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ABB CI502 interface module

1. Product Description

The ABB CI502 is a versatile industrial interface module designed for seamless communication between diverse industrial control devices and upper-level systems (such as ABB Advant OCS, AC 800M DCS, or third-party PLCs). As a critical communication bridge in industrial automation networks, it specializes in converting and transmitting data between different protocols or hardware interfaces, enabling interoperability between legacy equipment and modern control systems.

Equipped with robust communication circuitry, channel isolation, and a rugged industrial housing, the CI502 ensures stable data exchange even in harsh environments characterized by electromagnetic interference (EMI), temperature fluctuations, or mechanical vibration. It supports flexible configuration via dedicated software tools, allowing customization of communication parameters to match specific application requirements. Widely applied in industries like manufacturing, energy, and process control, the CI502 provides a reliable, cost-effective solution for integrating heterogeneous industrial devices into a unified control network.

2. Detailed Parameters

Parameter Category	Specifications
Model Number	CI502
Product Type	Industrial Communication Interface Module
Supported Interfaces	RS485/RS422 (2-wire/4-wire configurable), RS232-C (for local debugging/configuration)
Supported Protocols	Modbus RTU (Master/Slave), ABB MasterBus 300, Custom ASCII Protocols (configurable)
Data Transfer Rate	RS485/RS422: 300 bps - 115.2 kbps; RS232-C: 300 bps - 115.2 kbps (configurable per interface)
Communication Distance	RS485/RS422: Up to 1200 meters (twisted-pair cable); RS232-C: Up to 15 meters
Isolation Level	RS485/RS422 ports: 500 V DC (channel-to-channel); Interface-to-backplane: 1500 V DC
Operating Temperature	-40℃ to +70℃
Storage Temperature	-40℃ to +85℃
Power Supply	24 V DC (19.2-28.8 V DC); Typical power consumption: 4 W
Dimensions (W×H×D)	48.3 mm × 100 mm × 150 mm (compatible with standard DIN rail mounting)
Mounting Method	DIN rail mounting (35 mm standard rail, EN 50022)
Compatibility	ABB Advant OCS, AC 800M DCS; Third-party PLCs (Siemens S7 series, Rockwell Allen-Bradley ControlLogix)
Configuration Tool	ABB Control Builder M, ABB Panel Builder (for parameter setting and diagnostics)
Protection Class	IP20 (when installed in a control cabinet)
Certification	IEC 61000-6-2 (EMC immunity), IEC 60947-5-1 (industrial control equipment), CE, UL

3. Advantages & Features

Multi-Protocol & Multi-Interface Flexibility

Supports RS485/RS422 (2-wire/4-wire) and RS232-C interfaces, along with core industrial protocols like Modbus RTU and ABB MasterBus 300. This flexibility allows integration of diverse devices—such as legacy sensors, third-party PLCs, and HMIs—into a unified network, eliminating the need for multiple single-protocol modules.

Reliable Isolation & Anti-Interference Performance

500 V DC channel-to-channel isolation for RS485/RS422 ports prevents cross-signal interference, critical for systems with mixed high/low-voltage devices. Built-in EMI filters and shielded circuitry comply with IEC 61000-6-2 standards, ensuring stable communication near high-power motors, inverters, or power cables.

Long-Distance Communication Capability

RS485/RS422 interface supports up to 1200 meters of communication distance (using twisted-pair cable), making it ideal for large-scale industrial sites—such as factory workshops with distributed equipment or outdoor power substations.

Easy Configuration & Diagnostics

Configurable via user-friendly tools like ABB Control Builder M, allowing quick adjustment of baud rate, parity, protocol mode, and data format. Integrated diagnostic functions (e.g., communication error logging, port status monitoring) enable rapid troubleshooting of connectivity issues, reducing maintenance downtime.

Industrial-Grade Durability

-40℃ to +70℃ operating temperature range and rugged plastic housing (resistant to vibration and shock) ensure reliable performance in extreme environments, from cold storage facilities to high-temperature metallurgical workshops.

4. Application Fields

Manufacturing Automation

Used in automotive, electronics, or machinery manufacturing plants to connect distributed Modbus RTU sensors (e.g., temperature, pressure), third-party PLC-controlled machines (e.g., robotic arms, conveyor systems), and the central AC 800M DCS. Enables real-time data sharing for production line coordination and quality control.

Energy & Power Systems

Deployed in thermal power plants, wind farms, or solar installations to link MasterBus 300-compatible meters (e.g., power consumption, voltage), RS485-based inverter controllers, and the central control system. Facilitates remote monitoring of energy generation, transmission, and consumption data.

Water & Wastewater Treatment

Integrates RS485-connected water quality sensors (e.g., pH, dissolved oxygen), pump control panels (third-party PLCs), and the central SCADA system. Ensures seamless data transmission for optimizing treatment processes and responding to abnormal water quality conditions.

Building Automation

Used in commercial buildings or industrial facilities to connect RS485-based HVAC controllers, lighting systems, and access control devices to the building management system (BMS). Enables centralized monitoring and control of energy usage, improving operational efficiency.

Legacy System Upgrades

Acts as a bridge between outdated control equipment (e.g., legacy ABB Advant controllers with MasterBus 300) and modern DCS/PLC systems. Allows gradual migration to new technology without replacing existing functional devices, reducing upgrade costs and minimizing production disruption.

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