PM865K01 3BSE031151R1 ABB AC 800M Processor Unit High Integrity

ABB PM865K01 3BSE031151R1 Ethernet Port Controller for High Integrity Automation

The ABB PM865K01 3BSE031151R1 is a high performance processor unit. It belongs to the ABB AC 800M controller family. This module runs complex control logic with speed and stability. It suits high integrity and safety related applications. The unit offers four on board communication ports. Two are Ethernet ports. Two are serial ports. It also supports redundancy and S800 I/O expansion. This makes it a strong choice for critical process control.

Engineers often choose this controller for power plants, oil and gas sites, and heavy process lines. The module keeps the process running when a single fault occurs. It switches from primary CPU to backup CPU in less than 10 ms. That speed protects your production and reduces downtime. The PM865K01 also works as a PA controller with stable performance. When used as an HI controller, performance is lower but safety stays high.

For fast delivery, contact sales@powergearx.com or +86 18030005825. We ship in 12 to 24 hours by FedEx, UPS, or DHL.

Technical Specifications

• Brand: ABB
• Model: PM865K01
• Order Code: 3BSE031151R1
• Series: AC 800M
• Module Type: Ethernet Port Controller / Processor Unit
• Microprocessor: MPC862P at 96 MHz
• Memory: 32 MB RAM, 4 MB flash PROM, 32 MB SDRAM
• Communication Ports: CN1 and CN2 Ethernet (IEEE 802.3, 10BaseT); COM3 RS-232C with modem support; COM4 RS-232C for service tool
• Redundancy: Redundancy Control Link, switch over time less than 10 ms
• I/O Support: Up to 12 S800 I/O units on electrical ModuleBus
• Safety: High Integrity controller with SM810/SM811 and certified software; runs non SIL and SIL1-3 applications; supports S800 I/O High Integrity
• Protection: Overvoltage protection and internal voltage supervision
• Battery Backup: Internal battery minimum 235 hours; external SB821 minimum 24 weeks; external SB822 minimum 3 weeks when fully charged; recharge time about 7 hours
• Power Dissipation: 6.9 W typical; 11.9 W typical including full supply to ModuleBus and CEX Bus
• Current Consumption: 287 mA typical; 487 mA max excluding supply of ModuleBus and CEX Bus
• Power Input: Four pin screw connector L+, L-, SA, SB
• Power Supply: 24 V nominal, 19.2 V DC to 30 V DC
• Redundant Power Status Inputs: SA and SB, max 30 V, high level min 15 V, low level max 8 V
• Power Reservoir: Internal 5 ms reservoir for controlled power down
• Protection Rating: IP20 according to EN60529 and IEC 529
• Weight: 1200 g (2.6 lb)
• Dimensions: W 119 x H 186 x D 135 mm (4.7 x 7.3 x 5.3 in)

Performance and Compatibility

• The PM865K01 in single configuration peaks at twice the theoretical performance of the PM860.
• Real sustained improvement is often 10 to 50 percent, based on the application program.
• Redundant configuration gives slightly lower execution performance than single mode.
• Basic communication extends with extra communication interface units.
• Works with S800 I/O and High Integrity S800 I/O.
• Fits ABB AC 800M racks and DIN rail mounting.
• Compatible with SM810 and SM811 safety modules.

Installation Guide

• Mount the unit on a standard DIN rail.
• Keep the depth from the wall at 135 mm.
• Allow space for the lock mechanism and cable access.
• Connect L+ and L- to a 24 V DC supply.
• Use SA and SB for redundant power status inputs.
• Connect CN1 and CN2 to Ethernet networks.
• Use COM3 for modem links and COM4 for service tools.
• Attach up to 12 S800 I/O units to the ModuleBus.
• Check IP20 protection needs before installation.
• Verify all power and signal wiring before startup.

Commissioning and Maintenance

• Use COM4 for fast service access and diagnostics.
• Monitor the internal 5 ms power reservoir for controlled shutdown.
• Replace the internal battery within 235 hours of low backup.
• Use external SB821 or SB822 for longer backup time.
• Check redundant power status inputs during routine tests.
• Confirm switch over time stays below 10 ms.
• Review overvoltage and voltage supervision alarms.
• Keep firmware and certified software up to date.

Expert Review

The ABB PM865K01 3BSE031151R1 is a solid controller for high integrity duties. Its 96 MHz MPC862P processor and 32 MB RAM handle demanding logic. The dual Ethernet ports and two serial ports give useful connectivity. The redundancy link and fast switch over make it stand out. The 5 ms power reservoir adds another layer of safety. For plants that cannot afford sudden stops, this module is a practical and trusted option.

Manager’s Insight

From a maintenance and sourcing view, the PM865K01 offers strong value. It supports both non SIL and SIL1-3 applications. It works with existing S800 I/O, so upgrades stay simple. The battery options give flexible backup planning. The IP20 rating suits clean cabinet use. If you need a reliable ABB processor with fast redundancy, this model deserves a place on your shortlist.

Best Applications and Equipment

• Power generation and turbine control
• Oil and gas processing
• Chemical and petrochemical plants
• High integrity safety systems
• Process automation with S800 I/O
• Redundant control systems
• ABB AC 800M controller racks
• Plants needing SIL1-3 certified logic

FAQ

Q: What makes the ABB PM865K01 different from the PM860?

A: It has a faster processor and double the theoretical peak performance.

Q: Can I use this module in a redundant setup?

A: Yes. It supports a Redundancy Control Link and switches over in under 10 ms.

Q: How long does the internal battery last?

A: It lasts at least 235 hours. External SB821 gives up to 24 weeks.

Q: Does it support safety applications?

A: Yes. It runs non SIL and SIL1-3 applications with certified software.

Q: What communication ports are available?

A: Two Ethernet ports, one RS-232C modem port, and one RS-232C service port.

Q: How many S800 I/O units can connect?

A: Up to 12 units can connect to the electrical ModuleBus.

Q: What is the power supply range?

A: It uses 24 V nominal, from 19.2 V DC to 30 V DC.

Q: How fast do you ship this product?

A: We ship in 12 to 24 hours by FedEx, UPS, or DHL.

Q: What is the warranty?

A: We offer a 12 month warranty.

Q: How can I contact your team?

A: Email sales@powergearx.com or message +86 18030005825 on WhatsApp.

Q: Is the PM865K01 hard to install?

A: No. It mounts on a DIN rail and uses clear screw terminals.

Q: What should I check before buying?

A: Confirm your rack type, I/O count, power supply, and safety level need.

Q: Can I use it as a PA controller?

A: Yes. Performance stays as stated when used as a PA controller.

Q: What is included in the package?

A: One ABB PM865K01 3BSE031151R1 processor unit. Please confirm any extra items with our team.

Q: Why choose Powergear X?

A: We offer fast dispatch, global couriers, expert support, and a 12 month warranty.

Purchase Guidance

• Check your controller series before ordering.
• Match the order code 3BSE031151R1 exactly.
• Plan for redundancy if downtime is costly.
• Choose SB821 or SB822 for longer backup.
• Confirm SIL level and software certification needs.
• Count S800 I/O units before purchase.
• Ask our team for stock and lead time.
• Order now for 12 to 24 hour dispatch.

Contact Information

Inquiries: sales@powergearx.com or +86 18030005825

Copyright © 2026 Powergear X Automation Limited. All rights reserved.

Original Source: https://www.powergearx.com/

• Article number: 3BSE018157R1
• Life cycle status: Classic
• Redundancy: Yes (CPU, CEX-Bus, communication, S800 I/O)
• High Integrity: No
• Processor type: MPC860
• Clock frequency: 48 MHz
• Performance, 1000 boolean operations: 0.23 ms
• Memory: 16 MB total
• RAM available for application: 7.155 MB
• Flash memory for storage: Yes (2 MB for firmware)

Redundancy and Application Capacity

• Switch over time in redundant config: max 10 ms
• Applications per controller: 32
• Programs per application: 64
• Diagrams per application: 128
• Tasks per controller: 32
• Cycle time per application program: down to 1 ms

Power and Clock Synchronization

• Power supply: 24 V DC (19.2 – 30 V DC)
• Power consumption +24 V: typ. 250 mA / max 430 mA
• Power dissipation: typ. 6.0 W (max 10.3 W)
• Redundant power supply status input: Yes
• Built-in back-up battery: Lithium, 3.6 V
• Clock synchronization: 1 ms between AC 800M controllers (CNCP protocol)

Event Handling and Bus Capacity

• Event queue per OPC client: Up to 3000 events
• Transmission speed to OPC server: 36–86 events/sec, 113–143 data messages/sec
• Communication modules on CEX bus: 12
• Supply current on CEX bus: max 2.4 A

Modulebus and I/O Capacity

• I/O clusters on Modulebus (non-red. CPU): 1 electrical + 7 optical
• I/O clusters on Modulebus (red. CPU): 0 electrical + 7 optical
• I/O capacity on Modulebus: max 96 (single PM861A) or 84 (red. PM861A) modules
• Modulebus scan rate: 0–100 ms (depends on I/O count)
• Supply current on electrical Modulebus: 24 V: max 1.0 A; 5 V: max 1.5 A

Network and Serial Interfaces

• Ethernet channels: 2 (RJ45, IEEE 802.3, 10 Mbit/s)
• Control Network protocol: MMS and IAC
• Recommended Control Network backbone: 100 Mbit/s switched Ethernet
• Real-time clock stability: 100 ppm (approx. 1 h/year)
• RS-232C interface: 2 (one general, one for service tool)
• COM3 (non-red. only): RS-232C, 75–19 200 baud, RJ45, not opto isolated, full RTS-CTS
• COM4 (non-red. only): RS-232C, 9 600 baud, RJ45, opto isolated, no RTS-CTS

Environmental Tolerance and Immunity

• Temperature, operating: +5 to +55 °C (+41 to +131 °F)
• Temperature, storage: -40 to +70 °C (-40 to +158 °F)
• Temperature changes: 3 °C/min according to IEC/EN 61131-2
• Pollution degree: Degree 2 per IEC/EN 61131-2
• Corrosion protection: G3 compliant to ISA 71.04
• Relative humidity: 5 to 95 %, non-condensing
• Emitted noise: < 55 dB
• Vibration: 10–50 Hz: 0.0375 mm amplitude; 50–150 Hz: 0.5 g; 5–500 Hz: 0.2 g
• Rated isolation voltage: 500 V a.c.
• Dielectric test voltage: 50 V
• Protection class: IP20 per EN 60529, IEC 529
• Altitude: 2000 m per IEC/EN 61131-2
• Emission & Immunity: EN 61000-6-4, EN 61000-6-2
• Environmental conditions: Industrial
• CE Mark: Yes
• Electrical Safety: EN 50178, IEC 61131-2, UL 508
• Hazardous location: UOL 60079-15
• Marine certificates: ABS, BV, DNV-GL, LR (PM861AK01, PM861AK02)
• TUV Approval: No
• RoHS compliance: –
• WEEE compliance: DIRECTIVE/2012/19/EU

Dimensions and Weight

• Width: 196 mm (7.3 in.)
• Height: 119 mm (4.7 in.)
• Depth: 135 mm (5.3 in.)
• Weight (including base): 1200 g (2.6 lbs)

Installation Guide

• Use the unique slide & lock mechanism for DIN rail mounting.
• Attach or detach the base plate quickly without tools.
• Find the Ethernet address label on the TP830 base plate.
• Each CPU has a hardware identity via a unique Ethernet address.
• Connect CN1 and CN2 to the Control Network.
• Use COM3 for general RS-232C with modem control.
• Use COM4 for a configuration tool (opto isolated).
• IP20 protection means no enclosure is required.

Commissioning and Maintenance

• Configure the controller with 800xA Control Builder.
• Redundancy support gives higher availability.
• Simple fault diagnosis procedures reduce downtime.
• Modular design allows step-by-step expansion.
• Sectioned CEX-Bus using a pair of BC810.
• Built-in redundant Ethernet ports simplify wiring.

Compatibility Notes

• Works with ABB System 800xA control builder.
• Supports S800 I/O and PROFIBUS DP.
• Communicates via MMS and IAC protocols.
• Optimized for 100 Mbit/s switched Ethernet.
• Redundant CPU, CEX-Bus, and communication interfaces.
• Ideal for industrial environments with high EMC needs.

Certifications and Standards

• CE Mark: Yes
• Electrical safety: EN 50178, IEC 61131-2, UL 508
• Hazardous location: UOL 60079-15
• Marine: ABS, BV, DNV-GL, LR (PM861AK01, PM861AK02)
• Emission & immunity: EN 61000-6-4, EN 61000-6-2
• Protection class: IP20 per EN 60529, IEC 529
• WEEE: DIRECTIVE/2012/19/EU
• Corrosion: G3 compliant to ISA 71.04

Package Contents

• 1 x PM861AK01 CPU module
• 1 x TP830 base plate
• Documentation and certificates as applicable
• Weight including base: 1200 g (2.6 lbs)

Warranty and Shipping

• Warranty: 12 months
• Dispatch time: 12–24 hours
• Courier options: FedEx, UPS, DHL
• Fast global delivery from stock.

Expert Review

The PM861AK01 is a proven workhorse for ABB 800xA systems. Its redundant design and 10 ms switchover time keep processes running. The MPC860 processor handles 0.23 ms boolean operations. Memory is modest (16 MB), but adequate for most control tasks. The built-in Ethernet ports and RS-232C interfaces reduce extra hardware. For engineers who value stability and simple fault finding, this module delivers. It is not for high-integrity safety loops, but for standard redundant control it remains a solid choice.

Manager’s Insight

We stock the PM861AK01 because it solves real plant problems. Downtime costs money. This module offers redundancy and quick swap-out. The slide & lock base saves hours during maintenance. With 12-month warranty and 12–24 hour dispatch, you get reliability from day one. For 800xA users, it is a direct fit. We recommend keeping a spare on site. The classic lifecycle status means long-term availability. Pair it with BC810 for a sectioned CEX-Bus. This is a smart investment for continuous process industries.

Best Fit Equipment and Applications

• ABB System 800xA control systems
• Redundant process control loops
• Oil and gas, chemical, and power plants
• Marine and offshore installations (with certificates)
• Factory automation with S800 I/O
• Applications needing 32 programs and 1 ms cycle times
• Industrial networks with PROFIBUS DP and Ethernet

FAQ

Q: What is the switchover time for redundant configuration?
A: Maximum 10 ms. This keeps your process running smoothly during a CPU fault.

Q: How much RAM is available for my application?
A: You get 7.155 MB. This is enough for typical control logic and data handling.

Q: Does this module support hot swap?
A: Yes, with the slide & lock base plate. You can replace it quickly without long downtime.

Q: Can I use COM4 for a modem?
A: No, COM4 is opto isolated and designed for a configuration tool. Use COM3 for modem control.

Q: What is the power consumption?
A: Typically 250 mA at 24 V DC. Maximum is 430 mA. Plan your power supply accordingly.

Q: Is TUV approval included?
A: No. TUV approval is not available for this model. Check your local requirements.

Q: How fast do you ship?
A: We dispatch in 12–24 hours via FedEx, UPS, or DHL. You get tracking information.

Q: What is the warranty period?
A: 12 months from the date of delivery. Covers manufacturing defects.

Q: Does it work with PM861AK02?
A: Yes, marine certificates cover both PM861AK01 and PM861AK02. They share the same base.

Q: What is the real-time clock stability?
A: 100 ppm, which is about 1 hour per year. Good for event logging and scheduling.

Q: Can I use this in a high-integrity system?
A: No, High Integrity is not supported. Choose a different module for safety-critical loops.

Q: How many I/O modules can I connect?
A: Up to 96 modules with a single PM861A. Up to 84 modules with redundant PM861A.

Buying Guide

• Check your system needs redundancy. This module supports it.
• Confirm your power supply delivers 24 V DC at 430 mA minimum.
• Count your I/O points. 96 modules max for single CPU.
• Verify you have 800xA Control Builder for configuration.
• For marine use, ensure certificates match your project.
• Order spares. Classic status means long lead times later.
• Contact us for volume pricing and technical support.

Contact Information Inquiries: sales@powergearx.com or +86 18030005825

Copyright © 2026 Powergear X Automation Limited. All rights reserved.

Original Source: https://www.powergearx.com/