Product Overview
The ABB PM863K02 is a high-integrity AC 800M controller designed for demanding industrial automation environments. Its CPU board integrates a microprocessor, RAM memory, a real-time clock, LED indicators, an INIT push button, and a CompactFlash interface, delivering robust performance in a compact package.
With built-in CPU redundancy, the PM863K02 ensures high availability for your critical processes. The controller supports two RJ45 Ethernet ports (CN1, CN2) for Control Network connectivity and two RJ45 serial ports (COM3, COM4). The COM3 port offers RS-232C with modem control, while COM4 is isolated for configuration tool connection.
This controller enables high-integrity functionality when paired with an SM812 module and SIL-certified software, allowing non-critical schemes to be upgraded to SIL-certified operation. The AC 800M High-Integrity environment is IEC 61508 and TÜV-certified, combining safety and business-critical control in one unit.
Key Features & Benefits
-
ISA Secure certified for enhanced cybersecurity
- Up to SIL 3 certified using PM857/SM812, PM863/SM812, PM865/SM811, or PM867/SM812
- Supports S800 I/O High Integrity (PM857, PM863, PM865, PM66A, PM867, PM891)
- Configurable with 800xA control builder
- Full EMC certification
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TÜV Certified for SIL 2 and SIL 3
- Built-in redundant Ethernet communication ports
Technical Specifications
| Parameter |
Value |
| Article Number |
3BSE088382R1 (PM863K02) |
| Redundancy |
Yes |
| High Integrity |
Yes |
| Clock Frequency |
96 MHz |
| Performance (1000 boolean operations) |
0.17 ms |
| Memory |
32 MB |
| RAM available for application |
22.184 MB |
| Processor Type |
MPC866 |
| Switch over time in red. conf. |
Max 10 ms |
| No. of applications per controller |
32 |
| No. of programs per application |
64 |
| No. of diagrams per application |
128 |
| No. of tasks per controller |
32 |
| Cycle time per application programs |
10 ms |
| Flash PROM for firmware storage |
18 MB |
| Power supply |
24 V DC (19.2–30 V DC) |
| Power consumption +24 V typ/max |
210 / 360 mA |
| Power dissipation |
5.1 W (8.6 W max) |
| Built-in back-up battery |
Lithium, 3.6 V |
| Ethernet channels |
2 |
| Ethernet interface |
Ethernet (IEEE 802.3), 10 Mbit/s, RJ-45, female (8-pole) |
| Control Network protocol |
MMS and IAC |
| RS-232C interface |
2 (one general, 1 for service tool) |
| Operating temperature |
+5 to +55 °C (+41 to +131 °F) |
| Storage temperature |
-40 to +70 °C (-40 to +158 °F) |
| Protection class |
IP20 according to EN 60529, IEC 529 |
| Dimensions (W x H x D) |
119 mm x 186 mm x 135 mm |
| Weight (including base) |
2700 g (5.95 lbs) |
Applications
The ABB PM863K02 excels in process industries where safety and reliability are paramount. Typical applications include:
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Oil and gas – emergency shutdown systems and fire & gas control
-
Chemical processing – batch control and safety interlocks
-
Power generation – turbine control and protection systems
With its redundant architecture and SIL 3 capability, the PM863K02 ensures uninterrupted operation even in the most critical scenarios.
Installation & Setup
Mount the controller on a standard DIN rail, ensuring adequate clearance for airflow and cable connections. Connect the Ethernet ports (CN1, CN2) to the Control Network using shielded RJ45 cables. Use the COM3 port for RS-232C communication with modems or other serial devices, and COM4 for connecting the configuration tool. For high-integrity configurations, install the SM812 module and configure the system according to the Safety Manual.
Maintenance & Reliability
Routine maintenance includes checking the backup battery (lithium, 3.6 V) and verifying that the real-time clock remains accurate. The controller's robust design – with a wide operating temperature range and IP20 protection – ensures long service life. Periodic inspection of connectors and cables helps prevent downtime.
Compatibility & Integration
The PM863K02 integrates seamlessly with the AC 800M family and supports S800 I/O modules. It communicates over the Control Network using MMS and IAC protocols, and can be configured with 800xA control builder. The controller supports up to 12 communication modules on the CEX bus, providing extensive expansion options.
Buying Guide
When ordering the ABB PM863K02, verify the article number 3BSE088382R1 to ensure you receive the correct revision. This package includes two PM863K01 safety processor units, one TK850 CEX-bus expansion cable, and one TK851 RCU-Link cable. For guaranteed authenticity and reliable supply, choose PLC Source PRO as your trusted partner.