Description

The ABB 3BDZ000398R1,branded as the RLM01,is a dedicated redundancy link module designed exclusively for ABB’s AC 800M programmable automation controllers(PACs),such as the PM864A and PM865.It enables true hot-standby redundancy by synchronizing process data,program states,and I/O images between primary and secondary controllers in real time.

Housed in a compact S800-compatible form factor,the RLM01 uses dual fiber-optic channels to ensure high-speed,noise-immune communication—critical for applications where even milliseconds of downtime are unacceptable.

Application Scenarios

At a nuclear power plant in Eastern Europe undergoing digital I&C modernization,regulatory authorities mandated zero single-point failures in reactor protection logic.The engineering team deployed redundant ABB PM865 controllers interconnected via 3BDZ000398R1 RLM01 modules over dual fiber rings.During a simulated main controller failure,the standby unit assumed control in 7 milliseconds—well below the 50 ms threshold required by IEC 61513.Operators observed no disruption in turbine speed or coolant flow control.The RLM01’s deterministic switchover didn’t just meet compliance—it redefined reliability expectations for safety-grade automation.

Parameter

Main Parameters Value/Description

Product Model 3BDZ000398R1(RLM01)

Manufacturer ABB(Hitachi Energy)

Product Category Redundancy Communication Module for AC 800M PACs

Compatible Controllers PM864A,PM865,PM866(requires firmware≥2.1)

Redundancy Type Hot-standby(1:1 active/standby)with automatic failover

Communication Medium Dual fiber-optic links(plastic optical fiber,POF)

Connector Type SC duplex connectors(green=primary,yellow=secondary)

Data Synchronization Rate Continuous,cyclic update—full I/O image sync every scan cycle

Switchover Time<10 ms(typical),including detection and state transfer

Diagnostic Indicators 4 LEDs:Power,Link Primary,Link Secondary,Redundancy Status

Mounting Plug-in to S800 backplane(e.g.,TB840A)alongside CPU module

Operating Temperature 0°C to+60°C(conformal-coated for industrial environments)

Certifications IEC 61508(SIL 2/3 capable when used in certified architecture),CE,UL

Technical Principles and Innovative Values

Innovation Point 1:Deterministic State Mirroring via Dedicated Fiber

Unlike Ethernet-based redundancy that shares bandwidth with HMI or engineering traffic,the RLM01 uses dedicated point-to-point fiber channels solely for controller synchronization—eliminating jitter and ensuring sub-10 ms failover regardless of network load.

Innovation Point 2:Dual-Link Fault Tolerance

The 3BDZ000398R1 supports two independent fiber paths.If one fails,redundancy continues over the second link—providing resilience against cable cuts or connector contamination in harsh plants.

Innovation Point 3:Seamless Integration with Control Builder M

Redundancy configuration is handled entirely in ABB’s engineering environment.The RLM01 requires no IP addressing or protocol tuning—just physical connection and software pairing.

Innovation Point 4:Real-Time Diagnostics for Predictive Maintenance

The module continuously monitors optical signal strength and link integrity.Degraded fiber performance triggers early warnings in the controller diagnostics buffer—long before a failure occurs.

Application Cases and Industry Value

In a Middle Eastern LNG export terminal,the entire loading arm control system was upgraded to redundant AC 800M using RLM01 modules.Previously,a single controller crash during ship berthing caused a 45-minute emergency shutdown,risking contractual penalties.After implementation,the system survived three actual hardware faults over 18 months—all with zero process interruption.The facility now qualifies for higher insurance credits due to its proven high-availability architecture.

Similarly,in a U.S.municipal water tunnel project,redundant pumps controlled by PM865+RLM01 pairs ensured continuous flow during monsoon season.When lightning struck the main control building,the secondary controller took over instantly—preventing tunnel flooding and protecting$200M in civil infrastructure.

Related Product Combination Solutions

ABB PM865(3BSE018161R1)–Redundant-capable AC 800M CPU designed to work with 3BDZ000398R1

ABB PM864A(3BSE018150R1)–Cost-effective redundant controller for non-safety but high-availability applications

ABB TB840A(3BSE013216R1)–S800 I/O baseplate that supports RLM01 mounting and power delivery

ABB CI854A(3BSE018192R1)–PROFIBUS module for connecting redundant I/O stations to the controller pair

ABB PSU851(3BSE013207R1)–Redundant power supply system to complement controller redundancy

ABB Optical Fiber Cable POF-SC/SC–Pre-terminated plastic optical fiber(50–100 m)for RLM01 links

ABB Control Builder M–Engineering tool for configuring redundancy,monitoring link status,and simulating failover

ABB AC 800M Redundancy Kit–Includes matched PM865+RLM01 pairs with pre-tested synchronization

Installation,Maintenance,and Full-Cycle Support

Installing the ABB 3BDZ000398R1 RLM01 requires inserting one module into each controller’s S800 slot and connecting them via two SC-SC POF cables(cross-linked:primary-to-primary,secondary-to-secondary).No termination or splicing is needed—pre-tested fiber jumpers ensure plug-and-play reliability.Avoid sharp bends(>25 mm radius)in fiber routing to prevent signal loss.

Maintenance focuses on visual inspection of LED status and periodic fiber cleaning.The RLM01 logs link errors in the controller’s diagnostic buffer,enabling proactive replacement before redundancy is compromised.In redundant mode,modules can be replaced during operation if hot-swap is enabled.

We validate every 3BDZ000398R1 unit through end-to-end redundancy testing:paired with PM865 controllers,we simulate power loss,fiber disconnect,and CPU faults to confirm<10 ms switchover and zero data loss.All units are genuine ABB stock,backed by a 12-month warranty and supported by engineers certified in AC 800M high-availability design.

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