Product Overview of the ABB PM863K01 CPU Board

The ABB PM863K01 contains the main microprocessor and RAM memory. A real-time clock keeps accurate time for time-stamped events. LED indicators show the controller status at a quick glance. The INIT push button allows for easy system resets. A CompactFlash interface provides convenient storage expansion.

The base plate includes two RJ45 Ethernet ports for network connections. These ports are labeled CN1 and CN2 for the Control Network. Two serial ports (COM3 and COM4) expand communication options. The COM3 port is RS-232C with modem control signals. The COM4 port is isolated for configuration tool connections.

This controller supports CPU redundancy for higher system availability. Redundancy covers the CPU, CEX-Bus, communication interfaces, and S800 I/O. The ABB PM863K01 requires configuration according to the Safety Manual. High Integrity operation needs an SM812 module and SIL-certified software.

Technical Specifications of the PM863K01

• Article Number: 3BSE088381R1 (PM863K01)

• Redundancy: No (supports external redundancy configuration)

• High Integrity: Yes (with SM812 module)

• Clock Frequency: 96 MHz

• Performance (1000 boolean ops): 0.17 ms

• Memory (RAM): 32 MB

• RAM Available for Application: 22.184 MB

• Flash PROM for Firmware: 18 MB

• Processor Type: MPC866

• Number of Applications per Controller: 32

• Number of Programs per Application: 64

• Number of Tasks per Controller: 32

• Cycle Time per Application: 10 ms

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

• Power Consumption (24V typ/max): 210 / 360 mA

• Power Dissipation: 5.1 W (8.6 W max)

• Built-in Backup Battery: Lithium, 3.6 V

• Ethernet Channels: 2

• Ethernet Interface: 10 Mbit/s, RJ-45

• Switch Over Time in Redundant Config: Max 10 ms

• I/O Capacity on Modulebus: Max 96 I/O modules

• Real-time Clock Stability: 100 ppm (approx 1 hour/year)

• Operating Temperature: +5 to +55 °C

• Storage Temperature: -40 to +70 °C

• Protection Class: IP20

• Dimensions (W x H x D): 119 mm x 186 mm x 135 mm

• Weight (including base): 1200 g

High Integrity and Safety Features

The ABB PM863K01 offers TÜV Certified SIL 2 and SIL 3 capability. Adding an SM812 module enables the High Integrity functionality. This allows non-critical control schemes to upgrade to SIL-certified schemes. The AC 800M High-Integrity combines safety and business-critical process control.

You maintain safety integrity while running both control types in one unit. The controller supports S800 I/O High Integrity modules. Compatible models include PM857, PM863, PM865, PM66A, and PM891. The controller has full EMC certification for industrial environments.

ISA Secure certification adds cybersecurity protection for your system. Marine certificates from ABS, BV, and DNV-GL are available. The controller meets G3 corrosion protection standards per ISA 71.04. This makes the PM863K01 suitable for harsh industrial settings.

Communication and Network Capabilities

The ABB PM863K01 provides two Ethernet channels for network connectivity. The Control Network protocol uses MMS and IAC communications. A 100 Mbit/s switched Ethernet backbone is recommended for best performance. The Modulebus scan rate ranges from 0 to 100 ms depending on I/O load.

The COM3 serial port runs at 75 to 19,200 baud without opto isolation. This port supports full RTS-CTS handshaking for modem control. The COM4 serial port runs at 9,600 baud with opto isolation. No RTS-CTS support is available on the COM4 port.

Up to 12 communication modules can sit on the CEX bus. The Modulebus supports 1 electrical or 7 optical I/O clusters. For redundant CPU configurations, only optical clusters are supported. The supply current on the CEX bus reaches a maximum of 2.4 A.

Installation Guide for the PM863K01

Follow these steps to install the ABB PM863K01 correctly.

1. Mount the base plate on a DIN rail inside your control cabinet.

2. Ensure adequate ventilation around the controller for cooling.

3. Connect the 24V DC power supply to the designated terminals.

4. Verify the voltage range stays between 19.2 and 30 V DC.

5. Insert the CPU board onto the base plate firmly.

6. Connect the Control Network to Ethernet ports CN1 or CN2.

7. Attach the configuration tool to the isolated COM4 serial port.

8. Insert the CompactFlash card for application storage if needed.

9. Power on the system and check the LED indicators.

10. Configure the controller using 800xA control builder software.

The operating temperature must stay between +5 and +55°C. Keep relative humidity below 95% without condensation. Do not install in areas with pollution degree higher than 2.

Package Contents for ABB PM863K01

• 1 x ABB PM863K01 CPU board with microprocessor and RAM

• 1 x Base plate with two Ethernet ports and two serial ports

• 1 x Lithium backup battery (3.6 V, pre-installed)

• 1 x Quick start installation guide (printed)

• 2 x RJ45 connector dust covers

• 1 x INIT push button protective label

Frequently Asked Questions (FAQ)

1. Can the ABB PM863K01 run as a standalone safety controller?
No, the PM863K01 requires an SM812 module for High Integrity functionality. Without SM812, it works as a standard non-safety controller. Add the module and SIL software to achieve up to SIL 3 certification.

2. What is the maximum I/O capacity for this CPU board?
The ABB PM863K01 supports up to 96 I/O modules on the Modulebus. For redundant CPU configurations, the maximum is 84 I/O modules. The actual number depends on your specific system layout.

3. Does the PM863K01 support redundant power supplies?
Yes, this controller has a redundant power supply status input. You can connect two 24V DC power supplies for higher availability. The controller will detect and report any power supply failures.

4. How many applications can run simultaneously on the PM863K01?
The ABB PM863K01 runs up to 32 applications per controller. Each application can have 64 programs and 128 diagrams. You can define 32 different cycle times across all tasks.

5. What is the switch over time in a redundant configuration?
The PM863K01 achieves a maximum switch over time of 10 milliseconds. This fast transition ensures minimal disruption to your control process. The redundant configuration supports CPU, CEX-Bus, and S800 I/O.