Description
Product Introduction
The ABB BC810K01 is a specialized CEX-Bus interconnection unit designed for AC 800M controller hardware platforms within ABB System 800xA. It extends and divides the communication expansion bus (CEX-Bus), allowing engineers to segment communication interfaces like PROFIBUS, Modbus, or Ethernet modules without risking total bus collapse if a single node fails.
In redundant AC 800M controller setups (such as PM864A or PM866 pairs), the BC810K01 provides isolation barriers between primary and backup CPU communication racks. By isolating communication segments, it allows maintenance teams to hot-swap CPU baseplates or communication interfaces online, ensuring maximum availability for high-reliability process loops.
Key Technical Specifications
| Parameter | Specification |
| Kit Part Number | 3BSE031154R1 (Kit includes BC810, TP857 Baseplate, accessories) |
| Baseplate Type | TP857 (60mm width, DIN-rail mounted) |
| Operating Voltage | 24 V DC (19.2 to 30 V DC range) |
| Power Consumption | 50 mA typical (70 mA max at 24V DC) |
| Power Dissipation | 1.2 W typical |
| Compatible CPUs | PM857, PM861A, PM862, PM863, PM864A, PM865, PM866, PM867, PM891 |
| Redundancy Support | Yes (supports redundant CEX-Bus interfaces) |
| Hot Swap Capability | Supported (for CPU baseplates; see Tech Trap notes for module swaps) |
| Operating Temperature | 0°C to +55°C (32°F to 131°F) |
Application Scenarios & The “Trench” Experience
A continuous-process glass plant in Ohio ran into a nightmare scenario: a faulty PROFIBUS master module caused a physical layer short on the main CEX-Bus. Because the system lacked bus segmentation, the short crashed communication across the entire controller rack, dropping two downstream VFD banks instantly. Retrofitting the rack with a BC810K01 isolated the communication segments. When a similar field-bus transceiver failure occurred six months later, the BC810 trapped the fault inside its local segment—keeping the primary process running smoothly while techs swapped the bad card.
- Oil & Gas Offshore Platforms – Redundant Control Racks – Isolates primary and backup PM866 controllers to allow online servicing without dropping safety shutdown loops.
- Chemical Processing – Distributed Fieldbus Communications – Segments heavy PROFIBUS and Foundation Fieldbus master cards to prevent single-point bus noise from corrupting core CPU logic.
- Power Plants – High-Availability Steam Turbine Control – Ensures continuous CEX-Bus communication to speed governors during hot-swapping of secondary communication interfaces.
- BC810K01
- BC810K01
Transparency SOP: Quality Assurance & Testing
We test every BC810K01 kit on an actual AC 800M rack before it gets packed. Here is our bench SOP:
- Visual & Mechanical Inspection: Check the TP857 baseplate connectors for micro-fractures, inspect DIN-rail grounding clips, and verify original ABB label serials.
- Backplane Power & Voting Diode Check: Apply 24 V DC to the L+/L- supply terminals on the TP857 baseplate to verify voting diode operation, fuse continuity, and 3.3V internal rail conversion.
- Live Bus Signal Handshake: Install the unit between an AC 800M controller and a secondary CEX segment. Run diagnostic scripts in Control Builder M to confirm zero packet loss across the TK851 cable bridge.
- Hot-Swap Simulation: Pull adjacent CEX communication modules under power to verify that the BC810 maintains bus stability without tripping the controller into a hard fault.
- ESD Protection & Packaging: Clean terminal contacts with electrical solvent, enclose in thick anti-static shielding, and pack with moisture-absorbing desiccant.
The Veteran’s Tech Trap Guide (Crucial Value-Add)
⚠️ BC810 Module Removal Drops the Segment: While the BC810 allows you to hot-swap other CPU baseplates or comm modules, pulling the BC810 unit itself stops all traffic on that connected CEX segment. Don’t unseat a thinking the downstream segment will magically stay up; it won’t.
❗ Missing Cable Terminators (TB850): The CEX-Bus requires proper line termination. If you split a bus using the and forget to install the TB850 CEX-Bus terminators on the open ends of the new segment, signal reflections will cause intermittent communication timeouts that are a pain to diagnose.
⚠️ External 24V Power Polarity: Power for the internal logic drivers comes from the external 24 V DC connected directly to the TP857 baseplate terminals. Double-check wire polarity before powering up. Reversing L+ and L- won’t fry the card thanks to the internal voting diode, but your CEX extension segment will stay completely dead.
Frequently Asked Questions (FAQ for Conversion)
Q: What is the difference between and BC810K02?
A: The difference usually comes down to kit packaging and included revision items. The is the single-segment interconnection kit (includes 1x module, TP857 baseplate, and bus accessories), whereas the BC810K02 kit includes two complete units, two baseplates, a TK851 cable, and two TB850 terminators for a full dual-segment build out of the box.
Q: Does the draw power directly from the CPU backplane?
A: No. While it passes data across the CEX-Bus, the unit relies on an external 24 V DC power supply connected directly to the L+ and L- screw terminals on its baseplate.
Q: Can I hot-swap a failed module during plant operation?
A: You can physically pull it, but doing so will freeze all communication traffic on that specific CEX segment until the replacement is seated. If critical I/O or fieldbus links run through that segment, place those loops in manual before pulling the card.
Q: Is a special software license required in Control Builder M to use the ?
A: No additional software license is required. However, you must insert and configure the unit inside the hardware tree in Control Builder M so the controller correctly maps the CEX-Bus topology and diagnostic addresses.
Q: What warranty do you offer on new surplus or reconditioned kits?
A: We provide a full 12-month replacement warranty on all units. If the hardware fails or drops communication within one year, we will ship a replacement unit right away.
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