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ABB TK802F (Order Code: 3BDM000213R1) Controller Module 

1. Key Parameters

• Product Model: TK802F
• Order Code/Part Number: 3BDM000213R1 (unique identifier for procurement and AC 800M compatibility verification)
• Product Series: ABB AC 800M DCS Controller Modules
• Core Function: Executes control logic (PID, sequential control) for industrial processes; processes data from I/O modules; communicates with SCADA/HMI systems; ensures real-time process monitoring and control
• Processing Performance:
  • CPU: 32-bit RISC processor (500MHz clock speed)
  • Control Execution Speed: ≤1ms per basic PID loop; ≤5ms for complex sequential logic (ensures fast response to process changes)
  • Memory:
    • Flash Memory: 256MB (for firmware, control programs, configuration data)
    • RAM: 128MB (for real-time data processing, temporary variables)
  • Supported Control Functions: PID (single-loop/multi-loop), cascade control, ratio control, sequential function charts (SFC), function blocks (IEC 61131-3 standard)
• Communication Interfaces:
  • Backplane Interface: ABB proprietary PRONETA bus (100Mbps full-duplex; for connecting to AC 800M I/O modules, e.g., FI840F, AM801F)
  • Ethernet Port: 1× 10/100Base-TX (RJ45; for communication with SCADA, HMI, or other controllers; supports Modbus-TCP, Ethernet/IP protocols)
  • Serial Port: 1× RS-485 (for legacy device integration; supports Modbus-RTU protocol)
• Electrical Specifications:
  • Power Supply (Backplane): 5V DC (from AC 800M rack power supply; typical current: 1.8A; maximum current: 2.5A)
  • Power Consumption: ≤12.5W (total, including processing and communication)
  • Isolation: 1kVrms (between communication ports and backplane; 500Vrms between Ethernet/RS-485 ports)
  • Surge Protection: IEC 61000-4-5 (±2kV contact; ±4kV air discharge for Ethernet/RS-485 ports)
• Mechanical Specifications:
  • Housing Type: Metal-reinforced flame-retardant plastic (UL94 V-0; for EMI shielding and mechanical strength)
  • Dimensions (W×H×D): 25mm × 100mm × 160mm (1-module width; fits AC 800M standard I/O racks)
  • Mounting: Rack-mounted (dedicated slot in AC 800M racks; tool-less installation via snap-in clips)
  • Weight: Approximately 220g
  • LED Indicators:
    • Power (PWR): Green (module powered on); Red (power fault)
    • CPU Status (CPU): Green (normal operation); Amber (high CPU load >80%); Red (CPU fault)
    • Backplane Communication (BUS): Green (PRONETA bus normal); Red (bus fault)
    • Ethernet (ETH): Green (link active); Blinking Green (data transmission)
    • RS-485 (SER): Green (link active); Blinking Green (data transmission)
• Environmental Ratings:
  • Operating Temperature Range: -25℃~+70℃ (-13℉~158℉)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Humidity Tolerance: ≤95% RH (non-condensing, 40℃)
  • Vibration Resistance: 10~500Hz, 2g acceleration (IEC 60068-2-6; no processing interruptions)
  • Shock Resistance: 30g acceleration (11ms duration, IEC 60068-2-27; maintains communication and control logic)
• Compliance Standards: IEC 61131-3 (programmable controllers), IEC 61000-6-2 (EMC immunity), UL 508 (industrial control safety), CE, RoHS

2. Key Features

• High-Speed Control Execution: 500MHz RISC CPU enables fast processing of control loops (≤1ms for PID) and complex logic, ensuring rapid response to process deviations (e.g., sudden pressure spikes in chemical reactors)—critical for maintaining process stability and product quality.
• Seamless AC 800M Integration: PRONETA bus interface enables plug-and-play connectivity with AC 800M I/O modules (digital/analog inputs/outputs, fieldbus modules) and rack components, eliminating custom wiring and simplifying system commissioning.
• Multi-Protocol Communication: Supports Ethernet (Modbus-TCP, Ethernet/IP) and RS-485 (Modbus-RTU), enabling integration with diverse systems (e.g., Siemens SCADA, Rockwell HMI, legacy flow meters)—enhancing interoperability and reducing retrofitting costs.
• Robust Fault Tolerance: Built-in diagnostics (CPU load monitoring, communication fault detection, power anomaly alerts) trigger visual/remote alarms to notify operators of issues. The module retains configuration data in flash memory during power outages, ensuring fast system recovery.
• IEC 61131-3 Compliance: Supports standard programming languages (ladder logic, function block diagram, SFC) via ABB’s Control Builder M software, enabling engineers to use familiar tools for control logic development and reducing training time.
• EMI Shielding & Isolation: Metal-reinforced housing and 1kVrms isolation between ports minimize interference from industrial noise (e.g., motor startups, variable-speed drives), ensuring reliable communication and control even in high-EMI environments.
• Compact & Durable Design: 1-module width saves rack space for other critical components, while UL94 V-0 flame-retardant housing and wide temperature range (-25℃~+70℃) ensure durability in harsh industrial settings (e.g., oil refineries, power plants).

3. Application Fields

• Chemical & Petrochemical Industry: Controls reactor temperature, pressure, and chemical dosing in batch/continuous processes (e.g., polymer synthesis, crude oil refining)—maintaining compliance with safety standards and ensuring product consistency.
• Power Generation: Manages auxiliary systems in thermal, nuclear, and renewable energy plants (e.g., boiler water level control, turbine bearing temperature monitoring, solar inverter output regulation)—supporting grid stability and efficient energy production.
• Oil & Gas Upstream/Downstream: Controls drilling parameters (e.g., torque, mud flow) in offshore rigs and pipeline flow/pressure in midstream operations—withstanding salt spray, vibration, and extreme temperatures to ensure safe, uninterrupted operations.
• Pharmaceutical Manufacturing: Executes precise PID control for sterilization autoclaves, freeze dryers, and batch mixing systems—meeting FDA/GMP regulations by maintaining strict process parameters (e.g., 121℃ for 15 minutes in autoclaves).
• Water & Wastewater Treatment: Regulates aeration blower speed, chemical dosing rates, and filter backwashing cycles—optimizing treatment efficiency and ensuring effluent meets environmental discharge standards.
• Food & Beverage Production: Controls pasteurization temperature (e.g., 72℃ for dairy), filling machine speed, and cold storage humidity—preventing bacterial growth and ensuring food safety compliance.

4. Precautions

• System Compatibility: Use exclusively with ABB AC 800M DCS racks and compatible I/O modules. Installation in non-AC 800M systems (e.g., Siemens PCS 7, Allen-Bradley PlantPAx) will cause backplane communication failure and render the module inoperable.
• Firmware Compatibility: Ensure the module’s firmware version matches the AC 800M rack’s firmware (via Control Builder M). Mismatched firmware causes protocol errors and may prevent control logic execution—update firmware before commissioning.
• Power Supply Stability: Connect the AC 800M rack to a regulated power supply (±5% tolerance for 5V DC). Voltage fluctuations (e.g., <4.75V or >5.25V) can cause CPU crashes or data corruption—use UPS systems for critical applications.
• Wiring Safety:
  • Use shielded Ethernet cables (CAT5e or higher) for network connections; ground the shield at both ends to minimize EMI.
  • Keep RS-485 wiring distance ≤1200m (for Modbus-RTU) and avoid routing near high-voltage power cables (≥30cm spacing).
  • Tighten backplane connector screws to 0.8~1.0N·m to ensure secure electrical contact—loose connections cause intermittent communication faults.
• Environmental Protection: Install in a sealed, climate-controlled rack cabinet in corrosive/dusty environments. For outdoor applications (e.g., solar farms), use weatherproof enclosures with temperature control (heaters/coolers) to maintain operating temperature within -25℃~+70℃.
• Configuration Backup: Regularly back up control logic and configuration data to a secure server or external storage. In case of module failure, restore data to a replacement TK802F to minimize downtime—do not modify logic without testing in a simulation environment.
• Maintenance Checks: Inspect quarterly:
  • Verify LED status (no red faults; CPU load <80%).
  • Test communication with I/O modules and SCADA systems (check for data dropouts).
  • Clean the module’s vents with compressed air (avoid moisture) to prevent overheating—blocked vents cause CPU thermal throttling

The structure and details of the product：

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