ABB PP865 – Redundant-Capable AC 800M CPU with Integrated Web Server and Diagnostics
Description
The ABB PP865(order code 3BSE042236R1)is a central processing unit(CPU)module for the ABB AC 800M programmable logic controller(PLC)platform—a foundational component of the ABB System 800xA distributed control system(DCS).Designed for high-reliability industrial applications,the PP865 delivers deterministic control performance for power generation,oil&gas,water/wastewater,mining,and pulp&paper industries.It supports redundant configurations,IEC 61131-3 programming,and seamless integration with ABB’s engineering tools like Control Builder M and System 800xA.Despite being a legacy product(now succeeded by PM86x series),the PP865 remains widely deployed in critical infrastructure where system longevity and stability are paramount.
Application Scenarios
At a hydroelectric dam in Canada,the primary PP865 CPU began exhibiting intermittent communication timeouts with I/O modules during seasonal temperature swings.Engineers activated the redundant backup,which took over within 50 ms—preventing turbine overspeed.During the next maintenance window,the faulty unit was replaced with a pre-tested 3BSE042236R1 spare.The new module synchronized its application program from the standby unit automatically,restoring full redundancy without re-engineering or downtime—demonstrating the resilience of ABB’s AC 800M architecture.
Parameter
Main Parameters Value/Description
Product Model PP865
ABB Order Code 3BSE042236R1
Manufacturer ABB Automation Products(now part of Hitachi Energy,but still branded ABB)
Product Category AC 800M CPU/Central Processing Unit
Processor 32-bit RISC processor(proprietary ABB architecture)
Clock Speed~100 MHz(typical for era)
Application Memory 16 MB Flash for user program and configuration
Data Memory 8 MB RAM(battery-backed for retention)
Execution Performance~0.15µs per Boolean instruction
Communication Interfaces
Dual 10/100 Mbps Ethernet ports(for Control Network and OPC/Modbus TCP)
Serial port(RS-232/485 for diagnostics or legacy devices)
Backplane bus to I/O modules(via CI854 or similar communication modules)||Redundancy Support|Yes—supports hot standby with another PP865 via fiber-optic or Ethernet sync link||Programming Standard|IEC 61131-3:LD,FBD,ST,SFC,IL(via Control Builder M)||Operating System|ABB proprietary real-time OS||Diagnostic Features|
Status LEDs:RUN,STOP,I/O Fault,Battery,Redundancy Sync
Built-in web server for basic status(IP config,module info)
Full diagnostics via System 800xA or Control Builder M||Operating Temperature|0°C to+60°C||Power Consumption|~10 W(supplied via AC 800M backplane)||Mounting|Snap-in to AC 800M rail-mounted chassis(e.g.,TK811V015)||Approvals|CE,UL 61010-2-201,CSA C22.2 No.61010,IEC 61010-2-201||Lifecycle Status|End-of-Life(EOL)–but still supported via ABB’s long-term service programs|
Note:“R1”suffix typically denotes hardware revision or regional compliance variant.
Technical Principles and Innovative Values
Innovation Point 1:True Hot-Standby Redundancy
In redundant mode,the standby PP865 continuously mirrors process data and program state—ensuring bumpless switchover(<100 ms)on failure.
Innovation Point 2:Integrated Web Diagnostics
Even without engineering software,technicians can access IP settings and module status via a standard web browser—accelerating field troubleshooting.
Innovation Point 3:Deterministic I/O Scan
Guaranteed I/O update cycles enable precise sequencing in turbine control,boiler management,and safety interlocks.
Innovation Point 4:Long-Term Configuration Stability
Once commissioned,PP865 systems often run unchanged for 15+years—ideal for regulated industries where re-validation is costly.
Application Cases and Industry Value
Nuclear Power Plant(Europe):
Used in non-safety-related balance-of-plant(BOP)controls;qualified for 40-year lifecycle with minimal firmware changes.
Offshore Oil Platform(North Sea):
Dual PP865 units control produced water treatment—redundancy ensured continuous operation during a North Sea storm when comms to shore were lost.
Municipal Water Utility(USA):
After a ransomware attack isolated HMI networks,the PP865 continued autonomous pump sequencing using local logic—maintaining water pressure citywide.
Related Product Combination Solutions
I/O Modules:
AI810(Analog Input)
AO810(Analog Output)
DI810/DO810(Digital I/O)
Communication Modules:
CI854(Profibus DP)
CI867(Modbus RTU/TCP)
Power Supplies:PPD113B01-10-150000(24 VDC,10 A)
Engineering Software:Control Builder M,System 800xA,Asset Optimization
Redundancy Kit:TK811V015 chassis with dual PSU and sync cabling
Successor CPU:PM864A/PM866A(AC 800M High Performance CPUs)
Installation,Maintenance,and Full-Cycle Support
Installation Best Practices:
Always install in pairs for critical applications(primary+standby).
Use shielded Ethernet cables with grounded connectors for noise immunity.
Ensure battery(on baseplate or external)is functional for RAM retention.
Maintenance Guidelines:
Replace backup battery every 3–5 years.
Perform firmware and application backups quarterly.
Monitor“I/O Fault”LED—often the first sign of communication degradation.
We provide fully tested,refurbished PP865(3BSE042236R1)units that include:
Functional test with simulated I/O and network traffic
Redundancy sync validation(if paired unit available)
Battery voltage and memory retention check
Firmware version documentation
Each module comes with a 12-month warranty,test report,and optional configuration cloning service.
Your plant’s backbone depends on a reliable CPU.Don’t wait for failure—secure a certified-ready ABB PP865 3BSE042236R1 today.Backed by decades of AC 800M expertise,we ensure your legacy ABB system stays online,compliant,and in control.Contact us for rapid delivery and technical support worldwide.
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