SAIA KOP128 Modules

Technical Dossier

Product Details And Specifications

SAIA KOP128 Series: Comprehensive Module Range and Technical Overview

The SAIA-Burgess KOP128 series represents a mature generation of programmable logic controllers deployed extensively across global heavy industry verticals, including petrochemical refineries, nuclear auxiliary systems, water treatment infrastructure, and continuous-process manufacturing. Manufactured in Switzerland by SAIA-Burgess Controls AG (later integrated into Honeywell's building and industrial automation portfolio), the KOP128 platform established a benchmark for modular, rack-based PLC architecture in European industrial markets during the 1990s and 2000s. Installed base density remains high in legacy facilities across Germany, France, the Benelux region, and Southeast Asia, creating sustained demand for spare parts, replacement modules, and lifecycle extension services.

The Evolution of KOP128 Architecture

The KOP128 series was developed as part of SAIA's PCD (Programmable Control Device) ecosystem, sharing a common instruction set and programming environment (SAIA PG5) with the broader PCD1, PCD2, PCD3, and PCD6 families. The KOP128 designation identifies a specific rack-mount controller form factor with a 128-point I/O addressing capacity per base unit. Early revisions used proprietary S-Bus serial communication; subsequent hardware revisions introduced Ethernet-capable variants and expanded memory addressing. The series is fully compatible with SAIA PG5 programming software versions 1.x through 2.x, though PG5 3.x support requires firmware verification on a per-module basis. As the KOP128 platform has entered end-of-life status with the OEM, compatibility with modern SAIA PCD3.Mxxx controllers is achievable via S-Bus gateway bridging, making migration planning a critical consideration for facilities still operating KOP128 infrastructure.

KOP128 Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly sourced modules within the SAIA KOP128 and directly compatible PCD-series ecosystem. Each entry reflects a distinct hardware function:

KOP128J7CAVPN14: CPU control module, J7 processor variant, CAVPN14 firmware designation, rack-mount base unit.
KOP128J5: Base CPU module, J5 processor core, standard S-Bus serial interface, 128-point I/O capacity.
KOP128J6: Enhanced CPU module, J6 core, expanded program memory, supports PG5 ladder and FBD programming.
PCD2.M480: High-performance CPU module, Ethernet + S-Bus, compatible rack partner for KOP128 installations.
PCD2.E110: 16-channel digital input module, 24VDC, compatible with KOP128 I/O bus.
PCD2.E120: 32-channel digital input module, 24VDC, high-density I/O expansion.
PCD2.A460: 16-channel digital output module, transistor type, 24VDC/0.5A per channel.
PCD2.A480: 16-channel relay output module, 250VAC/2A, for high-voltage switching applications.
PCD2.W200: Analog input module, 8-channel, 0–10V / 4–20mA, 12-bit resolution.
PCD2.W300: Analog output module, 4-channel, 0–10V / 4–20mA, 12-bit resolution.
PCD2.F520: Fast counter/positioning module, 4-channel incremental encoder input, 500kHz max.
PCD2.C200: S-Bus communication module, RS-485, multi-drop network support up to 250m.
PCD2.C300: Profibus-DP slave communication adapter, 12Mbps, for integration into Siemens/ABB DCS networks.
PCD2.C400: Ethernet TCP/IP communication module, 10/100Mbps, Modbus TCP and S-Bus over IP.
PCD2.B100: Rack backplane, 4-slot, for KOP128-compatible module mounting.
PCD2.B200: Rack backplane, 8-slot, extended I/O chassis for high-density configurations.
PCD7.D457: Operator panel interface module, compatible with KOP128 CPU via S-Bus.
PCD2.K106: Memory expansion cartridge, Flash EPROM, for extended program storage on J5/J6 CPU variants.

Sourcing Hard-to-Find & Obsolete KOP128 Parts

The KOP128 series has been formally discontinued by SAIA-Burgess/Honeywell, with OEM new-stock availability effectively exhausted. DriveKNMS maintains a dedicated inventory of tested, pull-out, and refurbished KOP128 modules sourced from decommissioned plant equipment, controlled dismantling projects, and verified secondary-market channels across Europe and Asia. For facilities operating KOP128 infrastructure under long-term maintenance contracts — particularly in nuclear auxiliary, water treatment, and continuous chemical processing environments where control system replacement is cost-prohibitive — DriveKNMS provides lifecycle extension support including module-level repair assessment, functional testing, and cross-reference to compatible PCD2/PCD3 replacement alternatives where direct substitution is feasible. All sourced units are documented with traceability records and shipped with inspection reports.

Quality Control for the KOP128 Range

KOP128 modules present specific test challenges due to their proprietary S-Bus backplane communication protocol and multi-layer PCB construction. DriveKNMS applies a structured verification process to all KOP128 units prior to dispatch: visual inspection for capacitor degradation, bus connector wear, and conformal coating integrity; powered functional test using SAIA PG5 diagnostic tools to verify CPU boot sequence, memory integrity, and I/O channel response; S-Bus communication verification at 9600 and 38400 baud; and burn-in testing under simulated load for CPU and analog modules. Modules that fail any stage are quarantined and not offered for sale. Test records are retained and available upon request for quality-audited procurement processes.