Saia PCD2 Modules: PCD2.K110 –

Technical Dossier

Product Details And Specifications

Saia-Burgess PCD2 Series: Comprehensive Module Range and Technical Overview

The Saia-Burgess PCD2 is a mid-range programmable controller platform deployed across heavy industrial sectors including petrochemical processing, nuclear power auxiliary systems, oil refinery automation, water treatment infrastructure, and building management systems. Manufactured in Switzerland by Saia-Burgess Controls AG (now part of Honeywell), the PCD2 platform holds a significant installed base across Europe, the Middle East, and Asia-Pacific. Its modular backplane architecture supports mixed I/O configurations, enabling system integrators to construct compact yet scalable control nodes without full rack replacement. The PCD2 remains operational in thousands of legacy installations where full migration to successor platforms (PCD3, PCD7) is deferred due to capital constraints or process continuity requirements.

The Evolution of PCD2 Architecture

The PCD2 platform was introduced in the early 1990s as a successor to the PCD1 compact controller, extending addressable I/O capacity and introducing a structured backplane bus. Early revisions used proprietary S-Bus communication over RS-485, which remains the dominant fieldbus in legacy PCD2 deployments. Mid-generation revisions introduced PROFIBUS-DP adapter modules, enabling integration with third-party field devices. Later firmware releases added Ethernet-based S-Bus (S-Bus over UDP/IP), allowing PCD2 CPUs to participate in supervisory SCADA networks without hardware replacement.

Compatibility constraints are a primary concern in PCD2 maintenance: CPU firmware versions must align with the PG5 programming software release used during original commissioning. Mixing module generations within a single rack requires verification of backplane bus protocol versions. The PCD2 has entered the mature/end-of-life phase of its product lifecycle; Saia-Burgess has transitioned active development to the PCD3 and PCD7 series. Spare parts and replacement modules are no longer manufactured in volume, making secondary-market sourcing the primary supply channel for ongoing maintenance.

PCD2 Full Catalog & Functionalities (SKU List)

CPU Modules

• PCD2.M110: Base CPU, 16KB program memory, S-Bus RS-485, no onboard I/O.
• PCD2.M150: Enhanced CPU, 64KB program memory, integrated RS-232/RS-485 ports.
• PCD2.M480: High-capacity CPU, 512KB memory, dual serial ports, real-time clock.
• PCD2.C100: CPU with integrated Ethernet S-Bus, 256KB program memory.
• PCD2.C150: CPU with Ethernet + RS-485, expanded data memory, web server function.

Digital Input Modules

• PCD2.E110: 16-channel 24VDC digital input module, sink/source compatible.
• PCD2.E160: 32-channel 24VDC digital input, high-density format, LED status per channel.

Digital Output Modules

• PCD2.A460: 16-channel transistor output, 24VDC/0.5A per channel, short-circuit protected.
• PCD2.A480: 8-channel relay output, 250VAC/2A, potential-free contacts.

Analog I/O Modules

• PCD2.W380: 4-channel analog input, 0–10V / 4–20mA selectable, 12-bit resolution.
• PCD2.W340: 2-channel analog output, 0–10V / 4–20mA, 12-bit DAC.
• PCD2.W300: Combined 4AI + 2AO module, mixed signal processing in single slot.

Communication & Fieldbus Modules

• PCD2.F2000: PROFIBUS-DP slave adapter, up to 244 bytes I/O, DIN rail mount.
• PCD2.F2100: PROFIBUS-DP master module, manages up to 32 slave devices.
• PCD2.F8000: LON network interface module for building automation integration.

Power Supply Modules

• PCD2.K106: 24VDC power supply module, 6A output, integrated surge protection.
• PCD2.K110: 24VDC/10A rack power supply, supports full 8-slot PCD2 backplane load.
• PCD2.K111: Redundant power supply module, hot-swap capable, for high-availability racks.

Cable & Accessory

• PCD2.K121: Programming cable, USB-to-RS-232 adapter for PG5 software connection.

Sourcing Hard-to-Find & Obsolete PCD2 Parts

DriveKNMS maintains a dedicated inventory of decommissioned and refurbished PCD2 modules sourced from plant shutdowns, equipment upgrades, and controlled dismantling projects. For end-users operating PCD2-based systems beyond the manufacturer's active support window, DriveKNMS provides lifecycle extension services including: verified replacement modules with functional test documentation, cross-reference matching for discontinued part numbers, and advisory support for identifying compatible substitute modules within the PCD2 or PCD3 range. All obsolete PCD2 inventory is catalogued by firmware revision and hardware generation to ensure compatibility with existing rack configurations. Customers are advised to provide their current CPU firmware version and PG5 software release when requesting obsolete module sourcing.

Quality Control for the PCD2 Range

PCD2 modules undergo a structured inspection and functional test protocol prior to dispatch. Each module is visually inspected for backplane connector wear, capacitor condition, and relay contact integrity. CPU modules are bench-tested using a dedicated PCD2 test rack running a standardized PG5 diagnostic program that exercises all memory regions, serial communication ports, and onboard I/O. Analog modules are calibrated against a traceable reference standard to verify input accuracy within ±0.1% of full scale. Communication modules (PROFIBUS, LON) are tested for correct bus termination behavior and data throughput under simulated load. Power supply modules are load-tested at 100% rated current for a minimum burn-in period before shipment. Test records are retained and available upon request.