Product Short Description
The ABB PM865K02 is a high‑performance, fully redundant processor unit kit designed for the ABB AC 800M controller family and fully integrated with the ABB 800xA Distributed Control System (DCS). As a High‑Integrity certified module, it delivers superior real‑time performance, robust data processing, and ultra‑high system availability for mission‑critical and safety‑related industrial automation applications. This complete redundant kit includes two PM865K01 CPU modules, two TK850 CEX‑bus expansion cables, one TK851 RCU‑Link cable, and all necessary accessories, providing a ready‑to‑install, fault‑tolerant control core. Engineered for industrial‑grade reliability and supporting IEC 61508 SIL 2/SIL 3 safety certification when combined with SM810/SM811 modules, it ensures uninterrupted operation, seamless integration with I/O subsystems, HMIs, and supervisory systems, making it ideal for demanding large‑scale industrial automation environments where safety and availability are paramount.
Description
Technical Specifications
| Parameter | Detail |
|---|---|
| Manufacturer | ABB |
| Model | PM865K02 (Order No.: 3BSE031150R1) |
| Product Type | AC 800M High‑Integrity Redundant Processor Unit Kit |
| Processor | 32‑bit MPC862P RISC, 96 MHz clock frequency |
| Memory | – Total RAM: 32 MB
– Available RAM for Application: 22.184 MB – Flash Memory: 4 MB for firmware storage – Backup Battery: 3.6 V lithium battery for real‑time clock and data retention |
| System Compatibility | ABB AC 800M Controller, ABB 800xA Distributed Control System |
| Power Supply | 24 V DC nominal (19.2–30 V DC) |
| Power Consumption | Typical: 6.9 W; Maximum: 11.4 W |
| Redundancy Support | Full redundancy (CPU, CEX‑bus, communication interfaces, S800 I/O); Maximum switch‑over time: 10 ms |
| Communication Interfaces | – 2 × Ethernet Ports (10 Mbps, RJ‑45): MMS/IAC protocols
– 2 × RS‑232C Serial Ports: One general‑purpose port (COM3), one isolated service port (COM4) for configuration tools – Supports Modbus RTU/TCP, Profibus DP, OPC DA/UA via expansion modules |
| Control Performance | – Minimum Application Scan Cycle: 1 ms
– 1000 Boolean Operations Execution Time: 0.17 ms – Max PID Control Loops: 64 – Max Tasks per Controller: 32 – Max Programs per Application: 64 |
| I/O Capacity | – Max I/O Modules on ModuleBus: 96 (single configuration) / 84 (redundant configuration)
– Max CEX‑bus Communication Modules: 12 – Modulebus Scan Rate: 0–100 ms |
| Environmental Ratings | – Operating Temperature: +5 °C to +55 °C
– Storage Temperature: -40 °C to +70 °C – Relative Humidity: 5%–95% (non‑condensing) – Protection Rating: IP20 – Pollution Degree: Degree 2 – Corrosion Protection: G3 (ISA 71.04) |
| Physical Characteristics | – Width: 119 mm
– Height: 186 mm – Depth: 135 mm – Weight: 2.3 kg (complete kit) – DIN‑rail mountable for industrial control cabinets |
| Certifications | IEC 61508 SIL 2/SIL 3 (with SM810/SM811), TÜV, CE, UL, cULus, ABS, BV, DNV‑GL, LR, RS, CCS, EN 50178, IEC 61131‑2, RoHS, WEEE |
Functional Features
Core Performance & Reliability
- High‑Speed Processing: 96 MHz MPC862P RISC processor delivers exceptional computational power for executing complex control algorithms and multi‑tasking operations in large‑scale systems.
- Deterministic Real‑Time Control: Minimum 1 ms scan cycle and 0.17 ms execution time for 1000 boolean operations ensure precise, responsive regulation of critical industrial processes.
- Full Redundancy: Hot‑standby CPU redundancy with 10 ms maximum switch‑over time eliminates single points of failure, ensuring 99.999% system availability.
- High‑Integrity Safety: SIL 2/SIL 3 certification when paired with SM810/SM811 modules enables safe integration of business‑critical and safety‑related processes in a single controller.
Communication & Connectivity
- Dual Redundant Ethernet: Two 10 Mbps Ethernet ports provide reliable, redundant communication for control networks, supporting MMS/IAC protocols for seamless integration with 800xA systems.
- Isolated Serial Communication: Dedicated isolated RS‑232C port (COM4) for configuration tools ensures secure, interference‑free setup and maintenance without disrupting production.
- Rich Protocol Support: Extends communication capabilities via expansion modules to connect with third‑party devices (Modbus, Profibus) and enterprise systems (OPC DA/UA).
- High‑Performance Data Exchange: Supports up to 3000 events per OPC client client and 36–86 events/sec transmission speed to OPC servers, facilitating efficient data sharing.
System Flexibility & Maintainability
- Modular Scalability: Easily integrates with AC 800M I/O modules and communication expansion cards, supporting flexible system scaling to meet evolving application needs.
- Online Configuration & Maintenance: Enables online program editing, parameter adjustment, and firmware updates without system shutdown, minimizing production downtime.
- Comprehensive Diagnostics: Built‑in self‑monitoring, LED indicators, and event logging enable proactive fault detection and efficient troubleshooting.
- Precise Clock Synchronization: CNCP protocol synchronizes clocks between AC 800M controllers with 1 ms accuracy, ensuring coordinated system performance.
- Non‑Volatile Data Retention: Backup battery preserves critical control programs, process data, and real‑time clock settings during power outages.
Industrial Durability
- Robust Environmental Resistance: Designed to withstand extreme temperatures, vibration, and electrical interference, ensuring reliable operation in harsh industrial environments.
- Marine & Hazardous Location Approval: Certifications (ABS, BV, DNV‑GL, cULus Class 1, Zone 2) make it suitable for marine, offshore, and hazardous area applications.
- EMC Compliance: Meets EN 61000‑6‑4 (emission) and EN 61000‑6‑2 (immunity) standards for robust performance in electrically noisy environments.
Application Scenarios
Process Industries
- Oil & Gas: Offshore platforms, refineries, and pipeline networks for process control, safety shutdown systems (SIS), compressor control, and asset management in hazardous areas.
- Chemical & Petrochemical: Reactor control, distillation columns, batch processing, and GMP‑compliant automation with SIL 2/SIL 3 safety requirements.
- Pharmaceuticals: High‑precision process control for drug manufacturing, ensuring compliance with strict safety and quality standards.
Power & Energy
- Power Generation: Fossil fuel, combined‑cycle, and renewable power plants for boiler control, turbine governing, generator synchronization, and balance‑of‑plant automation.
- Power Transmission & Distribution: Substation control, grid monitoring, and load management with high availability and safety certifications.
Manufacturing & Infrastructure
- Pulp & Paper: Production line control, digester and dryer management, and quality assurance for high‑volume manufacturing.
- Metals & Mining: Ore processing, smelting, and material handling systems in harsh, high‑vibration environments.
- Water & Wastewater: Municipal treatment plants, desalination facilities, and regional water distribution networks for pump control and filtration automation.
- Building Automation: Large commercial complexes, airports, and hospitals for HVAC control, energy management, and facility monitoring.
Specialized Applications
- Marine & Offshore: Shipboard control systems, offshore wind farms, and marine propulsion systems with marine certifications.
- Cement & Minerals: Kiln control, raw material handling, and finished product packaging for high‑temperature, dusty environments.
- Machine Automation: Large‑scale packaging machinery, conveyor systems, and industrial robots for precise motion control and production line optimization.
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