Description

The ABB PFSK164 3BSE021180R1​ is a PROFIBUS F-Slave communication interface module for the ABB AC 800M High Integrity controller family. It enables robust, high-speed, and deterministic data exchange between the safety-related AC 800M controller and a standard PROFIBUS-DP network, acting as a critical gateway in integrated control and safety systems.

Application Scenarios

In a pharmaceutical batch plant, a safety instrumented system (SIS) controlling critical reactor shutdown logic must reliably receive process variables (like temperature and pressure) from the distributed control system (DCS) to make its safety decisions. A standard communication link lacks the deterministic timing and diagnostic integrity required for safety functions. The ABB PFSK164 3BSE021180R1​ module is installed in this precise role. It resides in the AC 800M High Integrity controller rack, establishing a dedicated PROFIBUS F-Slave connection to the DCS’s PROFIBUS master. This specialized F-Profile (“F” for functional safety) link ensures that process data is transferred with guaranteed response times and advanced diagnostic coverage. It solves the key pain point of integrating safety and control systems by providing a certified, reliable data highway that maintains the safety controller’s integrity while enabling seamless interoperability, allowing the SIS to act on real-time process data without compromise.

Parameter

Technical Principles and Innovative Values

Innovation Point 1: Certified Integration of Safety and Standard Networks via PROFIsafe

The core innovation of the ABB PFSK164 3BSE021180R1​ is its implementation of the PROFIsafe profile. It allows safety-related data (up to SIL 3) to be transmitted over a standard PROFIBUS-DP network alongside standard data. It achieves this by adding a safety layer with mechanisms like consecutive numbering, time monitoring, and authentication codes to the standard PROFIBUS telegram. This eliminates the need for separate, hardwired signals for every safety interlock, drastically reducing wiring complexity and cost while maintaining the highest levels of functional safety integrity.

Innovation Point 2: Deterministic Performance for Critical Control Loops

Unlike generic communication cards, the PFSK164​ is engineered for deterministic data exchange. It provides predictable, guaranteed response times for safety-related messages between the AC 800M controller and the PROFIBUS master. This determinism is crucial for safety functions where a delayed or lost command could have serious consequences. The module manages communication cycles and safety protocol handshakes in hardware, ensuring that safety logic scan times in the controller are not adversely affected by network traffic.

Innovation Point 3: Deep Diagnostics and Seamless AC 800M Integration

The module offers deep diagnostic capabilities that go beyond simple link status. It can detect communication errors, sequence errors, and configuration mismatches, providing detailed fault information to both the AC 800M controller’s engineering station and the PROFIBUS master. This allows for rapid troubleshooting and maintenance. Furthermore, its design is fully integrated with the AC 800M hardware and software ecosystem (e.g., Control Builder M), allowing for unified configuration, commissioning, and asset management within a single engineering tool.

Application Cases and Industry Value

A chemical plant with an older distributed control system needed to upgrade its burner management system (BMS) to meet modern safety standards without a complete DCS overhaul. The solution involved installing a new ABB AC 800M High Integrity controller for the BMS logic. The challenge was integrating the new safety controller with the existing DCS to receive process variables and send commands. Using the ABB PFSK164 3BSE021180R1​ as the communication bridge provided the answer. The module was configured as a PROFIsafe slave on the plant’s existing PROFIBUS-DP network, with the DCS acting as the master. This allowed all critical flame, pressure, and temperature signals to be communicated safely to the BMS, and permissive/trip signals to be sent back. The project lead stated: “The PFSK164​ module was the linchpin of our safety upgrade. It allowed us to implement a state-of-the-art SIL 3 BMS using the AC 800M, while seamlessly re-using our existing fieldbus infrastructure. The integration was flawless, and the certified safety communication gave us and the regulatory body complete confidence in the system’s integrity.”

Related Product Combination Solutions

ABB PM803F or PM861A Controller:​ The main CPU of the AC 800M High Integrity controller where the PFSK164​ module is installed, executing the SIL-rated application logic.

ABB CI871K Ethernet Module:​ Provides the standard plant network connection for the AC 800M controller, working alongside the PFSK164​ for communication to different system levels.

ABB SD822 or SD823 Safety Digital I/O Module:​ The primary safety I/O modules that interface directly with field devices (e.g., E-Stop buttons, safety valves); their data can be processed and communicated via the PFSK164.

ABB SA511F or SA521F Safety Analog I/O Module:​ For interfacing with analog safety devices, providing data that can be communicated over the PROFIsafe link established by the PFSK164.

Siemens SIMATIC S7-400H/F (with PROFIsafe Master):​ A typical DCS or master station that would act as the PROFIsafe Class 1 Master, communicating with the PFSK164​ (Slave) in a integrated architecture.

ABB Control Builder M Engineering Software:​ The configuration and programming environment used to configure the PFSK164​ module’s parameters, map I/O data, and integrate it into the safety application.

Installation, Maintenance, and Full-Cycle Support

Installation and Maintenance: The ABB PFSK164 3BSE021180R1​ module is designed for installation in an AC 800M controller unit’s communication module slot. Installation must be performed with the controller powered down. The module connects to the PROFIBUS-DP network via its 9-pin D-sub connector, requiring proper network termination and shielding. Configuration is performed entirely within the ABB Control Builder M software, where the module is added to the hardware configuration, its PROFIsafe address and parameters are set, and the safety I/O data is mapped. Its hot-swap capability (in redundant configurations) allows for replacement without a full system shutdown. Routine maintenance is primarily monitoring-based, using the system diagnostics to check communication health and error counters.

We provide comprehensive support for the ABB PFSK164 3BSE021180R1​ and the broader AC 800M safety system. Our technical team is proficient in the configuration and integration of PROFIsafe networks and can assist with both hardware setup and software configuration. We are committed to supplying genuine, fully tested modules and can provide expert guidance to ensure your safety communication network is implemented correctly, reliably, and in compliance with relevant safety standards.