Description

ABB BC810K01 3BSE031154R1

I. Overview

ABB BC810K01 3BSE031154R1 is a CEX bus interconnection unit kit, with its core positioning as a universal CEX bus communication interconnection kit for single-link/redundant architecture. Designed specifically for high-speed data interaction between devices in industrial scenarios, this kit builds a stable CEX bus link through the combination of standardized components, realizing data encoding, decoding, transmission and exchange between different modules, controllers and terminal devices. It is a key communication component for constructing high-reliability Distributed Control Systems (DCS).

The BC810K01 kit adopts a modular structure design, which balances installation flexibility and operation & maintenance convenience. It supports multiple industrial communication protocols such as PROFIBUS, Modbus and CEX-Bus, and can be seamlessly integrated into ABB AC 800M series controllers and various automation systems. Equipped with core features including redundant communication support and hot-swapping, it can adapt to harsh industrial working conditions. It is widely used in many fields such as electric power, oil and natural gas, chemical industry, water treatment, automobile manufacturing and intelligent manufacturing, providing solid support for global data interconnection and stable operation of the system.

II. Kit Composition

The BC810K01 3BSE031154R1 is a standardized integrated kit, and each component cooperates to realize the complete CEX bus interconnection function. The specific composition is as follows, which is suitable for single-link construction and redundant expansion requirements:

BC810 Interconnection Unit: 1 core unit, consisting of a TP857 backplane and a power/logic board. It is the core component for signal reception, conversion, encoding/decoding and bus interconnection transmission. The logic board integrates a +3.3V voltage converter, a CEX bus interconnection driver and cable connectors.
TP857 Backplane: 1 adapter backplane with a width of 60mm. It integrates CEX bus connectors and external power interfaces, and is equipped with external power voting diodes and fuses. It provides an installation carrier and power supply circuit protection for the interconnection unit, and is grounded with 35mm DIN rails through the metal parts of the housing to enhance anti-interference capability.
TB850 CEX Bus Terminator: 1 terminal component, installed at one end of the CEX bus. It is used to suppress signal reflection, stabilize bus waveforms, avoid communication abnormalities caused by signal interference during high-frequency data transmission, and ensure the integrity of data transmission.

III. Product Features

Multi-protocol Compatibility and Global Interconnection: Supports multiple mainstream industrial communication protocols such as PROFIBUS, Modbus and CEX-Bus. It can realize data interaction and transmission exchange between different buses and devices, adapting to the heterogeneous device integration requirements of complex automation systems.
Redundant Expansion and High Reliability: Supports the configuration of redundant communication interface units, and can be flexibly expanded into a dual-link redundant architecture, effectively avoiding communication interruption caused by single-link faults. Combined with the circuit protection components integrated on the backplane, it significantly improves the communication stability and uninterrupted operation capability of the system.
Hot-swapping and Online Maintenance: Supports hot-swapping function and online CPU replacement. In the redundant system configuration, the CPU backplane can be replaced online without interfering with CEX bus communication traffic, minimizing maintenance downtime and ensuring production continuity and operation & maintenance efficiency.
Modular Design for Easy Operation & Maintenance: The interconnection unit adopts a split structure of "backplane + power/logic board". The components have clear division of labor and simple structure, facilitating separate inspection, repair and replacement of faulty parts without replacing the entire kit, thus greatly reducing operation & maintenance costs and cycles.
Wide Working Condition Adaptability: Adopts industrial-grade component packaging, with an operating temperature range of -20℃ to +60℃, and supports stable 24V DC power supply. It can withstand harsh industrial environments with heavy dust, large temperature differences and strong electromagnetic interference, adapting to various complex application scenarios.
High-speed Real-time Data Transmission: Has high-speed data transmission capability, can quickly complete signal encoding/decoding and data interaction, meets the response requirements of industrial automation systems for real-time monitoring and precise control, and ensures the real-time performance and accuracy of data transmission.

IV. Technical Parameters

Parameter Name	Specification
Product Model	ABB BC810K01 3BSE031154R1
Product Type	CEX Bus Interconnection Unit Kit
Product Series	ABB Advant 800xA Series
Compatible Protocols	PROFIBUS, Modbus, CEX-Bus, etc.
Power Supply	24V DC
Operating Temperature	-20℃ ~ +60℃
Storage Temperature	Refer to the same series standard, usually -40℃ ~ +70℃
Relative Humidity	5% ~ 95%, non-condensing
Dimensions	18.5cm (length) × 6.5cm (width) × 12.6cm (height)
Kit Weight	Approximately 0.77kg (including full set of components)
Country of Origin	Sweden/Switzerland
Backplane Specification	TP857 type, 60mm in width, integrating power supply and bus interfaces

V. Working Principle

The core working principle of the ABB BC810K01 3BSE031154R1 kit is a closed-loop process of link construction - signal conversion and encoding - data transmission - status monitoring and protection. Through the coordinated operation of various components, it achieves high-speed and stable communication across devices and buses. The specific working process can be divided into four core stages:

Stage 1: Link Construction and Power Supply Startup

Install the BC810 interconnection unit on the TP857 backplane, and install the TB850 terminator at the corresponding end of the CEX bus to suppress signal reflection, completing the basic construction of a single link. The external 24V DC power supply is connected through the backplane interface, and the power supply is distributed through the voting diodes. The fuse provides overcurrent protection for the power supply circuit. The backplane is grounded through the DIN rail to ensure power supply safety and anti-interference capability.

Stage 2: Signal Reception, Conversion and Encoding

Signals from external controllers, I/O modules or terminal devices are connected to the BC810 unit through the CEX bus connector. The +3.3V voltage converter on the logic board converts the input voltage into the internal working voltage, driving the bus interconnection driver and encoding/decoding module to work. It converts signals from different devices into standard signals compatible with protocols such as CEX-Bus and PROFIBUS, realizing signal normalization processing.

Stage 3: Data Transmission and Interaction

The processed standard signals are transmitted to the target devices through the bus link, and feedback signals from other devices are received at the same time. These signals are decoded and converted into signals recognizable by the corresponding devices, completing two-way data interaction. In case of redundant configuration, the dual units synchronize the communication status in real time. When the main link fails, the standby unit quickly switches to take over, ensuring uninterrupted data transmission.

Stage 4: Status Monitoring and Fault ProtectionThe circuit protection components integrated on the backplane monitor the power supply status in real time. If overcurrent or voltage abnormality occurs, the fuse immediately blows to cut off the circuit and protect the internal circuit of the unit. The BC810 unit feeds back its own working status and link connection integrity in real time. If problems such as terminator faults or loose interfaces are detected, it sends alarm signals to the upper system in a timely manner to facilitate quick troubleshooting by maintenance personnel.

VI. Common Fault Troubleshooting

1. Bus Communication Interruption, Unable to Transmit Data

Phenomenon: No data interaction between system devices; the upper computer displays "bus communication fault"; the status indicator of the BC810 unit is abnormal (off or flashing); terminal devices cannot receive control commands.

Causes: The TB850 terminator is not installed correctly or is damaged, causing signal reflection interference; poor contact between the BC810 unit and the TP857 backplane, hindering signal transmission; unstable power supply voltage or blown fuse; mismatched communication protocol configuration, failing to realize data decoding.

Solutions: 1. Confirm that the TB850 terminator is installed in the correct position, test the performance of the terminator, and replace the damaged one with the same model. 2. Disconnect the power supply, re-plug the connection between the BC810 unit and the backplane, clean the oxide layer on the contact pins to ensure reliable contact. 3. Detect the power supply voltage to ensure stable 24V DC power supply. If the fuse is blown, replace it with the same specification and troubleshoot the power supply circuit fault. 4. Check the system communication protocol configuration to ensure it is consistent with the protocols supported by the kit. Restart the device to synchronize parameters after reconfiguration.

2. High Data Transmission Latency and Packet Loss

Phenomenon: Poor real-time performance of data transmission, with latency exceeding industrial control requirements; partial data loss, leading to abnormal execution of control commands; incomplete data received by the upper computer.

Causes: Strong electromagnetic interference in the industrial site without using shielded bus lines; excessive bus load exceeding the data transmission capacity of the kit; unreasonable communication protocol parameter settings with poor adaptability; poor grounding of the backplane, generating interference loops.

Solutions: 1. Replace with shielded bus lines, reliably ground the shield layer at one end, and route the lines away from power lines to reduce electromagnetic interference. 2. Optimize the system bus load, split the network segments to avoid connecting too many devices to a single link. 3. Adjust the communication protocol parameters to adapt to the actual data transmission requirements, improving protocol compatibility and transmission efficiency. 4. Check the grounding status of the backplane to ensure reliable grounding through the DIN rail and eliminate interference loops.

3. Switching Failure After Redundant Configuration

Phenomenon: After expanding the redundant architecture, the standby link cannot take over communication when the main link fails; the dual units cannot synchronize the communication status; the system experiences short-term communication interruption.

Causes: Poor contact or mismatched model of the interconnection cable between the dual BC810 units; incorrect redundant configuration parameters, leading to abnormal switching logic; the standby unit is not correctly connected to the bus, failing to synchronize signals.

Solutions: 1. Check the connection of the redundant interconnection cable, ensure the connectors are fastened, and replace with the compatible cable to ensure signal synchronization. 2. Check the redundant configuration parameters of the dual units, restart the units to synchronize the switching logic and ensure parameter consistency. 3. Confirm that the standby unit is correctly connected to the bus and the backplane, and test the communication function of the standby unit separately to rule out unit faults.