Description

Product Overview

At the heart of any modern ABB 800xA automation solution lies the ABB PM864AK01-eA 3BSE018161R2—a powerhouse CPU engineered for reliability, speed, and scalability. Unlike standard PLCs, this module is purpose-built for continuous, 24/7 operation in safety-critical applications where unplanned downtime is not an option.

The PM864AK01-eA supports full hardware redundancy: two identical units can be installed in a redundant rack configuration, where one acts as the primary controller while the other remains in hot standby. In the event of a failure—power loss, communication fault, or internal error—the backup unit takes over within milliseconds, ensuring uninterrupted process control. This capability is indispensable in applications like turbine control, boiler management, or chemical reactor sequencing.

Importantly, the “-eA” suffix denotes an enhanced version with integrated 10/100 Mbps Ethernet port, enabling direct connection to ABB’s engineering station, operator clients, or enterprise networks without requiring a separate communication module—streamlining architecture and reducing points of failure.

Technical Specifications

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Key Innovations & Differentiators

True Hot-Swap Redundancy: The PM864AK01-eA enables seamless failover without program interruption—a critical advantage over non-redundant or cold-standby alternatives. State synchronization occurs continuously via a dedicated fiber-optic or copper sync link.

Integrated Ethernet for Simplified Architecture: The built-in Ethernet port eliminates the need for a separate CI854 or CI867 communication module in many applications, reducing cost, space, and complexity while enabling direct Modbus TCP or OPC UA data exchange.

Advanced Diagnostics & Cybersecurity: Onboard LEDs provide real-time status (RUN, STOP, REDUNDANCY, ERROR). It also supports secure firmware updates and user authentication via ABB’s Control Builder M engineering tool, aligning with IEC 62443 standards.

Scalability within AC 800M Ecosystem: From small skids to mega-plants, the PM864AK01-eA integrates effortlessly with S800 I/O, drive controllers (ACS880), and HMI/SCADA via 800xA, offering a unified engineering and operations experience.

Technical Summary (English):

The ABB PM864AK01-eA 3BSE018161R2 is a high-end redundant CPU module for the AC 800M controller platform, delivering deterministic control, integrated Ethernet connectivity, and millisecond-level failover capability. Designed for SIL2-compliant safety applications and large-scale process automation, it combines powerful dual-core processing with robust diagnostics and seamless integration into the ABB 800xA ecosystem. Its hot-swap redundancy and built-in networking make it ideal for power generation, refining, and chemical plants where uptime is non-negotiable.

Real-World Application Case

Project: Combined-Cycle Power Plant Control Upgrade (Europe)

A European utility upgraded its aging turbine control system to ABB 800xA, selecting dual PM864AK01-eA controllers in redundant configuration for the gas turbine island. The plant required zero tolerance for control interruption during grid frequency fluctuations.

Implementation: Two PM864AK01-eA units were installed with fiber-optic sync cables. All I/O was handled via S800 remote stations connected over Profibus. The built-in Ethernet ports enabled direct historian data logging and remote diagnostics.

Result: The system achieved 99.999% availability over three years. During a lightning-induced power dip, the redundant controller switched over in <10 ms—so fast that operators didn’t notice. Maintenance time dropped by 40% due to predictive diagnostics and hot-swap capability.

Recommended Companion Products

For a complete AC 800M solution, the PM864AK01-eA works synergistically with:

ABB AI810 / AO810: Analog I/O modules for sensor and actuator interfacing

ABB DI810 / DO810: Digital input/output modules for discrete signals

ABB CI854A: Profibus DP communication module (if additional fieldbus needed)

ABB TB805 / TB820: Terminal bases for S800 I/O wiring

ABB PS801 / PS802: Redundant power supply units for the controller rack

ABB SA811: Battery-backed RAM module for program retention during power loss

Installation, Maintenance & Lifecycle Support

Installing the PM864AK01-eA requires adherence to ABB’s redundancy guidelines:

Use shielded sync cables (max 10 m for copper, up to 2 km for fiber).

Ensure both units run identical firmware and application code.

Configure redundancy in Control Builder M before powering up.

Maintenance is simplified by LED diagnostics and hot-swap design—failed units can be replaced during operation. Firmware updates are performed online via the Ethernet port.

As a mature but actively supported product, the PM864AK01-eA remains a cornerstone of ABB’s installed base. While newer models like the PM866 offer higher performance, the PM864AK01-eA is still widely deployed and fully serviceable.

We supply 100% genuine ABB PM864AK01-eA 3BSE018161R2 units with full traceability. Every module undergoes functional testing—including redundancy handshake simulation—and comes with a 12-month warranty. Our engineers provide pre-sales compatibility checks and post-sales technical guidance.

Contact us today for competitive pricing, redundancy configuration support, or lifecycle management solutions for your ABB AC 800M system.