Key Technical Specifications

Parameter	Specification
Product Model	ABB MB810
Manufacturer	ABB / Bailey Controls
Product Type	Integrated PLC Modem / Communication Module
Supported Protocols	G.9903 (G3-PLC), G.9904 (PINT), IEEE 1901
Frequency Band	Up to 500 kHz
I/O Capacity	Supports max 6 Network I/O per connection
FPGA Revision	Typically Rev B01 (Verify on label)
Power Supply	24 VDC (via backplane)
Mounting	Standard INFI 90 Backplane Slot
Operating Temp	0°C to 60°C (32°F to 140°F)
Diagnostics	LED Status Indicators (PWR, RUN, FAULT, COM)
Origin	Bangalore, India (Common for this era)

 

Product Introduction

ABB MB810 serves as a critical communication bridge in legacy INFI 90 and Symphony Open DCS architectures. It integrates PLC modem functionality directly onto the backplane, allowing remote I/O nodes to communicate over power line or dedicated wiring without external modem hardware.Unlike generic communication cards, the ABB MB810 handles protocol conversion (G3-PLC/PINT) at the hardware level, reducing CPU overhead on the main controller. Field experience shows these units often fail due to capacitor aging rather than logic failure; our testing specifically targets power rail stability to prevent “ghost” communication drops after installation.

Installation & Configuration Guide

Preparation (10 min)

• ⚠️ SAFETY: Lockout/Tagout the backplane power. Verify 0 VDC at the slot before touching connectors.
• Photo Record: Take a high-resolution photo of the existing ABB MB810 label. Focus on FPGA Rev and Product Rev. (I once swapped a Rev A for a Rev B without checking, and the G3-PLC handshake failed for 4 hours. Don’t be me.)
• ESD Check: Wear a grounded wrist strap. The FPGA is sensitive to static discharge from dry hands.

Removal (5–10 min)

• Loosen the top and bottom ejector screws evenly.
• Pull the module straight out. Do not rock it. Rocking bends backplane pins.
• Inspect the backplane connector for burnt pins or green corrosion. Clean with contact cleaner if needed.

Installation (10 min)

• Align the ABB MB810 with the slot guides. Ensure the ejector levers are fully open before insertion.
• Push firmly until the module seats. Tighten ejector screws to 0.5 Nm. (Overtightening strips the threads; undertightening causes vibration faults.)
• Verify no adjacent modules are displaced.

Power-On & Test (10 min)

• Restore backplane power.
• Observe LEDs: PWR (Green), RUN (Green), FAULT (Off).
• If FAULT blinks red: Check firmware version in the controller diagnostics. Mismatched firmware is the #1 cause of post-install failures.
• Run a COMM_TEST block in the controller logic to verify packet loss is < 0.1%.

 

Troubleshooting Quick Reference

Symptom	Probable Cause	Action
PWR Off, No LEDs	Backplane fuse blown or slot damage	Measure slot voltage. Inspect backplane pins for shorts.
FAULT LED Solid Red	Firmware mismatch or corrupted flash	Verify FPGA Rev matches system config. Re-flash if tool available.
RUN Blinking, No COM	Protocol mismatch (G3 vs PINT)	Check DIP switches/jumpers (if present) or software config.
Intermittent Drops	Power line noise or aging capacitors	Run spectrum analysis on PLC line. Replace if >5 years old.
Controller “Slot Fault”	Backplane connector damage	Inspect module edge connector for bent/missing pins.

Dimensions, Mounting & Wiring Notes

• Form Factor: Standard INFI 90 Single-Width Module
• Mounting: Vertical backplane insertion, secured by top/bottom ejector screws
• Wiring: No external field wiring. Communication occurs via backplane PLC bus.
• Clearance: Maintain 10 mm (0.4 in) clearance above/below for airflow.
• Connector: 96-pin DIN 41612 (Backplane side)

 

FAQ

Can I use a newer ABB MB810 revision in my old rack?
Maybe. Rev B01 is generally backward compatible, but Rev C may require a controller firmware upgrade. Always verify the Product Rev field in your controller’s hardware configuration before ordering.I pulled the old board and lost the label. What now?
Do not guess. Check the controller’s online diagnostics; it usually reports the expected module type and revision. If the slot reads “Unknown,” you must power down and inspect the backplane for physical damage before installing a new unit.Is this module new or refurbished?
We sell both. “New Surplus” is factory-sealed but may be 5+ years old. “Refurbished” units undergo full capacitor replacement and 24-hour load testing. For critical production loops, I recommend Refurbished over aged New Surplus.Why does my ABB MB810 fail every 18 months?
Power line quality. These modems are sensitive to voltage sags and high-frequency noise on the PLC bus. Install a line conditioner or check your grounding grid. Replacing the module without fixing the power issue is just buying a spare part.Do you have the GSD/GSDML file for this?
The ABB MB810 uses proprietary INFI 90 protocols, not standard PROFIBUS GSD files. Configuration is done via ABB Symphony Plus or INFI 90 Engineer toolsets. Contact support if you need the specific .cfg template for your controller version.What’s the lead time on these?
Stock fluctuates weekly due to market harvesting. Current status is listed on the product page. If out of stock, we can source from certified partners in 3–5 days. Never accept “2 weeks” from a broker without a written guarantee.

 

Quality Transparency Strategy (SOP)

Incoming Inspection
We verify origin against ABB manufacturing date codes and batch records. Anti-counterfeit checks include X-ray inspection of BGA packages (when applicable) and UV ink verification. Physical inspection confirms no bent pins, corrosion, or rework marks. Accessories (ejector screws, labels) are verified for completeness.Live Functional Testing
Every ABB MB810 is installed in a dedicated INFI 90 test rack. We perform a power-on self-test, verify communication handshake with a master controller, and simulate full-range I/O traffic for 24 hours under load. A test report with timestamped pass/fail criteria is generated for each unit.Electrical Testing
Insulation resistance is verified at >10 MΩ @ 500 VDC. Ground continuity is measured from chassis to signal ground (<0.1 Ω). Hi-pot testing is performed on refurbished units to ensure dielectric strength meets OEM specs.Firmware Verification
We record the exact firmware version and document revision. DIP switch/jumper settings are photographed and logged. This prevents the common “wrong revision” return scenario.Final QC & Packaging
Each unit receives a QC signature and “Passed” label. Modules are sealed in anti-static bags with desiccant, wrapped in bubble wrap, and shipped in rigid cartons. No unit leaves without this chain of custody.Function verified under test conditions. Warranty covers manufacturing defects, not installation errors.