Description
ABB PM862K02 | AC 800M Redundant CPU Controller
Key Technical Specifications
| Parameter | Specification |
|---|---|
| Product Model | PM862K02 |
| ABB Article Number | 3BSE081636R1 |
| Controller Family | AC 800M |
| System Platform | System 800xA |
| Product Type | Redundant CPU / Processor Unit |
| Processor | MPC866 |
| Clock Frequency | 67 MHz |
| Memory | 32 MB |
| RAM Available for Application | 23.521 MB |
| Firmware Flash | 4 MB |
| CPU Redundancy | Yes |
| Redundant Controller Switchover | Max. 10 ms |
| Power Supply | 24 VDC |
| Supply Range | 19.2–30 VDC |
| Typical / Maximum Current | 210 / 360 mA at 24 VDC |
| Typical / Maximum Power Dissipation | 5.1 / 8.6 W |
| Ethernet Ports | 2 |
| Ethernet Interface | IEEE 802.3, 10 Mbit/s, RJ-45 |
| Control Network Protocol | MMS and IAC |
| RS-232C Ports | 2 |
| COM3 | 75–19,200 baud, non-isolated, RTS/CTS |
| COM4 | 9,600 baud, optically isolated |
| CEX-Bus Communication Modules | Up to 12 |
| CEX-Bus Supply Current | 2.4 A maximum |
| S800 I/O Capacity | Up to 96 I/O modules with single PM862; up to 84 with redundant PM862 configuration |
| Operating Temperature | 0 to +55°C |
| Storage Temperature | -40 to +70°C |
| Relative Humidity | 5–95%, non-condensing |
| Protection Class | IP20 |
| Dimensions | 119 × 186 × 135 mm |
| Weight | Approx. 2.9 kg including base for K02 configuration |
The PM862 hardware supports up to 32 applications per controller, 64 programs per application and cycle times down to 1 ms for application programs. ABB also specifies two Ethernet control-network ports and two RS-232C ports, although the serial interfaces have different functions and isolation characteristics.
Product Introduction
The ABB PM862K02 is a redundant CPU configuration within the AC 800M controller family used with ABB System 800xA automation systems. Its MPC866 processor operates at 67 MHz, with 32 MB of memory and up to 23.521 MB available for application use. The controller supports Ethernet-based control networking, CEX-Bus communication modules and S800 I/O.
The important distinction is the K02 redundancy configuration. ABB specifies PM862K02 as including two PM862 CPUs and the hardware required for redundant controller operation. Redundancy extends beyond simply having two processor boards: ABB documents redundancy support for the CPU, CEX-Bus, communication interfaces and S800 I/O architecture.
PM862K02
Application Scenarios & Field Pitfalls — The Engineer’s Perspective
Engineering Pain Point
Replacing a PM862K02 is not equivalent to replacing an ordinary PLC CPU. The controller is part of a configured AC 800M architecture, and the redundancy arrangement depends on the baseplates, RCU-Link, CEX-Bus, ModuleBus, power supplies and system software. A physically compatible PM862 CPU can still create commissioning problems if the firmware, Control Builder version, redundancy configuration or application database does not match the installed system.
Typical Applications
- System 800xA process control: Executes AC 800M control applications for continuous and batch automation.
- Redundant DCS controller architectures: Maintains controller availability through dual PM862 CPU operation.
- S800 I/O control: Interfaces with electrical and optical S800 I/O clusters through the AC 800M controller architecture.
- Industrial communication: Uses the integrated Ethernet ports and CEX-Bus for control-network and communication-module connectivity.
Technical Pitfalls to Avoid
- Do not confuse PM862K01 with PM862K02.
PM862K01 is the single-controller configuration, while contains two controller units for redundancy. ABB lists separate article numbers and configurations. - Verify the complete ABB article number.
For , ABB identifies the article number as 3BSE081636R1. The model designation alone should not be the only purchasing reference. - Check the Control Builder and System 800xA release.
ABB’s current data sheet specifies compatibility beginning with System 800xA 6.0.2 and Compact Control Builder 6.0.0-1. An older installed system therefore needs software-version verification before a controller swap. - Preserve the redundancy hardware.
The K02 package includes two CPUs, TP830 baseplates, ModuleBus terminators, CEX-Bus and RCU-Link cabling, plus backup batteries. The redundancy system is not created by simply installing two standalone CPUs. - Check the CEX-Bus load.
ABB specifies support for up to 12 communication modules on the CEX-Bus with a maximum CEX-Bus supply current of 2.4 A. Existing communication-module loading should be checked during system modifications. - Do not overlook the backup battery.
uses a 3.6 V lithium backup battery for memory/clock retention. Battery condition should be checked during maintenance rather than treating the CPU as a completely maintenance-free device. - Verify S800 I/O architecture before changing redundancy.
ABB lists different I/O capacity figures for single and redundant configurations: up to 96 I/O modules for a single and up to 84 in the redundant arrangement. Existing optical/electrical ModuleBus architecture therefore matters.
Related Products
- ABB PM862K01 — Single controller configuration. It uses the same basic CPU family but does not provide the K02 dual-controller package.
- ABB PM866AK02 — Higher-performance redundant AC 800M controller with 133 MHz processing and 64 MB memory. It belongs to the same controller family but is not a direct firmware/application-equivalent replacement.
- ABB PM864AK02 — Redundant AC 800M controller based on the PM864A Classic platform; hardware and application compatibility must be checked against the installed system.
- ABB PM863K02 — Redundant high-integrity AC 800M controller. It provides a different safety-oriented controller capability and should not be substituted for merely because both are redundant CPUs.
- ABB PM867K02 — Redundant high-integrity controller with higher processing capability than . System, firmware and application compatibility require verification.
- ABB PM891K02 — Redundant AC 800M controller with 256 MB memory and 450 MHz processor architecture; it represents a substantially different controller generation.
- ABB TP830 — controller baseplate used with the K02 package. Baseplate identity and Ethernet hardware address are important during controller replacement.
- ABB BC810K02 / BC820K02 — CEX-Bus interconnection units used for sectioned or redundant communication architectures around AC 800M controllers.
Procurement and Replacement Note
For procurement, specify ABB , article number 3BSE081636R1 and confirm whether the requirement is for the complete K02 redundant controller package or individual CPU hardware. ABB’s package definition includes two CPUs and associated TP830, TB807, TK850, TK851 and battery components.
Before replacing an installed unit, record the System 800xA version, Compact Control Builder version, CPU firmware, application/project backup, redundancy configuration, TP830 baseplate addresses, CEX-Bus modules and I/O topology. Those details determine whether the replacement can be commissioned without changing the existing control architecture.
