1. Introduction
The ABB PM865K02 CPU Board is a high-performance controller module designed for the System 800xA distributed control system (DCS). As part of ABB's AC 800M family, the PM865K02 delivers exceptional processing power, robust connectivity, and advanced redundancy capabilities – making it an ideal choice for demanding industrial applications in oil & gas, chemical processing, power generation, pulp & paper, and pharmaceutical manufacturing.
This package provides a complete CPU solution, including all necessary components for immediate deployment in both standard and high-availability architectures.
2. Package Contents
The PM865K02 package includes:
| Component | Quantity | Description |
|---|---|---|
| PM865K01 | 2 pcs | Processor units (CPU boards) – enabling CPU redundancy |
| TK850 | 1 pcs | CEX-bus expansion cable – connects the CPU to I/O and communication modules |
| TK851 | 1 pcs | RCU-Link cable – redundant communication link between two PM865 controllers |
Package Advantage: By including both CPU units and all necessary interconnection cables, the PM865K02 package simplifies ordering, reduces engineering effort, and ensures compatibility.
3. Physical Specifications
| Parameter | Specification |
|---|---|
| Dimensions | 119 × 186 × 135 mm (4.7 × 7.3 × 5.3 inches) |
| Weight | 2300 g (5.1 lbs) |
| Mounting | DIN rail or rack mount |
| Cooling | Passive convection – no fans required |
4. CPU Board Architecture
The PM865K01 processor unit (included in the package) contains the core processing hardware:
| Component | Description |
|---|---|
| Microprocessor | High-performance 32-bit CPU – optimized for real-time control |
| RAM Memory | Sufficient memory for control strategies, data logging, and communication buffers |
| Real-Time Clock | Battery-backed clock for time-stamping events and alarms |
| LED Indicators | Status LEDs for RUN, ERROR, FAULT, and link activity |
| INIT Pushbutton | Initiate system initialization or reset |
| CompactFlash Interface | Removable memory for firmware upgrades, system backups, and data storage |
5. Connectivity and Ports
The PM865 controller base plate provides extensive connectivity options:
| Port | Description | Function |
|---|---|---|
| CN1 (Ethernet) | RJ45 – Control Network Port 1 | Primary connection to System 800xA Control Network |
| CN2 (Ethernet) | RJ45 – Control Network Port 2 | Redundant connection to Control Network |
| COM3 (RS232C) | RJ45 serial port with modem control signals | Serial communication with modems or external devices |
| COM4 (RS232C) | RJ45 isolated serial port | Connection for configuration tool (e.g., engineering workstation) |
Redundancy Support: The dual Ethernet ports (CN1, CN2) enable connection to redundant Control Networks, ensuring communication survives a single network failure.
6. Redundancy and High Availability
The PM865K02 package includes two PM865K01 CPU units, enabling CPU redundancy for maximum system availability:
| Redundancy Level | Description | Benefit |
|---|---|---|
| CPU Redundancy | Two PM865K01 processors in hot-standby configuration | Seamless switchover if primary CPU fails – no interruption to control |
| CEX-Bus Redundancy | Dual CEX-bus interfaces for I/O and communication | Survives a CEX-bus failure |
| Communication Interface Redundancy | Dual Ethernet ports and dual serial ports | Survives network or serial link failure |
| S800 I/O Redundancy | Supports redundant I/O configurations | Survives I/O module or field wiring failures |
Why This Matters: In critical processes where unplanned downtime is unacceptable (e.g., refinery reactors or turbine protection), CPU redundancy ensures that a single hardware failure does not result in a production stop.
7. High-Integrity Functionality (SIL Capable)
The PM865 CPU platform supports high-integrity functionality for safety-critical applications:
| Feature | Description |
|---|---|
| SM81x Module Support | Plug-in safety module enables SIL-certified operation |
| SIL Certified Software | TÜV-certified software environment for safety applications |
| IEC 61508 Compliance | Certified for functional safety up to SIL 3 (Safety Integrity Level) |
| Combined Control | Safety and business-critical process control in one controller – without sacrificing safety integrity |
Key Advantage: By simply adding an SM81x module and selecting the appropriate software, existing non-critical control schemes can be upgraded to SIL-certified safety schemes – without replacing the entire controller.
