ABB PM862K01 3BSE076939R1 is the core processor unit of the AC 800M series, belonging to the ABB Ability System 800xA control system. It is a modular DIN‑rail mounted controller designed for industrial automation applications, equipped with the MPC866 processor at its core.
It features high computing performance, abundant communication interfaces, and flexible expansion capabilities. The controller supports CPU redundancy configuration to enhance system availability, and is suitable for a wide range of industrial field applications from basic logic control to complex process control.It has passed multiple authoritative certifications such as ISA Secure, enabling stable operation in various industrial environments. It is only compatible with System 800xA 6.0.2, Compact Control Builder 6.0.0‑1, and later software versions.
Core Hardware & Performance Specifications
Core Processor & Computing Performance
Equipped with the MPC866 processor at a clock frequency of 67 MHz.It takes only 0.18 ms to complete 1000 Boolean operations.The minimum application task cycle can reach 1 ms, and the maximum switchover time under redundant configuration is 10 ms, meeting the real-time requirements of industrial control.
Memory Configuration
- Total memory: 32 MB
- Available application RAM: 23.521 MB
- 4 MB Flash PROM for firmware storage
- Supports Flash memory storage
- Built-in 3.6 V lithium battery for RAM backup, ensuring data retention after power loss.
Task & Application Capacity
- Single controller supports up to 32 applications and 32 tasks, with 32 configurable cycle times.
- Single application can run up to 64 programs and 128 charts, satisfying multi-scenario and multi-process industrial control configuration requirements.
Communication & Expansion Capabilities
The PM862K01 features versatile, highly compatible communication interfaces and strong expansion capabilities, serving as the communication and control core for networked connections and I/O expansion in industrial field systems.
Basic Communication Interfaces
Ethernet
- 2 × RJ45 Ethernet ports (CN1, CN2)
- Complies with IEEE 802.3 standard
- Transmission rate: 10 Mbit/s, supports redundancy
- Control network protocols: MMS (Manufacturing Message Specification) and IAC (Inter-Application Communication)
- Recommended backbone: 100 Mbit/s switched Ethernet
- Clock synchronization of 1 ms between AC 800M controllers via CNCP protocol.
Serial Ports
- 2 × RJ45 RS232C serial ports (COM3, COM4)
- COM3: Non‑galvanically isolated, baud rate 75–19200, supports full RTS‑CTS with modem control signals.
- COM4: Galvanically isolated, baud rate 9600, no RTS‑CTS, dedicated for configuration tool connection.
Bus & Expansion
CEX Bus
- Supports segmentation via BC810/BC820
- Can mount up to 12 communication modules
- Maximum bus supply current: 2.4 A
- Compatible with standard fieldbuses such as PROFIBUS DP for connection to various field devices.
Modulebus
- Non‑redundant CPU: 1 electrical + 7 optical I/O clusters
- Redundant CPU: 7 optical I/O clusters
- Single PM862: up to 96 I/O modules; redundant configuration: up to 84 I/O modules
- Scan rate: 0–100 ms (adjustable based on number of I/O modules)
- Electrical Modulebus: 24 V max. 1.0 A, 5 V max. 1.5 A.
OPC Communication
- Single OPC client: controller event queue stores up to 3000 events
- Transmission rate to OPC server:
- 36–86 events per second
- 113–143 data messages per second
- Enables efficient data exchange with third-party HMIs and other systems.
Power Supply & Power Consumption
Power Requirements
- Power input: 24 V DC
- Voltage range: 19.2–30 V DC
- Supports redundant power status input
- Can work with AC800M series power supply units SD821/SD822/SD823 for redundant power supply and improved reliability.
Power Consumption
- Typical operating current at +24 V: 210 mA; maximum: 360 mA
- Typical power consumption: 5.1 W; maximum: 8.6 W
- Low power consumption allows compact mounting without additional cooling equipment.
Environmental Adaptability
Designed for industrial environments, this product features wide temperature operation, vibration resistance, and anti-interference capabilities. It has obtained multiple international authoritative certifications and is suitable for various industrial sites and even hazardous areas.
Operating Environment:
- Operating temperature: +5 °C to +55 °C
- Storage temperature: -40 °C to +70 °C
- Temperature change rate: 3 °C/min, complying with IEC/EN 61131-2
- Relative humidity: 5%–95% non-condensing
- Maximum operating altitude: 2000 m
- Vibration resistance:
- 0.0375 mm amplitude at 10 < f < 50 Hz
- 0.5 g acceleration at 50 < f < 150 Hz
- 0.2 g acceleration at 5 < f < 500 Hz
- Radiated noise: < 55 dB(A)
Protection & Corrosion Resistance:
- Protection class: IP20, usable without additional enclosure
- Pollution degree: 2 (IEC/EN 61131-2)
- Corrosion protection: complies with ISA 71.04 G3
- Rated isolation voltage: 500 V AC
- Dielectric test voltage: 50 V
Mechanical Characteristics & Installation
Dimensions:
- Width: 119 mm (4.7 in)
- Height: 186 mm (7.3 in)
- Depth: 135 mm (5.3 in)
- Total weight (including base): 1200 g (2.6 lbs)Compact size ideal for dense installation in industrial control cabinets.
Installation Method:Features a unique slide-lock mechanism for fast DIN‑rail mounting and removal.All bases are assigned a unique Ethernet address as the CPU hardware identification, which can be found on the Ethernet address label of the TP830 base.
Core Product Features & Advantages
High Reliability & Easy MaintenanceSupports redundant configuration of CPU, CEX bus, communication interfaces, and S800 I/O. ISA Secure certification ensures system security. Fault diagnosis is straightforward; LED indicators and an INIT reset button facilitate on-site troubleshooting.
Modularity & ScalabilityModular design supports step-by-step expansion via CEX bus and Modulebus. Supports up to 12 fieldbus modules and nearly 100 I/O modules, suitable for both simple and complex control system architectures.
Standardization & CompatibilityHardware designed based on industrial standards such as Ethernet and PROFIBUS DP, ensuring strong communication compatibility. Configurable via 800xA Control Builder, supports IEC 61131-3 standard programming languages, and is fully compatible with the System 800xA system.
Industrial Environment AdaptabilityIP20 protection, wide operating temperature range, vibration and interference resistance, plus certifications for hazardous areas and marine classification societies. Stable operation in general industrial sites, marine applications, hazardous areas, and other demanding environments.
Low Power Consumption & Compact Installation
Low power design eliminates the need for extra cooling. Small footprint and DIN‑rail mounting enable compact layout in control cabinets, minimizing installation space.
As the core processor unit of the AC 800M series, the ABB PM862K01 stands as a key control hardware component in industrial automation, supported by its high reliability, strong real-time performance, rich communication and expansion capabilities, and adaptability to various industrial environments.
It is mainly deployed in industries with stringent requirements for control system stability, safety and scalability, including process industries, energy and power, infrastructure, and intelligent manufacturing. Meanwhile, it can meet the automation control demands of special industrial scenarios such as marine applications and hazardous areas.
As the core processing unit of a Distributed Control System (DCS), it undertakes critical tasks including data acquisition, logic operation, real-time monitoring, and process regulation.
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