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ABB PM863K02 High Integrity CPU Processor Unit

The ABB PM863K02 3BSE088382R1, also cataloged as the PM863K02 High Integrity CPU Processor Unit, provides execution and communication control for AC 800M High Integrity controller platforms. The module manages CPU processing, RAM memory, real-time clock functions, Ethernet communication, serial interfaces, and redundant controller operation.

Hardware Specifications

Parameter	Specification
Model	PM863K02 3BSE088382R1
Brand	ABB
Product Type	High Integrity CPU Processor Unit
Origin	Sweden
Weight	2700 g including base
Dimensions	Width 119 mm, Height 186 mm, Depth 135 mm
Operating Temp	0 to +55 deg C
Power Consumption	5.1 W typical, 8.6 W maximum
Processor Type	MPC866
Clock Frequency	96 MHz
Memory	32 MB
RAM Available for Application	22.184 MB
Redundancy	Supported
High Integrity Function	Supported with SM812 module and SIL-certified software
Performance	0.17 ms per 1000 boolean operations
Firmware Storage	18 MB Flash PROM
Flash Memory for Storage	No
Power Supply	24 VDC, 19.2 to 30 VDC
Power Consumption Current	210 mA typical, 360 mA maximum at +24 VDC
Backup Battery	Lithium battery, 3.6 V
Ethernet Channels	2
Ethernet Interface	IEEE 802.3 Ethernet, 10 Mbit/s, RJ45 female
Control Network Protocol	MMS and IAC
Recommended Network Backbone	100 Mbit/s switched Ethernet
RS-232C Interfaces	2 ports
COM3 Interface	RS-232C, 75 to 19200 baud, modem control, RTS-CTS support
COM4 Interface	RS-232C, 9600 baud, isolated service tool connection
CEX Bus Communication Modules	Maximum 12
CEX Bus Supply Current	Maximum 2.4 A
ModuleBus I/O Capacity	Maximum 96 I/O modules single CPU, 84 I/O modules redundant CPU
ModuleBus Scan Rate	0 to 100 ms depending on I/O quantity
Event Queue	Up to 3000 events per OPC client
Clock Synchronization	1 ms between AC 800M controllers using CNCP protocol
Protection Class	IP20 according to EN 60529
Relative Humidity	5 to 95 %, non-condensing
Storage Temperature	-40 to +70 deg C
Isolation Voltage	500 VAC
CE Mark	Yes
Safety Certifications	IEC 61508, TÜV, UL 61010-1, UL 61010-2-201
Hazardous Location Certification	cULus Class 1 Zone 2, AEx nA IIC T4, Ex nA IIC T4Gc X

ABB AC 800M High Integrity Controller Architecture

The PM863K02 uses the AC 800M controller architecture with redundant CPU, CEX-Bus, communication interfaces, and S800 I/O support. The controller integrates two Ethernet ports for Control Network communication and provides two serial interfaces for engineering and service functions.

The High Integrity configuration requires an SM812 Safety Module and SIL-certified software. Therefore, the controller can execute safety-related applications according to IEC 61508 requirements when configured according to the applicable Safety Manual.

The CPU board includes the microprocessor, RAM memory, real-time clock, LED status indicators, INIT push button, and CompactFlash interface. However, the PM863K02 does not provide Flash memory for application storage.

Backplane Bus Communication and I/O Density Scaling

The PM863K02 supports industrial controller communication through CEX-Bus and ModuleBus interfaces. The controller provides deterministic data exchange between CPU resources, communication modules, and S800 I/O modules.

The module supports up to 12 communication modules on the CEX-Bus and provides ModuleBus expansion for electrical and optical I/O clusters. In redundant CPU configurations, the controller maintains coordinated operation between processor units and connected I/O resources.

The Ethernet interface operates according to IEEE 802.3 standards and supports MMS and IAC protocols for AC 800M Control Network communication.

Frequently Asked Questions

Q: Does the PM863K02 support CPU redundancy operation?
A: Yes. The PM863K02 supports redundant CPU configurations including CPU synchronization, CEX-Bus redundancy, communication interface redundancy, and S800 I/O redundancy.

Q: What additional hardware enables High Integrity functionality?
A: High Integrity operation requires an SM812 module together with SIL-certified software. Configuration must follow the AC 800M Safety Manual requirements.

Q: What are the available serial communication interfaces?
A: The controller provides two RJ45 serial ports. COM3 is a non-isolated RS-232C interface with modem control signals, while COM4 is an isolated RS-232C service tool interface.

Field Installation Guidelines

• Install the PM863K02 on the designated AC 800M controller base plate with correct mechanical alignment.
• Connect CN1 and CN2 Ethernet ports according to the Control Network topology requirements.
• Maintain proper separation between Ethernet cables, serial cables, and high-voltage wiring to reduce electrical interference.
• Connect shielded communication cables using approved grounding practices for industrial control systems.
• Verify the 24 VDC supply polarity before energizing the controller.
• Confirm redundant power supply status inputs and battery installation before system commissioning.
• Configure the SM812 safety module and safety software according to the applicable Safety Manual before enabling High Integrity functions.

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