ABB PM862K01 PM862K02 AC 800M High-Performance Redundant Controller

Product IDs: PM862K01 / PM862K02

Order Codes: 3BSE076940R1 (K01) / 3BSE081636R1 (K02)

Brand: ABB

Product Family: AC 800M

Type: Programmable Logic Controller (PLC) / Redundant Processor Unit

Product Overview

The ABB PM862K01 and PM862K02 are high-performance programmable logic controllers (PLC) within the renowned ABB AC 800M product family. Designed specifically for the System 800xA distributed control system (DCS) architecture, these controllers bridge the gap between high-end process automation and discrete manufacturing logic.

The key distinction between the two variants lies in system availability: the PM862K01 serves as a standalone CPU, while the PM862K02 is delivered as a complete Redundant Processor Unit (including dual CPUs and baseplates) designed for zero-downtime operations. With a 32 MB memory capacity and 0.18 ms Boolean execution speed, the PM862 series offers approximately double the performance of the PM861 series, making it ideal for complex logic and fast I/O scanning.

Key Features & SEO Keywords

CPU Redundancy Support (PM862K02): Supports complete CPU, CEX-Bus, communication, and power redundancy. The switchover time from primary to backup CPU is less than 10 ms, ensuring uninterrupted process control.

High Performance: Powered by a 67 MHz MPC866 processor. Handles 1000 boolean operations in just 0.18 ms, ensuring rapid scan cycles down to 1 ms.

Extended Memory Architecture: 32 MB RAM (23.5 MB available for applications) and 4 MB Flash PROM for firmware storage. Supports up to 32 applications and 64 programs per application.

Built-in Redundant Communication Ports: Features two RJ45 Ethernet ports (CN1, CN2) for redundant Control Network connections (MMS/IAC protocol), plus two RJ45 serial ports (COM3 RS-232C, COM4 isolated).

Robust Environmental Specs: G3 compliant corrosion protection (ISA 71.04) and IP20 protection class. Operates in temperatures ranging from +5°C to +55°C.

Comprehensive I/O Capacity: Supports up to 96 I/O modules on the Modulebus in a single configuration, and up to 12 communication modules on the CEX-Bus.

Security Certification: ISA Secure certified for cybersecurity robustness in industrial control systems.

Technical Specifications (Datasheet)

Specification PM862K01 (Standalone) PM862K02 (Redundant)

Order Code 3BSE076940R1 3BSE081636R1

Processor Type MPC866, 67 MHz MPC866, 67 MHz

Performance (1k Bool) 0.18 ms 0.18 ms

Memory (RAM) 32 MB (23.5 MB available) 32 MB (23.5 MB available)

Redundancy No (Supports CPU Redundancy via pairing) Yes (Complete redundant kit)

High Integrity (SIL) No (SIL2 capable with SM812) No (SIL2 capable with SM812)

Power Supply 24 V DC (19.2 - 30 V DC) 24 V DC (19.2 - 30 V DC)

Typical Current Draw 250 mA 210 mA (per unit)

Max Power Dissipation 10.3 W 8.6 W

Modulebus Capacity Max 96 I/O modules Max 84 I/O modules (Redundant config)

Ethernet Interface 2x RJ45 (10 Mbit/s) 2x RJ45 (10 Mbit/s)

Operating Temp +5 °C to +55 °C +5 °C to +55 °C

Dimensions (WxHxD) 119 x 186 x 135 mm 119 x 186 x 135 mm

Weight (including base) 1200 g (2.6 lbs) 2900 g (6.4 lbs)

Certifications CE, UL, cULus, DNV-GL CE, UL, cULus, DNV-GL

Data compiled from technical references

Applications & Use Cases

The ABB PM862 controller is the brain for mid-to-large-scale automation projects requiring high processing power and uptime:

Process Industries: Chemical, Pharmaceutical, Oil & Gas (DCS for batch control and continuous process management).

Power Generation: Turbine control, Balance of Plant (BoP) automation.

Marine & Offshore: DNV-GL certified for propulsion control and dynamic positioning systems.

Manufacturing: High-speed packaging lines and material handling systems.

Water/Wastewater: Large-scale SCADA integration and pump station control.

Why Choose ABB PM862K01/K02?

If you are currently using ABB System 800xA or need a high-performance PLC with an upgrade path to Safety Integrity Level (SIL2) via the SM812 module, the PM862 is the optimal choice. It offers superior processing speed compared to the older PM856/PM860 models while maintaining backward compatibility with S800 I/O families.

SEO Focus: ABB AC 800M, PM862K02 datasheet, 3BSE076940R1 manual, Redundant CPU controller, System 800xA hardware, ABB High Integrity controller.

Compatibility & Software Requirements

Compatibility: Only compatible with System 800xA 6.0.2 or higher, and Compact Control Builder 6.0.0-1 or onwards.

Baseplate: Requires TP830 baseplate (included with K02 kit).

Termination: Requires TB807 ModuleBus terminator (included with K02 kit).

Note for Engineers: The PM862K02 kit typically includes 2x PM862 CPUs, 2x TP830 Baseplates, 2x TB807 Terminators, 1x TK850 CEX-Bus cable, and 1x TK851 RCU-Link cable