The BC810K02 is a critical interconnection unit kit within the ABB Ability™ System 800xA® hardware platform, designed to enhance the availability and flexibility of the Communication Extension Bus (CEX-Bus). This kit is specifically engineered for industrial automation and control environments demanding high reliability, redundant communication, and online maintenance capabilities. As a core expansion and segmentation device for the CEX-Bus system, BC810K02 significantly improves system resilience during partial failures by physically isolating bus segments and supports the online replacement of key components, minimizing system downtime.
The BC810K02 kit contains two complete interconnection units. Each unit consists of the BC810 Interconnection Unit and the TP857 Baseplate, and includes necessary connection cables and terminators for a plug-and-play system integration. This product is widely used in applications with high availability requirements, such as power, process industries, marine, and rail transportation, making it an ideal choice for building redundant, maintainable, and high-performance control systems.
2. Product Composition and Design Features
2.1 Product Composition
The BC810K02 kit includes the following components, providing all hardware necessary for complete installation and configuration:
| Component Model | Component Name | Quantity | Functional Description |
| BC810 | CEX-Bus Interconnection Unit | 2 units | The core module enabling CEX-Bus segmentation, power conversion, and logic control. |
| TP857 | Baseplate (width 60 mm) | 2 units | Provides mechanical mounting, electrical connections, external power supply access, and grounding. |
| TK851 | Interconnection Cable | 1 piece (Length 1.0 m) | Used to connect two BC810 units for physical bus segment interconnection. |
| TB850 | CEX-Bus Terminator (male) | 2 units | Installed at the end of each CEX-Bus segment to ensure bus signal integrity. |
2.2 Hardware Structure
The BC810 unit is composed of two core parts:
Baseplate (TP857):
Provides connectors for the CEX-Bus and the external 24 V power supply.
Grounded to the DIN-rail through metal parts of the housing for electrical safety.
Integrates an external power voting diode and fuse for power input protection.
Power Supply and Logic Board:
Contains an internal +3.3 V converter to power the logic circuitry.
Includes the driver logic and interface circuits required for CEX-Bus interconnection.
Provides a dedicated interface for connecting the TK851 interconnection cable.
2.3 Design Features and Benefits
| Feature | Benefit Description |
| Supports Redundant Communication Interface Units | Allows deployment of redundant communication modules within the same system, installed on different BC810 segments, achieving physical isolation and fault tolerance for communication paths. |
| Supports Online CPU Replacement | In a fully redundant configuration (two interlinked BC810 units and a primary/backup CPU pair), the CPU baseplate can be replaced online without disturbing CEX-Bus traffic. |
| External Independent Power Supply | Uses an external 24 V DC power supply, separate from the processor unit power, enhancing system power supply reliability and supporting power status monitoring (EPOK indicator). |
| Supports Hot Swap | The BC810 unit can be safely replaced while the system is running. Note that all traffic to the connected CEX segment will be stopped during replacement. |
| Segmentation Enhances System Availability | Divides the CEX-Bus into two separate physical segments. A faulty device on one segment will not affect the processor unit or devices on the other CEX-Bus segment, significantly improving overall system availability. |
| Wide Processor Compatibility | Compatible with various System 800xA processor units: PM857, PM861A, PM862, PM863, PM864A, PM865, PM866, PM866A, PM867, and PM891. |
3. Functions and Indicator Description
3.1 Operation and Status Indicators
The BC810 unit front panel features multiple LED indicators for real-time monitoring of device status and bus activity:
| Indicator Designation/Color | Function Description |
| F (Fault) / Red | Power Supply Error. Controlled by hardware. Set and cleared by hardware during power-up. Illuminated indicates a detected fault such as internal short circuit or power overvoltage. |
| R (Run) / Green | Operating Status. Controlled by hardware. Illuminated during normal operation. Off indicates a hardware error or internal/external fuse blow. |
| EPOK (External Power OK) / Green | External Power Status. Illuminated when the external 24V power is correctly connected and powered. Off indicates no external power or blown external fuse (on TP857). |
| C1 / Yellow | Directly Connected CEX Segment Activity. Indicates communication traffic on the CEX-Bus segment directly connected to the local BC810. |
| C2 / Yellow | Interconnected CEX Segment Activity. Indicates communication traffic on the CEX-Bus segment connected via the interconnection cable. |
3.2 Fault-Finding Guidance
Based on the manual's fault-finding procedure, common issues can be quickly located:
| Fault Symptom | Possible Cause and Corrective Action |
| Fault (F) LED illuminated | No 3.3 V power, possibly caused by an internal short circuit or power overvoltage.
• Check the external 24 V supply with a voltmeter.
• If voltage is normal, the unit requires repair. |
| Run (R) LED is off | Hardware error.
• Check if the internal fuse of the BC810 or the external fuse on the TP857 is blown.
• Send the unit for repair. |
| EPOK LED is off with external power connected | Hardware error or blown external fuse on the TP857.
• Send the unit for repair. |
| C1 or C2 LED off despite accessing CEX units | Some CEX-Bus units (e.g., CI851) do not use interrupt signals. This is normal and requires no action. |
4. Application Scenarios and System Integration
4.1 Key Application Value
Enhances System Availability: By physically segmenting the CEX-Bus, the impact of faults is contained, ensuring a single module failure does not cripple the entire communication bus. This is crucial for process control and safety systems with extreme continuous operation requirements.
Enables Redundant Architecture: Supports redundant configuration of Communication Interface (CI) units. Combined with BC810's segmentation capability, primary/backup modules can be placed on different bus segments, achieving true physical path redundancy.
Facilitates Online Maintenance: In systems configured with dual BC810 units and redundant CPUs, a faulty CPU baseplate can be replaced online without interrupting process communications, significantly reducing maintenance windows and improving operational efficiency.
Extends Communication Capabilities: The CEX-Bus extends the processor unit's onboard communication ports to connect various communication interface units (e.g., Ethernet, fieldbus, serial), meeting the diverse communication needs of complex systems.
4.2 Typical System Configuration Diagram
(A description or reference to the manual's block diagram can be included here: Two BC810 units interconnected via a TK851 cable, each connected to the CEX-Bus of primary and backup CPUs. Each BC810 supports multiple communication interface units. Each CEX-Bus segment is terminated with a TB850 terminator at its end. An external 24V power supply powers each BC810 independently.)
5. Installation, Configuration, and Maintenance Key Points
5.1 Installation Guidelines
Location and Grounding: BC810 units must be mounted directly onto the CEX-Bus on the processor unit baseplate (TP830). The TP857 baseplate ensures reliable grounding to the DIN-rail through its metal housing.
Bus Termination: A bus terminator (TB850 or TB851) must be fitted at the end of each CEX-Bus segment. A TB851 (female) terminator is required when using a TK850 extension cable.
Cable Limitations: A maximum of one TK850 extension cable (length 0.7 m) may be used in any CEX-Bus. Interconnection between BC810 units uses the dedicated TK851 cable (included in BC810K02 kit, length 1.0 m).
Redundant Unit Placement: When the system uses redundant CEX-Bus units (e.g., redundant communication interfaces), these redundant units must be mounted on different CEX-Bus segments managed by different BC810 units.
5.2 Maintenance Considerations
Replacement Impact: When replacing a BC810 unit, all traffic to its connected CEX segment(s) will be stopped. Therefore, in non-redundant configurations, replacement should be scheduled during a downtime window. In redundant configurations, ensure the alternate path is functional.
Power Supply Check: If a fault indicator lights up, first use a multimeter to verify the input 24 V DC power is within the normal range (19.2 - 30 V DC).
Fuse Check: If the Run LED is off or the EPOK LED is abnormal, check the external fuse on the TP857 baseplate and the internal fuse within the BC810.
