ABB PM865K01 PM865K02 AC 800M High-Integrity Controller SIL2 SIL3 Safety Applications

Part Numbers:

PM865K01: 3BSE031151R1 (Single/Base Unit)

PM865K02: 3BSE031150R6 (Redundant Kit)

Brand: ABB

Product Family: AC 800M High-Integrity (HI)

Type: Programmable Logic Controller (PLC) / Safety Controller

Product Overview

The ABB PM865K01 and PM865K02 are high-performance processor units belonging to the AC 800M High-Integrity series. Unlike standard controllers, these units are specifically engineered for mission-critical process safety and business-critical continuous control.

The primary distinction between the two is simple:

PM865K01 is the single processor unit. It is used for simplex (non-redundant) applications or as the building block for a redundant pair.

PM865K02 is the pre-configured redundant kit. It includes two PM865K01 processor units, one TK850 CEX-Bus extension cable, and one TK851 RCU-Link cable. This kit arrives ready for "hot standby" configuration, ensuring zero downtime in the field .

High-Integrity (HI) Architecture

A unique feature of the PM865 series is the "Plug-in Safety" concept. The base controller handles standard automation (Non-SIL). However, by inserting a SM811K01 module, the controller instantly upgrades to a TÜV-certified SIL 3 environment. This allows you to run safety logic (ESD, F&G) and standard process control in the same hardware chassis without wiring to a separate safety PLC .

Key Features & SEO Keywords

TÜV Certified Safety: Certified for IEC 61508. Achieves SIL 2 with SM810; achieves SIL 3 with SM811 .

Redundancy Ready (PM865K02): Supports CPU redundancy, CEX-Bus redundancy, and Communication interface redundancy. The K02 kit facilitates 1:1 hot standby for maximum system availability .

Robust Communication: Built-in dual Ethernet ports (Control Network) and dual RS232C/Config serial ports.

High Memory & Speed: Equipped with a powerful microprocessor and large RAM capacity to handle complex safety matrices and regulatory control loops.

S800 I/O Integration: Seamlessly integrates with ABB S800 I/O, including High-Integrity I/O for safety applications .

Onboard Diagnostics: Features LED status indicators, a CompactFlash interface for firmware, and a real-time clock.

Dual Functionality: Combines Process Control (Continuous, Sequential) and Safety Logic (Emergency Shutdown) in one unit.

Technical Specifications

Specification Details

Model Numbers PM865K01 (Single) / PM865K02 (Kit of 2) 

Order Codes 3BSE031151R1 / 3BSE031150R6 

Safety Integrity SIL 2 (with SM810) / SIL 3 (with SM811) 

Redundancy Yes (1:1 Hot Standby via RCU Link) 

Communication Ports 2 x RJ45 Ethernet (Control Net), 2 x RJ45 Serial (RS232C/Config)

I/O Bus CEX-Bus (S800 I/O)

Memory Backup Lithium Battery (4943013-6) / CompactFlash 

Mounting S800 I/O Base Plate (TB850/TB851) 

Weight (Kit) Approx. 2.3 kg 

Certifications CE, TÜV, ATEX/IECEx for hazardous locations

Applications & Use Cases (The "Why")

The PM865K02 is the industry standard for High Availability and High Integrity in one package.

Oil & Gas: Wellhead control, Pipeline leak detection, Emergency Shutdown (ESD) systems (SIL 3).

Refining & Petrochemical: Burner Management Systems (BMS), Reactor temperature safety loops.

Power Generation: Turbine overspeed protection, Boiler safety.

Pharmaceuticals: Batch control with validated safety interlocks.

Why buy the K02 kit?

Procuring the PM865K02 (3BSE031150R6) instead of two separate PM865K01 units ensures you receive the correct length of TK851 RCU-Link cable and TK850 CEX-Bus cable required for certified redundant operation. Using mismatched cables may violate the SIL rating .

Comparison: PM865K01 vs. PM865K02

Feature PM865K01 PM865K02

Configuration Simplex (Single Unit) Redundant (1+1)

Contents 1 CPU Unit + Accessories 2 CPU Units + RCU Cable + CEX Cable 

Uptime Standard (Maintenance requires downtime) High Availability (Hot Swap)

Use Case Standalone machines, Skids Continuous processes, Pipelines, Refineries

Datasheet & Ordering Information

For engineers looking to upgrade existing ABB 800xA or S800 I/O stations:

The PM865K02 (3BSE031150R6) is currently in the Active lifecycle phase but check the "No longer for sale" notes if replacing an older revision; newer stock is typically 3BSE031150R1 .

Required Accessories: To build a full safety system, you will need the SM811K01 (Safety module) and TB850/TB851 terminators