ABB PM860AK01 3BSE066495R1 – AC 800M CPU kit for reliable, scalable process control

The ABB PM860AK01 (article no. 3BSE066495R1) is a PM860-based controller kit for the AC 800M platform. From my experience, this is the kind of CPU you pick when you need stable performance, broad protocol options, and long-term lifecycle support in DCS and high-availability PLC environments. You might notice that it doesn’t carry onboard I/O—by design it centralizes control while flexibly connecting to S800 I/O, S900 I/O, or field networks via communication modules. It typically fits right into modernization projects where downtime and re-engineering risk must be kept low.

Company’s Order Placement Process and Guarantees

• Warranty: 365 days
• Delivery time: 1 week for in-stock; no more than one month at the latest
• Payment: 50% advance payment, full payment for delivery
• Express options: FedEx, UPS, DHL

Key Features

• AC 800M platform CPU – Works within ABB’s modular architecture for large and mid-size process control.
• Flexible networking – Dual 10/100 Ethernet (RJ45) for plant and control networks; serial service access for commissioning.
• No onboard I/O by design – Connects to S800 I/O and fieldbuses (e.g., PROFIBUS, Modbus) through interface modules on the CEX-bus.
• Redundancy-ready – Supports controller redundancy in many AC 800M configurations to reduce unplanned downtime.
• Industrial temperature range – Designed for cabinet-mounted use in typical plant conditions.
• Serviceable storage – Uses removable memory media for firmware, configuration, and backup workflows.
• Lifecycle-friendly – Common spare strategy across AC 800M family helps simplify inventory in multi-unit sites.

Technical Specifications

Application Fields

The PM860AK01 is widely used where deterministic control and robust networking matter: power generation (boiler/turbine auxiliaries), oil & gas (compressor stations, dehydration units), chemicals and petrochemicals (reactor control, utilities), pulp & paper (stock prep, machine sections), metals & mining (water balance, material handling), and water/wastewater (filters, blowers, SCADA integration). One thing I appreciate is how easily it ties into existing S800 I/O and third‑party devices, which in many cases cuts migration effort dramatically.

Advantages & Value

• Reliability – Proven AC 800M hardware with redundancy options to meet availability targets.
• Compatibility – Integrates with S800 I/O, common ABB engineering tools, and popular fieldbuses via interface modules.
• Lifecycle cost – Simplified spares across PM8xx families and re‑use of existing I/O typically lowers total ownership cost.
• Scalability – Add communication modules as the process grows instead of replacing the controller.
• Supportability – Clear service routines (firmware, backups) help maintenance teams keep systems current with minimal risk.

A maintenance lead at a combined‑cycle plant told us they swapped a PM8xx CPU during a short outage and—after loading the image—had it syncing with the redundant partner in under an hour. That’s the kind of turnaround most operations aim for.

Installation & Maintenance

• Cabinet & environment – Mount on DIN‑rail base in a clean, ventilated enclosure (IP54 or better is typical). Keep ambient 0–55 °C, non‑condensing.
• Power & grounding – Stable 24 V DC supply, proper protective earth, and segregated cable routing for power vs. signal lines.
• Networking – Use industrial Ethernet switches; separate control and plant networks when possible. Label ETH ports clearly for maintenance.
• I/O and buses – Connect S800 I/O and fieldbus modules via the CEX‑bus; follow ABB guidelines for segment lengths and termination.
• Safety & ESD – De‑energize before insertion/removal; use ESD protection when handling the CPU and memory media.
• Routine maintenance – Schedule backups of the controller image to the removable media, keep firmware at approved revisions, inspect connectors, and clean dust filters. Replace the real‑time clock battery as recommended by the manufacturer.

Quality & Certifications

• CE compliant; designed for use in industrial control panels
• UL recognition for relevant modules in the AC 800M system
• RoHS compliant materials
• Manufacturer production under ISO 9001 quality systems
• Warranty: 365 days (our supply terms)

Note: Specifications can vary slightly by hardware revision and installed firmware. If you’re matching an existing system, share the current controller revision and engineering tool version so we can align the exact PM860AK01 kit configuration for a drop‑in fit.