnostic logs in System 800xA Operations for recurring communication errors,which may indicate cable degradation or EMI interference.Inspect the D-SUB connector for corrosion or loose pins during outages.If bus faults persist,use a PROFIBUS analyzer to validate signal quality.In redundant systems,perform annual switchover tests to validate failover functionality.Always power down the controller rack before removing the 086406-002 to avoid backplane damage.

Product Guarantee

Every 086406-002 is sourced from ABB-authorized distribution channels or professionally refurbished to meet original factory specifications.Each unit undergoes full functional testing,including PROFIBUS master initialization,slave polling at multiple baud rates,redundancy handover simulation,and diagnostic buffer validation.We provide a 12-month warranty against defects in materials and workmanship,backed by direct access to ABB-certified System 800xA engineers for configuration support and troubleshooting.Our commitment ensures that your fieldbus infrastructure remains reliable,secure,and future-ready—because in industrial automation,seamless communication isn’t optional;it’s the foundation of operational excellence.

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