{"product_id":"pm857k02-safety-processor-abb-system-800xa-redundant-controller-module","title":"PM857K02 Safety Processor ABB System 800xA Redundant Controller Module","description":"\u003ch3\u003eExecutive Engineering Overview\u003c\/h3\u003e\n\u003cp\u003eThe ABB \u003cb\u003ePM857K02\u003c\/b\u003e is a TÜV-certified safety controller bundle engineered for the \u003cb\u003eSystem 800xA\u003c\/b\u003e automation architecture. Built to fulfill SIL 3 safety integrity requirements, this redundant processor package merges business-critical process control with high-integrity safety instrumented functions (SIF) into a unified controller node. Powered by an MPC866 microprocessor operating at 96 MHz with 32 MB of onboard RAM, it delivers deterministic execution speeds for complex industrial safety loops.\u003c\/p\u003e\n\u003cp\u003eControl system architects deploy the \u003cb\u003ePM857K02\u003c\/b\u003e unit in hazardous and mission-critical process plants where fault tolerance and high availability are mandatory. The complete bundle configuration provides full CPU, CEX-bus, communication interface, and S800 I\/O redundancy to minimize process downtime and maintain continuous plant operations.\u003c\/p\u003e\n\u003ch3\u003eComprehensive Technical Parameters\u003c\/h3\u003e\n\u003cul\u003e\n\u003cli\u003e\n\u003cb\u003eBrand Manufacturer:\u003c\/b\u003e ABB\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eProduct Series:\u003c\/b\u003e \u003cb\u003eSystem 800xA\u003c\/b\u003e Control Builder \/ AC 800M High-Integrity\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eModel Designation \/ Article No.:\u003c\/b\u003e \u003cb\u003ePM857K02\u003c\/b\u003e (3BSE088386R1)\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003ePackage Contents:\u003c\/b\u003e 2 pcs \u003cb\u003ePM857K01\u003c\/b\u003e Safety Processor units, 1 pc \u003cb\u003eTK850\u003c\/b\u003e CEX-bus expansion cable, 1 pc \u003cb\u003eTK851\u003c\/b\u003e RCU-Link cable\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eProcessor Type \u0026amp; Clock Speed:\u003c\/b\u003e Motorola MPC866 @ 96 MHz\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eExecution Performance:\u003c\/b\u003e 1000 boolean operations in 0.17 ms\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eMemory Allocation:\u003c\/b\u003e 32 MB RAM total (22.184 MB available for application runtime)\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eRedundancy Switchover Time:\u003c\/b\u003e Maximum 10 ms in redundant configuration\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eI\/O Capacity Limits:\u003c\/b\u003e Max 128 I\/O signals total (Max 96 single or 84 redundant I\/O modules on Modulebus)\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003ePower Supply Requirements:\u003c\/b\u003e 24 V DC nominal (19.2V to 30V DC operating range)\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003ePower Consumption \/ Dissipation:\u003c\/b\u003e 210 mA typical \/ 360 mA max at 24V DC; 5.1 W typical dissipation (8.6 W max)\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eCommunication Ports:\u003c\/b\u003e 2 x RJ45 Ethernet ports (CN1, CN2) supporting MMS and IAC protocols; 2 x RS-232C serial ports (COM3 with modem control, COM4 optically isolated for service tool)\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eEnvironmental Specifications:\u003c\/b\u003e Operating temperature +5°C to +55°C; storage temperature -40°C to +70°C; 5% to 95% relative humidity (non-condensing); G3 corrosive gas protection compliant to ISA 71.04; IP20 protection class; operating altitude up to 2000 m\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eCertifications \u0026amp; Compliance:\u003c\/b\u003e ISA Secure certified; TÜV-certified SIL 2 \/ SIL 3; cULus Class 1 Zone 2 hazardous location; ABS, BV, DNV-GL marine certificates; RoHS and WEEE compliant\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003ePhysical Dimensions \u0026amp; Weight:\u003c\/b\u003e Width 119 mm x Height 186 mm x Depth 135 mm; Net assembly weight with base plate approx. 2700 g (5.95 lbs)\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003ch3\u003eGlobal PLC Spare HUB's Insight\u003c\/h3\u003e\n\u003cp\u003eAccording to Global PLC Spare HUB's Insight, deploying high-integrity safety controllers like the \u003cb\u003ePM857K02\u003c\/b\u003e requires rigorous verification of the CEX-bus and RCU-Link cable connections (\u003cb\u003eTK850\u003c\/b\u003e and \u003cb\u003eTK851\u003c\/b\u003e) during initial setup. Field engineers emphasize that synchronization failures between redundant processor halves typically stem from improper fiber-optic or serial link termination rather than hardware faults. Ensuring clean, G3-compliant enclosure environments prevents micro-corrosion on backplane pins in harsh chemical processing facilities.\u003c\/p\u003e\n\u003ch3\u003eTarget Industrial Equipment \u0026amp; Application Scenarios\u003c\/h3\u003e\n\u003cul\u003e\n\u003cli\u003e\n\u003cb\u003eOil \u0026amp; Gas Upstream Platforms:\u003c\/b\u003e Emergency shutdown (ESD) and fire and gas (F\u0026amp;G) safety instrumented systems.\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eChemical Refining Complexes:\u003c\/b\u003e High-integrity pressure protection systems (HIPPS) and reactor temperature interlocks.\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003ePower Generation Facilities:\u003c\/b\u003e Turbine overspeed protection and burner management systems (BMS).\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003ePharmaceutical Batch Reactors:\u003c\/b\u003e Integrated process control and safety interlock sequencing on shared controller nodes.\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eMarine \u0026amp; Offshore Vessels:\u003c\/b\u003e Dynamic positioning and propulsion safety management under DNV-GL compliance.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003ch3\u003eDiagnostic Capabilities \u0026amp; Fault Monitoring\u003c\/h3\u003e\n\u003cp\u003eThe \u003cb\u003ePM857K02\u003c\/b\u003e controller architecture interfaces directly with the System 800xA engineering environment to provide deep runtime diagnostic visibility:\u003c\/p\u003e\n\u003cul\u003e\n\u003cli\u003e\n\u003cb\u003eRedundancy Health Tracking:\u003c\/b\u003e Monitors switchover readiness and heartbeat signals across the RCU-Link cable to detect potential failover anomalies within the 10 ms window.\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eCEX-Bus Communication Error Flags:\u003c\/b\u003e Detects dropped communication frames or power drops on expansion modules linked via the \u003cb\u003eTK850\u003c\/b\u003e cable.\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eEvent Queue Logging:\u003c\/b\u003e Records up to 3000 time-stamped system events per OPC client for sequence-of-events (SOE) forensic analysis.\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eInternal Battery Status:\u003c\/b\u003e Monitors the 3.6V Lithium backup battery voltage to prevent volatile memory loss during power loss transitions.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003ch3\u003eExpress Logistics \u0026amp; 12-Month Warranty Coverage\u003c\/h3\u003e\n\u003cul\u003e\n\u003cli\u003e\n\u003cb\u003eWarranty Terms:\u003c\/b\u003e Fully backed by a comprehensive 12-month replacement warranty covering component defects.\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eDispatch Lead Time:\u003c\/b\u003e Expedited order processing and secure worldwide dispatch within 24 to 48 hours.\u003c\/li\u003e\n\u003cli\u003e\n\u003cb\u003eGlobal Shipping Network:\u003c\/b\u003e Express international delivery handled via trusted carrier partners FedEx, UPS, and DHL.\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003ch3\u003eProfessional Frequently Asked Questions (FAQ)\u003c\/h3\u003e\n\u003cp\u003e\u003cb\u003eQ1: What hardware components are included inside the PM857K02 package bundle?\u003c\/b\u003e\u003c\/p\u003e\n\u003cp\u003eA1: The package includes 2 pcs \u003cb\u003ePM857K01\u003c\/b\u003e safety processor units for redundant operation, 1 pc \u003cb\u003eTK850\u003c\/b\u003e CEX-bus expansion cable, and 1 pc \u003cb\u003eTK851\u003c\/b\u003e RCU-Link synchronization cable.\u003c\/p\u003e\n\u003cp\u003e\u003cb\u003eQ2: Can the PM857K02 controller achieve SIL 3 certification out of the box without additional modules?\u003c\/b\u003e\u003c\/p\u003e\n\u003cp\u003eA2: While the processor unit supports high-integrity functions, achieving full SIL 3 certification requires the addition of an appropriate plug-in SM81x series module (such as the SM812) along with TÜV-certified safety software configured according to the safety manual.\u003c\/p\u003e\n\u003cp\u003e\u003cb\u003eQ3: What specific precautions must be taken when mounting this controller in corrosive industrial atmospheres?\u003c\/b\u003e\u003c\/p\u003e\n\u003cp\u003eA3: Although the unit features G3 corrosion protection compliant with ISA 71.04, it must be housed within an IP20 or better sealed enclosure located in a clean or purged indoor area free from conductive dust buildup.\u003c\/p\u003e\n\u003cp\u003e\u003cb\u003eQ4: How do I troubleshoot an intermittent synchronization failure between redundant PM857K01 processors?\u003c\/b\u003e\u003c\/p\u003e\n\u003cp\u003eA4: Inspect the seating and shielding of the \u003cb\u003eTK851\u003c\/b\u003e RCU-Link cable, verify that firmware revisions match identically across both CPU halves, and check the diagnostic event queue in Control Builder for communication timeout flags.\u003c\/p\u003e\n\u003cp\u003e\u003cb\u003eQ5: What is the recommended purchasing and spare parts strategy for legacy System 800xA hardware?\u003c\/b\u003e\u003c\/p\u003e\n\u003cp\u003eA5: When procuring critical safety spares like the \u003cb\u003ePM857K02\u003c\/b\u003e, always verify that the hardware revision index and firmware compatibility match your existing plant engineering station library to ensure seamless online configuration downloads.\u003c\/p\u003e","brand":"ABB","offers":[{"title":"Default Title","offer_id":67613506666678,"sku":"PM857K02","price":116.0,"currency_code":"USD","in_stock":true}],"thumbnail_url":"\/\/cdn.shopify.com\/s\/files\/1\/0722\/7863\/8774\/files\/PM857K02-1_472b4d57-b1d8-49ee-80a4-94aeeb5c7f57.jpg?v=1791614155","url":"https:\/\/www.plcsparehub.com\/products\/pm857k02-safety-processor-abb-system-800xa-redundant-controller-module","provider":"Global PLC Spare Hub","version":"1.0","type":"link"}