ABB PM857K01 PM857K02 AC 800M High-Integrity Redundant Controller

Order Codes: PM857K01 (3BSE088385R1) | PM857K02 (3BSE088386R1)

Brand: ABB

Product Family: AC 800M

Type: High-Integrity Programmable Logic Controller (PLC) / Safety Controller

Product Overview

The ABB PM857K02 (and its single-unit variant PM857K01) is a high-performance, High-Integrity controller belonging to the AC 800M series. Engineered for mission-critical process automation, this controller uniquely combines standard business-critical control with SIL 3 safety functionality without sacrificing performance.

The "K02" package specifically provides a complete 1:1 redundant processor solution, including two CPU units and all necessary synchronization cables. This configuration ensures zero downtime for applications running in Oil & Gas, Power Generation, and Chemical processing.

Key Features & SEO Keywords

SIL 3 / TÜV Certified High-Integrity: Achieves IEC 61508 SIL 3 certification when paired with an SM812 module. Allows non-critical control loops to be upgraded to safety-certified schemes via a plug-in module .

Built-in Redundancy (PM857K02): The redundant package includes 2 x PM857K01 units, 1 x TK850 CEX-Bus cable, and 1 x TK851 RCU-Link cable. Supports seamless switchover (<10 ms) for CPU, CEX-Bus, and S800 I/O .

ISA Secure Certified: Ensures cybersecurity robustness against network threats in industrial control systems .

High-Speed Processing: 96 MHz processor with 0.17 ms execution time per 1000 Boolean operations. Available RAM for applications is 7.147 MB (or up to 22 MB depending on firmware) .

Flexible I/O Capacity: Supports up to 128 I/O signals and handles up to 12 communication modules on the CEX-Bus. Fully compatible with S800 I/O and S800L I/O families .

Integrated Communication: Features dual redundant Ethernet ports (CN1/CN2) for Control Network connectivity and dual serial ports (COM3 RS-232C, COM4 Isolated) .

Technical Specifications

Specification PM857K01 / PM857K02

Order Codes 3BSE088385R1 (K01) / 3BSE088386R1 (K02)

Processor MPC866, 96 MHz

Memory (RAM) 32 MB (Application available: 7.1 to 22 MB) 

Performance 0.17 ms / 1k Boolean operations

Redundancy K01: No (Single) / K02: Yes (1:1 Hot Standby)

Safety Integrity Up to SIL 3 (with SM812) 

I/O Capacity Max 128 I/O signals / 96 I/O modules (single) 

Power Supply 24 V DC (19.2 - 30 V DC)

Typical Consumption 210 mA (5.1 W) to 360 mA (8.6 W) 

Operating Temp +5 °C to +55 °C (+41 °F to +131 °F)

Protection Class IP20

Dimensions (WxHxD) 119 mm x 186 mm x 135 mm

Weight Approx. 2.7 kg (5.95 lbs) 

PM857K02 vs. PM857K01: What is the difference?

While the core CPU board is identical, the ordering codes determine the package contents and capability:

PM857K01 (3BSE088385R1): Single controller unit. Suitable for standard, non-redundant applications where high availability is not required. It is also used as a base component for custom redundant setups .

PM857K02 (3BSE088386R1): The "Redundant Package." It contains 2 pieces of PM857K01, the TK850 expansion cable, and the TK851 RCU link cable. This is the recommended SKU for engineers looking to implement a turnkey redundant safety system .

High-Integrity Functionality (SIL Certification)

The PM857 platform is unique in the ABB portfolio. By adding an SM812 module to the controller and installing SIL-certified software, the standard PM857 transforms into a High-Integrity Controller. This setup allows a single hardware platform to run both standard process control and safety logic (e.g., Emergency Shutdown - ESD) on the same hardware set, provided configuration follows the Safety Manual guidelines .

Applications & Use Cases

The ABB PM857K02 is essential for industries requiring high process availability and stringent safety compliance:

Oil & Gas: Pipeline monitoring, wellhead control, refinery ESD systems.

Power Generation: Turbine control, balance of plant (BOP) automation.

Chemical & Petrochemical: Batch processing with SIL-rated interlocks.

Water/Wastewater: Large-scale SCADA integration with redundant backbone.

Why Choose the ABB PM857K02?

If you are building a System 800xA or Compact Product Suite (CPS) installation requiring high availability, the PM857K02 is the certified redundant solution. Unlike using two separate CPU units, the K02 package ensures proper synchronization via the dedicated RCU Link (TK851), providing deterministic switchover times of less than 10 milliseconds.

*ABB PM857K02 datasheet, 3BSE088386R1 manual, AC 800M High Integrity, SIL 3 Controller, Redundant PLC, S800 I/O compatibility, 800xA hardware.*