ABB PM862K02 (3BSE081636R1) – High-reliability AC 800M CPU kit for medium-to-large process control

The ABB PM862K02 is a controller kit for the AC 800M platform, designed for continuous process industries that need stable cycle times, solid Ethernet networking, and straightforward expandability. From my experience, this model sits in the sweet spot for plants looking to refresh an existing AC 800M installation or add a redundant CPU pair without changing the I/O backbone. You might notice that engineering stays familiar—Control Builder M and IEC 61131‑3 languages—so commissioning is typically quick and low-risk.

The “K02” kit designation usually means you’re getting the PM862 CPU with the essential accessories (CompactFlash with firmware image and battery-backed real-time clock included), prepared for standard cabinet installation. If you’re migrating from older PM86x units, this is a clean path with minimal downtime and easy rollback thanks to the removable CF media. In many cases, customers deploy PM862K02 in a redundant pair to meet higher availability targets while keeping S800 I/O and existing field networks in place.

Company’s Order Placement Process and Guarantees

• Warranty: 365 days coverage from delivery.
• Lead time: 1 week for in‑stock items; no more than one month at the latest.
• Payment: 50% advance payment; full payment prior to delivery.
• Express options: FedEx, UPS, DHL.
• Packing & ESD: Industrial-grade packaging with anti‑static protection and moisture barrier, suitable for international air freight.

Key Features

• AC 800M platform compatibility: Works seamlessly with S800 I/O and AC 800M communication modules to scale from small skids to plant-wide control.
• Dual 10/100 Ethernet: Two RJ45 ports for controller/plant network segregation, engineering access, or redundant network topologies.
• Redundancy-ready: Supports CPU redundancy configurations to improve availability in critical units.
• CompactFlash firmware/media: Removable storage for firmware, project backup, and fast field replacement—very handy during upgrades.
• Service/serial access: Onboard serial service port simplifies local diagnostics and maintenance.
• IEC 61131‑3 engineering: Programmed with Control Builder M (function block, structured text, ladder, etc.), easing cross-team collaboration.
• Flexible networking: Extend to PROFIBUS DP, Modbus, EtherNet/IP, ControlNet, or PROFINET via AC 800M CI modules as needed.

Technical Specifications

Brand / Model	ABB PM862K02 (3BSE081636R1) – AC 800M CPU Kit
HS Code	8537.10 (Programmable control equipment, ≤1000 V)
Power Requirements	24 VDC nominal supplied via AC 800M base; typical consumption 5–8 W
Dimensions & Weight	Approx. 186 × 59 × 127 mm; ~0.6 kg (single-width controller module form factor)
Operating Temperature	0 to +55 °C; 5–95% RH non-condensing
Signal I/O Types	No direct field I/O on CPU; interfaces S800 I/O via ModuleBus (digital/analog via I/O modules)
Communication Interfaces	2× 10/100BASE‑TX (RJ45), 1× service/serial (RS‑232); expansion via CI modules (e.g., PROFIBUS DP, Modbus, EtherNet/IP, PROFINET, ControlNet)
Engineering & Firmware	Control Builder M, IEC 61131‑3; CompactFlash media for firmware/project storage; battery-backed RTC
Installation Method	DIN-rail mounted on AC 800M baseplate inside control cabinet; front wiring/service access
Redundancy	Supports CPU redundancy configurations and redundant networks; S800 I/O redundancy supported

Application Fields

The PM862K02 is commonly used in:

• Oil & Gas (compressor stations, dehydration units, utility balance-of-plant)
• Power & Water (boiler/HRSG auxiliaries, water treatment trains, pumping stations)
• Pulp & Paper and Metals (stock prep, drives coordination, furnace auxiliaries)
• Chemicals and Pharma (batch units, skids, packaging lines)
• Marine and Terminals (machinery control, cargo handling, utilities)

A maintenance lead at a midstream facility mentioned that swapping a failed PM862 took under an hour: “We restored the app from the CF card, hot-checked comms, and were back online before the next shift.”

Advantages & Value

• Lifecycle-friendly upgrades: Reuse S800 I/O and existing networks to avoid unnecessary capex.
• Reliability: Proven AC 800M runtime with redundancy options and robust diagnostics.
• Open connectivity: Add fieldbuses your plant already uses—keeps integration costs predictable.
• Serviceability: Front-access media and service port shorten turnaround during maintenance windows.
• Global support: ABB’s ecosystem, spares availability, and mature documentation reduce operational risk.

Installation & Maintenance

• Cabinet environment: 24 VDC supply with proper grounding; maintain 50 mm clearance for ventilation; ambient 0–55 °C.
• Mounting: Install on the AC 800M baseplate fixed to 35 mm DIN rail; secure wiring and verify shield terminations.
• Networking: Use industrial Ethernet switches; consider redundant rings or dual-homing for critical services.
• Safety: De-energize before inserting/removing modules; follow ESD procedures when handling CF media.
• Routine tasks: Back up application to CF after changes, check battery status annually, clean dust filters, and align firmware revisions across redundant pairs.
• Change control: Validate cycle times and network loads after adding I/O or protocols—typically a quick test in Control Builder M.

Quality & Certifications

• CE compliant; typically UL/cUL listed
• RoHS compliant; manufactured under ISO 9001 quality systems
• Designed for industrial EMC and vibration standards commonly required in process automation
• Supplier warranty: 365 days

Related and Supporting Components

For typical builds, teams often pair the PM862K02 with:

• S800 I/O modules (e.g., AI810, AO810, DI810, DO810) for field signal termination
• Communication interfaces: CI854A (PROFIBUS DP), CI868 (EtherNet/IP), CI871 (PROFINET), CI853 (ControlNet) as project requirements evolve
• Industrial Ethernet switches with redundancy features (ring/VRRP) for resilient plant networks

If you’re replacing a legacy AC 800M CPU or planning a redundant controller pair, this kit seems to be the dependable choice—fast to commission, easy to service, and friendly to existing S800 I/O architectures.