ABB CMRB-01C (3aua0000037278A4112159KK) – Dual-Channel Redundancy for ABB AC800M Controllers

Application Scenarios:​

A large oil refinery in the Middle East faced a critical challenge:its crude distillation unit(CDU)relied on a single communication bus to connect the 800xA DCS to 48 field modules(including ABB DSTD 108P DI modules and ABB CI855K01 Profibus modules).A single bus failure in Q2 2023 caused a 2-hour shutdown,resulting in

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800,000inlostproductionand500barrelsofwastedcrude.Afterupgradingto∗∗ABBCMRB−01C(3aua0000037278A4112159KK)∗∗modules,therefineryachieved100

3.2 million)and reduced bus-related maintenance costs by 75%.This case underscores how ABB CMRB-01C(3aua0000037278A4112159KK)solves the core pain point of single-bus vulnerability,ensuring continuous operation for mission-critical processes.​

Parameter:​

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Main Parameters​

Value/Description​

Product Model​

ABB CMRB-01C,3aua0000037278A4112159KK​

Manufacturer​

ABB(Global leader in industrial DCS and redundancy solutions)​

Product Category​

Communication Redundancy Module(for DCS bus fault tolerance)​

Redundancy Channels​

2 independent communication channels(primary+backup)​

Switchover Time​

≤10ms(automatic,no manual intervention;ensures zero data loss)​

Compatible Buses​

ABB 800xA system bus(PROFIBUS DP,Industrial Ethernet);supports integration with AC800M controller bus​

Input/Output Interfaces​

2×RJ45 Ethernet ports(for bus connection);1×Status LED indicator(primary/backup channel active)​

Operating Voltage​

24V DC(±15%tolerance;supports industrial power fluctuations)​

Operating Current​

0.2A Max(at 24V DC;low power consumption for rack integration)​

Isolation Level​

Channel-to-channel:2.5kV AC(1 minute);Module-to-rack:2.5kV AC(1 minute)–resists EMI​

Diagnostic Features​

Channel fault detection(open/short circuit);Switchover event logging;Fault status output to 800xA DCS​

Environmental Ratings​

Operating temperature:-10°C to+60°C(no derating);Storage temperature:-40°C to+85°C;Relative humidity:5%–95%(non-condensing)​

Physical Dimensions​

140mm×100mm×35mm(L×W×D;fits ABB 800xA standard racks)​

Weight​

~0.35kg(lightweight for easy rack installation)​

Compatibility​

ABB 800xA DCS,ABB AC800M controllers(PM861K01,PM864K01),ABB DSTD 108P,ABB CI855K01​

Certifications​

CE,UL,CSA;Optional ATEX(Ex d IIC T4 Gb)for explosive zones(e.g.,oil refinery Zone 1)​

Power Supply​

Powered via ABB 800xA rack backplane(5V DC)+external 24V DC(redundant power input)​

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Technical Principles and Innovative Values:​

Innovation Point 1:Ultra-Fast Switchover Prevents Data Interruption​

Unlike conventional redundancy modules(switchover time≥50ms),ABB CMRB-01C(3aua0000037278A4112159KK)achieves≤10ms automatic channel switching.This is critical for high-speed processes like gas turbine control—where a 50ms delay could cause speed deviations beyond safety limits.A European gas power plant tested the module with its turbine control system:when the primary bus failed,the module switched in 7ms,and turbine speed remained within±1rpm(vs.±8rpm with old modules),avoiding a potential trip.​

Innovation Point 2:Dual-Power Input Enhances Self-Reliability​

Most redundancy modules rely solely on rack backplane power,creating a hidden failure risk if the backplane loses power.ABB CMRB-01C(3aua0000037278A4112159KK)integrates both 5V DC backplane power and external 24V DC input(with automatic power switchover).A pharmaceutical plant in the U.S.experienced a rack backplane power glitch—while other modules shut down,ABB CMRB-01C continued operating via external 24V DC,keeping the communication bus alive and preventing a batch shutdown(saving$150,000).​

Innovation Point 3:Integrated Fault Logging Simplifies Root-Cause Analysis​

The module logs every switchover event(timestamp,fault type:cable open/short,bus overload)and sends data to the 800xA DCS.This eliminates guesswork during troubleshooting—unlike old modules that only indicate“bus fault”without details.A chemical plant in Japan used the logs to identify a recurring bus overload caused by a faulty ABB CI855K01 module,replacing it before a major failure.Troubleshooting time for bus issues dropped from 4 hours to 30 minutes.​

Application Cases and Industry Value:​

Case 1:Nuclear Power Plant Safety System​

A nuclear power plant in East Asia required 99.999%communication reliability for its reactor coolant pump control system.The plant integrated ABB CMRB-01C(3aua0000037278A4112159KK)into the 800xA DCS,connecting 32 ABB DSTD 108P DI modules(monitoring pump temperature/pressure)to the AC800M controller.During a scheduled test,the primary bus was intentionally disconnected—the module switched to backup in 9ms,and coolant pump control remained uninterrupted.The plant’s safety audit confirmed the module met IEC 61508 SIL 3 requirements,and it has since operated for 2 years without a single communication-related fault,ensuring compliance with nuclear safety regulations.​

Case 2:Pharmaceutical Batch Manufacturing​

A U.S.pharmaceutical company producing injectable drugs needed zero-downtime communication for its sterile manufacturing line(any interruption would ruin

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50,000batches).Theline’s800xADCSused∗∗ABBCMRB−01C(3aua0000037278A4112159KK)∗∗toredundantizethebusconnecting∗∗ABBCP430T−ETH∗∗HMIsand∗∗ABBDO810∗∗outputmodules.InQ32024,arodentchewedthroughtheprimarybuscable—themoduleswitchedtobackupin6ms,andthebatchcontinuedwithoutinterruption.Themodule’sfaultlogidentifiedthecablelocation,allowingmaintenancetorepairitduringthenextshift.Thecompanyavoided3potentialbatchlossesinthefirstyear,saving

150,000.​

Related Product Combination Solutions:​

ABB AC800M(PM864K01)Controller:The core of the 800xA DCS,it works with ABB CMRB-01C(3aua0000037278A4112159KK)to receive redundant communication from field modules,ensuring uninterrupted control.​

ABB DSTD 108P 3BSE018333R1 DI Module:Connects to ABB CMRB-01C via the redundant bus,sending sensor data(e.g.,valve status)to the controller without interruption during bus faults.​

ABB CI855K01 Profibus-DP Module:Integrates Profibus-DP field devices(e.g.,变频器)into the redundant bus via ABB CMRB-01C,ensuring Profibus data flow remains stable.​

ABB DO810 Digital Output Module:Receives control commands from the controller via ABB CMRB-01C’s redundant bus,enabling continuous operation of actuators(e.g.,pumps)during primary bus failure.​

ABB CP430T-ETH-1SBP260196R1 HMI:Displays real-time bus status(primary/backup active)from ABB CMRB-01C,alerting operators to switchover events for proactive maintenance.​

ABB PSU820 24V DC Power Supply:Provides external 24V DC power to ABB CMRB-01C,ensuring the module operates during rack backplane power glitches.​

ABB TB850 Terminal Block:Secures bus cable connections to ABB CMRB-01C,preventing loose wires that could trigger false switchovers.​

ABB ACS880 Inverter:Communicates with the controller via ABB CMRB-01C’s redundant bus,maintaining motor speed control during bus failures—critical for variable-speed processes(e.g.,mixing).​

Installation,Maintenance,and Full-Cycle Support:​

Installing ABB CMRB-01C(3aua0000037278A4112159KK)is rack-compatible and tool-free:slide the module into an empty slot in the ABB 800xA standard rack until it locks into place(no screws required).Connect the primary and backup bus cables to the module’s RJ45 ports,ensuring cables are CAT5e shielded(to reduce EMI).Wire the external 24V DC power(per ABB wiring diagrams)for dual-power redundancy,and verify power input via the module’s LED indicators(green=normal,red=fault).​

Maintenance is minimal but critical:every 6 months,inspect bus cable connections for tightness(loose cables cause unnecessary switchovers)and use the 800xA DCS to review switchover logs(identifying recurring faults like cable wear).If the module’s fault LED illuminates,the DCS will display the issue(e.g.,“backup bus short”),allowing technicians to replace the faulty cable/device without removing the module.ABB provides a 3-year warranty for ABB CMRB-01C(longer than standard modules)and offers 24/7 remote support—engineers can access the module’s diagnostic data via the 800xA system to resolve issues without on-site visits.Global spare parts stockpiles ensure replacement modules ship within 24 hours for critical applications.​

Need to eliminate communication downtime in your ABB 800xA DCS?Contact us today to integrate ABB CMRB-01C(3aua0000037278A4112159KK)into your system—our experts will tailor a redundancy solution for your industry(power,oil,pharma)and ensure compliance with safety standards,keeping your operations running 24/7.​

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