ABB NSSM01

Description

Product Overview

The ABB NSSM01 is a specialized, high-availability communication and synchronization module designed for ABB’s System 800xA and AC 800M controller families. Its primary function is to enable and manage redundant controller configurations, specifically for the PM8xx series of high-performance controllers. The ABB NSSM01 module is the critical link that allows two identical CPU modules (e.g., PM861, PM864, PM858) to operate as a fault-tolerant pair in a hot-standby configuration. By continuously synchronizing the application program, data, and communication states between the primary and standby controllers, the ABB NSSM01 ensures bumpless, automatic switchover in the event of a failure in the active unit, thereby maximizing system availability. For mission-critical processes where unplanned downtime is unacceptable, integrating the ABB NSSM01 into the control architecture is a fundamental design decision. The reliability and precision of the ABB NSSM01 are what make seamless, high-integrity redundancy possible within the AC 800M platform.

Product Parameters and Specifications

• Manufacturer: ABB

• Product Series: System 800xA / AC 800M Redundancy Solution

• Module Type: Network Synchronization and Switchover Module (NSSM)

• Primary Function: Manages synchronization and communication between two redundant AC 800M controller units (e.g., PM861, PM864, PM858) in a hot-standby pair.

• Compatibility: Designed specifically for use with the high-performance AC 800M PM8xx controller series within a System 800xA architecture.

• Synchronization Method: Facilitates high-speed, real-time data exchange between the paired controllers over a dedicated, isolated synchronization link to maintain identical application states.

• Switchover Logic: Monitors the health of the primary controller and automatically initiates a controlled switchover to the standby controller upon detection of a fault, with minimal impact on the controlled process.

• Physical Connection: Typically connects to a dedicated port on the AC 800M controller CPU and links to the matching NSSM module in the partner controller’s rack.

• Power Supply: Powered from the controller’s base unit or rack.

• Indicators: Features LED status indicators for power, synchronization status, active/standby role, and fault conditions.

Advantages and Key Features

1. Enables High-Availability (HA) Operation: The core advantage of the ABB NSSM01 is that it transforms a single controller into a fault-tolerant system. It is the essential hardware component that makes redundant AC 800M controller configurations possible, safeguarding continuous operation.

2. Bumpless, Automatic Switchover: It manages a smooth and rapid transition of control from the failing primary unit to the synchronized standby unit. This process is designed to be transparent to the process, preventing trips or disruptions.

3. Dedicated Synchronization Link: Uses a dedicated, high-integrity communication channel for state synchronization, ensuring this critical data is isolated from the plant network traffic and protected from interference or congestion.

4. Simplified Redundancy Configuration: While the underlying technology is complex, the ABB NSSM01 module is designed to be configured relatively straightforwardly within ABB’s Control Builder M engineering software, with dedicated function blocks and wizards to guide setup.

5. Proven in Critical Applications: This module is deployed in thousands of critical processes worldwide, including power generation, oil & gas, and chemical industries, where its reliability is proven under demanding conditions.

Application Case Studies

• Offshore Oil & Gas Production Platform: On an unmanned platform, redundant AC 800M controllers with ABB NSSM01 modules manage the critical emergency shutdown (ESD) and process shutdown (PSD) systems. The redundancy ensures that a single controller hardware fault does not lead to a catastrophic situation or production loss, allowing time for maintenance.

• Base-Load Power Plant Boiler Control: In a coal-fired power station, the combustion control system for the boiler is run by a redundant controller pair linked by the ABB NSSM01. This guarantees that control of fuel, air, and feedwater—critical for safety and efficiency—is never lost, even during a controller failure, preventing a forced unit outage.

• Pharmaceutical Continuous Reactor: For a 24/7 continuous fermentation process, the main reactor temperature, pressure, and pH control loops are managed by a redundant AC 800M system. The ABB NSSM01 ensures that any controller issue does not compromise the batch, which could represent millions of dollars in lost product.

Comparison with Competing Products

Selection Suggestions and Important Notes

• Selection Suggestion:

  • The ABB NSSM01 is not an optional accessory but a mandatory component when designing a redundant (high-availability) controller configuration using the AC 800M PM8xx series processors within System 800xA.

  • It should be specified for any application where the cost of an unplanned process stoppage due to a controller failure significantly outweighs the cost of the redundancy hardware.

  • Selection is inherently linked to the choice of the CPU; you must select an NSSM01 module for each controller in the redundant pair.

• Important Notes:

  • Strict Pairing Requirement: The ABB NSSM01 modules and their associated controllers must be of identical hardware and firmware revisions to ensure flawless synchronization. Mixing revisions can cause switchover failures.

  • Correct Cabling: The synchronization cable connecting the two NSSM01 modules is critical. It must be the correct ABB-specified cable, of the proper length, and routed to avoid electrical interference.

  • Software Configuration is Key: Simply installing the hardware does not enable redundancy. The redundant application must be correctly created, compiled, and downloaded using the redundancy features in Control Builder M.

  • Testing is Mandatory: After installation, a full redundancy test must be performed. This includes simulating a failure in the primary controller (e.g., removing it, disconnecting power) and verifying that the standby assumes control without process disturbance and that all diagnostics are correctly reported.

  • Spare Parts Strategy: For the highest availability systems, consider keeping a spare NSSM01 module in stock, as its failure would degrade the system to a non-redundant state.

HIEE210004R0001 ABB PLC
HIEE305082R0001 ABB
ABB NDBU-85 PLC
ABB YPP-110A PLC
YPK117A ABB dcsplc