ABB CI855 communication interface module

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ABB CI855 Communication Interface Module

Product Description

Key Specs

• System Compatibility:
  Exclusive to ABB AC 800M DCS (all CPU models, e.g., PM851, PM864) and Advant OCS controllers (MasterPiece 200/300); connects to the controller via ABB’s proprietary CEX bus (for internal data transfer); compatible with ABB Control Builder M software (v6.0+) for configuration, diagnostics, and network management.
• Fieldbus Performance:

  Parameter	Specification
  Fieldbus Protocol	PROFIBUS DP V1/V2 (compliant with IEC 61158-3-1)
  Operation Modes	PROFIBUS DP Master (controls up to 124 DP slaves) / DP Slave (for controller-to-controller communication)
  Communication Speed	9.6 kbps ~ 12 Mbps (auto-negotiation or manual configuration via DIP switch)
  Maximum Bus Length	1000m (at 9.6 kbps, using twisted-pair shielded cable); 100m (at 12 Mbps)
  Slave Address Range	1 ~ 125 (configurable via DIP switch or Control Builder M)

• Electrical & Isolation:
  • Isolation Ratings: Bus interface to CEX bus — 2.5kV AC (1min); power circuit to signal circuit — 1kV AC (1min) — prevents ground loops and EMI interference from field wiring.
  • Bus Termination: Built-in selectable bus terminator (150Ω resistor) — no external terminator required for end-of-line installation.
  • Power Supply: Takes 24V DC from the AC 800M/Advant OCS backplane (via CEX bus); power consumption ≤3W (active mode).
• Mechanical & Environmental:
  • Dimensions (W×H×D): 160mm×130mm×220mm (19-inch rack-mounted, matches AC 800M module footprint); weight ~1.1kg.
  • Protection Degree: IP20 (mounted inside control cabinets, protected against solid objects ≥12mm).
  • Operating Conditions: -10°C~+50°C, 5%-95% RH (non-condensing); vibration resistance: 10-500Hz (1g acceleration); shock resistance: 20g (11ms half-sine).
• Compliance: EN 50170 (PROFIBUS standard), IEC 61131-2 (industrial I/O safety), EN 61000-6-2 (industrial EMC immunity), and UL 508 (industrial control equipment).

Core Functions

1. PROFIBUS DP Master/Slave Operation
   • Adapts to diverse network architectures based on application needs:
     • DP Master Mode: Acts as the central controller of the PROFIBUS DP network, managing up to 124 distributed DP slaves (e.g., ABB’s DSQC robotic I/O modules, Siemens ET 200 remote I/O, Danfoss VFDs). It schedules data exchange (cyclic/acyclic), configures slave parameters, and monitors slave health—critical for large-scale distributed systems (e.g., a petrochemical plant with 50+ remote pump VFDs).
     • DP Slave Mode: Enables communication between two AC 800M controllers (e.g., "Controller A (Master) ↔ CI855 (Slave) ↔ Controller B") for cross-controller data sharing (e.g., transmitting boiler pressure data from one controller to another for coordinated turbine control).
2. Real-Time Cyclic & Acyclic Data Exchange
   • Supports two key data transmission modes for industrial scenarios:
     • Cyclic Data Transfer: Transmits time-critical process data (e.g., sensor readings, VFD speed setpoints) at fixed intervals (configurable from 1ms to 1s). Ensures low latency (<1ms at 12 Mbps) for dynamic control tasks (e.g., adjusting conveyor speed based on real-time product flow).
     • Acyclic Data Transfer: Handles non-time-critical data (e.g., slave configuration parameters, fault logs, device identification) on demand. For example, it can retrieve a VFD’s fault history (e.g., "overtemperature at 14:30") or update a remote I/O module’s filter settings without interrupting cyclic data flow.
3. Network Diagnostics & Fault Management
   • Enables proactive monitoring and troubleshooting of the PROFIBUS DP network:
     • Real-Time Status Indicators:
       • Green "Bus Active" LED (flashing = cyclic data transmission; solid = bus idle).
       • Yellow "Slave Fault" LED (ON = one or more DP slaves disconnected/faulty).
       • Red "Module Fault" LED (ON = power loss, CEX bus communication failure, or internal error).
     • Diagnostic Data Transmission: Sends detailed network health data to the AC 800M controller via the CEX bus, including:
       • Slave connection status (e.g., "Slave 12: Disconnected").
       • Bus error statistics (e.g., "10 CRC errors in 5 minutes" — indicating wiring issues).
       • Terminator status (e.g., "Terminator ON for end-of-line").
4. Seamless Integration with AC 800M Control Logic
   • Simplifies system programming and data mapping:
     • Automatic Data Mapping: Control Builder M software automatically maps PROFIBUS DP data (e.g., 4-20mA sensor values from a DP slave) to the AC 800M controller’s memory addresses—no manual code writing required for basic data exchange.
     • PROFIBUS Function Blocks: Provides pre-built IEC 61131-3 function blocks (e.g., "PB_Master_Control", "PB_Slave_Data") for advanced operations (e.g., starting/stopping cyclic data transfer, handling acyclic read/write requests).
     • Configuration Backup/Restore: Saves PROFIBUS network configurations (slave addresses, communication speed, data mapping) to the controller’s memory or external USB drive—enabling quick replication across multiple CI855 modules (e.g., 10 identical production lines).

Core Advantages

1. High Compatibility with PROFIBUS Ecosystem
   Compliant with PROFIBUS DP V1/V2, it works seamlessly with third-party DP slaves (e.g., Siemens, Rockwell, Schneider) — eliminating vendor lock-in and enabling flexible system expansion (e.g., adding a new VFD to an existing network without replacing the interface module).
2. Dual-Mode Flexibility
   Switchable Master/Slave modes adapt to diverse network topologies (e.g., Master mode for distributed I/O control, Slave mode for controller-to-controller communication) — reducing the need for multiple specialized communication modules.
3. Robust Industrial Design
   2.5kV isolation, wide temperature range (-10°C~+50°C), and EMI immunity ensure reliable operation in harsh environments (e.g., power plant turbine halls with high vibration, petrochemical refineries with chemical fumes) — outperforming consumer-grade PROFIBUS interfaces.
4. Simplified Maintenance
   Built-in diagnostics, LED status indicators, and automatic configuration reduce troubleshooting time (e.g., identifying a disconnected slave in 2 minutes vs. 30 minutes with non-diagnostic modules) — lowering maintenance costs for large-scale networks.

Applications

1. Power Plant Auxiliary System Control
   • Used in a 600 MW coal-fired power plant’s AC 800M DCS: Operates as a PROFIBUS DP Master to control 30+ DP slaves (e.g., remote I/O modules for pump status, VFDs for fan speed). Cyclic data transfer (50ms interval) ensures real-time adjustment of fan speed based on boiler temperature, while acyclic data retrieval monitors VFD fault logs for predictive maintenance.
2. Petrochemical Pipeline Valve Control
   • Integrates with Advant OCS in a crude oil pipeline system: Acts as a DP Slave to exchange valve position data between two AC 800M controllers (one for pipeline inlet, one for outlet). Ensures synchronized valve opening/closing (latency <1ms) to maintain stable pipeline pressure, preventing overpressure-related leaks.
3. Metallurgical Rolling Mill VFD Coordination
   • Controls 20 Danfoss VFDs (DP slaves) in a steel rolling mill: Operates as a DP Master to send cyclic speed setpoints (10ms interval) to VFDs, coordinating roll speed across 4 rolling stands. Built-in diagnostics alert operators to a faulty VFD (e.g., "Slave 8: Overcurrent"), enabling quick replacement and minimizing production downtime.
4. Automated Manufacturing Line I/O Integration
   • Connects an AC 800M controller to 50 Siemens ET 200 remote I/O modules (DP slaves) in an automotive assembly line: Maps sensor data (e.g., "robot gripper position", "conveyor product detection") to the controller via cyclic transfer, and uses acyclic transfer to update I/O filter settings for different production batches (e.g., switching from car doors to bumpers).

Precautions

1. Compatibility Check
   • Confirm use with ABB AC 800M DCS or Advant OCS controllers—incompatible with ABB low-voltage PLCs (e.g., AC500) or third-party DCS platforms (e.g., Emerson DeltaV) due to proprietary CEX bus and configuration software. Verify Control Builder M is v6.0+ to support PROFIBUS DP V2 features (e.g., acyclic data with large payloads).
2. Network Wiring Guidelines
   • Use PROFIBUS-specific twisted-pair shielded cable (impedance 100Ω ±20%, conductor cross-section 0.64mm²) — non-compliant cables cause signal attenuation and CRC errors (especially at 12 Mbps).
   • Keep bus length within limits (e.g., ≤100m at 12 Mbps); use repeaters (e.g., ABB RPBA-01) for longer distances (up to 10 repeaters per network).
   • Enable the built-in terminator only for the first and last CI855 modules in the bus—multiple terminators cause signal reflection and communication failure.
3. Slave Address Configuration
   • Ensure no duplicate DP slave addresses in the network (e.g., two slaves set to address 5) — this causes bus collisions and data loss. Use DIP switches for initial address setting, then lock configurations via Control Builder M to prevent accidental changes.
   • For DP Master mode, limit the number of slaves to 124 (PROFIBUS DP maximum) — exceeding this causes network overload and increased latency.
4. Installation Safety
   • Disconnect the control cabinet’s main power (lockout/tagout) before installing the module—CEX bus voltage (24V DC) can cause electric shock if handled incorrectly.
   • Use anti-static gloves and a grounded workbench—ESD can damage the module’s bus interface chip, leading to intermittent communication failures.
5. Environmental Protection
   • Operate within -10°C~+50°C—temperatures above 50°C increase bus interface chip temperature, reducing communication speed; below -10°C, the terminator resistor’s performance degrades, causing signal distortion.
   • Ensure the control cabinet is well-ventilated (airflow ≥0.3m/s) — overheating is the leading cause of premature CI855 failure in high-load networks (e.g., 124 slaves at 12 Mbps).
6. Genuine Replacement
   • Use only ABB-genuine CI855 modules—counterfeit units lack proper isolation and PROFIBUS compliance, leading to network instability (e.g., random slave disconnections) or damage to DP slaves (e.g., overvoltage from faulty bus drivers)

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