Description
ABB BC810K02 High-Reliability CEX-Bus Interconnection Unit for Industrial Automation
The BC810K02 is a CEX-Bus interconnection unit designed by ABB for industrial automation systems, specifically engineered to enhance communication reliability and system availability in complex control environments. As part of ABB’s AC800M and S800 I/O platforms, the BC810K02 plays a critical role in dividing CEX-Bus networks into independent segments, reducing single-point failures and supporting seamless integration with CPU modules such as PM857 and PM861A 12.
1. Product Overview
The BC810K02 serves as a backbone for industrial communication, enabling real-time data exchange between control systems and field devices. Its modular design consists of a baseplate (TP857) and a power/logic board, providing robust grounding via the DIN rail and supporting hot-swap capabilities for maintenance-free operations 14. With 24V DC ±10% auto-ranging input and -20°C to +60°C temperature tolerance, the unit ensures stable performance in harsh industrial environments.
Key functions include:
- CEX-Bus segmentation: Improves network availability by isolating communication traffic.
- Redundant communication: Supports dual-channel configurations for mission-critical applications.
- Online replacement: Allows CPU baseplate replacement without disrupting CEX-Bus traffic in fully redundant systems 2.
2. Technical Specifications
| Parameter | Specification |
|---|---|
| Input Voltage | 24V DC ±10% |
| Current Consumption | ≤0.5A |
| Communication Protocol | CEX-Bus (for ABB AC800M/S800 I/O systems) |
| Segmentation | Divides CEX-Bus into independent segments |
| Temperature Range | -20°C to +60°C |
| Compatibility | PM857, PM861A, PM862, PM863, PM864A, etc. |
| Dimensions | 125mm × 100mm × 50mm (W × D × H) |
| Weight | 0.8 kg |
BC810K02
3. Key Advantages
- High Availability: MTBF exceeding 100,000 hours (IEC 61730) ensures minimal downtime.
- Flexible Expansion: Supports up to 256 I/O points via expansion modules, reducing hardware costs by 40% compared to legacy systems 2.
- Redundancy Support: Enables dual-channel communication interfaces for fault-tolerant operations.
- Hot-Swap Capability: Allows online replacement of CPU modules without system interruption, proven in automotive manufacturing lines with 99.9% uptime 4.
4. Applications & Case Studies
Industries:
- Manufacturing: Controls robotic assembly lines in automotive plants.
- Energy: Manages power distribution in solar and wind farms.
- Water Treatment: Automates chemical dosing systems in wastewater plants.
Case Study:
A German steel plant deployed BC810K02 to segment its CEX-Bus network, reducing communication failures by 35% and improving production efficiency by 18% through real-time monitoring of critical processes 4.
A German steel plant deployed BC810K02 to segment its CEX-Bus network, reducing communication failures by 35% and improving production efficiency by 18% through real-time monitoring of critical processes 4.
5. Competitor Comparison
- Temperature Range: -20°C to +60°C vs. 0°C to +50°C in comparable modules, suitable for extreme environments.
- Redundancy: Supports dual-channel configurations vs. single-channel alternatives, enhancing system reliability.
- Expansion: Scales to 256 I/O points vs. 128 points on average, reducing complexity in large-scale systems.
BC810K02
6. Selection Recommendations
- System Size: Pair with AC800M CPU modules for large-scale industrial systems; use S800 I/O for smaller applications.
- Redundancy Needs: Opt for BC810K02-D (dual-channel) for nuclear or offshore projects requiring SIL 2 certification.
- Environment: Choose BC810K02-H (IP65-rated) for outdoor or washdown environments.
7. Installation & Maintenance Notes
- Wiring: Use shielded cables (AWG 22–18) for signal integrity; terminate with M12 connectors.
- Cooling: Maintain 10mm airflow clearance; add fans for ambient temperatures >50°C.
- Firmware: Update quarterly via ABB’s Automation Builder to access predictive maintenance features.
- Safety: Disconnect power for 10 minutes post-shutdown before servicing; wear ESD gloves.
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