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- Product Core Brief
- Model: ABB PM858K02 3BSE082896R1
- Brand: ABB
- Series: AC 800M High Performance
- Core Function: Redundant process control CPU
- Product Type: Processor module (redundant pair)
- Key Specs: 16 MB RAM; 33 MHz MPC866; 0.36 ms/1000 bool ops
- Condition: New Original / New Surplus
- Key Technical Specifications
| Parameter | Value |
|---|---|
| Clock frequency | 33 MHz |
| Performance (1000 bool ops) | 0.36 ms |
| Processor type | MPC866 |
| RAM total | 16 MB |
| RAM for application | 7.147 MB (800xA 5.1 FP4+) |
| Flash memory | 4 MB for firmware |
| Redundancy | Yes (<10 ms switchover) |
| High Integrity | No |
| Ethernet ports | 2 x RJ45 (CN1, CN2) |
| Serial ports | 2 x RJ45 (COM3 RS-232C, COM4 isolated) |
| Power supply | 24 V DC (19.2-30 V) |
| Power consumption | 210/360 mA typ/max @ 24 V |
| Operating temperature | 0 to +55 °C |
| Dimensions (W x H x D) | 119 x 186 x 135 mm |
| Weight | 1.2 kg (per CPU) |
| CEX bus modules | Max 12 |
- PM858K02
- Product Introduction
The ABB PM858K02 3BSE082896R1 is a redundant processor module for AC 800M controllers in System 800xA. It ships as a pair with baseplates, providing dual CPUs that sync via RCU-Link for automatic failover under 10 ms. Handles logic, I/O, and fieldbus in critical processes.
You spec this when single-point CPU failure equals downtime dollars—paper lines, batch plants, or drives where 16 MB and 33 MHz cover the load without simplex risk. Pairs with S800 I/O and CI8xx modules over sectioned CEX bus.
- Troubleshooting Quick Reference
| Symptom | Possible Cause | Relevance to this Part | Quick Check Method | Recommendation |
|---|---|---|---|---|
| No power LED on primary/secondary | Baseplate 24 V fault or battery dead | ✅ Medium | Measure 24 V at TP830 pins; check battery voltage (3.6 V lithium) | Replace battery first; reseat CPU if power good but no boot. |
| Sync failure / RCU-Link fault | TK851 cable bad or switchover disabled | ✅ High | Verify RCU-Link LEDs; swap TK851 cable; check Control Builder redundancy config | Confirm pair config; test switchover manually before blaming hardware. |
| Application won’t load post-failover | CF mismatch or RAM test fail on standby | ✅ High | Run DTMTool diagnostics on both; verify identical CF firmware | Sync CF cards; replace pair if standby fails self-test. |
| Ethernet CN1/CN2 no link | IP conflict or Control Network down | ✅ Medium | Ping both IPs; check CNCP sync status in diagnostics | Verify network switch; reload app if one CPU holds old IP. |
| Watchdog on active CPU only | Task overload or CEX bus glitch | ✅ High | Monitor CPU load and CEX traffic in Control Builder | Balance tasks; check BC810/820 extenders before full pair replacement. |
| COM3/4 unresponsive | Baud mismatch or isolation fault | ✅ Low | Loopback RJ45 test; confirm DTMTool port settings | Match config to manual; swap serial cable if isolated COM4 dead. |
| High scan jitter | I/O overload or Modulebus noise | ✅ Medium | Check Modulebus current (1 A @ 24 V limit); scan rate in diagnostics | Add optical repeaters; derate I/O count if pushing 84 modules. |
| Frequent failovers | Power ripple or sync cable noise | ✅ High | Scope 24 V supply; inspect TK851 shielding and routing | Stabilize power/ground; replace RCU-Link if failovers persist under load. |
Photo the front panel LEDs, RCU-Link status, and diagnostics screen before power-off—pins down primary vs. standby issues quick.
- Frequently Asked Questions (FAQ)
Q1: What’s included in the ABB PM858K02 3BSE082896R1 package?
Full redundant kit: 2x PM858 CPUs, 2x TP830 baseplates, 2x TB807 terminators, TK850 CEX extender, TK851 RCU-Link, 2x backup batteries. Bolts into DIN rail for immediate pair install.
Q2: Direct upgrade path from PM856/857 simplex?
Yes—same baseplate footprint, but backup your app first. Cold start both CPUs, load identical CF firmware, wire RCU-Link, enable redundancy in Control Builder. Failover tests in 30 minutes.
Q3: Minimum 800xA version for PM858K02?
Requires 800xA 6.0.2 Compact Control Builder or later. Older projects need firmware bump on CF cards—mismatch throws sync errors on startup.
Q4: Hot-swap possible during operation?
No live CPU swaps—cut 24 V to baseplate, pull failed unit, insert spare, repower. Standby takes over instantly if RCU-Link healthy; full resync runs during restart.
Q5: How many I/O points before adding extenders?
84 optical Modulebus modules max in redundant setup (7 clusters). Hits limit fast with S800; plan BC810/820 early if pushing dense I/O racks.
Q6: New Surplus difference from factory pair?
Unused OEM pairs from upgrades or spares—same performance, no allocation delays. Bench test verifies CF load, Ethernet link, and RCU sync before ship.
Q7: Expected warranty on surplus PM858K02?
12 months on the full redundant kit, after power-up test showing dual boot, app load, and manual failover under simulated load. Match serials to test report for traceability.
