Product Core Brief
- Model:
- Full OEM Part Number: 3BSE018173R1
- Brand: ABB Hitachi Energy
- Series: Safety CPU submodule for ABB MasterPiece AC800M & Ability 800xA Distributed Control System Safety Instrumented Systems (SIS)
- Core Function: High-integrity SIL3 safety logic processor that operates in collaboration with PM865 standard process CPU. It independently executes safety interlock, emergency shutdown (ESD), fire & gas, anti-runaway and machine protection logic separated from normal process control to avoid common-cause failures.This complete assembly package includes three parts:
- SM811 safety CPU core module
- TP868 dedicated rack baseplate
- TK852V10 synchronization link cable for redundant SM811 hot-backup pairingKey notes for this part:
- Non-RoHS compliant: Only valid as repair spare for systems delivered before 22 July 2017; new installations must use upgraded SM812K01 RoHS safety CPU.
- Dedicated CEX bus connection via BC810 interconnection box to exchange safety data with main PM865 controller.
- Supports redundant hot-standby safety architecture with bumpless switchover if one safety CPU fails.
- Implements PROFIsafe over Ethernet for safety field I/O communication, fully isolated from standard DCS process bus.
- Product Type: Rack-slotted SIL3 safety CPU submodule assembly
- Key Specs: SIL3 / PL e safety integrity certified; 300 MHz safety processor; 128 MB RAM + 64 MB safety Flash memory; 24 VDC ±10% logic power (15 W typical consumption); dual Ethernet ports for PROFIsafe safety communication; dedicated synchronization interface for redundant pairing; front RUN/FAULT diagnostic LEDs; standard slot mounting on AC800M controller rack; IP20 enclosure for indoor control cabinet
- Note: The AC800M legacy safety platform is end-of-life. Only remaining factory-sealed original assemblies and fully cyclic-tested surplus units are supplied as maintenance spares for thermal power, chemical, offshore and pulp & paper plant SIS cabinet renovation. Cannot be cross-replaced with SM812K01 without full safety system re-certification.
Key Technical Specifications
| Parameter | Value |
|---|---|
| Full OEM Article Code | 3BSE018173R1 |
| Safety Integrity Level | SIL 3 (IEC 61508), PL e (EN 61511) |
| Processor Clock | 300 MHz dedicated safety microprocessor |
| Memory | 128 MB safety RAM, 64 MB non-volatile Flash for safety program storage |
| Operating Power Supply | 24 VDC ±10% SELV logic power |
| Typical Power Consumption | 15 W |
| Safety Communication | Dual Ethernet ports supporting PROFIsafe safety protocol |
| Redundancy Function | Hot redundant operation via TK852V10 sync cable, bumpless failover |
| Backplane Bus Interface | CEX safety bus via BC810 interconnection box |
| Front Indicators | Green RUN (normal), Red FAULT (safety logic failure / communication loss) |
| Mechanical Form Factor | Standard AC800M rack slot, mates with TP868 baseplate |
| Overall Dimensions | 127.5 mm D × 185 mm H × 59 mm W |
| Net Weight | 0.6 kg total assembly |
| Operating Ambient Temp | -10 °C ~ +60 °C indoor cabinet; storage: -40 °C ~ +85 °C |
| Humidity Limit | ≤75% RH non-condensing |
| Compliance Standards | IEC 61508 SIL3, IEC 61511 SIS, TÜV fully safety certified, CE; Exempt from EU RoHS 2011/65/EU for legacy spare repair use |
Product Introduction
The (3BSE018173R1) is the mandatory independent safety CPU for all SIL3-rated ABB AC800M safety instrumented systems, solving the critical risk of safety logic interference from ordinary process control CPU faults.
Four Core Design Advantages for Safety-Critical Plants
- Independent Safety Logic Execution (Separation from Normal Process CPU)Standard PM865 CPU handles routine process monitoring, regulation and DCS data exchange; runs isolated safety program code on a dedicated safety processor. If the main PM865 CPU crashes or suffers software corruption, safety interlock, ESD and equipment protection logic remains fully active, eliminating single-point safety failure risks.
- Redundant Hot-Standby Safety Architecture SupportTwo identical modules connected via TK852V10 synchronization cable form active/standby safety pair. The standby unit continuously mirrors all safety logic, I/O status and fault logs; upon primary safety CPU failure, seamless switchover occurs within milliseconds without triggering unplanned plant shutdown.
- Isolated PROFIsafe Safety Ethernet CommunicationDual dedicated Ethernet ports transmit only safety-critical signals (valve status, emergency stop, flame detection, transformer fault trip) via PROFIsafe protocol. Physically separated from non-safety plant Ethernet to prevent safety signal tampering or communication crosstalk.
- Dedicated CEX Bus Data Exchange With Main ControllerThrough BC810 CEX interconnection box, exchanges safety event logs, fault alarms and safe operating setpoints with PM865 CPU for unified plant SCADA display, while maintaining strict electrical isolation to avoid safety bus contamination from process bus noise.
This module is only permitted for maintenance repair of systems commissioned before 22 July 2017. For new SIS projects, ABB specifies SM812K01 RoHS-compliant safety CPU instead. Without a functional , the entire plant safety interlock system enters disabled state and cannot meet safety certification requirements.
QA & Testing SOP (Transparency Building)
- Incoming Visual Inspection: Cross-check full part number 3BSE018173R1 against ABB legacy DCS spare parts database to reject RoHS SM812K01 mismatched units; inspect front RUN/FAULT LEDs, Ethernet communication ports, sync cable connector and module housing for cracks, discoloration or pin bending; record serial numbers and production batches for safety traceability.
- Full Redundant Linkage Bench Test: Mount two modules on standard rack TP868 baseplates, connect TK852V10 sync cable and matched CPU; supply stabilized 24VDC logic power, run 24-hour cyclic safety program testing, simulate single safety CPU power loss to verify bumpless redundant switchover, test PROFIsafe Ethernet safety I/O data transmission, confirm FAULT LED alarm triggers correctly for bus communication failure.
- Electrical Safety Test: Insulation resistance ≥ 10 MΩ between 24VDC logic power and safety Ethernet signal terminals; chassis protective earth continuity resistance < 0.5 Ω.
- Hardware Record Backup: Photograph front interface pin definitions, CEX bus BC810 wiring and redundant sync cable connection rules for on-site safety commissioning reference.
- Final QC Packaging: Wipe module housing with anti-static microfiber cloth, cover Ethernet and sync ports with insulating dust caps, place full assembly (SM811 + TP868 + TK852V10) into ESD shielding bag, attach unified printed QC test tag with full 24-hour redundant safety test runtime timestamp, then pack into foam shockproof carton for power plant transportation.
Installation Pitfalls & 4-Step Replacement Guide
Common Installation Hazards
❗ Mandatory Safety Qualification Rule: Only personnel holding ABB safety system certification are allowed to replace ; unqualified modification invalidates safety certification of the entire plant SIS.❗ Non-RoHS Legacy Spare Restriction: This unit cannot be used on new post-2017 DCS installations; only permitted for repair of pre-2017 systems.❗ Redundant Sync Cable Matching Error: Must use original synchronization cable; generic serial cables break real-time safety logic mirroring and disable bumpless switchover.❗ ESD PCB Damage Risk: Wear certified anti-static wrist strap during all disassembly and installation work; bare finger contact with internal safety processor chips permanently impairs safety calculation accuracy.❗ 24VDC Polarity Reversal Risk: Reversed logic power input instantly locks safety CPU and erases downloaded safety program, requiring full safety logic re-write.
4-Step Safety CPU Module Replacement Guide
- Pre-install Preparation: Perform full lockout/tagout of cabinet 24VDC auxiliary power feeding the safety rack, wait for internal capacitor complete discharge, wear ESD wrist strap, photograph CEX bus wiring, redundant sync cable connection and Ethernet PROFIsafe safety wiring connected to front ports.
- Removal Operation: Unplug all Ethernet, sync and CEX bus signal cables, release rack slot front latch, slide the old module out of TP868 baseplate slot.
- Installation & Wiring: Insert new fully into dedicated safety slot on baseplate until front latch clicks locked; replicate 24VDC logic power polarity, PROFIsafe Ethernet and sync cable wiring strictly following photographed sequence, tighten all terminal screws to ABB specified torque values.
- Power-on Safety Commissioning Test: Restore cabinet 24VDC auxiliary power, observe front green RUN LED steady on with red FAULT LED off; re-download validated safety program via engineering tool; simulate redundant safety CPU power loss to confirm bumpless safety logic switchover without ESD interlock reset, verify all safety fault alarms upload normally to plant SCADA system.
FAQ
Q: What is the core difference between (3BSE018173R1) and SM812K01?
- 3BSE018173R1: Legacy non-RoHS safety CPU, only for repair of systems commissioned before 22 July 2017; cannot be used for new projects.
- SM812K01: RoHS-compliant upgraded safety CPU, standard for all new 800xA safety DCS installations, different internal component layout and regulatory certification. The two cannot be cross-replaced without full SIS safety re-certification.
Q: Can run without pairing with main CPU?It can execute safety logic standalone, but safety fault logs, event history and safety setpoint parameter upload/download functions will be disabled. The CEX bus connection to is mandatory for full plant safety monitoring integration.
Q: Can be hot-swapped with cabinet 24VDC auxiliary power energized?Strictly prohibited. The module connects to live safety bus signal lines and charged internal RAM backup capacitors; live extraction causes safety bus surge and permanent loss of active safety logic, creating an unprotected safety blind zone. Full auxiliary DC power lockout is mandatory before replacement.
Q: What warranty applies to stocked 3BSE018173R1 assemblies?Factory-new original legacy safety CPU kits carry a 12-month official ABB manufacturer warranty covering safety processor logic, redundant synchronization circuits, Ethernet PROFIsafe transceivers and front diagnostic indicators. Bench-tested surplus units provide a 6-month functional warranty; damage caused by power polarity reversal, missing sync cable, uncertified unqualified installation or ungrounded ESD handling voids all safety warranty and certification validity.
Q: Has ABB discontinued production?Yes, formal EOL issued for the MasterPiece safety platform including . New industrial SIS projects adopt ABB Ability 800xA with integrated safety CPU cards without separate SM811 series modules. is only available as limited stock legacy repair spare parts.
Q: What typical faults indicate a defective module?Common failure symptoms: Permanent red FAULT LED alarm after power-on with intact CEX bus and Ethernet wiring, loss of redundant sync function unable to mirror safety logic between paired SM811 units, random safety interlock reset triggered by brief power fluctuation, failure to transmit safety fault alarms to SCADA, inability to re-download safety program via engineering tool, loss of safety logic memory after every cabinet power cycle.
