ABB PM665 3BDS005799R1 redundant CPU module

ABB PM665 3BDS005799R1: Advanced Controller 160 High Performance Redundant Processor Module

Product Overview

ABB PM665 (order number: 3BDS005799R1) is a high-performance processor module in the ABB Advant Controller 160/AC160 series, designed based on the PowerPC architecture and is a core component of the ABB Advant Master distributed control system (DCS) and 800xA automation platform.

PM665 is officially defined as one of the processor modules in the Advant Controller 160 series, suitable for the Advant OCS system. It can serve as a central processing unit to execute control logic, manage I/O communication, and perform diagnostics. In ABB's official product list, PM665 is also listed as the Advant Controller 160 series, alongside models such as PM640, PM644, PM645, and PM646.

Core technical characteristics

2.1 Redundant voter and high availability

The PM665 module integrates a hardware redundant voter and supports a dual machine hot standby redundancy architecture. In the redundant configuration, two PM665 modules work in parallel, and the voter compares the two outputs in real time to ensure seamless takeover of the backup card in case of a main card failure and uninterrupted control. This hardware level redundancy design effectively eliminates single point of failure and is suitable for critical processes that require extremely high continuous operation.

2.2 PowerPC processors and performance leaps

PM665 adopts Motorola MPC8240 PowerPC microprocessor, which has a larger RAM capacity and about six times the performance improvement compared to models such as PM640 based on MC68360 in AC160 series. This module includes:

1 MByte non-volatile flash memory for user applications

2 MByte non-volatile flash memory for system software

64 MByte SDRAM

2.3 High speed Link and Speed Input

The module is equipped with a high-speed link interface for high-speed data exchange between processors, and the speed input port can be directly connected to a speed encoder or frequency signal without the need for an additional high-speed counting module.

2.4 Multi protocol communication capability

PM665 supports a wide range of communication protocols, including:

Profibus DP (can function as a master or slave)

Modbus TCP/IP

Ethernet/IP

2.5 Safety Features and Certification

PM665 supports SIL2 (IEC 61508) security level and can be extended to SIL3. Adopting a dual core Lockstep redundant architecture - two identical CPUs verify the execution of the same instruction at the same time and have dedicated comparators verify the output results in real time, fundamentally eliminating silent faults.

Attention: There are claims on the market that PM665 is classified as part of the AC 500-S safety PLC family. It is recommended to follow the official ABB manual for selection confirmation.

Programming and Engineering Support

PM665 can be programmed and configured through Control Builder A (formerly known as AMPL Control Configuration). Control Builder A 1.0 version specifically provides "AC 160 with PM66x 2.1" target platform support for PM665, using ABB Master Programming Language (AMPL) programming language to achieve control functions through a rich PC component library.

Control Builder A software includes tools such as Application Builder, Function Chart Builder, and Bus Configuration Builder, which support online debugging, parameter adjustment, and database configuration. After installing AC160 AMPL Libraries 3.0, PM665 can be used as the target platform in Application Builder.

Hardware specifications and physical parameters

Dimensions: Width 40mm x Height 273mm x Depth 252mm

Net weight: 2.04 kg

Power supply: 24V DC

Installation method: Advant Master dedicated rack

Protection level: IP20 (suitable for installation inside control cabinets, compliant with IEC 529 standard)

Environmental adaptability: Supports wide temperature operation

Compliance: Complies with the requirements of EU Directive 2011/65/EU (RoHS) regarding restrictions on hazardous substances

Key dimension description: The above dimension data (40 × 273 × 252 mm) are ABB's official nominal dimension values for PM665 products. Individual suppliers may provide differential values based on different measurement standards (such as whether installation brackets and connector heights are included), and it is recommended to follow ABB's official manual.

Typical application areas

The PM665 processor module is suitable for industrial automation applications that require strict real-time, reliability, and security requirements, including:

Power industry: thermal power/hydropower/nuclear power DCS system, turbine control, boiler interlock protection

Petrochemical Industry: Cracking Unit Control System, Reactor Temperature and Pressure Interlocking, Safety Instrumented System (SIS)

Metallurgical industry: Rolling line control system, blast furnace closed-loop control and interlock protection

Paper industry: paper machine transmission control, material preparation and bleaching process control

Water treatment: Process control and pump station interlocking for sewage treatment/water treatment plants

Mining and Infrastructure: Elevator Control, Material Handling System

Product positioning and selection instructions

PM665 is a high-performance redundant processor based on PowerPC in the AC160/Advant Master series, with significantly better performance than the PM640/644/645/646 models in the same series. Please note when selecting:

PM665 supports both redundant and non redundant configuration modes, which need to be selected according to actual system requirements.

The programming software requires the use of Control Builder A and the installation of AC160 AMPL Libraries 3.0 or higher version.

There is inconsistency in the market information sources regarding the platform ownership of PM665 (Advant Master vs AC800M vs AC500-S). It is recommended to follow the information in ABB's official manual and this product introduction for selection confirmation.