PM863K02 ABB High Integrity Controller 96 I/O Redundant Ethernet AC 800M Series

Core Architecture

• PM863K02 AC 800M Controller (3BSE088382R1)
  • CPU board with MPC866 processor 96 MHz
    • 32 MB total memory | 22.184 MB available for apps
    • 18 MB Flash PROM for firmware | Real-time clock with battery
    • LED indicators | INIT push button | CompactFlash interface
• Built for High Integrity & Redundancy
  • Supports CPU redundancy for higher availability
  • Add SM812 module for SIL 3 certified safety
  • Combine safety and business control in one unit

Package Contents

• 2 x PM863K01 Safety Processor units
• 1 x TK850 CEX-bus expansion cable
• 1 x TK851 RCU-Link cable

Connectivity at a Glance

• Base plate connections
  • 2x Ethernet ports (CN1, CN2) – Control Network
    • 10 Mbit/s, IEEE 802.3, RJ-45
    • MMS and IAC protocols | 100 Mbit/s backbone recommended
  • 2x Serial ports (COM3, COM4)
    • COM3: RS-232C with modem control, 75-19200 baud
    • COM4: Isolated RS-232C for configuration tool, 9600 baud

Performance That Matters

• Speed
  • 1000 boolean ops in 0.17 ms
  • Switchover time in redundant config: max 10 ms
• Capacity
  • Max 96 I/O modules (single) | 84 (redundant)
  • 32 applications per controller | 64 programs per app
  • 128 diagrams per app | 32 tasks per controller
  • Cycle time per app: 10 ms
• Communication
  • Up to 12 communication modules on CEX-bus
  • 3000 events queue for OPC client
  • 36-86 events/sec to OPC server

Power & Reliability

• Power supply
  • 24V DC (19.2-30V DC)
  • Consumption: 210/360 mA typ/max
  • Power dissipation: 5.1W (8.6W max)
  • Redundant power supply status input
• Battery backup
  • Lithium 3.6V built-in
  • Real-time clock stability: 100 ppm (~1h/year)
• Clock sync
  • 1 ms between controllers via CNCP protocol

Built Tough: Environment & Safety

• Operating conditions
  • Temperature: +5 to +55°C | Storage: -40 to +70°C
  • Humidity: 5-95% non-condensing
  • Altitude: 2000m | Pollution degree 2
  • Corrosion protection: G3 compliant to ISA 71.04
• Certifications
  • ISA Secure certified | TÜV Certified SIL 2 & SIL 3
  • cULus Class 1 Zone 2 hazardous location
  • Marine: ABS, BV, DNV-GL (LR pending)
  • CE marked | RoHS | WEEE compliant
• EMC & protection
  • Full EMC certification (EN 61000-6-4, EN 61000-6-2)
  • IP20 protection | Rated isolation 500V AC

Dimensions & Weight

• Width: 119 mm (4.7 in)
• Height: 186 mm (7.3 in)
• Depth: 135 mm (5.3 in)
• Weight: 2700 g (5.95 lbs)

Professional FAQ

• Q: How is PM863K02 different from PM863K01?A: PM863K02 (3BSE088382R1) is the complete safety processor package. It includes two PM863K01 units plus TK850 and TK851 cables. K01 is just the single processor.
• Q: Can I use this controller for SIL 3 applications without extra hardware?A: No. You need to add the SM812 module and use SIL-certified software. The controller hardware supports it but requires the safety module.
• Q: What is maximum I/O capacity for redundant setup?A: With redundant CPUs you can connect up to 84 I/O modules on Modulebus. Total I/O points depend on module types.
• Q: Is this suitable for offshore oil and gas platforms?A: Yes. It has ABS, BV, DNV-GL marine approvals and G3 corrosion protection. Also cULus hazardous location certified.
• Q: What happens if one CPU fails in redundant mode?A: The second CPU takes over within 10 ms. No process interruption. Both CPUs run in parallel.

Selection & Purchase Guide

• Need redundancy? PM863K02 includes 2 CPUs for hot-standby operation.
• Safety level required: Add SM812 module for SIL 3 certification.
• I/O expansion: Use S800 I/O modules for best compatibility.
• Network speed: Use 100 Mbit/s switched Ethernet for optimal performance.
• Warranty: 12 months from invoice. Fast shipping via FedEx, UPS, DHL.

Shipping & Warranty

• Express shipping: FedEx, UPS, DHL – fully tracked and insured
• 12 months warranty: Covers defects in materials and workmanship
• Packaging: Anti-static foam, double box protection

Contact Us

• Email: sales@powergearx.com – 24h response
• WhatsApp: +86 180 3005 825 – technical support

Copyright © 2026 Powergear X Automation Limited. All rights reserved.
Original Source: https://www.powergearx.com/